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Tm115 - Tm165 Repair Manual Complete Contents: 2002 New Holland North America, Inc. Printed in U.S.A

This document outlines the contents of a repair manual for TM115-TM165 tractors. It includes 15 sections covering various tractor systems and components. The sections range from general information to specific chapters on the engine, transmission, brakes, hydraulics and other systems. The document provides an overview of what is contained in the repair manual to aid technicians in servicing and repairing these tractor models.

Uploaded by

Adam Michalak

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100% found this document useful (4 votes)

12K views1,898 pages

Tm115 - Tm165 Repair Manual Complete Contents: 2002 New Holland North America, Inc. Printed in U.S.A

Uploaded by

Adam Michalak

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

TM115--TM165 REPAIR MANUAL

COMPLETE CONTENTS
SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 23 - DRIVE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 25 - MECHANICAL FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 27 - MECHANICAL REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . 9

SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 33 - BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 41 - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 44 - FRONT AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 50 - AUXILIARY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

The following pages are the collation of the contents pages from each section and
chapter of the TM Series Repair manual.

The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.

The sections listed above are the sections utilized for the TM Series Tractors.

 2002 NEW HOLLAND NORTH AMERICA, INC. 87015506 5/02

Printed In U.S.A.
SECTION 00 -- GENERAL
BOOK 1 - 87015499

HEALTH AND SAFETY

CONTENTS

Section Description Page

HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . 5
ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . 6
BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . 6
DO’S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . 6
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . 8
GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . 10
SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . 10
SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2
SECTION 10 -- ENGINE
BOOK 1 - 87015499

Chapter 1 -- Engine
CONTENTS

Section Description Page

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel Test Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Greases and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine stripdown -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 001 Engine removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 100 Engine disassembly and overhaul:--
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front cover and timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil pan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connecting rods, bearings pistons and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cylinder block overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Main bearings and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Rear cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Oil pump and oil filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Camshaft, tappets and camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10 200 Fuel system components:--
Fuel pump -- Removal, Timing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 400 Cooling system components:
Radiator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Thermostat removal, testing and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Temperature warning sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Viscous clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fan blade removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fan belt and tensioner removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Water pump removal, overhaul and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3
SECTION 18 -- CLUTCH
BOOK 1 - 87015499

CONTENTS

Section Description Page

23 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
23 101 Removal--Installation--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 25 -- MECHANICAL FRONT AXLE

BOOK 3 - 87015501

Chapter 1 -- Mechanical Front Axle

CONTENTS

Section Description Page

25 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25 100 Standard Axle -- Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Suspended Axle -- Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Supersteer Axle -- Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hub Cassette Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Front Axle Overhaul -- All Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dog Clutch Differential Lock -- Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Multi Wet Plate Differential Lock -- Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . 36
Crown Wheel/Differential -- Disassembly/Reassembly -- All Options . . . . . . . . . . . . . . . . . 38
Pinion Shaft Removal -- All Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pinion Shaft Adjustment/Installation -- All Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Crown Wheel Adjustments -- All Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Swivel Pin & Potentiometer -- Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Axle Reassembly -- All Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Checking the Alignment of Steering & Drive Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8
SECTION 25 -- FRONT AXLE
BOOK 3 - 87015501

Chapter 2 -- Terraglide (Front Axle Suspension)

CONTENTS

Section Description Page

25 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 000 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 000 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Block Component Locations / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Terraglide Operation -- Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terraglide Operation -- Axle Levelling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
25 000 Automatic Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
25 000 Error Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
25 000 Error Code retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
25 000 Clearing Stored Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
25 000 H9--Vehicle Sensor and Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
25 000 Error Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
25 100 Suspended Front Axle Assembly--Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 62
25 100 Suspension Cylinder Removal and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
25 000 Suspension Control Valve Assembly--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Chapter 2 -- Air Trailer Brakes

CONTENTS

Section Description Page

33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33 000 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
33 000 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

11
SECTION 35 -- HYDRAULIC SYSTEMS
BOOK 4 - 87015502

CONTENTS

Section Description Page

35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 114 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

14
SECTION 35 -- HYDRAULIC SYSTEMS
BOOK 4 - 87015502

Chapter 6 -- Closed Centre Remote Control Valves

CONTENTS

Section Description Page

35 000 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Flow In Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Flow in Raising (Cylinder Extend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Flow in Lowering (Cylinder Retract) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil Flow in Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation of Detent Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation of Two or More Control Valves Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Finding and Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Individual Valve Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Complete Valve Stack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remote Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 35 -- HYDRAULIC SYSTEMS

BOOK 4 - 87015502

Chapter 7 -- Open Centre Remote Control Valves

CONTENTS

Section Description Page

35 000 Specifications --Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
35 204 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

15
SECTION 35 -- HYDRAULIC SYSTEMS
BOOK 4 - 87015502

Chapter 8 -- Trailer Brake Auxiliary Valve

CONTENTS

Section Description Page

SECTION 35 -- HYDRAULIC SYSTEMS

BOOK 4 - 87015502

Chapter 9 -- Assist Ram

CONTENTS

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Senders, sensors & switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Servicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 55 -- ELECTRICAL SYSTEM

BOOK 6 - 87015504

Chapter 6 -- Starting System

CONTENTS

Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 201 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 6 - 87015504

Chapter 7 -- Charging System

CONTENTS

Section Description Page

SECTION 55 -- ELECTRICAL SYSTEM

BOOK 6 - 87015504

Chapter 8 -- BATTERY
CONTENTS

Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 300 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Common Causes of Battery Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

22
SECTION 55 -- ELECTRICAL SYSTEM

BOOK 7 - 87015505

Chapter 9 -- Wiring Diagrams

CONTENTS

Description Page

Wiring diagram circuit descriptions (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How to use the linear wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component identification and wiring diagram location key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wiring Diagrams:
Power Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Range Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Dual Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Shuttle Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Wire identification key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Electrical system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

23
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 7 - 87015505

Chapter 10 -- Component Testing

CONTENTS

Section Description Page

55 000 Thermostart Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water in Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diff. Lock Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4WD Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Transmission Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handbrake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Filter Restriction Switch (open centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PTO Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Forward / Reverse Shuttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clutch Pedal Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Range Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dual Command Lever Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Range Command Lever Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PWM Valves A,B,C,D & E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure Switches -- Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Forward / Reverse Potentiometer -- Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transmission Side Cover Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
40 Degree Switch -- CCLS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Intake Filter Restriction Switch -- CCLS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Low Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Steering Angle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Transmission Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Load Sensing Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EDC Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EDC Raise & Lower Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lift Arm Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Range Clutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Foot Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Engine Torque/RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electronic Draft Control (EDC) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Multi--function Switch, Lights, Indicators, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Multi--function Switch, Wipers and Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

24
SECTION 55 -- ELECTRICAL SYSTEM
BOOK 7 - 87015505

Chapter 11 -- Diagnostic H Routines

CONTENTS

Section Description Page

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Range Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dual Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electronic Draft Diagnostic Test Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 55 -- ELECTRICAL SYSTEM

BOOK 7 - 87015505

Chapter 12 -- Electrical Harnesses

CONTENTS

Section Description Page

5500 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wire Identification and colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lighting Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front Main (Engine) Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Main (Transmission) Harness, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab Main Harness, All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Command Right Hand Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

25
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SECTION 21 -- TRANSMISSION -- CHAPTER 1
SECTION 21 -- TRANSMISSION

Chapter 1 -- Semi--Powershift Transmission (Range Command)

CONTENTS

Section Description Page

21 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS -- SEMI--POWERSHIFT TRANSMISSION AND RANGE GEARS

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--speed with constant--mesh gears
controlled by three independent
clutches.
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 forward ranges and 1 reverse range
for a total of 18 forward and 6 reverse
speeds
-- Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical toothed
-- Reduction ratios:
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 15) : (46 x 55) = 1 : 7.03
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 25) : (46 x 37) = 1 : 2.84
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed and range shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by three buttons located on the control
lever
Shift and range gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced--fed by a gear pump (same as
the power steering circuit pump)
Number of driven discs--Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of driven discs -- Clutch A . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs -- Clutch A 7
-- Thickness of drive discs -- Clutch A . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch A thickness under a load of
163 kg (1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32.7 to 32.9
Number of Belleville springs -- Clutch A . . . . . . . . . . . . . . . . . . mm 9
-- Free spring length -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
-- Compressed spring length under a load of
215 kg (2108 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.28
(to be continued)

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SPECIFICATIONS -- SEMI--POWERSHIFT TRANSMISSION AND RANGE GEARS
Number of driven discs--Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of driven discs -- Clutch B . . . . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch B thickness under a load of 163 kg (1600 N) mm 32.7 to 32.9
Number of Belleville springs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
-- Free spring length -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
-- Compressed spring length under a load of 215 kg (2108 N) mm 3.28
Number of driven discs--Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Thickness of driven discs -- Clutch C . . . . . . . . . . . . . . . . . . . . mm 2.70 to 2.80
Number of drive discs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Thickness of drive discs -- Clutch C . . . . . . . . . . . . . . . . . . . . . mm 1.5
Multi--pack clutch C thickness under a load of 163 kg (1600 N) mm 26.2 to 26.4
Number of Belleville springs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Free spring length -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.1
-- Compressed spring length under a load of 182 kg (1784 N) mm 3.22
Number of driven discs--Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Thickness of driven discs -- Clutches D--E . . . . . . . . . . . . . . . mm 2.70 to 2.80
Number of drive discs -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Thickness of drive discs -- Clutches D--E . . . . . . . . . . . . . . . . mm 1.5
Multi--pack clutches D--E thickness under a load of
163 kg (1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 26.2 to 26.4
Number of Belleville springs -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Free spring length -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . mm 4.1
-- Compressed spring length under a load of 182 kg (1784 N) mm 3.22
PTO drive shaft (7) diameter at the bushing . . . . . . . . . . . . . . . . . mm 31.950 to 31.975
Press--fit bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 to 32.085 ( ° )
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . mm 0.015 to 0.135
Transmission input shaft adjust shim (6) . . . . . . . . . . . . . . . . . . . . mm 3.80 -- 3.85 -- 3.90 --3.95 -- 4.00 --
4.05 -- 4.10 -- 4.15 -- 4.20 -- 4.25 --
4.30 -- 4.35 -- 4.40 -- 4.45 -- 4.50 --
4.55 -- 4.60 -- 4.65 -- 4.70 -- 4.75 --
4.80
Transmission input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . see page 47
Transmission output shaft adjust shim (26) . . . . . . . . . . . . . . . . . . mm 9.80 -- 9.825 -- 9.85 -- 9.875 -- 9.90 --
9.925 -- 9.95 -- 9.975 -- 10.00 --
10.025 -- 10.05 -- 10.075 -- 10.10 --
10.125 -- 10.15 -- 10.175 -- 10.20 --
10.225 -- 10.25 -- 10.275 -- 10.30 --
10.325 -- 10.35 -- 10.375 -- 10.40 --
10.425 -- 10.45 -- 10.475 -- 10.50 --
10.525 -- 10.55 -- 10.575 -- 10.60 --
10.625 -- 10.65 -- 10.675 -- 10.70
Transmission output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . see page 48
Transmission output shaft thrust washer mm . . . . . . . . . . . . . . . . . . . . . . . . 3.95 to 4.00
(°) Final dimension to be obtained without grinding (to be continued)

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SPECIFICATIONS -- SEMI--POWERSHIFT TRANSMISSION AND RANGE GEARS
(continued)
Range gear input shaft bearing adjustment see pag. 48
Range gear input shaft bearing adjust shims (12, Fig. 11) . . . . . mm 1.70 -- 1.75 -- 1.80 --1.85 -- 1.90
--1.95 -- 2.00 -- 2.05 -- 2.10 -- 2.15 --
2.20 -- 2.25 -- 2.30 --2.35 -- 2.40 --
2.45 -- 2.50 -- 2.55 -- 2.60 -- 2.65 --
2.70 -- 2.75 -- 2.80 -- 2.85 -- 2.90 --
2.95 -- 3.00 -- 3.10 -- 3.20 -- 3.30
Range gear output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . see pag. 48
Range gear output shaft adjust shims (14, Fig. 11) . . . . . . . . . . . mm 1.70 --1.75 -- 1.80 --1.85 -- 1.90
--1.95 -- 2.00 -- 2.05 -- 2.10 -- 2.15 --
2.20 -- 2.25 -- 2.30 --2.35 -- 2.40 --
2.45 -- 2.50 -- 2.55 -- 2.60 -- 2.65 --
2.70 -- 2.75 -- 2.80 -- 2.85 -- 2.90 --
2.95 -- 3.00 -- 3.10 -- 3.20 -- 3.30
Low pressure regulation valve spring (9, Fig. 12):
-- Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
-- Compressed spring length under a load of 278 to 304
N (28.4 to 31 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 102.5
Low pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 to 17.6 (17 to 18)
Lubrication pressure regulation valve spring (32, Fig. 11):
-- Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.5
-- Compressed spring length under a load of 37 to 41 N 25.5
(3.8 to 4.2 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 2.7 to 3.4 (2.8 to 3.5)

SPECIFICATIONS -- CREEPER GEARS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic spur gear set
-- Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through a lever on LH side of the
driver’s seat
Creeper housing and driven gear thrust washer thickness . . mm 1.465 to1.535

TIGHTENING TORQUES
Tightening Torques
Thread Torque
size
Bolts and nuts, clutch/transm housing to engine . . . . . . . . . . . . . . . . . . . (see C3 and C4, page 2, Sec. 18)
Bolts, clutch/transm housing to rear axle housing . . . . . . . . . . . . . . . . . M14 x 1.5 176 18
Bolts, cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 1
(continued)
Bolts, clutch front cover (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2,4
Bolts, transmission housing cover (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screws, range rear bearing retaining plate (C3) . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Nut, range output shaft (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M47.5 x 1.5 294 30
Nut, transmission output shaft (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M45 x 1.5 490 50
Screws, damper to flywheel(C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 60to74 6.1to7.5
Screws, range drive piston housing(C7) . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screw, solenoid valve(C8) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 5.4to81 0.55to0.83
Screw, solenoid valve pin(C9) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 47to54 4.8to5.5
Screws, range rear bearing support plate . . . . . . . . . . . . . . . . . . . . . . . . M14 x 1.5 142 14.5
Screws, transmission input shaft cover plate . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4

(*) Apply a couple of drops of New Holland Thread Seal 82995768

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SPECIAL TOOLS
CAUTION
X 293808 Output shaft tool.
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X). 292176 Range input and output shaft end play
To work safely and achieve the best technical results test tool (use with tools nos. 50013 and
with additional savings of time and effort, these 50018).
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated 291525 Transmission and rear axle housing
with the self--made ones for which you will find the alignment pins.
necessary construction drawings and specifications
directly on this Manual. 291051 Range input shaft bearing and gear
puller.
List of special tools necessary to carry out the different
operations described in this Section: X 293869 Output shaft bearing installer (use with
tool no. 50108).
295027 Cab lifting adapter (use with tool no.
290740) 292927 Slide hammer.

290740 Cab lifting hook (use with tool no. X 293975 Clutch C drum bearing adjustment tool.
295027)
293510 Clutch C drum bearing adjustment
290090 Overhaul rotary stand. gauge.

292320 Tractor separation stand. 295021 Clutch spring compressor.

291517 Transmission housing lifting hook. 294035 Pressure test kit (use with tool no.
295024).
293971 Transmission overhaul front bracket
(use with tool no. 290090). 295024 Fitting (kit no. 294035).

293972 Transmission overhaul rear bracket 295047 Adapter (use with tool no. 293975 or
(use with tool no. 290090). 293510).

292888 Clutch cover alignment pins 295049 Range gear output shaft retaining tool.

292906 Drum snap ring installation pliers

293343 Output shaft spanner.

X 293805 Input shaft bearing puller (use with tool

no. 50062).

21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 1

2
Tool to be fabricated for range input and output shaft bearing adjustment (Mark tool with no. 50018 --
Dimensions in mm).
Fabricate tool using Aq 42 material.

21- 6
SECTION 21 -- TRANSMISSION -- CHAPTER 1

3
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 --
Dimensions in mm).
Fabricate tool using UNI C40 material. -- Use only part (a).

25844
4 5
Tool to be fabricated for clutch B circlip Tool to be fabricated for range output shaft bearing
assembly(Mark tool with no. 50115 -- Dimensions in assembly (Mark tool with no. 50061 --
mm). Dimensions in mm).
Fabricate tool using UNI C40 material. Make 3. Fabricate tool using C30 material.

21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 1
Tool to be fabricated for range input shaft
bearing assembly (Mark tool with no. 50060 --
Dimensions in mm.)
Fabricate tool using C30 material.

107
53

6
Bracket to be fabricated to fix the transmission on the
rotary stand. Use with bracket tool no. 293971 (Mark
tool with no. 50110 -- Dimensions in mm).
Fabricate tool using Fe 42 C material.

25290

21- 8
SECTION 21 -- TRANSMISSION -- CHAPTER 1
Tool to be fabricated for input and output shaft bearing
assembly (Mark tool with no. 50108 -- Dimensions in
mm).
Fabricate tool using UNI C40 material.

25291

8
Alignment pins to be fabricated for engine and speed
clutch/transmission housing removal/installation
(Mark tool with no. 50117 --
Dimensions in mm).
Fabricate tool using UNI C40 material.

25292

9
Adapter to be fabricated for reverse idler gear pin
removal (Mark tool with no. 50143 --
Dimensions in mm).
Fabricate tool using UNI C40 material.

25280

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 1

11
Transmission Longitudinal and Cross Sections
1. Damper coupler. 17. Clutch E driven discs.
2. Clutch housing. 18. Clutch E housing.
3. Clutch A drive discs. 19. Clutch E drive discs.
4. Clutch A driven discs. 20. Belleville springs, clutches D and E.
5. Cover plate. 21. Clutch D housing.
6. Transmission input shaft adjust shim 22. Clutch C driven discs.
7. Transmission input shaft. 23. Clutch C drive discs.
8. Clutch D driven discs. 24. Clutch C housing.
9. Clutch D drive discs. 25. Clutch C Belleville springs.
10. Range gear input shaft. 26. Transmission driven gear end play adjust shim
11. Reverse idler gear. 27. Transmission driven shaft.
12. Range input shaft adjust shim. 28. Clutch B Belleville springs.
13. Range output shaft. 29. Clutch A Belleville springs.
14. Range output shaft adjust shim. 30. Range gear and transmission lubrication control line.
15. Medium range and reverse control synchroniser. 31. Valve spring (32).
16. Low and high range control synchroniser. 32. Lubrication pressure regulation valve

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 1

a
b

12
Range Control Valve Assembly Sections and Views
A. Top view. 8. Low pressure regulation valve.
B. Bottom view. 9. Valve (8) spring.
1. Reverse solenoid valve. 10. Pressure sensor.
2. High range solenoid valve. 11. PTO brake solenoid valve.
3. Low range solenoid valve. 12. FWD solenoid valve.
4. Medium range solenoid valve. 13. Circlips.
5. Diff lock solenoid valve. 14. Piston housing.
6. PTO solenoid valve. 15. Range drive pistons.
7. Valve. 16. By--pass valve.

NOTE: During installation apply New Holland liquid gasket, 82995771, on surfaces marked with an X as detailed
on page 46.

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 1

13
SEMI--POWERSHIFT Transmission Control Valve Assembly Sections and Views
C1. SEMI--POWERSHIFT control valve retaining screw, 3. Pressure test port -- Clutch C.
24.5 Nm (2.5 kgm). 4. Pressure test port -- Clutch A.
C2. Solenoid valve pin retaining screw, 14.9 to 20.3 Nm 5. Pressure test port -- Clutch B.
(1.520 to 2.071 kgm). 6. Clutch A control solenoid valve.
C3. Solenoid valve retaining screw, 1.72 to 2.79 Nm 7. Clutch B control solenoid valve.
(0.175 to 0.285 kgm). 8. Clutch C control solenoid valve.
1. Pressure test port -- Clutch E. 9. Clutch D control solenoid valve.
2. Pressure test port -- Clutch D. 10. Clutch E control solenoid valve.

NOTE: Apply a couple of drops of New Holland Thread Seal, 82995768, to screws C2 and C3 .

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 1
DESCRIPTION AND OPERATION
The SEMI--POWERSHIFT transmission is actuated by 1 2
5 wet clutches which allow hydraulic engagement of 6
speed gears or ratios per range. Speed selection is
electronically managed by the Electronic Management
Unit.
Clutch design allows shifting from one speed into
another when the tractor is moving. Clutches are
operated by the control oil from the respective solenoid
valves located into the control valve assembly
attached to the right side of the transmission housing.
3
Shifts from one speed gear or ratio into another is done 25804

using the relevant shift lever located at the right side of

the operator’s seat. 14
There are three buttons on the lever. Buttons (1 and 2)
are located on the rear of the lever and are used for
shifting through all the ratios within the same range.
To shift from one range into another, press one of the
above buttons (1 or 2) while pressing the button (3)
located to the front of the lever.
The range gears are operated by two hydraulic
cylinders acting on two synchronisers. Hydraulic
cylinders are actuated by control oil from the respective
solenoid valves located into the control valve assembly
attached to the right side of the transmission housing.
The transmission and range gear assembly provide:
-- 18 forward and 6 reverse ratios in the 40 KPH
option; 1
-- 31 forward and 12 reverse ratios in the 40 KPH
option fitted with creeper gears;
-- 17 forward and 6 reverse ratios in the 30 KPH
option;
-- 30 forward and 12 reverse ratios in the 30 KPH
option fitted with creeper gears.
The SEMI--POWERSHIFT transmission is not fitted
with a central clutch on the engine flywheel.
Consequently, the clutch pedal should not be pressed 25805
for speed or range shifting.
15
The clutch pedal should be used to stop the tractor,
connect implements and operate the tractor in
restricted areas.

21- 13
SECTION 21 -- TRANSMISSION -- CHAPTER 1

Trapped oil

Pressure oil

Lubrication pressure oil

16
SEMI--POWERSHIFT Transmission Oil Flow with 1st Gear Forward Engaged
When the 1st gear or ratio is selected using the control Pressure oil lubrication is fed to all the
buttons (1 and 3, Fig. 13), the solenoid valves (6 and SEMI--POWERSHIFT transmission components. Oil
8, Fig. 12) direct oil from the hydraulic pump to clutches pressure is regulated by the valve (2, Fig. 10).
A and C, respectively. If the clutch pedal is pressed, the solenoid valves (6
Oil reaches the pistons (1 and 3), moves them against and 8) stop sending oil to the clutches A and C and
the force of the Belleville springs (2 and 4, respectively) consequently pistons (1 and 3) are pushed away from
and compresses the two clutches A and C. The 1st the clutch discs by the action of the Belleville springs
gear or ratio is engaged. (2 and 4). Clutches are then released.

21- 14
SECTION 21 -- TRANSMISSION -- CHAPTER 1

Trapped oil

Pressure oil

Lubrication pressure oil

17
SEMI--POWERSHIFT Transmission Oil Flow with 6th Gear Forward Engaged
When the 6th gear or ratio is selected using the control Pressure oil lubrication is fed to all the
buttons (1 and 3, Fig. 13), the solenoid valves (7 and SEMI--POWERSHIFT transmission components. Oil
10, Fig. 12) direct oil from the hydraulic pump to pressure is regulated by the valve (32, Fig. 10).
clutches B and E, respectively. If the clutch pedal is pressed, the solenoid valves (7
Oil reaches the pistons (2 and 4), moves them against and 10) stop sending oil to the clutches B and E and
the force of the Belleville springs (1 and 3, respectively) consequently pistons (2 and 4) are pushed away from
and compresses the two clutches B and E. The 6th the clutch discs by the action of the Belleville springs
gear or ratio is engaged. (1 and 3). Clutches are then released.

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT
TRANSMISSION HOUSING

Removal -- Installation (Op. 21 111 10)

DANGER
Lift and handle all heavy components using lifting
equipment of appropriate [Link] that units or
parts are supported by suitable slings or [Link]
that no--one is in the vicinity of the load to be lifted.

Remove the transmission housing from the tractor as

follows:

1. Open and raise engine hood.

2. Detach the negative cable (1) from the battery and
insulate.

1
3. Connect the engine hood to a hoist using a nylon
cable (1) and disconnect the struts (2) (one on the
LH side and one on the RH side).

2
4. Loosen the screws (3) which retain engine hood to
engine, disconnect front light electrical connector
and remove hood using the hoist. Ensure that the
hood is displaced without obstructions and that no
other components are interfering.

23353

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Unscrew the retaining screws and remove side
panels (1) (one on each side).

4
6. Jack up rear tractor and place two suitable stands
(2) under the final drive cases to raise the wheels
off the ground. If necessary, detach lift rods from
lower links.

5
7. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the left wheel.

6
8. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect tool to a hoist using hook tool no. 290740
and keep hook tensioned.

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 1
9. Detach connectors at the washer motor. Detach
windscreen washer bottle (1) lines and remove
tank.

8
10. Remove the clip and detach the creep gear control
idler lever (2). Loosen the parking brake control
cable retaining screw (3).

9
11. Remove the pin and withdraw the pin securing the
fork (4) to the parking brake actuator lever. Loosen
the nut securing the cable to the fork (4) and
release cable.

10
12. Loosen the attaching nut and detach the ground
cable (5) between the cab and rear axle.

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 1
13. Release the clamp (1) and detach the main tank
bleeding line.

12
14. Detach the ground synchronised PTO control
cable (2) from the rail.

13
15. Detach the two connectors (3 and 4) located under
the cab floor.

14
16. Detach both engine to cab connectors (5 and 6).

21- 19
SECTION 21 -- TRANSMISSION -- CHAPTER 1
17. Disconnect radar and fuel filter connectors (4 and
3, respectively). Remove protection and
disconnect connectors (1 and 2) from starting
motor.

16
18. Detach light connector (5) located on the handrail
(repeat for both tractor sides).

17
19. Detach heater to engine connecting lines (6)
located under the right hand front side of the cab.

18
20. Loosen the nut and detach the throttle control cable
(7) from injection pump.

21- 20
SECTION 21 -- TRANSMISSION -- CHAPTER 1
21. Detach connectors (1) from brake master
cylinders.
22. Loosen fittings (2) and detach brake control hoses.
23. Detach the line to the master cylinder reservoir.

20
24. Loosen the power steering valve connecting lines
(4) to the control pump.

21
25. Detach the power steering valve connecting lines
(5) to the steering cylinders.

22
26. Loosen fittings and detach the air conditioning lines
(6).

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 1
27. Loosen the locknut, slide out the cotter pin and
detach the PTO control cable (1).

24
28. Remove pins (2), loosen the retaining screws (3)
and detach the auxiliary valve control cables, right
hand side.
29. If auxiliary valves are fitted also on left hand side,
repeat step 28 for left hand side auxiliary valves.

25
30. Loosen the screw attaching steps (6) to the
bracket.

26
31. Loosen the screw attaching steps (1) to the cab
platform.
32. Repeat steps 30 and 31 on opposite side and
remove steps.

21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 1
33. Raise the cab mat (2) and loosen the cab mounting
bolt while holding the locknut under the cab floor.
Retrieve bolt and washer. Repeat for both tractor
sides.

28
34. Loosen the rear cab bolts (on both sides).
35. Slowly raise the cab taking care that no
components are connected, hooked or interfering.
Remove the cab and lower on a suitable support
base.

29
36. Loosen the plug (3) and drain oil from the rear axle
and transmission housing into a suitable container.

30
37. Drain fuel tanks, then loosen the clamp (1)
retaining the connecting line between the main and
auxiliary tanks.

21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 1
38. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
39. Detach the fuel return line (2) from the injection
pump to the auxiliary tank. Remove auxiliary tank.

32
40. Loosen the clamp and detach the injection pump
supply line (5). Detach connectors (4), then
unscrew and remove the fuel level sensor
assembly.

33
41. Loosen the nut of the metal strap (6) securing the
main tank. Remove the strap and tank.

34
42. Loosen the retaining screws and remove the cab
and fuel tank support bracket (1). (Repeat on both
sides of the speed clutch--transmission housing).

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 1
43. Loosen the retaining screws and remove the main
tank support bracket (2)

36
44. Loosen the attaching screws and remove the radar
unit and mounting bracket (3).

37
45. Loosen the attaching screws and remove the brake
control line bracket (4).
NOTE: Do not bend the brake control tubes sharply
when moving them away from the transmission
housing to avoid damages.

38
46. Loosen the clamps and separate the rear axle oil
cooler hoses (1) from tubes.

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 1
47. Detach and remove the accumulator (2) tubes,
loosen the retaining screws and remove
accumulator.

40
48. Detach all connectors from the range control valve
assembly, SEMI--POWERSHIFT clutch control
valve assembly and different sensors.
NOTE: Before detaching connectors from both control
valve housings, mark each connector and respective
solenoid valve to assist reassembly and avoid reversal
of connections.

41
49. Detach and remove the PTO and lift lubrication
valve (3) and by--pass valve (4) lines.

42
50. Detach and remove the power steering supply and
return lines (1 and 2).

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 1
51. Disconnect all accessory control lines from their
fittings located in the lower part of the range control
valve assembly (3).

44
52. Loosen retaining screws and remove the range
control valve housing (3) using two alignment pins.

45
53. Detach hose from the by--pass valve (4).
54. Disconnect and remove the clutch A control line
(5).

46
55. Release retaining screws and remove the
SEMI--POWERSHIFT control valve assembly (1).

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 1
56. Loosen the retaining screws and remove the
propshaft guard.
57. Remove circlip (4) and slide out sleeve (5). Repeat
for transfer box circlip and sleeve.

48
58. Loosen the bearing--support (3) retaining screws
at the transmission housing, detach and remove
the front diff lock control line (2).

49
59. Place stand tool no. 292320 with one of the two
trolley jacks (6) under the engine and the other
under the transmission housing.
60. Place two wooden wedges (one each side)
between the front axle support and front axle to
prevent engine oscillation.

50
61. Loosen the retaining screws and remove starting
motor (1).

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 1
62. Remove the transmission housing to engine
attaching bolts.

52
63. Loosen the metal spacer retaining screw (2) at the
transmission housing.
64. Separate the engine from the transmission
housing.

53
65. Loosen two bolts from the transmission housing
top cover (3), screw in chains of hook tool no.
291517 to the housing and keep them tensioned
using a hoist.
66. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool no.
292320 under the rear axle housing.
67. Detach the transmission housing retaining bolts
and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.
54
68. Reinstall the transmission housing to the rear axle
housing and engine observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 67 back to step 1.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 30.
-- Tighten to correct torques as detailed on page
3.

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 1

20270

55
Pattern for application of sealant during installation of the speed clutch--transmission housing to rear axle housing.

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT TRANSMISSION

Disassembly--Reassembly (Op. 21 111 85)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Prior to servicing the SEMI--POWERSHIFT

transmission, it is necessary to remove the
transmission housing following the procedure detailed
on pages 16 to 29.
1. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets, tools
nos. 293971 (1) and 293972 (2), respectively.
2. Perform steps 3 to 5 to remove the range and
transmission control valve assemblies, if not
previously removed.

1
3. Detach the line (3) from transmission control valve
assembly and transmission housing.

2
4. Loosen the transmission control valve housing
retaining screws (4) and remove housing

21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Withdraw control lines (3) of clutches B, C, D and
E and discharge fitting (1). Loosen and remove
clutch A control line (2).

4
6. Loosen retaining screws and remove the range
control valve assembly (1) using a 80 mm long bolt
as an alignment pin.

5
7. Loosen retaining screws and slide the guard (5) to
one side by a few centimetres, along the wires

6
8. Remove retaining rings and washers. Slide out
sensors (6).

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 1
9. Loosen retaining bolts and remove sensors (1 and
2).

8
10. Loosen retaining bolts and detach cover (6).

9
11. Loosen the bolts attaching the clutch A cover (3) to
the transmission housing. Insert three bolts (4) into
the threaded holes and screw them in until
detaching the cover (3) along with clutch A from the
transmission housing.

10
12. Remove circlip (5) and retrieve clutch discs and
centering springs.

21- 33
SECTION 21 -- TRANSMISSION -- CHAPTER 1
13. Assemble tool no. 295021 (6) on clutch B housing,
turn the tool bolt to compress clutch B release
Belleville springs and remove spring retaining ring.
Remove tool from the bell housing and retrieve
Belleville springs.
14. Blow compressed air into the oil supply hole to
clutch B to expel the clutch drive piston.

12
15. Remove the retaining ring (1) and withdraw the
clutch B housing.

13
16. Loosen the cover (1) retaining screws, place tool
no. 295049 (2) on the transmission housing,
loosen the output shaft locknut using spanner tool
no. 293343 (3) and retrieve cover.

14
17. Remove retaining bolts and detach the range gear
output and input shaft bearing cap (1).

21- 34
SECTION 21 -- TRANSMISSION -- CHAPTER 1
18. Using a puller tool no. 291051 (1) and a suitable
insert, remove the medium range driven gear,
bearing and bush.

16
19. Using a puller (2) and suitable support insert,
remove the medium range drive gear, bearing and
bush.

17
20. Loosen the plugs (3) and retrieve springs and
actuating balls. Remove plug from the
transmission housing and withdraw the medium
and reverse control fork lock pin.

18
21. Slide out the range selector dog (4) retaining spring
pins and remove rails.

21- 35
SECTION 21 -- TRANSMISSION -- CHAPTER 1
22. Remove the medium and reverse control fork (1)
along with the synchroniser (2).

20
23. Remove the reverse driven and drive gears (3 and
4, respectively).

21
24. Loosen the reverse idler gear shaft setscrew (5).

22
25. Mount adapter tool no. 292313 (7) and slide puller
tool no. 292927 (6) on the reverse idler gear shaft
(8).

21- 36
SECTION 21 -- TRANSMISSION -- CHAPTER 1
26. Slide out the low range driven gear (1).

24
27. Remove the low and high range control fork (4),
synchroniser (3) and output shaft (2).

23476

25
28. Remove input shaft (5).

26
29. Remove the position sensor control forks (6).
Retrieve bushings and seals at the outside of the
transmission housing.

21- 37
SECTION 21 -- TRANSMISSION -- CHAPTER 1
30. Loosen the retaining screws and remove the front
cover plate (1).

28
31. Slide out the drive gear (2) and bearing. (3).

29
32. Remove the ring (4) retaining the gears on the input
shaft.

30
33. Slide out the input shaft (5) with the bearing inner
races from the opposite side of the housing.
Retrieve gears, thrust washer and adjustment
shim.

21- 38
SECTION 21 -- TRANSMISSION -- CHAPTER 1
34. Install tool no. 293808 (1) on the output shaft, insert
a spanner (2) to hold the shaft in position, screw
tool no. 293805 (3) to the housing and tighten the
tool screw to support the tool.

32
35. Unstake and loosen the nut, retrieve the bush and
Belleville spring.

33
36. Withdraw the manifold (4) and bearing thrust
washer from the output shaft. Detach tool no.
293805 (3), spanner (2) and tool no. 293808 (1)
from rear side.

34
37. Remove the output shaft (5) seals and, using an
aluminium punch and a hammer, partially remove
the shaft.

21- 39
SECTION 21 -- TRANSMISSION -- CHAPTER 1
38. Turn the transmission housing upright, withdraw
the output shaft (1) and retrieve the
clutch/gear/bearing assembly along with the
bearing.

36
39. Loosen the lubrication oil fitting (2) and retrieve
inner bush.

37
40. Detach the fitting from the housing and slide out the
lubrication line from the inside of the transmission
housing.

38
41. Dismantle the clutch C by removing the circlip (3)
and collecting the clutch driven and drive discs.

21- 40
SECTION 21 -- TRANSMISSION -- CHAPTER 1
42. Fix tool no. 295021 (1) to the clutch bell housing,
screw in the tool bolt until compressing the
Belleville springs, then remove the spring retaining
ring. Loosen tool bolt, retrieve Belleville springs
and detach tool from the clutch bell housing.

40
43. Screw two bolts into the threaded holes in the
piston (2), then withdraw piston pulling it out using
the bolts.
44. Repeat steps 40 to 42 to disassemble clutches D
and E.

41
45. Remove the retaining ring (1), the bearing inner
lock ring and retrieve the hubs of the clutches A and
B along with the bearing and clutch A discs and
centering springs.

42
46. Remove seal (3).

21- 41
SECTION 21 -- TRANSMISSION -- CHAPTER 1
47. Remove the outer (4) and inner circlips from the
outside of clutch A (5), withdraw clutch A from the
cover. Retrieve the bearing.

44
48. Position tool no. 295021 (6) on clutch A (5), turn the
tool bolt to compress the clutch release Belleville
springs and remove the retaining ring.
Disassemble tool no. 295021 (6) and retrieve
Belleville springs.

45
49. Place the clutch A housing on the cover (2), blow
compressed air into the control oil inlet hole and
remove the piston (1).

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

50. Reinstall the SEMI--POWERSHIFT transmission

into the transmission housing observing the
following:
-- Reinstallation follows the removal procedure in
reverse, from step 49 back to step 1.
46
-- Refer to figures on pages 10, 11, and 12 for
correct orientation of the different parts.
-- Ensure the housing is thoroughly cleaned
(especially inner compartments).
-- Check seals and replace if damaged.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 46.
-- Tighten to correct torques as detailed on page
3.
-- Carry out following operations and
adjustments as detailed on pages 47 to 50.

21- 42
SECTION 21 -- TRANSMISSION -- CHAPTER 1
51. Assemble retaining tool no. 293808 (1) on the
transmission output shaft, insert a spanner (3) to
hold it and support tool (1) by attaching tool no.
293805 (2) to the housing.

47
52. While assembling clutches C, D, and E and their
shafts to the transmission housing, take care to
match reference marks (1).

48
53. Install front bearing (7) using tools no. 50108 (6)
and 293869 (5).

49
54. After installing the details of the output shaft, lock
the shaft with the nut. Temporarily install the front
cover (9) and insert the three clutch control lines
(8).

21- 43
SECTION 21 -- TRANSMISSION -- CHAPTER 1
55. Blow compressed air into the lines (1) and check
for correct operation of the clutches C, D, and E.
After this test, remove lines (1) and detach front
cover. Install the input shaft complete with its
accessory parts. After installing the front cover and
tightening attaching bolts, perform again the above
test to check that there are no leaks from the
manifold.

51
56. Upon reassembly of the clutch A, install the bearing
(1), then raise the hub (8) using a suitable tool and
insert the circlip (10).

52
57. While reinstalling the circlip (1) on to the clutch
cover (8), check that the oil leak--off hole (7) is
exactly in the middle of the outer circlip ends.

53
58. To assist assembly of clutch B disc retaining ring,
insert two suitable dowels (1) into two oil discharge
holes to keep the clutch centering springs
compressed.

21- 44
SECTION 21 -- TRANSMISSION -- CHAPTER 1
59. Using an expanding puller tool no. 292906 (5),
position tool no. 50018 (3) with three legs tool no.
50112 (2) (see page 6). Turn the puller screw and
position the clutch disc retaining ring into its seat.

55
60. With the clutch A housing assembled to the
transmission housing, install the bearing (7) using
tool no. 293869. Fix bearing with the retaining rings
and install the seal.

56
61. Heat and install the bearing (3) on to the input shaft
using tool no. 50060 (2) shown on page 8. Using
tool no. 50013 (1) (see page 7), keep the bearing
properly seated against the gear during cooling.

57
62. Heat and install the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 7.
Using tool no. 50018 (1) (see page 6), keep the
bearing properly seated against the gear during
cooling.
NOTE: Remove tools nos. 50060 (2, Fig. 57) and
50061 (2, Fig. 58) when the bearings (3 and 1) have
completely cooled down.

21- 45
SECTION 21 -- TRANSMISSION -- CHAPTER 1

59
Pattern for application of sealant during installation of: range control valve housing, top cover, front cover of
clutches A and B.

21- 46
SECTION 21 -- TRANSMISSION -- CHAPTER 1
TRANSMISSION HOUSING

Transmission input shaft end play adjustment

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
63. Place the transmission input shaft (1) on a bench,
slide on the gear (6), spacer (5), a 3.5 mm test shim
(4), gear (3). Lock the assembly with a circlip (2).
64. Settle the assembly. Using a feeler gauge (7),
measure the end play between the circlip (2) and
gear (3).
65. Shim to be assembled is given by the measured
dimension plus the test shim minus the specified
end play.

Example:

Gauge reading:= 0.90 mm

Test shim:= 3.50 mm 60
Specified end play= 0 to 0.15 mm
Shim to be assembled: = 0.90 + 3.50 -- 0.10 = 4.30
mm.
NOTE: Available adjust shims are detailed on page 2.
66. Remove circlip (2), withdraw the gear (3) and test
shim (4). Add shim (8) as previously found, gear (3)
and lock the assembly with the circlip (2).
67. Settle the assembly. Using a feeler gauge (7)
check that end play is to specification.

21- 47
SECTION 21 -- TRANSMISSION -- CHAPTER 1
TRANSMISSION HOUSING

Transmission driven gear bearing adjustment

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
68. Place tool no. 293975 (6) in a vice, add bearings (2
and 5), spacer (4), test shim (3), tool no. 295047 (1)
and tighten the tool nut(6).
69. Using a depth gauge, measure the distance (L1)
between end of tool no. 293975 and top of the tool 62
retaining threaded pin. Dismantle the assembly.
70. Insert the two bearings (2 and 5), gear (7), tool no.
295047 (4) on tool no. 293975 (6) and tighten the
tool nut (6). Using a depth gauge, measure the
distance (L) between the end of tool no. 293975
and top of the tool retaining threaded pin.
71. Adjust shim to be assembled is given by:
S = L -- L1 + P -- 0.05 mm
where
S = Adjust shim to be assembled
L and L1 = Readings on tool no 293975.
P = Test shim.
0.05 mm = Decrease necessary to compensate
for bearing increased load deriving from tightening
of the transmission output shaft locknut
63
If necessary, round off the value (S) to the previous
0.025 mm.
Example:
Reading L = 18.50 mm
Reading L1 = 11.30 mm
Test shim = 3.00 mm
Adjust shim to be assembled
S = 18.50 -- 11.30 + 3.00 -- 0.05 = 10.15 mm.
NOTE: Available adjust shims for the
SEMI--POWERSHIFT transmission driven gear are
listed on page 2.

21- 48
SECTION 21 -- TRANSMISSION -- CHAPTER 1
TRANSMISSION HOUSING

Range input and output shaft taper bearing

adjustment
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
72. Install cover (2) without adjust shim. Install tool no.
50013 (1) on to the input shaft (see page7).

65
73. Screw installer tool no. 292176 (2) on tool no.
50013 (3). Place a dial indicator (1) with the stylus
touching the bearing inner race. Turn the shafts to
settle the bearing rollers, reset dial to zero ensuring
that the assembly is bottoming. Through the lever
of installer tool no. 292176 (2). bring the assembly
to touch the cover (4) and read the travel (L) on the
dial indicator.
Adjust shim to be added is given by:
S = L -- (0 to 0.06 mm)
where:
S = Test shim.
L = Travel reading.
0 to 0.06 mm =Input shaft bearing end play.
66
NOTE: Available adjust shims for the range input shaft
bearings are listed on page 3.
74. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 73 to
check that end play is to specification, 0 to 0.06
mm.
Remove tools (2 and 3).

21- 49
SECTION 21 -- TRANSMISSION -- CHAPTER 1
75. Install disc (1) with a test shim (Sp). Remove
output shaft lubrication [Link] tool no.
50018 (4) (see on page 6), installer tool no. 292176
(3) and dial indicator (2). Ensure indicator stylus is
located on the bearing inner race.
Ensure indicator stylus is located on the bearing
inner [Link] the shafts to settle the bearing
rollers and reset the indicator ensuring that the
assembly is [Link] the lever of installer
tool no. 292176 (3) bring assembly to touch the
disc (1) and read travel (H) on the dial indicator.
Shim to be assembled is given by:

S1 = H + Sp -- (0 to 0.06 mm)
67
where:
S1 = Adjust shim.
Sp = Test shim.
H = Travel reading.
0 to 0.06 mm = Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 3.
76. Dismantle tools (3 and 4), remove disc (1), replace
test shim (Sp) with adjust shim (S1), reinstall disc
(1) and tools (3 and 4). Repeat step 75 to check that
end play is to specification, 0 to 0.06 mm. Remove
tools (3 and 4) and screw in the output shaft
lubrication plug.

21- 50
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT RANGE CONTROL
VALVE ASSEMBLY

Removal -- Installation (Op. 21 133 30)

DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity.
Ensure that units or parts are supported by suitable
slings or hooks.
Ensure that no--one is in the vicinity of the load to be
lifted.

Remove the SEMI--POWERSHIFT range control valve

assembly as follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Loosen the screw attaching the steps (6) to the
bracket.

2
4. Loosen the screw attaching the steps (1) to the cab
platform.

21- 51
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Drain fuel tanks, then loosen the clamp (1)
retaining the fuel line between the main and
auxiliary tanks.

4
6. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
7. Detach the fuel return line (2) from the pump to the
auxiliary tank. Remove the auxiliary tank.

5
8. Detach and remove the accumulator (2) tubes.
Loosen the retaining screws and remove
accumulator.

6
9. Detach all connectors from the range control valve
assembly and sensors.
NOTE: Before detaching connectors from the control
valve housing, mark each connector and respective
solenoid valve to assist reassembly and avoid reversal
of connections.

21- 52
SECTION 21 -- TRANSMISSION -- CHAPTER 1
10. Loosen retaining screws and remove accumulator
(1).

8
11. Disconnect all accessory control lines from their
fittings located in the lower part of the range control
valve housing (2).

9
12. Loosen PTO and lift lubrication line fittings (3 and
4), loosen retaining screws and remove the
SEMI--POWERSHIFT range control valve
assembly (3) using two alignment pins.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

10
13. Reinstall the SEMI--POWERSHIFT range control
valve assembly to the transmission housing
observing the following:
-- Reinstallation follows the removal procedure
in reverse, from step 12 back to step 1.
-- Before reassembling the
SEMI--POWERSHIFT range control valve
assembly thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 46.
-- Tighten to correct torques as detailed on page
3.

21- 53
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT RANGE CONTROL
VALVE ASSEMBLY

Disassembly--Reassembly (Op. 21 133 32)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To overhaul the SEMI--POWERSHIFT range control

assembly it is necessary to remove it from the
transmission housing following the
removal--installation procedure described on pages 51
to 53.
1. Loosen the screw (1) and remove the diff lock
solenoid valve (2).

1
2. Loosen the fitting (3). Loosen plug on opposite
side.

2
3. Retrieve the pressure regulation valve (4) and
spring (5).

21- 54
SECTION 21 -- TRANSMISSION -- CHAPTER 1
4. Loosen the fitting (1) and retrieve the by--pass
valve.

4
5. Remove the FWD pressure sensor (2).

5
6. Loosen retaining screws and remove the range
drive pistons (3).

6
7. Loosen the oil suction valve for the power steering
circuit (for when the engine is shut--off) and all
solenoid valves.

21- 55
SECTION 21 -- TRANSMISSION -- CHAPTER 1
8. Remove the retaining ring (1). Remove the sliding
guide cover, inner ring and piston.

8
9. Using a suitable punch, drive out the inner retaining
ring (2) and retrieve inner ring.

9
10. Range drive piston components.
NOTE: If it is necessary to replace the seals (3) and
back--up rings, insert them in as fast as possible to
prevent bending. Wait 15 minutes before installing the
piston into the bore.
11. Reassemble the SEMI--POWERSHIFT range
control valve assembly observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 10 back to step
1.
-- Refer to figures on page 11 for correct
orientation of different components.
-- Ensure all components are thoroughly
cleaned. 10
-- Check seals and replace if damaged.
-- Tighten to correct torques as detailed on page
3.

21- 56
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT RANGE CONTROL
SOLENOID VALVE

Replacement(Op. 21 133 72)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Replace one of the solenoid valves from the

SEMI--POWERSHIFT range control valve assembly
as follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Detach connector (1) from the solenoid valve.

2
4. Loosen the retaining nut (2) and remove the
solenoid (3).

21- 57
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Unscrew the pin (1) and remove.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

6. Reinstall the solenoid valve into the

SEMI--POWERSHIFT range control valve
assembly observing the following:
-- Reinstallation follows the removal procedure
in reverse, from step 5 back to step 1.
-- Check seals and replace if damaged.
-- Tighten to correct torques as detailed on page
3. 4

21- 58
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT TRANSMISSION
CONTROL VALVE ASSEMBLY

Removal--Installation(Op. 21 133 40)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the SEMI--POWERSHIFT TRANSMISSION

control valve assembly as follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Loosen the screw attaching the steps (6) to the
bracket.

2
4. Loosen the screw attaching the steps (1) to the cab
platform.

21- 59
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Drain fuel tanks, then loosen the clamp (1)
retaining the fuel lines between the main and
auxiliary tanks.

4
6. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
7. Detach the fuel return line (2) from the pump to the
auxiliary tank. Remove the auxiliary tank.

5
8. Detach all connectors (4) from the
SEMI--POWERSHIFT clutch control solenoid
valve assembly.
NOTE: Before detaching connectors from the control
valve housing, mark each connector and respective
solenoid valve to assist reassembly and avoid reversal
of connections.

6
9. Disconnect lines (5 and 6), loosen retaining screws
and remove the control valve housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

10. Reinstall the SEMI--POWERSHIFT control valve

assembly observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 9 back to step 1.
-- Tighten to correct torques as detailed on page
12.
7

21- 60
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SEMI--POWERSHIFT TRANSMISSION
SOLENOID VALVE

Replacement (Op. 21 133 70)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Replace one of the solenoid valves from the

SEMI--POWERSHIFT transmission control valve
assembly as follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Loosen the screw attaching the steps (6) to the
bracket.

2
4. Loosen the screw attaching the steps (1) to the cab
platform.

21- 61
SECTION 21 -- TRANSMISSION -- CHAPTER 1
5. Drain fuel tanks, then loosen the clamp (1)
retaining the fuel line between the main and
auxiliary tanks.

4
6. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
7. Detach the fuel return line (2) from the pump to the
auxiliary tank. Remove the auxiliary tank.

5
8. Detach connector (4) from the solenoid valve to be
replaced.

6
9. Unscrew the locknut (6) and remove solenoid (5).

21- 62
SECTION 21 -- TRANSMISSION -- CHAPTER 1
10. Unscrew the pin (1) and remove.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

11. Reinstall the solenoid valve into the

SEMI--POWERSHIFT transmission control valve
assembly observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 10 back to step 1.
-- Check seals and replace if damaged.
-- Tighten to correct torques as detailed on page
12. 8

21- 63
SECTION 21 -- TRANSMISSION -- CHAPTER 1
NOTES

21- 64
SECTION 21 -- TRANSMISSION -- CHAPTER 2
SECTION 21 -- TRANSMISSION

Chapter 2 -- Range Command Transmission

Calibrations, Fault Finding, Pressure Testing And Limp Home

CONTENTS

Section Description Page

21 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Error Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Limp Home Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 2
Introduction Refer to Section 55 for complete wiring diagrams.
Where the fault finding procedure requires checks for
continuity a visual inspection of the wiring should be
Error Codes and Fault Finding
made prior to conducting tests to ensure that obvious
The transmission electronic management system has ‘mechanical’ damage has not occurred to the harness
an inbuilt self diagnostic facility. This facility utilises the or the connectors.
digital display of the gear shift handle assembly to
A good quality multi--meter is an essential item to
indicate, in coded format, any malfunction in the
perform fault finding. It should be capable of measuring
electrical and electronic circuitry and in the
resistance of at least 20,000 ohms and measuring
micro--processor. It should be noted that the self
voltage and current. When using the multi--meter it is
diagnostic capability is generally limited to diagnosis of
good practice to select a high range and work
the electrical and electronic circuitry and related
downwards to avoid damaging the instrument.
components, however, there are some codes, which
can be generated if pressure switch circuits are not IMPORTANT: Care should be used when using the
closed because of an actual lack of hydraulic pressure. multi--meter, only use the instrument as instructed to
Any malfunction of the mechanical and hydraulic avoid damage to the internal elements of the
components must be diagnosed using conventional micro--processor. When checking the continuity of
techniques, performance characteristics and tooling, wiring, sensors or switches it is necessary to isolate the
such as pressure testing equipment. electronic micro--processor and ensure the keystart is
turned off to prevent possible further damage. The
Trouble--shooting and fault finding should always be
keystart should only be switched on and the processor
carried out in a logical and planned sequence, many
connected where specifically instructed in the fault
apparent faults associated with electronic components
finding procedure.
are often hastily diagnosed and result in the
replacement of expensive components. An extra few If it is found necessary to clean the connectors a
minutes confirming the apparent fault will result in a contact spray should be used. DO NOT USE ANY
more positive and cost effective repair. OTHER METHOD FOR CLEANING TERMINALS. Do
not use a cleaner that contains Trichloro--ethylene, this
With the use of micro--processors it is often that this
solvent will damage the plastic body of the connector.
item is blamed for any malfunction but the real truth is
It is preferable to use a cleaner with a Freon T.F. base.
that this item is usually sound and that the fault is due
to poor contacts in the associated connectors.
Each electrical connector illustrated and identified in
the wiring diagrams in Section 55 and referred to in the
following fault finding procedure, has the same
identification reference. For example, the main
transmission processor connectors are referred to as
Connectors C100 and C101 in the illustration and also
referred to as C100 and C101 in the fault finding
procedure. Often in the fault finding flow chart the
connector and pin are abbreviated and will read, for
example, C100--21. The C100 refers to the connector
and the 21 to the pin number. Alternatively, for
connectors with fewer pins, the identification will read,
C014--FM3100--B/G/S. This is broken down as
follows:
C014 Connector number TA60--21--014
FM3100 Front Main harness, circuit number 3100
1
B/G/S Wire colour

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES -- RANGE COMMAND
ERROR DISPLAY LOGIC
1. Errors are displayed on the liquid crystal display
portion of the gear shift and display assembly. A
Power Command transmission error code is
prefixed with an ‘F’.
2. Error codes always flash.
3. There are four types of errors: Disabling, “N”, “CP”,
and Hidden.
4. Disabling erros disable the transmission
permanently (until the next power-up).
TA11

2
5. Disabling and hidden errors are accompanied by a
steady alarm for 5 seconds. After 5 seconds, the
error code continues flashing on the LCD, but the
alarm stops. If the error clears during the 5 second
period, the alarm will stop when the error clears,
and the LCD will return to normal display.
6. If there are multiple disabling or hidden errors to
display, they will be displayed sequentially.
Example, for codes F2A, F2b and F2C:
LCD: | F2A------ | F2b------ | F2C------ | F2A | F2C
| F2A |
Time: | 5 sec | 1 s | 5 sec | 1 s | 5 sec | 1s | 5 sec
| 5 sec | 5 sec | 5 sec | etc... TA11
Alarm: |steady |off|steady |off|steady |off|
3
off--------------------------------------
NOTE: The display sequence may not always start
with the lowest error number, and the errors may not
be displayed in numerical order at first. There is some
“randomness” depending on the exact timing and
sequence of events.
7. “N” and “CP” errors are accompanied by a pulse
alarm and require action from the driver. The alarm
will continue and the transmission is disabled until
the driver takes action.
“CP” can be cleared by cycling the clutch pedal. In
some cases, “CP” can also be cleared by cycling
the shuttle lever.
“N” can be cleared by shifting the shuttle lever to MM7
neutral. 4

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 2
“N” and “CP can result from improper action by the
driver, or they can result from faults in the system
which require action from the driver to re-start
operation.
8. Normal error display mode:
If there are any disabling errors, only disabling
errors will be displayed.
If there are no disabling errors and at least one “N”
error is active, “N” will flash.
If there are no disabling errors and no “N” errors,
and at least one “CP” error is active, “CP” will flash.
Hidden errors will not be displayed.
5
9. Hd in the diagnostic menu will enable “display all
errors” mode. Also, a new module (or an old
module after the memory has been reset using H8)
will automatically be in “display all errors” mode
until there are no errors to display for 6 minutes.
The six minutes must be during one power-on
cycle, i.e. turning off the key switch zeros the timer.

6
If there are any disabling errors, ALL errors will be I
displayed sequentially. “N” and “CP” will not be
displayed; instead, the error codes associated with
the “N” or “CP” fault will be displayed.
If there are no disabling errors and there is at least
one “N” error, the first “N” error will be displayed.
The display will alternate at one second each
between “N” (to tell the driver what to do) and the
associated error code (to assist with trouble
shooting).

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 2
If there are no disabling errors or “N” errors, and
there is at least one “CP” error, the first “CP” error
will be displayed. The display will alternate at one
second each between “CP” (to tell the driver what
to do) and the associated error code (to assist with
trouble shooting).
If there are no disabling errors, “N” errors, or “CP”
errors, any hidden errors will be displayed
sequentially.

8
A new module, or an old module after the memory
has been reset using H8, will automatically be in
“display all errors” mode until there are no errors to
display for 6 minutes. The six minutes must be
during one power-on cycle, i.e. turning off the key
switch zeros the timer. After six minutes with no
errors, the module switches automatically to
normal error display mode, and all stored error
codes are erased.

21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 2
Error Code Listing
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
F02 Fast/Slow Synchro -- bad calibration value in NVM or not cali- 42 Enabled
brated
F03 M/R Synchro -- bad calibration value in NVM or not calibrated 41 Enabled
F11 Inching pedal potentiometer undervoltage 14 & Disabled Pulse
71 Enabled
F12 Inching pedal potentiometer overvoltage 13 & Disabled Pulse
70 Enabled
F13 Upshift and downshift switches both closed 78 Enabled
F20 Synchroniser did not engage -- range shift 23 Enabled
F21 Coils disconnected -- Limp home or harness error 1 Disabled
F22 Synchroniser did not disengage -- range shift 24 Enabled
F23 Creeper engaged, speed or gear to high 35 Enabled
F24 All clutches/synchronisers need calibration 11 Disabled
F27 ERPM to low -- circuit open or short 60 Enabled
F31 Synchroniser did not engage -- shuttle shift 19 Disabled Pulse
F32 Synchroniser did not engage after power up 20 Disabled Pulse
F33 Synchroniser did not disengage -- shuttle or neutral 21 Disabled Pulse
F34 Synchroniser did not disengage after power up 22 Disabled Pulse
F35 Failed to engage previous range after error codes F20 & F22 18 Disabled Pulse
F36 Synchroniser not engaged (possibly jumped out) 17 Disabled Pulse
F37 Solenoid power switch circuit open 31 Disabled
F38 Disabled range selected by operator 25 & Enabled
16 & Disabled Pulse
15 Disabled Pulse
F40 Medium/reverse synchroniser potentiometer overvoltage 43 Enabled
F41 Medium/reverse synchroniser potentiometer undervoltage 44 Enabled
F42 Fast/slow synchroniser potentiometer overvoltage 45 Enabled
F43 Fast/slow synchroniser potentiometer undervoltage 46 Enabled
F44 Medium/reverse synchroniser potentiometer out of calibrated 76 Enabled
range
F45 Fast/slow synchroniser potentiometer out of calibrated range 77 Enabled
F47 Solenoid power switch misadjusted (clutch pedal) 69 Enabled
F48 Solenoid power switch circuit short to 12 volts 68 Enabled
F49 Wheel speed sensor circuit open 47 Enabled
F50 Wheel speed sensor circuit short 48 Enabled
F51 Temperature sensor circuit open 66 Enabled
F52 Temperature sensor circuit short to ground 67 Enabled
F53 Regulated 5/7 volts too high 7 Disabled

21- 6
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
F54 Regulated 5/7 volts too low 8 Disabled
F55 Regulated 8 volts too high 9 Disabled
F56 Regulated 8 volts too low 10 Disabled
F59 Forward/reverse/neutral switch disagreement 12 Disabled
Pulse
F60 Upshift input undervoltage 50 Enabled
F61 Upshift input overvoltage 51 Enabled
F62 Downshift input undervoltage 52 Enabled
F63 Downshift input overvoltage 53 Enabled
F64 Range shift input undervoltage 54 Enabled
F65 Range shift input overvoltage 55 Enabled
F66 Forward input undervoltage 56 Enabled
F67 Forward input overvoltage 57 Enabled
F68 Reverse input undervoltage 58 Enabled
F69 Reverse input overvoltage 59 Enabled
F73 Mid speed sensor circuit open 79 Enabled
F74 Mid speed sensor circuit short to ground or 12V 80 Enabled
F75 Swapped mid and rear speed sensors 82 Enabled
F77 No signal from wheel speed sensor 49 Enabled
F78 No signal from mid speed sensor 81 Enabled
F79 Engine RPM >3000 34 Enabled Pulse
F80 Wheel speed too high for gear selected 33 Enabled Pulse
F81 Proper ratio not detected 30 Disabled Pulse
F1A Clutch A open or short to earth 36 Disabled
F1b Clutch B open or short to earth 37 Disabled
F1C Clutch C open or short to earth 38 Disabled
F1d Clutch D open or short to earth 39 Disabled
F1E Clutch E open or short to earth 40 Disabled
F2A Clutch A short to 12V 2 Disabled
F2b Clutch B short to 12V 3 Disabled
F2C Clutch C short to 12V 4 Disabled
F2d Clutch D short to 12V 5 Disabled
F2E Clutch E short to 12V 6 Disabled
F1P Reverse solenoid open or shorted to ground 27 & Disabled Pulse
73 Disabled Steady
F1L Slow range solenoid open or shorted to ground 28 & Disabled Pulse
74 Disabled Steady

21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
F1U Mid range solenoid open or shorted to ground 26 & Disabled Pulse
72 Disabled Steady
F1h Fast range solenoid open or short to ground 29 & Disabled Pulse
75 Disabled Steady
FCA Clutch A not calibrated 61 Enabled
FCB Clutch B not calibrated 62 Enabled
FCC Clutch C not calibrated 63 Enabled
FCD Clutch D not calibrated 64 Enabled
FCE Clutch E not calibrated 65 Enabled
CP Depress clutch pedal or select neutral to re--enable 32 Disabled Pulse
CALIBRATION ERRORS
U19 Oil temperature below 20°C
U21 Engine RPM too low
U22 Engine RPM too high
U23 Shuttle lever is in neutral
U26 Clutch pedal is not released
U31 Output speed sensed -- tractor is moving
U36 Maximum allowed clutch calibration value exceeded
U37 ERPM dropped too soon during clutch cal
U81 No mid--reverse synchro movement sensed
U82 No low--high synchro movement sensed
U83 Synchro potentiometer connectors swapped
U84 Reverse and high synchro solenoid connectors swapped
U85 Mid and low synchro solenoid connectors swapped
U86 Mid--reverse synchro neutral error
U87 Low--high synchro neutral error
U88 Mid--rev synchroniser calibration values out of tolerance
U89 Low--high synchroniser calibration values out of tolerance
CALIBRATION MESSAGES
CF Calibration procedure completed successfully
CH Oil temperature above 50°C -- Press upshift to proceed
CL Oil temperature between 10 and 20°C -- press upshift to
proceed

21- 8
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F02
FAST/SLOW SYNCHRO UNCALIBRATED OR BAD CALIBRATION
EFFECT -- Cannot obtain low or high range & mid range (if applicable) selected automatically

Perform calibration
procedure -- low & Tractor O.K.
high obtainable?

Replace processor
with one of known
performance

ERROR CODE F03

MED/REV SYNCHRO UNCALIBRATED OR BAD CALIBRATION
EFFECT -- Cannot obtain mid or reverse range & low range (if obtainable)

Perform calibration
procedure -- Tractor O.K.
med/rev obtainable
after calibration?

Replace processor

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F11 -- CLUTCH POT OPEN CIRCUIT
F12 -- CLUTCH POT SHORT TO +12V
EFFECTS -- Occurrence while driving will disable transmission. Cycling shuttle lever will
re--enable Transmission. Tractor may be used on shuttle lever. If CP Depressed Transmission
will disable again until cleared by cycling shuttle lever.
For transmission wiring diagram and connector location refer to the end of this Section.

Check operation of potentiometer. Remove left hand lower

side panel below instrument cluster to expose potentiometer
Replace
and wiring. Disconnect connector C077 to potentiometer and
potentiometer as
check operation of potentiometer between the orange and
required
green wires. With pedal released, is resistance between
3.1kΩ and 3.9kΩ gradually changing to between 640kΩ and
2.1kΩ as the clutch pedal is depressed?

Disconnect the GCM processor connectors C100 and C101

and connect an ohm meter in turn between clutch
potentiometer connector C077 pin No. 3 (7070--B) and pin
No. 2 (7430--Y/R/B) then pin No. 1 (7525--G/B/S) and pin No. Trace and repair
2 and finally pin No. 1 and pin No. 3. Is an open circuit short circuit
indicated in each case?

Connect an ohm meter between pin No. 1

(7525--G/B/S) of harness connector C077 and ground. Trace and repair
Is an open circuit indicated? short to ground

Connect an ohm meter between pin No. 2

Trace and repair
(7430--Y/R/B) of harness connector C077 and ground.
short to ground
Is an open circuit indicated?

Connect an ohm meter between pin No. 3 (7070--B) of Trace and repair
harness connector C077 and ground. short to ground
Is an open circuit indicated?

Reconnect the GCM processor. With the

keystart ON, is the voltage at C077--1 Check continuity of wire
5 volts? from C077--1 to C101--5

Check continuity of wire from C077--2 to C100--19 and

continuity of wire from C101--1 to 3. Trace and repair open
Are both wires O.K.? circuits as required

Suspect faulty ETC module, replace with a

module of known performance

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F13
UPSHIFT & DOWNSHIFT SWITCHES BOTH CLOSED
EFFECT -- Tractor will continue to drive but attempts to shift will not be recognised.

Operator error. Both switches Normal operation

depressed by driver? resumed when
switches released
Enter H5 menu mode.
Determine faulty switch and
replace

ERROR CODE F20

RANGE SHIFT SYNCHRONISER DID NOT ENGAGE
EFFECT -- Transmission attempts change and returns to previously engaged range

Slow tractor and

Was tractor speed too excessive re--attempt.
during shift? i.e. range downshift Change okay?
while accelerating downhill.

Were any other error codes

displayed. Key off and key on again Refer to error code displayed fault
and observe display of gears. For finding flow diagram and rectify.
error codes i.e. 40, 41, 42, 43, 44, 45, Does transmission shift?
FIP, FIL, FIU, FIh.

Enter H menu mode ‘Hd’ to verify

if the processor is detecting any Attempt recalibration of
synchroniser movement. Is transmission. Is error cleared?
movement verified?

Pressure test at appropriate solenoid Remove transmission side cover. Check

test point on side cover. Is pressure synchroniser operating piston is not
within 15--18 bar? stuck/sticking and check synchroniser
within transmission is able to engage.
Rectify as required. While side cover is
Remove solenoid valve assy. removed also inspect potentiometer and
& inspect. Clean/replace. locknut
Recheck pressure -- O.K.?

Remove side cover and

inspect seals of operating
cylinder

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F21
TRANSMISSION EXTENSION HARNESS TO MAIN HARNESS DISCONNECTED.
EFFECT -- Transmission inoperable

Inspect harness connectors

C019 and C020. Reconnect if
necessary.

If harness connectors okay, check

connectors C024, C025, C026 to
clutch solenoids, C, D & E. and
synchroniser solenoids C031,
C032, C039 and C040

ERROR CODE F22

RANGE SYNCHRONISER DID NOT DISENGAGE
EFFECT -- Transmission attempts change and returns to previously engaged range

Were any other

error codes Rectify as required. Does
displayed? synchroniser disengage?

Enter H menu mode ‘HL’ to verify

if the processor is detecting any Attempt recalibration of
synchroniser movement. Is transmission. Is error cleared?
movement verified?

Pressure test. Is Remove transmission side cover:

pressure within Check: -- synchroniser operating Piston --
15--18 bar? synchroniser -- potentiometer & Linkage

Remove transmission side cover:

Check synchroniser operating Piston
Check synchroniser
Check potentiometer & Linkage

Remove side cover and inspect

seals of operating cylinder

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F23
CREEPER ENGAGED (SPEED OR GEAR TOO HIGH)
EFFECT -- Upshifts are inhibited.

Downshift to C1 (or lower)

[shifting to neutral or depressing Tractor
clutch will also cause transmission to okay
downshift to C1. ]

Does error code occur on less

creeper tractors or when creep is
disengaged?

Suspect creeper switch C021 or wiring going Replace processor for one of
open circuit. Use mode H5 to check switch known performance
transition. Is a transition sensed in H5?

Check switch adjustment. If

Okay check switch operation.
If Okay check wiring from
C100--2 to switch,
C021--RM7460--W/O/B, for
open circuit and check other
side of switch for +12V with
Ignition on. Repair as
required.

ERROR CODE F24

ALL CLUTCHES & SYNCHRONISERS REQUIRE CALIBRATION
EFFECT -- Transmission is disabled.

Has a new
processor been Perform calibration
installed

Calibration values have been

corrupted in processor. Attempt
calibration. If unable to maintain
calibration install a new
processor.

21- 13
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F27
ERPM SIGNAL NOT PRESENT
EFFECT -- No speed matching. Delay in upshifts after auto take off. Minor reduction in shift
performance (2,300 rpm assumed by processor)

Is the alternator Replace drive belt

drive belt broken?

Establish if there is a speed

output from the alternator.
Connect a volt meter between the Repair or replace
alternator speed connector and alternator
ground. Is there approximately 7
volts when the engine is running?

The following checks must be carried out with

the engine stopped and keystart switched OFF

Check alternator wiring for Check for short circuit in

Locate and
continuity: Disconnect wiring. With C100
repair short
connector C100 from processor disconnected and
circuit to
module and check between alternator wire
ground
C100--15 and alternator speed disconnected check
sender connection. Is resistance to ground
resistance less than 10Ω? from pin C100--15. Is Suspect TCM
resistance less than 10Ω. module.
Substitute with
Check for continuity a module of
between C100--15 and Locate and repair known
C001--6 open circuit performance
(CM2015--W/B/S).
Is wire O.K.?

Check for continuity

between alternator Locate and repair
connector C013--W open circuit
and C001--6
(FM2015--W/S).
Is wire O.K.?

21- 14
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F31
SYNCHRONISER DID NOT ENGAGE DURING SHUTTLE SHIFT
EFFECT -- Transmission disabled.

Were any other

error codes Rectify as required. Does
displayed? synchroniser disengage?

Enter H menu mode ‘HL’ to verify

if the processor is detecting any Attempt recalibration of
synchroniser movement. Is transmission. Is error cleared?
movement verified?

Pressure test. Is Remove transmission side cover:

pressure within Check: -- synchroniser operating Piston,
15--18 bar? synchroniser, potentiometer & Linkage

Remove transmission side cover:

Check synchroniser operating Piston
Check synchroniser
Check potentiometer & Linkage

Remove side cover and inspect

seals of operating cylinder

ERROR CODE F32

HIGH RANGE SYNCHRONISER DID NOT ENGAGE DURING START UP SEQUENCE,
WITHIN SPECIFIED TIME. (THIS IS PART OF A SYSTEM TEST DURING START UP)
EFFECT -- Transmission disabled

If low oil pressure light is on repair low pressure circuit as

described in hydraulic section.

Otherwise, cycle shuttle lever. If problem still persists a different

error code will occur, probably F31. Refer to new error code page.

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F33
SYNCHRONISER DID NOT DISENGAGE, SHUTTLE OR NEUTRAL
EFFECT -- Transmission disabled

Were any other

error codes Rectify as required. Does
displayed? synchroniser disengage?

Enter H menu mode ‘HL’ to verify

if the processor is detecting any Attempt recalibration of
synchroniser movement. Is transmission. Is error cleared?
movement verified?

Pressure test. Is Remove transmission side cover:

pressure within Check: -- synchroniser operating Piston,
15--18 bar? synchroniser, potentiometer & Linkage

Remove transmission side cover:

Check synchroniser operating Piston
Check synchroniser
Check potentiometer & Linkage

Remove side cover and inspect

seals of operating cylinder

ERROR CODE F34

SYNCHRONISER DID NOT DISENGAGE AFTER POWER UP. (PART OF START UP
SEQUENCE)
EFFECT -- Transmission disabled

If low oil pressure light is on repair low pressure circuit as

described in hydraulic section.

Otherwise, cycle shuttle lever. If problem still persists a different

error code will occur, probably F33. Refer to new error code page.

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F35
SYNCHRONISER FAILED TO ENGAGE PREVIOUS RANGE AFTER ERROR F20 OR F22.
EFFECT -- Transmission disabled
RECOVER -- Cycle shuttle lever to try again or select another range while in neutral.

Was the tractor speed excessive during Slow tractor and try again.
the shift. Investigate error F20 or F22

Enter H menu mode ‘HL’ to verify

if the processor is detecting any Attempt recalibration of
synchroniser movement. Is transmission. Is error cleared?
movement verified?

Pressure test at Remove transmission side cover. Check synchroniser

appropriate test operating piston is not stuck and check synchroniser
point on side cover. within transmission is able to engage. With the side
Is pressure within cover removed, also inspect potentiometer operation
15--18 bar. and linkage

Remove solenoid valve

assembly.
Clean/replace and
re--check pressure --
OK?

Remove side cover and

inspect seals of operating
piston

ERROR CODE F36

SYNCHRONISER DISENGAGED WITHOUT DRIVER INITIATION
EFFECT -- Transmission disabled
Suspect faulty potentiometer or
potentiometer linkage. Using menu
Cycle shuttle lever. Does the error Mode H9, Channel 0, Check
clear? potentiometer/linkage operation.
Repair as required.
Drive tractor and
attempt to reproduce synchroniser possibly jumped
error. Does error out due to only partial
reoccur? engagement initially.

If error reoccurs, suspect

synchroniser fault. Inspect
synchroniser and
repair/replace as required.

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F37
CLUTCH PEDAL SWITCH OPEN CIRCUIT
EFFECT -- Transmission disabled

Cycle clutch pedal. Switch was temporarily stuck. Inspect switch.

Does error clear? Clean or replace.

Remove steering column left hand side panel.

Disconnect switch connector C076 and test Adjust or replace switch as
operation of switch using multimeter. Does required
switch function OK?

Disconnect connectors C100 & C101 from

processor and check for open circuit
between C100--27 and switch C076--2 and
4 (7420--Y/P/B) and C101--30 and switch
C076--3 (7050--R/G/B).
Trace fault and repair wiring.

ERROR CODE F38

DISABLED RANGE SELECTED BY OPERATOR
(i) synchroniser range shift (to Mid) not completed
(ii) synchroniser for/rev not completed
(iii) Reverse not selected from a gear higher than C1

NOTE: This error code will be displayed in conjunction with another error code, usually
informing of a solenoid or potentiometer failure.

For items (i) and (ii)

Key off and key on.

Observe error codes.
Rectify error codes
and attempt selection
of ranges. Error F38
will be eliminated if
other faults are
rectified.

(iii) If reverse has been attempted in a gear higher than C1 when there was a wheel speed
sender error (F49, F50 or F77) reverse will not be selected. The transmission will be dis-
abled but can be recovered, to forward drive, by cycling the shuttle lever or clutch pedal.
Reverse cannot be obtained for 10 seconds. The processor then assumes that the tractor
has slowed sufficient to make the shift. Rectifying the wheel speed sender error will elimin-
ate the reoccurrence of F38.

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F40
MEDIUM/REVERSE SYNCHRONISER POTENTIOMETER OVERVOLTAGE
EFFECT -- Med/Reverse ranges cannot be obtained.

Disconnect connector,
C030, to med/rev
synchroniser
potentiometer. Key on
tractor. Using a
voltmeter, check Trace short circuit in
voltage on each pin wiring and repair
Pin No. 3 should have
8 volts, other two
should be 0 volts. Are
voltages correct?

Remove med/rev synchroniser potentiometer

from transmission and check operation using
multimeter. Does the meter show a smooth Replace potentiometer
increase/decrease in OHMS as the
potentiometer. is operated?

Suspect faulty processor.

Substitute with one of known performance

ERROR CODE F41

MEDIUM/REVERSE SYNCHRONISER POTENTIOMETER UNDERVOLTAGE
EFFECT -- Med and rev ranges cannot be obtained

Disconnect connector to med/rev

synchroniser potentiometer and disconnect
processor connectors C100 & C101. Trace short or open
Check for a short to earth or an open circuit circuit in wiring and
from C100--33 to the potentiometer, repair
connector C030--2. Is either indicated?

Remove potentiometer and check operation

using a multimeter. Does the meter show a Replace
smooth increase/decrease in OHMS as the potentiometer
potentiometer is operated?

Substitute processor for one of

known performance

21- 19
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F42
FAST/SLOW SYNCHRONISER POTENTIOMETER OVERVOLTAGE
EFFECT -- Low and high ranges cannot be obtained.

Disconnect connector
C029 to fast/slow
synchroniser
potentiometer. Key on
tractor, using a
voltmeter. Check
voltage on each pin
Trace short circuit in
Pin No. 3 should have
wiring and repair
8 volts, other two
should be 0 volts. Are
voltages correct?

Remove fast/slow synchroniser potentiometer

from transmission and check operation using
multimeter. Does the meter show a smooth Replace potentiometer
increase/decrease in OHMS as the
potentiometer. is operated?

Suspect faulty processor.

Substitute with one of known performance

ERROR CODE F43

FAST/SLOW SYNCHRONISER POTENTIOMETER UNDERVOLTAGE
EFFECT -- Low and high ranges cannot be obtained

Disconnect connector C029 to fast/slow

synchroniser potentiometer and disconnect Trace short or open
processor connectors C100 & C101. circuit in wiring and
Check for a short to earth or an open circuit repair
from C100--11 to the potentiometer
connector C029--2. Is either indicated?

Remove potentiometer and check operation

using a multimeter. Does the meter show a Replace
smooth increase/decrease in OHMS as the potentiometer
potentiometer is operated?

Substitute processor for one of

known performance

21- 20
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F44
MEDIUM/REVERSE SYNCHRONISER POTENTIOMETER OUT OF CALIBRATED RANGE

EFFECTS -- Transmission functions normally but may lead to premature detection of

synchroniser engagement and subsequent synchroniser damage.

Perform clutch and synchroniser

calibration routine to clear error.
NOTE: This error may be indicating
wear on transmission components or a
failing potentiometer.

ERROR CODE F45

FAST/SLOW SYNCHRONISER POTENTIOMETER OUT OF CALIBRATED RANGE

EFFECTS -- Transmission functions normally but may lead to premature detection of

synchroniser engagement and subsequent synchroniser damage.

Perform clutch and synchroniser

calibration routine to clear error.
NOTE: This error may be indicating
wear on transmission components or a
failing potentiometer.

ERROR CODE F47

CLUTCH PEDAL SWITCH MISADJUSTED
EFFECT -- Inching may be jerky and at a higher than normal pedal position.

Indicates an open circuit in

When the clutch pedal is released is switch or wiring.
Error F37 displayed? Refer to Error F37

Remove left hand steering column cover and Adjust switch.

check switch adjustment. Switch adjusted OK?

Switch may be ‘sluggish’,

especially in cold weather.
Replace switch.

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F48
CLUTCH PEDAL SWITCH SHORT CIRCUIT
EFFECT -- No effect on normal operation but will not cut off power to any clutch solenoids.

Remove steering column left hand side

cover and check switch adjustment and Adjust or replace switch
operation -- OK?

Disconnect clutch switch connector,

C076. With key start ‘ON’ check for
voltage on C076--3
(CM7050--R/G/B)
Voltage should be zero.
If voltage is evident trace and repair
short circuit in wiring.

ERROR CODES;
F49 -- TRANSMISSION OUTPUT SPEED SENSOR OPEN CIRCUIT
F50 -- TRANSMISSION OUTPUT SPEED SENSOR SHORT TO GROUND
EFFECT -- (i) Upshifts in high range are inhibited
(ii) 1--2 second delay in allowing upshifts after clutchless take off

Disconnect processor connectors C100 & C101 and disconnect

transmission output speed sensor connector, [Link] wiring for
open/short circuit 7400--Y/N/B to C101--6 and repair as required. If
wiring checks out OK test sensor.

With the sender installed in the transmission, check for a short to

earth on each sender terminal. Check resistance of the sender which
should be approximately 0.8--1.2KΩ at 20_C. Replace if outside
specification.

21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F51 -- TEMPERATURE SENDER OPEN CIRCUIT
F52 -- TEMPERATURE SENDER SHORT TO GROUND
EFFECT -- Hot oil is assumed, if oil is cold sluggish shifting and a higher than normal clutch
pedal position will be apparent.

Disconnect processor connectors C100 & C101 and disconnect

temperature sender, C023. Test the wire 7500 B/G for open/short
circuit to C100--18 and repair as required. If wiring checks out OK
test temperature sender.

With the sender installed check for a short to earth, and an open
circuit from the terminal of the sender to the chassis.

21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F53 -- 5 VOLT REFERENCE VOLTAGE TOO HIGH
F54 -- 5 VOLT REFERENCE VOLTAGE TOO LOW
EFFECT -- Transmission disabled

Disconnect the following components, one at a time, to

isolate area of fault.

Disconnect Clutch Pedal potentiometer, Replace potentiometer

C077, are F53/54 cleared?
NOTE: Should cause error F11 if
potentiometer is faulty

Disconnect forward/reverse connector,

Replace
C075, (under steering column shroud).
forward/reverse switch
Are F53/54 cleared?
NOTE: Should cause errors F66 and
F68 if switches are faulty.

Disconnect the upshift/downshift and range

Replace
switches connector, C103. Are F53/54 cleared?
upshift/downshift &
NOTE: Should cause errors F60 and F62 if
range switch assembly
switches are faulty.

Check wire 7525 G/B/S from each of the

above components back to processor Trace and repair
connector C101--5. Is either a short or open faulty wiring
circuit indicated?

Suspect faulty processor. Replace

with one of known performance

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 2

ERROR CODES;
F55 -- REGULATED 8 VOLTS SUPPLY TOO HIGH
F56 -- REGULATED 8 VOLTS SUPPLY TOO LOW
EFFECT -- Transmission disabled

Remove the following components one at a time to attempt

to isolate area of fault.

Disconnect transmission Mid/Rev Synchroniser Replace mid/Rev Synchroniser

Potentiometer, C030. Are F55/56 cleared? Potentiometer
NOTE: Should cause errors F41 or F44 if
potentiometer faulty.

Disconnect transmission Low/High Synchroniser

potentiometer, C029. Are F55/56 cleared? Replace low/high synchroniser
NOTE: Should cause errors F43 or F45 if potentiometer
potentiometer faulty.

Check wire 7520--G/N/S back from each

Trace faulty wiring and
of the above components to C101--25. Is
repair
either a short or open circuit indicated?

Suspect faulty processor.

Replace with one of known performance.

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F59
FORWARD/REVERSE/NEUTRAL SWITCH DISAGREEMENT
(MORE THAN ONE SWITCH ENGAGED)
EFFECT -- Transmission is Disabled
Disconnect processor connectors C100 & C101. Trace and repair
Disconnect connector, C075, to FNR switch. Is an open wiring
circuit indicated between C100--27 and C075--4?

Replace forward/neutral
reverse switch.

ERROR CODES;
F60 -- UPSHIFT SWITCH INPUT VOLTAGE LOW
F61 -- UPSHIFT SWITCH INPUT VOLTAGE HIGH
EFFECT -- Upshift switch will not function, higher gears cannot be selected.
NOTE: If required, key off and restart to select B1/R1.

Disconnect processor connectors C100 & C101, and

disconnect connector, C103, to upshift/downshift/range shift
assembly. Using a suitable multimeter, check between Trace and repair
C100--32 & C103--3 (CM7210--S/LG/B). For: (1) Open faulty wiring
Circuit (2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave up/down range switch

assembly disconnected with key start on. Check for voltage on
C103--3 (CM7210--S/LG/B). Is +5v, +8v or +12V indicated?

Trace and repair Reconnect up/down/range

short circuit, using switch connector if error is still
voltage previously indicated. Inspect connector
indicated to and check operation of
determine possible switches with multimeter. If no
area of faults. fault found, substitute module
with one of known
performance.

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F62 -- DOWNSHIFT SWITCH INPUT VOLTAGE LOW
F63 -- DOWNSHIFT SWITCH INPUT VOLTAGE HIGH
EFFECT -- Downshift switch will not function, lower gears cannot be selected.
NOTE: If required, key on and restart to select B1/R1.

Disconnect processor connectors C100 & C101, and

disconnect connector, C103, to upshift/downshift/range shift
assembly. Using a suitable multimeter, check between Trace and repair
C100--6 & C103--4 (CM7200--S/K/B). For: (1) Open Circuit faulty wiring
(2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave up/down range switch

assembly disconnected with key start on. Check for voltage on
C103--4 (CM7200--S/K/B). Is +5v, +8v or +12V indicated?

Trace and repair Reconnect up/down/range

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F64 -- RANGE SWITCH INPUT VOLTAGE LOW
F65 -- RANGE SWITCH INPUT VOLTAGE HIGH
EFFECT -- Range switch will not function. Another range may be selected by depressing the
clutch pedal or shifting into neutral.

Disconnect processor connectors C100 & C101, and

disconnect connector, C103 to upshift/downshift/range shift
assembly. Using a suitable multimeter, check between Trace and repair
C100--17 & C103--CM4101--TQ/B. For: (1) Open Circuit (2) faulty wiring
Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave up/down range switch

assembly disconnected with key start on. Check for voltage on
C103 (CM4101--TQ/B). Is +5v, +8v or +12V indicated?

Trace and repair Reconnect up/down/range

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F66 -- FORWARD SWITCH INPUT VOLTAGE TOO LOW
F67 -- FORWARD SWITCH INPUT VOLTAGE TOO HIGH
EFFECT -- Tractor will operate normally, except there will be a short delay recognising that
forward has been selected.

Disconnect processor connectors C100 & C101, and

disconnect connector, C075 to forward/reverse/neutral
switch assembly. Using a suitable multimeter, check Trace and repair
between C100--20 & C075--2 (CM7250--S/R/B). For: (1) faulty wiring
Open Circuit (2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

switch assembly disconnected with key start on. Check for voltage
on C075--2 (CM7250--S/R/B). Is +5v, +8v or +12V indicated?

Trace and repair Reconnect

short circuit, using forward/reverse/neutral switch
voltage previously connector if error is still
indicated to indicated. Inspect connector
determine possible and check operation of
area of faults. switches with multimeter. If no
fault found, substitute module
with one of known
performance.

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F68 -- REVERSE SWITCH INPUT VOLTAGE TOO LOW
F69 -- REVERSE SWITCH INPUT VOLTAGE TOO HIGH
EFFECT -- Tractor will operate normally, except there will be a slight delay recognising that
reverse has been selected.

Disconnect processor connectors C100 & C101, and

disconnect connector, C075 to forward/reverse/neutral
switch assembly. Using a suitable multimeter, check Trace and repair
between C100--7 & C075--3 (CM7260--S/U/B). For: (1) Open faulty wiring
Circuit (2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

switch assembly disconnected with key start on. Check for voltage
on C075--3 (CM7260--S/U/B). Is +5v, +8v or +12V indicated?

Trace and repair Reconnect

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
F73 -- MID SPEED SENSOR OPEN CIRCUIT
F74 -- MID SPEED SENSOR SHORT CIRCUIT
EFFECT -- Centrifugal compensation assumes 2300 rpm for clutch B, minor shift performance
loss at other speeds. Gears affected 2, 4 and 6.

Is the mid speed sensor

Reconnect connector, C037
connected to harness

Disconnect mid speed sender connector,

C037, to harness and disconnect C100 &
C101 from the processor. With a suitable Trace and repair
multimeter check wiring from C101--2 to wiring fault
C037--RM7401--P/B/G. For open/short
circuit. Is fault found?

With the mid speed sensor installed,

check between the sensor connector
terminals for a short or open circuit
within the sensor. Replace the
sensor assembly if a fault is
indicated.

ERROR CODE F75

SWAPPED MID AND REAR SPEED SENSORS
EFFECT -- After error is detected the tractor will operate normally.

Swap speed sensor

connectors, C037 and C038.

21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F77
NO SIGNAL FROM REAR WHEEL SPEED SENSOR.
EFFECT -- Upshifts in high range inhibited. Jerky or sluggish shuttle shifting and automatic
take off generally poor shifting.

Mechanical fault within

Is tractor moving transmission/rear axle
preventing drive.
Is the sensor installed
correctly? Remove and
reinstall correctly
Replace rear speed sensor
assembly.

ERROR CODE F78

NO SIGNAL FROM MID SPEED SENSOR.
EFFECT -- Centrifugal compensation assumes 2,300 rpm for Clutch B. Minor shift quality loss
at other speeds, only affect gears 2, 4 and 6.

Mechanical fault within

Is tractor moving transmission/rear axle
preventing drive.
Is the sensor installed
correctly? Remove and
reinstall correctly
Replace mid speed sensor.

ERROR CODE F79

ENGINE RPM EXCEEDS 3000 REV/MIN.
EFFECT -- General shift quality poor and/or delayed.

When engine speed reduced below 2,800 rev/min Tractor

does error code clear? operating OK

Check output from speed output terminal of NO Replace/repair alternator

alternator, C013--W. Is voltage approx. 7 volts at
idle?
Inspect wiring from the alternator to
C100--15 of the processor. Check
for possible intermittent short circuit
to +12V. Repair as necessary.

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE F80
TRANSMISSION OUTPUT REV/MIN TOO HIGH FOR SELECTED GEAR.
EFFECT -- None

Self clearing when speed OK

for gear selected.

ERROR CODE F81

CORRECT RATIO NOT DETECTED (OUTPUT SPEED TOO LOW FOR GEAR SELECTED)
EFFECT -- Transmission disabled.

Are connectors
C027 Clutch A and
C028 Clutch B Refit connectors correctly
correctly fitted?

Possible slipping clutch.

Pressure check clutches. Have all clutches
Are clutches ≐ 16 bar? low pressure?

Clutch discs worn. Low pressure Possible faulty

Dismantle transmission and hydraulic PWM valve or
inspect. system fault. piston seal leakage
Refer to or other leakage in
Hydraulic clutch showing low
Section. pressure.

21- 33
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODE CP
DEPRESS CLUTCH PEDAL TO RE--ENABLE TRANSMISSION
EFFECT -- Transmission disabled.
Depress clutch pedal or cycle shuttle switch to re--enable
transmission. If CP does not extinguish proceed.

Inspect for loose harness Inspect connector

connectors at C100, C101, and ensure a tight Test drive tractor to
C019 and C001. Are any fit. Is Error Code ensure code does
connections loose? eliminated? not re--appear

Check for an intermittent short to ground on the neutral start switch

wiring: Locate
With the keystart OFF and the FNR lever in either F or R, connect a and repair
continuity meter between connector C100--27 and ground. An open short
circuit should be indicated. Twist the harness from C100 to the circuit
shuttle switch. Is continuity indicated at any time?

Check for an intermittent short to ground on the shuttle switch wiring:

Locate
With the keystart OFF and the FRN lever in N, connect a continuity
and repair
meter between connector C100--27 and C075--4 (CM7420--Y/P/B).
open
Continuity should be indicated. Twist the harness from C100 down to
circuit
C075. Is an open circuit indicated at any time?

Check for an intermittent fault in +12V supply to processor module. Locate and
Check for continuity between fuse 13 output and C101--34 and repair open
C101--35. Is an open circuit indicated at any time? circuit

Check for an intermittent fault in ground wiring to processor module. Locate and
Check for continuity between C101--32, C101--33 and C101--9 and repair open
ground. Is an open circuit indicated at any time? circuit

Remove and inspect the shuttle neutral switch. Replace with a Discard of
switch of known performance. Test drive tractor. Is Error Code removed
eliminated? switch

Substitute
processor with one
of known
performance

21- 34
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES F1A TO F2E

F1A -- CLUTCH A OPEN OR SHORT TO EARTH

F2A -- CLUTCH A SHORT TO 12V
F1B -- CLUTCH B OPEN OR SHORT TO EARTH
F2B -- CLUTCH B SHORT TO 12V
F1C -- CLUTCH C OPEN OR SHORT TO EARTH
F2C -- CLUTCH C SHORT TO 12V
F1D -- CLUTCH D OPEN OR SHORT TO EARTH
F2D -- CLUTCH D SHORT TO 12V
F1E -- CLUTCH E OPEN OR SHORT TO EARTH
F2E -- CLUTCH E SHORT TO 12V

Error codes F1A through to F2E indicate either a short or open circuit in the wiring of one of the
PWM solenoids. Using a suitable multi--meter check the wiring from the PWM solenoid back to
the processor module. Locate the short/open circuit, repair or replace wiring as necessary.

If wiring is okay disconnect the PWM solenoid from the harness and check that the resistance
of the PWM coil is approximately 10Ω at 20_C. If not, replace the PWM solenoid.

If wiring and PWM solenoids are okay replace the micro processor with one of known
performance.

A B C D E LO MED HI REV

21- 35
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES F1P TO F1H

F1P -- REVERSE SOLENOID OPEN OR SHORTED TO EARTH

F1L -- SLOW RANGE SOLENOID OPEN OR SHORTED TO EARTH
F1U -- MID RANGE SOLENOID OPEN OR SHORTED TO EARTH
F1H -- FAST RANGE SOLENOID OPEN OR SHORTED TO EARTH

Error codes F1P, F1L, F1U and F1H indicate open or short circuits to earth in the wiring to the
solenoid. Using a suitable multimeter check the wiring from the solenoid back to the processor.
Locate the wiring fault and repair or replace wiring as necessary.

If wiring is okay, disconnect the solenoid from the harness and check the solenoid resistance is
approximately 6--8Ω at 20_C. If not correct or open/short circuit is indicated replace solenoid.

A B C D E LO MED HI REV

21- 36
SECTION 21 -- TRANSMISSION -- CHAPTER 2
ERROR CODES;
FCA -- CLUTCH A NOT CALIBRATED
FCB -- CLUTCH B NOT CALIBRATED
FCC -- CLUTCH C NOT CALIBRATED
FCD -- CLUTCH D NOT CALIBRATED
FCE -- CLUTCH E NOT CALIBRATED
EFFECTS -- Poor clutch performance of uncalibrated clutch.

Perform calibration procedure.

Does the error clear? Tractor Okay

Are any errors or messages Refer to calibration errors

displayed during calibration?

Remove PWM valve, clean and

reinstall or replace. Can calibration Tractor Okay
be performed successfully?

Pressure test clutch. Is pressure Possible clutch piston seal leakage

approximately 16 bar? or leakage to piston from PWM
valve

Mechanical fault within transmission.

Dismantle and inspect clutch pack
assemblies

21- 37
SECTION 21 -- TRANSMISSION -- CHAPTER 2

CALIBRATION ERRORS AND MESSAGES

U19 -- Oil temperature below10_C

Warm oil to above 10_C before processing with calibration.

U21 -- Engine RPM too low

Increase engine RPM to 1200 100

U22 -- Engine RPM too high

Reduce engine RPM to 1200 100

U23 -- Shuttle lever is in neutral

Place shuttle lever in forward

U26 -- Clutch pedal not released

Release clutch pedal

U31 -- Output speed sensed -- tractor moving

Ensure handbrake is applied and wheels choked. If error persists check that the
Mid and Rear transmission speed sensor connectors are not swapped, if okay
then possible mechanical fault within transmission.

U36 -- Maximum allowed clutch calibration value exceeded

Current value exceeded without lugging engine down. Possible PWM valve faulty.
Low Hydraulic Pressure fault or a faulty synchroniser not transmitting drive.

U37 -- Engine RPM dropped too soon

Engine lugged down too soon. Possible PWM fault or
mechanical fault within transmission.

21- 38
SECTION 21 -- TRANSMISSION -- CHAPTER 2

CALIBRATION ERRORS AND MESSAGES (Continued)

U81 -- No Mid/Reverse synchroniser movement sensed

U82 -- No Low/High synchroniser movement sensed

21- 39
SECTION 21 -- TRANSMISSION -- CHAPTER 2

CALIBRATION ERRORS AND MESSAGES (Continued)

U88 -- Mid/Reverse synchroniser calibration values out of tolerance

U21 -- Low/High synchroniser calibration values out of tolerance

Check potentiometer operation, removed from transmission, if to
specification remove side cover and inspect potentiometer linkage.

CF -- Calibration procedure completed successfully

CH -- Oil temperature above 50_C

Message for information only. Press upshift to proceed.

CL -- Oil Temperature between 10 and 20 degrees

Message for information only. Press upshift to proceed.

21- 40
SECTION 21 -- TRANSMISSION -- CHAPTER 2
LIMP HOME
1

WARNING
Care should be taken when operating the tractor
with the limp home harness connected. Clutch
engagement will be harsher than normal. Do not
leave the limp home harness connected when the
operation has been completed.
2
In the unlikely event of an electrical fault developing
within the transmission that renders the tractor
immobile, for example, failure of the supply voltage to
the PWM valves, the emergency ‘Limp Home 1
Harness’, Special Tool No. NH.21--100 for
Semi--Powershift and Hi--Lo transmissions, is
available to enable the tractor to be driven onto a
transporter or hard standing, in order that the repair
can be carried out in a suitable location. The Limp
Home device is not and must not be used as a means
to continue operating the tractor in its work
environment.

To engage and operate the ‘Limp Home Harness’

proceed as follows:--

[Link] the parking brake.

[Link] the engine and turn keystart off.

[Link] the electronic draft control panel. 2

[Link] and disconnect the rear main harness access
connector, Figure 2, enabling the connection of the
limp home harness connector, Figure 1, marked with
‘HARNESS’, into the rear main harness of the
tractor, Figure 4.

[Link] the other connector of the Limp Home

harness, Figure 1, marked ‘DIAGNOSTIC’, to the
‘WHITE’ diagnostic plug, Figure 4.

[Link] the vehicle.

[Link] forward or reverse by operating

forward/reverse switch, (2) Figure 1, for 2 seconds
on the Limp home harness control box. Return the
switch to the centre position. 3
[Link] the momentary switch, (1) Figure 1, of the
Limp Home Harness to move the vehicle. If
necessary, depress the foot throttle to increase
engine speed.

[Link] the tractor has been delivered to the repair

area, disconnect the Limp Home Harness and
reconnect the limp home access connector of the
rear main harness and proceed with diagnosing and
repairing the fault.

21- 41 4
SECTION 21 -- TRANSMISSION -- CHAPTER 2
PRESSURE TESTING
Transmission Clutches, A,B,C,D and E

1. Prepare the tractor for pressure testing:

(i) Ensure the handbrake is fully applied and wheels

chocked.

(ii) Install diagnostic switch, Tool No.4FT.950 into the

white diagnostic plug of the tractor harness.

(iii) Start and run the tractor to warm the transmission

oil to a minimum operating temperature of 50°C
(122°F). 5

A B
E D C
2. Install suitable pressure gauges (0--40bar, 0--600
lbf.in2), five if available, into each of the clutch
pressure test points, located in the raised
horizontal manifold, under the right hand foot step.
Figure 6. Reference Figure 5 for gauge, hose and
adaptor details:
1. Pressure gauge, FT8503A, with adaptor
FT8503--8
2. Adaptor, NH.35--103 (10--1.00 mm x 7/16
JIC)
3. Hose, (Finis Code 3936707)
TA6021003
6

3. Start the engine and enter HJ mode. Depress the

clutch pedal and move the shuttle lever into
forward. Release the clutch. The upper character
on the display will show ‘A’, indicating that clutch ‘A’
solenoid will be energised. To energise the
solenoid press and hold the downshift button and
observe the pressure reading on the gauge which
should be 17±1 bar.

4. To select other clutches, B, C ,D or E, repeatedly 7

press the upshift button and then depress the
downshift button to energise the solenoid.

5. The pressure can be controlled with the clutch

pedal. When the pedal is depressed the lower two
digits will change to a number 0--16 indicating the
approximate pressure in bars, as long as the clutch
pedal is correctly calibrated. With the pedal fully
released ‘FP’ will be displayed indicating Full
Pressure.

21- 42 8
SECTION 21 -- TRANSMISSION -- CHAPTER 2
Low, Medium, High and Reverse Synchroniser
Pressure testing
2
1
Figure 9 -- 1. Reverse synchroniser test point
2. High synchroniser test point

Figure 10 -- 1. Low synchroniser test point

2. Medium synchroniser test point
TIA35159

2
Due to the operating characteristics of the transmisson
it is not possible to pressure test the synchroniser
circuits during normal tractor operation.
1

To check the pressure within the synchroniser circuits it

is recommended that the clutch calibration procedure
using, H1, mode ‘N’ is used.

TIA355160
10
1. Prepare the tractor for pressure testing:

(i) Ensure the handbrake is fully applied and wheels

chocked.

(ii) Install diagnostic switch, Tool No.4FT.950 into the

white diagnostic plug of the tractor harness.

(iii) Start and run the tractor to warm the transmission

oil to a minimum temperature of 50°C (122°F).

2. Install suitable pressure gauges, Figure 11, 11

1. Pressure gauge, FT8503A, with adaptor
FT8503--8
2. Adaptor, NH.35--102 (10--1.25 mm x 7/16
JIC)
3. Hose, (Finis Code 3936707),
(0--40bar, 0--600 lbf.in2), four if available, into each
of the synchroniser pressure test points, located in
the transmission side cover, Figure 12.

TA6021013

21- 43 12
SECTION 21 -- TRANSMISSION -- CHAPTER 2
3. Srart the engine and enter mode H1.

4. Depress the clutch pedal and position the shuttle

lever in forward.

5. Set engine speed to 1100 rev/min.

6. Cycle through H1 to ‘N’, using the upshift button.

7. Depress the downshift button to activate all of the

synchroniser solenoids.

8. Each gauge should indicate 17±1 bar when the

solenoids are activated and zero when
deactivated, Figure 15.
14

9. If all gauges read low, suspect a fault in the low

pressure hydraulic system, refer to section 35.

10. If one or more gauges read correct and the other

gauges are low this indicates that the hydraulic
system is okay and that the fault lies within the
transmission assembly. Remove and inspect the
solenoid valve assembly, if no fault is found
remove the transmission side cover and inspect
the operating piston and seals.

TA6021004
15
21- 44
SECTION 21 -- TRANSMISSION -- CHAPTER 2
CLUTCH AND SYNCHRONISER CALIBRATION

The Semi--powershift transmission has 5 clutch packs

and 2 synchronisers that require periodic calibration to
compensate for wear. Calibration should only be
necessary only if a deterioration in gear shift quality is
noted.
NOTE: During the calibration procedure the electronic
management system detects precisely the point at
which the clutches start to engage . The engagement
is detected by a reduction in engine speed. During
calibration it is essential that no action is taken to to
cause the engine speed to vary. Be sure that the air
conditioner and all electrical equipment is switched off. 16
Do not operate the PTO or any hydraulic lever or move
the hand or foot throttle.
There are two methods to enter the calibration mode:
(i) Through the white diagnostic connector, using
special tool No. 4FT.950 and menu mode H1, or,
(ii) By depressing both up/down shift buttons together
during start up.

Tractor Preparation

NOTE: The clutches should be adjusted when the

transmission oil temperature is between 20°C (68°F)
and 50°C (122°F).
17

Park the tractor on level ground, away from obstacles

(in case of unexpected tractor movement).

Apply handbrake, switch off all electrical equipment

and air conditioning if fitted. Stop the engine and place
remote levers in neutral and lower hydraulic equipment
to the ground.

Place the shuttle in neutral. Block the wheels, front and

rear.
18

Either, (i) Install tool 4FT.950 into the diagnostic plug or

(ii) press and hold both Up/down shift buttons and start
the engine. Select H1 by depressing the diagnostic
switch once.

21- 45 19
SECTION 21 -- TRANSMISSION -- CHAPTER 2
Release the buttons. The display will change to show
transmission temperature. Press the up or downshift
button to proceed.

If the temperature is less than 10°C Error Code ‘U19’

will be displayed. If the temperature is between 10°C
and 20°C ‘‘CL” will be displayed. If the temperature is
to high, above 50°C, ‘‘CH” will be displayed.

If ‘U19’ is displayed calibration will not be possible and

the oil will have to be warmed before proceeding.

If ‘CL’ or ‘CH’ are displayed after 4 seconds the display 20

will return to oil temperature and the tractor may be
operated to obtain the correct transmission oil
temperature. If it is not practical to wait for the oil
temperature to change press either of the up or down
shift buttons while ‘CL’ or ‘CH’ is being displayed. The
display will then show an ‘A’ and calibration can
proceed.

Move the shuttle lever to forward and release the

clutch pedal.

Set engine speed to 1200 ERPM ±100.

21
The transmission is now ready for calibration.

Press and hold the downshift button to calibrate clutch

If the start up procedure was incorrect a ‘‘U” code will

appear.

Hold the downshift button until the engine speed

decreases by 50 RPM and the calibration number
stops increasing. 22

Release the downshift button, the display will change

to ‘b’, indicating that clutch B is ready for calibration.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

21- 46 23
SECTION 21 -- TRANSMISSION -- CHAPTER 2
Repeat the above steps for clutches C, D and E. After
clutch E has been calibrated, release the downshift
button and the display will change to F.

Press the downshift button again. The synchronisers

will be shifted to neutral and synchroniser stroke
relationship will be checked. If satisfactory the display
will show ‘CF’.

Pressing the downshift button again will select mode

‘N’. This mode engages clutches A and C with the
synchronisers in neutral. This can be used to ‘free’
transmission components that may be suspected of 24
sticking , i.e,synchronisers. It should be noted that if a
synchroniser is not actually in neutral, this mode can
cause the tractor to move.
When the display alternates between ‘N’ and ‘750’ this
indicates that the mode has completed.

Turn the key start switch off for at least 2 seconds to

store the calibration values.

NOTES: Transmission output speed and clutch pedal

position are constantly monitored. Calibration cannot
proceed unless the tractor is stationary and the clutch 25
pedal released.

Repeatedly depressing the upshift button will cycle

through each clutch mode, enabling a particular clutch
to be calibrated several times if required.

During each clutch calibration the synchroniser

positions are also calibrated:--
26
• During Clutch A -- Mid range synchroniser
calibrated
• During Clutch B -- Reverse range synchroniser
calibrated
• During Clutch C and D -- High range synchroniser
calibrated
• During Clutch E -- Low range synchroniser
calibrated

21- 47 27
SECTION 21 -- TRANSMISSION -- CHAPTER 2
NOTES

21- 48
SECTION 21 -- TRANSMISSION -- CHAPTER 3
SECTION 21 -- TRANSMISSION

Chapter 3 -- Dual Command Transmission (HI--LO)

CONTENTS

Section Description Page

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Chapter 4
21 112 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

21 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS -- HI--LO TRANSMISSION & RANGE GEARS

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed with constant--mesh gears and
synchronisers on all speed gears,
controlled by two independent clutch
packs
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Helically toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 forward and 3 reverse ranges for a
total of 12 forward and 12 reverse
speeds
-- Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Helically toothed
-- Reduction ratios:
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 15) : (46 x 55) = 1 : 7.03
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 29) : (46 x 37) = 1 : 2.45
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed and range shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, by two hand levers at the
operator’s right side and two
push--buttons located on the main shift
lever
Speed and range gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced--fed by a gear pump (same as
the power steering circuit pump)
Number of driven discs--Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of driven discs -- Clutch A . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of drive discs -- Clutch A . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch thickness under a load of163 kg
(1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32.7 to 32.9
Number of Belleville springs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . 9
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
-- Compressed length under a load of 215 . . . . . . . . . . . . . . mm 3.28
(to be continued)

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 3
SPECIFICATIONS -- HI--LO TRANSMISSION AND RANGE GEARS
(continued)
Number of driven discs--Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of driven discs -- Clutch B . . . . . . . . . . . . . . . . . mm 2.65 to 2.75
Number of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Thickness of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch B thickness under a load of 163 kg
(1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32.7 to 32.9
Number of Belleville springs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . 9
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2
-- Compressed length under a load of 215 kg (2108 N) . . . mm 3.28
Speed driven gear inner diameter . . . . . . . . . . . . . . . . . . . . . . . mm 60.060 to 60.090
Bush outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Speed output shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055
Range driven gear inner diameter . . . . . . . . . . . . . . . . . . . . . . . mm 60.060 to 60.090
Bush outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Range output shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055
PTO drive shaft diameter (at the bush) . . . . . . . . . . . . . . . . . . mm 31.950 to 31.975
Press--fit bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 to 32.085 ( ° )
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . mm 0.015 to 0.135
Shuttle gear end play adjust ring (9, Fig. 11) . . . . . . . . . . . . . mm 5.00 -- 5.15 -- 5.30
Shuttle gear end play adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 40
Speed output shaft thrust washer . . . . . . . . . . . . . . . . . . . . . . . mm 3.95 -- 4.00
Range input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 45
Range input shaft (12, Fig. 11) bearing adjust shims 1.70 -- 1.75 -- 1.80 --1.85 -- 1.90 -- 1.95
(12, fig. 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm -- 2.00 -- 2.05 -- 2.10 -- 2.15 -- 2.20 --
2.25 -- 2.30 --2.35 -- 2.40 -- 2.45 -- 2.50
-- 2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 --
2.80 -- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.10
-- 3.20 -- 3.30
Range output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . see page 45
Range output shaft (13, Fig. 11) adjust shims (13, fig. 11) . mm 1.70 --1.75 -- 1.80 --1.85 -- 1.90 -- 1.95 --
2.00 -- 2.05 -- 2.10 -- 2.15 -- 2.20 -- 2.25
-- 2.30 --2.35 -- 2.40 -- 2.45 -- 2.50 --
2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 -- 2.80
-- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.10 --
3.20 -- 3.30
( ° ) Final dimension to be obtained without grinding (to be continued)

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 3
SPECIFICATIONS -- HI--LO TRANSMISSION AND RANGE GEARS
(continued)
Implement pressure regulating valve spring (12, Fig. 12):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
-- Compressed length under a load of 278 to 304 N (28,4 to 31kg) 102.5
Implement working pressure . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 to 17.6 (17 to 18)
Lubrication pressure regulating valve spring (28, Fig. 11):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 29
-- Compressed length under a load of 48 (4.94 to 5.46kg) . mm 24.5
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 4.4 to 5.9 (4.5 to 6)

SPECIFICATIONS -- CREEP GEARS

Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Epicyclic spur gear set
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By a dedicated lever at the operator’s
left side
Creeper support and driven gear thrust washer thickness . . mm 1.465 to 1.535

SPECIFICATIONS -- SHUTTLE GEARS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, with helically toothed
gears, assembled as a standard
Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through a synchroniser by a dedicated
lever located at the steering wheel left
side
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (43 x 37 x 39) : (37 x 39 x 44) = 1 : 1.02
Driven gear bearing adjust shims (19, Fig. 11) . . . . . . . . . . . mm 2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 -- 2.80
-- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.05 --
3.10 -- 3.15
Driven gear bearing adjustment ............................... see page 43

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 3
TIGHTENING TORQUES
continued
Torque
DESCRIPTION Thread size
Nm kgm
Bolts and nuts, speed clutch/transm housing to engine . . . . . . . . . (see C3 and C4, page 2, Sec. 18)
Bolts, speed clutch/transm housing to rear axle . . . . . . . . . . . . . . . M14 x 1.5 176 18
Bolts, cab to rubber mounts SILENTBLOCK . . . . . . . . . . . . . . . . . . -- 340 to 420 34.7 to 42.8
Bolts, cab support bracket (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 114 to 148 11.6 to 15.1
Bolts, cab support bracket (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 250 to 309 25,5 to 31,5
Bolts, clutch housing front cover (C1) . . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4
Bolts, transmission housing cover (C2) . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Bolts, range rear bearing retaining plate (C3) . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Bolts, creeper gear fixed plate (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 54 5.5
Bolts, range rear bearing support plate(C5) . . . . . . . . . . . . . . . . . . . M14 x 1.5 142 14.5
Nut, range output shaft (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M47.5 x 1.5 294 30
Nut, speed output shaft (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M45 x 1.5 490 50
Bolts, damper assembly to flywheel (C8) . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 60 to 74 6.1 to 7.5
Screw, solenoid valve (C9) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 5.4 to 81 0.55 to 0.83
Screw, solenoid valve pin (C10) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . -- 47 to 54 4.8 to 5.5
Bolts, range and speed control lever support (C11) . . . . . . . . . . . . M10 x 1.25 49 5
Plug, lubrication pressure regulating valve . . . . . . . . . . . . . . . . . . . M18 x 1.5 49 5
Bolts, transmission input shaft support cover . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4

(*) Apply a couple of drops of New Holland Thread Seal 82995768

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 3

21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 3
SPECIAL TOOLS 293343 Output shaft nut spanner.
CAUTION X 293805 Input shaft bearing puller (use with tool
Operations described in this Section of the Manual no. 50062)
must be performed using the following ESSENTIAL X 293808 Output shaft retaining tool
tools marked with the identification code (X).
To work safely and achieve the best technical results 292176 Range input and output shaft end play
with additional savings of time and effort, these test tool (use with tools nos. 50013 and
mandatory tools should be used in conjunction with the 50018)
suggested special tools listed below and integrated 291525 Transmission and rear axle housing
with the self--made ones for which you will find the alignment pins
necessary construction drawings and specifications
directly on this Manual. 291051 Range input shaft bearing and gear
puller
List of special tools necessary to carry out the different X 293869 Output shaft bearing installer (use with
operations described in this Section. tool no. 50108)
295027 Cab lifting adapter (use with tool no. 292927 Slide hammer
290740)
292888 Clutch cover alignment pins
290740 Cab lifting hook (use with tool no.
292906 Drum snap ring installation pliers
295027)
295021 Clutch spring installer
290090 Overhaul rotary stand
292870 Pressure test kit (use with tool no.
292320 Tractor separation stand
295024)
291517 Transmission housing lifting hook
295024 Fitting (kit no. 292870)
293971 Transmission overhaul front bracket
295049 Range output shaft retaining tool
(use with tool no. 290090)
293972 Transmission overhaul rear bracket
(use with tool no. 290090)

2
Tool to be fabricated for range input and output shaft bearing adjustment (Mark tool with no. 50018 -- Dimensions in
mm).
Fabricate tool using Aq42 material.

21- 6
SECTION 21 -- TRANSMISSION -- CHAPTER 3

3
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 -- Dimensions in mm).
Fabricate tool using UNI C40 material. -- Use only part (a)

25844
4 5
Tool to be fabricated for clutch B snap ring (Mark tool Tool to be fabricated for range output shaft bearing
with no. 50115 -- Dimensions in mm assembly (Mark tool with no. 50061 -- Dimensions in
Fabricate tool using UNI C40 material. mm).
Fabricate tool using C30 material.

21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 3
Tool to be fabricated for range input shaft bearing
assembly (Mark tool with no. 50060 -- Dimensions in
mm).
Fabricate tool using C30 material.

6
Bracket to be fabricated to place the transmission on
the rotary stand, to be used with bracket tool no.
293971. (Mark tool with no. 50110 -- Dimensions in
mm).
Fabricate tool using Fe 42 C material.

25290

21- 8
SECTION 21 -- TRANSMISSION -- CHAPTER 3
Tool to be fabricated for input and output shaft bearing
assembly. (Mark tool with no. 50108 -- Dimensions in
mm).
Fabricate tool using UNI C40 material.

25291

8
Alignment pins for engine and speed
clutch/transmission housing and engine
removal/installation. (Mark tool with no. 50117 --
Dimensions in mm).
Fabricate tool using UNI C40 material.

25292

9
Adapter for reverse idler gear pin removal. (Mark tool
with no. 50143 -- Dimensions in mm).
Fabricate tool using UNI C40 material.

25280

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 3

27
11
Transmission Longitudinal and Sectional Views
1. Damper coupler 16. 1st and 2nd speed control synchroniser.
2. Clutch A housing 17. 3rd and 4th speed control synchroniser
3. Clutch A drive discs 18. Speed output shaft
4. Clutch A driven discs 19. Speed driven gear adjust shim
5. Clutch B housing 20. Under drive drive shaft
6. Direct drive and reverse drive shaft 21. Clutch B Belleville springs
7. Cover plate 22. Clutch A Belleville springs
8. Shuttle control synchroniser 23. O ring
9. Shuttle adjust shim 24. Shuttle control lever
10. Speed drive gear 25. Shuttle control fork
11. Range input shaft 26. Fork (25) stop pawl
12. Range input shaft adjust shim 27. Lubrication pressure regulating valve
13. Range output shaft adjust shim 28. Valve (27) spring
14. Low range control sleeve 29. Speed and range gear lubrication hose
15. Medium and high range control synchroniser

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on page 47

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 3

12
Range and Speed Control Assembly Sectional Views
1. FWD solenoid control valve 8. Control cable attach point
2. Hi--Lo control valve oil supply solenoid valve 9. PTO brake solenoid control valve
3. Control cable attach point 10. PTO solenoid control valve
4. Control cable attach point 11. Diff lock solenoid control valve
5. Speed gear control rail 12. Implement pressure regulating valve
6. Range gear control rail 13. Valve (12) spring
7. Control cable attach point 14. Pressure sensor

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on page 47.

13
Hi--Lo Control valve -- View and Cross Section
C1. Solenoid valve 1.72 to 2.79 Nm (0.175 to 0.285 kgm) 6. Reverse speed solenoid control valve
C2. Solenoid pin 14.9 to 20.3 Nm (1.520 to 2.071 kgm) 7. O ring.
1. Clutch A solenoid control valve 8. Drive piston
2. Clutch A oil supply fitting 9. O ring
3. Clutch B oil supply fitting. 10. Snap ring
4. Clutch B solenoid control valve 11. Cover
5. Forward speed solenoid control valve.

NOTE: Apply a couple of drops of New Holland Thread Seal 82995768 to screws C1 and C2 .

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 3
DESCRIPTION AND OPERATION
The Hi--Lo transmission is actuated by 2 multi--pack
clutches in oil bath, which allow hydraulic control of 4
speed gears or ratios in each range, both forward and
reverse.
Speed gears are selected using the main shift lever (2)
located at the right side of the operator’s seat. Range 1
gears are selected using lever (1).
To shift through speed or range gears, it is necessary
to press the clutch pedal to end of travel and move the
lever (1 or 2) involved. 2
On the main shift lever there are two buttons, identified
with a tortoise and a hare, respectively. By pressing
these buttons it is possible to select direct drive or
under drive within the same speed gear or ratio. This
is obtained hydraulically and with the tractor on the
move. 25804

Clutch A controls under drive, clutch B controls direct TI/17

drive and reverse gears. 14
Range gears provide 3 ranges, namely high, medium
and low. High and medium ranges are engaged
through a synchroniser while the low range is engaged
1
through a sliding sleeve.
Shuttle gears allow to shift through the 3 ranges also
in reverse.
The Hi--Lo transmission with range and shuttle gear
assemblies provides:
-- 24 forward and 12 reverse ratios in the 40 KPH
option;
-- 48 forward and 24 reverse ratios in the 40 KPH
option fitted with creeper gears; 25805
-- 23 forward and 12 reverse ratios in the 30 KPH
option; 15
-- 46 forward and 24 reverse ratios in the 30 KPH
option fitted with creeper gears.
To shuttle from forward to reverse, it is necessary to
move the lever at the left of the steering wheel. It is not
necessary to press the clutch pedal, but engine rpm
and tractor speed must be reduced.

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 3

Static oil
Pressure oil
Pressure lubrication oil

16
Hi--Lo Transmission Oil Flow with Direct Drive Engaged
Direct drive is selected using the button (hare symbol) Pressure oil lubrication is fed to all the Hi--Lo
on the lever (2, Fig. 14). The double piston (3) is in the transmission components. Oil pressure is regulated by
position of forward engaged. Oil from the hydraulic the valve (14, Fig. 12).
pump flows through the solenoid valve (4, Fig. 14) and If the clutch pedal is pressed to shift the speed gear, the
enters clutch B. solenoid valve (4, Fig. 13) stops sending oil to clutch B
Oil moves the piston (2) against the force of the and consequently the piston (2) is pushed away from
Belleville springs (1) and compresses clutch B. Under the clutch discs under the action of the Belleville
these conditions, direct drive is engaged. springs (1). The clutch is released.

21- 13
SECTION 21 -- TRANSMISSION -- CHAPTER 3

Static oil
Pressure oil
Pressure lubrication oil

17
Hi--Lo Transmission Oil Flow with Under Drive Engaged
Under drive is selected using the button (tortoise Pressure oil lubrication is fed to all the Hi--Lo
symbol) on the lever (2, Fig. 14). The double piston (3) transmission components. Oil pressure is regulated by
is in the forward engaged position. Oil from the the valve (14, Fig. 12).
hydraulic pump flows through the solenoid valve (1, If the clutch pedal is pressed to shift the speed gear, the
Fig. 13) and enters clutch A. solenoid valve (1, Fig. 13) stops sending oil to clutch A
Oil moves piston (1) against the force of the Belleville and consequently the piston (1) is pushed away from
springs (2) and compresses clutch A. Under these the clutch discs under the action of the Belleville
conditions, under drive is engaged. springs (2). The clutch is released.

21- 14
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION HOUSING

Removal -- Installation (Op. 21 112 10)

Remove the transmission housing from the tractor as

follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Connect the engine hood to a hoist using a nylon
cable (1) and disconnect the hood struts (2) (one
on the LH side and one on the RH side).

23353

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 3
5. Unscrew the retaining screws and remove side
panels (1) (one on each side).

4
6. Jack up rear tractor and place two suitable stands
(2) under the final drive cases to raise the wheels
off the ground. If necessary, detach lift rods from
lower links.

5
7. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the left wheel.

6
8. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect tool to a hoist using hook tool no. 290740
and keep hook tensioned.

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 3
9. Detach connectors at the washer motor. Detach
washer bottle (1) lines and remove bottle.

8
10. Remove the clip and detach the creep gear control
idler lever (2). Loosen the parking brake control
cable retaining screw (3).

9
11. Remove the pin securing the fork (4) to the parking
brake actuator lever. Loosen the nut securing the
cable to the fork (4) and release cable.

10
12. Loosen the attaching nut and detach the ground
cable (5) between the cab and rear axle.

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 3
13. Release the clamp (1) and detach the main tank
breather tube.

12
14. Detach the ground synchronised PTO control
cable (2) from the rail.

13
15. Detach the two connectors (3 and 4) located under
the cab floor.

14
16. Detach both engine to cab connectors (5 and 6).

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 3
17. Disconnect radar and fuel filter connectors (4 and
3, respectively). Remove protection and
disconnect connectors (1 and 2) from starting
motor.

16
18. Detach light connector (5) located on the handrail
(repeat for both tractor sides).

17
19. Detach heater to engine connecting lines (6)
located under the right hand front side of the cab..

18
20. Loosen the nut and detach the throttle control cable
(7) from injection pump.

21- 19
SECTION 21 -- TRANSMISSION -- CHAPTER 3
21. Detach connectors (1) from brake master
cylinders.
22. Loosen fittings (2) and detach brake control
hoses.
23. Detach the brake master cylinder lines to the
reservoir.

20
24. Loosen the power steering motor connecting
lines (4) to the steering pump.

21
25. Detach the power steering motor connecting
lines (5) to the steering cylinders.

22
26. Loosen fittings and detach the air conditioning lines
(6).

21- 20
SECTION 21 -- TRANSMISSION -- CHAPTER 3
27. Loosen the locknut, slide out the cotter pin and
detach the PTO control cable (1).

24
28. Remove pins (2), loosen retaining screws (3) and
detach the remote valve control cables, right hand
side.
29. If remote valves are fitted also on left hand side,
repeat step 28 for left hand side remote valves.

25
30. Loosen the screw attaching steps (6) to the
bracket.

26
31. Loosen the screw attaching steps (1) to the cab
platform.
32. Repeat steps 30 and 31 on opposite side and
remove steps.

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 3
33. Raise the cab mat (2) and loosen the cab mounting
bolt while holding the locknut under the cab floor.
Retrieve bolt and washer. Repeat for both tractor
sides.

28
34. Loosen the rear cab bolts (on both sides).
35. Slowly raise the cab taking care that no
components are connected, hooked or interfering.
Remove the cab and lower on a suitable support
base.

29
36. Loosen the plug (3) and drain oil from the rear axle
and transmission housings into a suitable
container (see specified quantity on page 6,
Section 00).

30
37. Drain fuel tanks, then loosen the clamp (1)
retaining the connecting line between the main and
auxiliary tanks.

21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 3
38. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
39. Detach the fuel return line (2) from the injection
pump to the auxiliary tank. Remove auxiliary tank.

32
40. Loosen the clamp and detach the injection pump
supply line (5). Detach connectors (4), then
unscrew and remove the fuel level sensor
assembly.

33
41. Loosen the nut of the metal strap (6) securing the
main tank. Remove the strap and tank.

34
42. Loosen the retaining screws and remove the cab
and fuel tank support bracket (1). (Repeat on both
sides of the transmission housing).

21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 3
43. Loosen the retaining screws and remove the main
tank support bracket (2).

36
44. Loosen the attaching screws and remove the radar
unit and mounting bracket (3).

38
46. Loosen the clamps and separate the oil cooler
hoses (1) from tubes.

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 3
47. Loosen retaining screws and detach speed and
range gear control cables (1 and 2).

40
48. Detach all connectors from the speed and range
control valve assembly and from rail position
sensors.
NOTE: Before detaching connectors, mark each
connector and respective solenoid valve or position
sensor to assist reassembly and avoid reversal of
connections.

41
49. Loosen the retaining screws and remove the
propshaft guard.
50. Remove snap ring (4) and slide out sleeve (5).
Repeat for transfer box snap ring and sleeve.

42
51. Loosen the bearing--support (3) retaining screws
at the transmission housing, detach and remove
the front diff lock control line (2).

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 3
52. Place stand tool no. 292320 with one of the two
trolley jacks (6) under the engine and the other
under the transmission housing.
53. Place two wooden wedges (one each side)
between the front axle support and front axle to
prevent engine oscillation.

44
54. Loosen the retaining screws and remove starting
motor (1).

45
55. Remove the transmission housing to engine
attaching bolts.

46
56. Loosen the metal spacer retaining screw (2) at the
transmission housing.
57. Separate the engine from the transmission
housing.

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 3
58. Loosen two bolts from the transmission housing
top cover (1), screw in two eyebolts, secure two
cables and keep them tensioned using a hoist.
59. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool no.
292320 under the rear axle housing.
60. Loosen the transmission housing to rear axle
housing attaching bolts and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

48
61. Reinstall the transmission housing to the rear axle
housing and engine observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 60 back to step 1.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 28 and on page 13, Section 18.
-- Tighten to correct torques as detailed on page
4.

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 3

20270

49
Pattern for application of sealant during installation of the transmission housing to rear axle housing.

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION

Disassembly--Reassembly (Op. 21 112 85)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Prior to servicing the Hi--Lo transmission, it is

necessary to remove the transmission housing
following the procedure detailed on pages 15 to 27.
Then, proceed as follows:
1. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets, tools
nos. 293971 and 293972.
2. Perform steps 3 to 5 to remove the range valve and
control assembly, if not previously removed.
3. Loosen retaining screws and remove rheostat (1)
from the Hi--Lo valve.

1
4. Loosen retaining screws and detach the Hi--Lo
transmission valve/top cover (2) using a lever.

2
5. Loosen retaining screws and remove the Hi--Lo
range and speed rail assembly (3).

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 3
6. Detach oil supply fittings (1 and 2) to clutches A and
B, respectively.

4
7. Loosen the screws retaining clutch A cover (3) to
the transmission housing. Screw in 3 bolts (4) into
the threaded holes until complete separation of the
cover (3). Remove the cover along with clutch A
from the transmission housing.

5
8. Remove snap ring (5) and retrieve clutch discs and
centring springs.

6
9. Assemble tool no. 295021 (6) on clutch B bell
housing, turn the tool bolt to compress clutch
release Belleville springs and remove Belleville
spring retaining ring. Remove tool from the bell
housing and retrieve Belleville springs.
10. Blow compressed air into the oil supply hole to
clutch B to expel clutch B drive piston.

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 3
11. Remove the retaining ring (1) and withdraw clutch
B bell housing (2).

8
12. Loosen the lubrication line (4) fitting. Loosen
screws retaining the cover (3) with the valve and
remove cover.

9
13. Remove lubrication oil outer fitting (5) and retrieve
washer and seal. Retrieve the line (4) from inside
the housing.

10
14. Loosen the cover (1) retaining screws, place tool
no. 295049 (2) on the transmission housing,
loosen the output shaft locknut using spanner tool
no. 293343 (3) and retrieve cover (1).

21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 3
15. Remove retaining bolts and detach the range
output and input shaft bearing cap (1).

12
16. Using a puller tool no. 291051 (1) and a suitable
insert (2), remove gear (3), bearing and bush. Be
careful to keep the bearing off the input shaft.

13
17. Loosen the plugs (1) and retrieve springs and
actuating balls. Remove plug (2).

14
18. Slide out the low and medium--low range control
fork retaining springs (1). Also, slide out roll pins (7)
from both range selector dogs.

23383

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 3
19. Remove the fork (1) along with the engagement
sleeve, withdraw the rail (2) and retrieve selector
dog (3).

16
20. Withdraw the control rail (1) and safety pawl (2)
from both rails (1 and 2, Fig. 17).

17
21. Withdraw the medium--low and medium--high
gears (1 and 2, respectively) along with their inner
bushings and thrust washer (3).

18
22. Remove the synchroniser (1) (if fitted) or the
engagement sleeve along with the control rail and
output shaft (2).

21- 33
SECTION 21 -- TRANSMISSION -- CHAPTER 3
23. Remove the range input shaft (1).

20
24. Loosen the plug (1) and retrieve spring and
actuating pawl.

21
25. Partially slide out the roll pin until releasing the
control lever (3) from the fork (1). Remove control
lever and fork.

22
26. Remove the snap ring (1), withdraw the input shaft
from the rear side of the transmission housing.

21- 34
SECTION 21 -- TRANSMISSION -- CHAPTER 3
27. While sliding out the shaft, retrieve drive gear, snap
ring (2) and half--rings (1).

24
28. Also retrieve oil seal (2) and bush (1) from the input
shaft front side.

25
29. Remove the snap ring (1) and retrieve adjust shim
(2).

26
30. Slide out the shaft along with the bearing from the
transmission housing front side. At the same time,
retrieve the shuttle gears and control synchroniser
assembly from the inner side of the housing.

21- 35
SECTION 21 -- TRANSMISSION -- CHAPTER 3
31. Remove the snap ring and, using adapter tool no.
50143 (1, see page 9) and a slide puller tool no.
292927, remove the reverse idler gear pin. Leave
gear inside.

28
32. Loosen plugs (1) and remove springs and
actuating balls.

29
33. Loosen the stop plugs (5), slide out the two selector
dog (6) retaining roll pins and the inner fork
retaining roll pin.

30
34. Slide out the rails from the rear side and retrieve
forks and selector dog.

21- 36
SECTION 21 -- TRANSMISSION -- CHAPTER 3
35. Install shaft holding tool (1) and wrench (2).

32
36. Unstake the transmission output shaft locknut (1),
loosen the locknut and retrieve the bush.

33
37. Using an aluminium punch from the front side,
release shaft from bearing.

34
38. Set the transmission housing upright, withdraw the
output shaft (1) and retrieve the group of gears.

21- 37
SECTION 21 -- TRANSMISSION -- CHAPTER 3
39. Remove snap ring (2), bearing inner retaining ring
and retrieve hubs for clutches A and B (1) along
with the bearing and clutch A discs along with the
centring springs.

36
40. Remove seal (3).

37
41. Remove outer (4) and inner snap rings. Acting on
the outer side of clutch A (5), slide out clutch from
cover. Retrieve the bearing.

38
42. Position tool no. 295021 (6) on clutch A (5). Turn
the tool screw to compress the clutch release
Belleville springs and remove stop ring. Remove
tool no. 295021 (6) and retrieve Belleville springs.

21- 38
SECTION 21 -- TRANSMISSION -- CHAPTER 3
43. Place clutch A bell housing on the cover (2), blow
compressed air into control oil supply hole and
remove piston (1).

40
44. Loosen the lubrication oil pressure regulating valve
(3). Disassemble the valve and inspect
components.
45. Reassemble the speed and range gears into the
transmission housing observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 44 back to step
1.
-- Refer to figures on pages 10 and 11 for correct
orientation of the different parts.
-- Ensure the housing is thoroughly cleaned
(especially inner compartments).
-- Check seals and replace if damaged.
41
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 47.
-- Tighten to correct torques as detailed on page
4.
-- Consider the following operations and perform
adjustments as detailed on pages 43 to 46.
46. After removing the snap ring and thrust washer,
disassemble the transmission input shaft bearings
using tools nos. 293805 (1) and 50062 (2) (see on
page 6, Chap. 5). Heat the bearings to reinstall
them and settle using a brass punch.

21- 39
SECTION 21 -- TRANSMISSION -- CHAPTER 3
47. Mount retaining tool no. 293808 (1) on the
transmission output shaft and insert a spanner (3)
to hold it in place. Support tool (1) using tool no.
293805 (2) attached to the housing.

43
48. Install front bearing (2) on to the transmission
output shaft using tool no. 293869 (1).

44
49. Using a feeler gauge (9), check that clearance is to
specification (0 to 0.15 mm). Adjust shims
available are listed on page 2.

45
50. When reassembling clutch A, reassemble bearing
(1), then raise the hub (8) using a suitable tool and
insert the snap ring (10).

21- 40
SECTION 21 -- TRANSMISSION -- CHAPTER 3
51. When reassembling the snap ring to the clutch
cover (8), ensure that the leak oil discharge hole (7)
is exactly in--between the two ends of the outer
snap ring.

47
52. To assist reassembly of clutch B disc retaining ring,
it is necessary to insert two suitable punches (1)
into two oil discharge holes to keep the clutch disc
centring springs compressed.

48
53. Using an expanding puller tool no. 292906 (5),
position tool no. 50018 (3) with three legs tool no.
50115 (2, see page 7). Turn the puller screw and
position the clutch disc retaining ring into its seat.

49
54. With the clutch A housing assembled to the
transmission housing, install the bearing (7) using
tool no. 293869. Fix bearing with the retaining rings
and install the seal.

21- 41
SECTION 21 -- TRANSMISSION -- CHAPTER 3
55. Prior to transmission housing installation, it is
necessary to position the drive shaft (1) and seal
(2).

51
56. Heat and press--fit the bearing (3) on to the input
shaft using tool no. 50060 (2) shown on page 8.
Using tool no. 50013 (1) (see page 7), keep the
bearing properly seated during cooling.

52
57. Heat and press--fit the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 7.
Using tool no. 50018 (1) (see page 6), keep the
bearing properly seated during cooling.
NOTE: Remove tools nos. 50060 (2, Fig. 52) and
50061 (2, Fig. 53) when the bearings (1 and 3) have
completely cooled down.

21- 42
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION HOUSING

Shuttle gear bearing adjustment

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
58. Remove the snap ring (5) and slide out adjust shim
(4), front bearing (3), spacer (2) and rear bearing
(1).

54
59. Reassemble all parts without the adjust shim.
Ensure the assembly is bottoming. Measure
distance (L1) from top of gear (2) to the bearing
outer race (1).
L1

55
60. Place the gear on a suitable bush (1) to raise the
inner assembly. Ensure also the snap ring is
raised.

21- 43
SECTION 21 -- TRANSMISSION -- CHAPTER 3
61. Measure distance (L2) from top of gear (2) to the
bearing outer race(1). Adjust shim (2, Fig. 57) to be
added is given by:
S = L1 -- L2 -- 0.05 mm
where:

L2
S = Adjust shim (2).
L1 and L2 = Readings on the gear
0.05 mm = Decrease necessary to compensate
for bearing increased pre--load deriving from
tightening of the transmission output shaft locknut.
If necessary, round off the value (S) to the previous
0.05 mm.

Example: 57
Reading L1 = 10.25 mm.
Reading L2 = 7.33 mm.
Adjust shim:
S = 10.25 -- 7.33 -- 0.05 = 2.87 mm.
Adjust shim to be assembled is 2.85 mm.
NOTE: Available adjust shims for the shuttle driven
gear are listed on page 3.
62. Remove snap ring (1), assemble adjust shim (2) as
previously found and lock the assembly reinstalling
snap ring (1).

21- 44
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION HOUSING

Range Input and Output Shaft Taper Bearing

Adjustment
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
63. Install cover (2) without the adjust shim. Install tool
no. 50013 (1) (see page 7) on to the input shaft.

59
64. Screw installer tool no. 292176 (2) on tool no.
50013 (3). Place a dial indicator (1) with the stylus
touching the bearing inner race. Turn the shafts to
settle the bearing rollers, reset gauge to zero
ensuring that the assembly is bottoming. Through
the lever of installer tool no. 292176 (2), bring the
assembly to touch the cover (4) and read the travel
(L) on the dial indicator.
Adjust shim to be added is given by:
S = L-- (0 to 0.06 mm)
where:
S = Adjust shim
L = Travel reading
0 to 0.06 mm = Input shaft bearing end play.
NOTE: Available adjust shims for the range input shaft
bearings are listed on page 2.
65. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 64 and
check end play is to specification, 0 to 0.06 mm.
Remove tools (2 and 3).

21- 45
SECTION 21 -- TRANSMISSION -- CHAPTER 3
66. Install disc (1) with a test shim. Remove output
shaft lubrication [Link] tool no. 50018 (4)
(see on page 6), installer tool no. 292176 (3) and
dial indicator (2). Ensure the indicator stylus is on
the bearing inner race.
Ensure the indicator stylus is on the bearing inner
[Link] the shafts to settle the bearing rollers
and reset gauge to zero ensuring that the assembly
is bottoming.
Using the lever of installer tool no. 292176 (3) bring
assembly to touch the disc (1) and read travel (H)
on the dial indicator.
Shim to be added is given by:
S1 = H + Sp -- (0 to 0.06 mm) 61
where:

S1 = Adjust shim.
Sp = Test shim
H = Travel reading.
0 to 0.06 mm =Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 2.
67. Dismantle tools (3 and 4), remove disc (1), replace
test shim (Sp) with adjust shim (S1), reinstall disc
(1) and tools (3 and 4). Repeat step 66 to check end
play is to specification, 0 to 0.06 mm. Remove tools
(3 and 4) and screw in the output shaft lubrication
plug.

21- 46
SECTION 21 -- TRANSMISSION -- CHAPTER 3

62
Pattern for application of sealant during installation of speed and range control assembly, upper cover and front
cover of clutches A and B.

21- 47
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION VALVE

Removal--Installation Disassembly--Assembly
(Op. 21 134 40 -- 21 134 46)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To service the Hi--Lo transmission valve, it is necessary

to remove the cab following the procedure described
on pages 15 to 22
Proceed as follows
1. Loosen retaining screws and remove the
synchroniser position sensor (1) from the Hi--Lo
valve.

1
2. Loosen retaining screws and detach the Hi--Lo
transmission valve (2) using a lever.

2
3. Remove the retaining ring (3). Using a screwdriver,
retrieve piston (4).

21- 48
SECTION 21 -- TRANSMISSION -- CHAPTER 3
4. Using a screwdriver, remove the O ring (1) from the
piston seat.

4
5. Slide out piston assembly (2).

5
6. Remove the snap ring (3) and withdraw the bush.

6
7. Remove the oil temperature sensor (4).

21- 49
SECTION 21 -- TRANSMISSION -- CHAPTER 3
8. Loosen the locknut (1) and slide out solenoid valve
(2).

8
9. Loosen valve pin (3) and slide it out.
10. Reassemble and reinstall the Hi--Lo transmission
valve observing the following:
-- Reassembly and reinstallation follow the
disassembly and removal procedures in
reverse, from step 9 back to step 1.
-- Refer to figures on page 11 for correct
orientation of the different parts.
-- Ensure the valve body is thoroughly clean
(especially inner compartments).
-- Check seals and replace if damaged.
-- Before reinstalling the Hi--Lo transmission
valve, thoroughly clean and degrease mating 9
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 47.
-- Tighten to correct torques as detailed on page
4.

21- 50
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION CONTROL
ASSEMBLY

Removal--Installation (Op. 21 134 30)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the Hi--Lo transmission control assembly as

follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Raise rear tractor, place a stationary stand (1)
under the RH final drive case and remove rear RH
wheel.

2
4. Disconnect speed and range control cables (1)
from rails (2) and supports (3).

21- 51
SECTION 21 -- TRANSMISSION -- CHAPTER 3
5. Detach all electrical connectors (1) from solenoid
valves and sensors.
NOTE: Before detaching connectors from the control
assembly, mark each connector and respective
solenoid valve or sensor to assist reassembly and
avoid reversal of connections.

4
6. Loosen all lines (1) from the speed and range
control rail assembly.

5
7. Loosen two retaining screws and insert two
alignment pins (1) into the holes. Loosen all
retaining screws and remove control assembly.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

8. Reinstall the speed and range control rail assembly

to the speed clutch/transmission housing
observing the following:
-- Reinstallation follows the removal procedure
in reverse, from step 7 back to step 1.
-- Before reassembling the speed and range
6
control rail assembly to the speed
clutch/transmission housing, thoroughly clean
and degrease mating surfaces and apply a 2
mm. bead of sealant following the pattern
shown in the figure on page 47.
-- Tighten to correct torques as detailed on page
4.

21- 52
SECTION 21 -- TRANSMISSION -- CHAPTER 3
HI--LO TRANSMISSION CONTROL
ASSEMBLY

Disassembly--Assembly
(Op. 21 134 32 -- 21 134 70)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To service the Hi--Lo transmission control assembly it

is necessary to remove it from the transmission
housing following the procedure described on pages
51 and 52.
Proceed as follows:
1. Remove the four gear status sensors (1).

23608

1
2. Remove control rods (2 and 3) and idler levers (4
and 5) from the outer side of the assembly.

23609

2
3. Acting from the control assembly inner side, loosen
retaining screws and remove speed and range
control levers (6 and 7).

23610

21- 53
SECTION 21 -- TRANSMISSION -- CHAPTER 3
4. Disassemble the power steering oil suction valve
(1).

23611

4
5. Loosen the auxiliary service circuit oil pressure
regulating valve (2) and retrieve spring and piston.

23612

5
6. Loosen the nut (2) and slide out the solenoid valve.

6
7. Loosen valve core (1) and remove.

21- 54
SECTION 21 -- TRANSMISSION -- CHAPTER 3
8. Loosen and remove pressure sensors and fittings.

8
9. Reassemble the Hi--Lo transmission control
assembly observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 8 back to step
1.
-- Refer to figures on page 11 for correct
orientation of different components.
-- Check seals and replace if damaged.
-- Upon reassembly, ensure that, with the inner
transmission control rail in the normal position
(rail fully in), the line passing for the rod attach
points (1 and 2) is parallel to the control rail. If
not, adjust the rod (3) until correct length is
obtained. 9
Repeat for attach points (5 and 6) and adjust
rod (4) if necessary.
-- Tighten to correct torques as detailed on page
4.

21- 55
SECTION 21 -- TRANSMISSION -- CHAPTER 3
NOTES

21- 56
SECTION 21 -- TRANSMISSION -- CHAPTER 4
SECTION 21 -- TRANSMISSION
Chapter 4 -- Dual Command (Hi--Lo) Transmission
-- Calibrations, Fault Finding, Pressure Testing And Limp Home Procedures

CONTENTS

Section Description Page

21 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limp Home Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Error Code Fault Finding Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Introduction With the use of micro--processors it is often that this

item is blamed for any malfunction but the real truth is
The transmission electronic management system has that this item is usually sound and that the fault is due to
an inbuilt self diagnostic facility. This facility utilises the poor contacts in the associated connectors.
digital display of the gear shift handle assembly to
indicate, in coded format, any malfunction in the Each connector illustrated and identified in the wiring
electrical and electronic circuitry and in the diagrams in Section 55 and referred to in the following
micro--processor. It should be noted that the self fault finding procedure, has the same identification
diagnostic capability is generally limited to diagnosis of reference. For example, the main transmission
the electrical and electronic circuitry and related processor connectors are referred to as Connectors
components, however, there are some codes, which C100 and C101 in the illustration and also referred to
can be generated if pressure switch circuits are not as C100 and C101 in the fault finding procedure. Often
closed because of an actual lack of hydraulic pressure. in the fault finding flow chart the connector and pin are
Any malfunction of the mechanical and hydraulic abbreviated and will read, for example, C100--21. The
components must be diagnosed using conventional C100 refers to the connector and the 21 to the pin
techniques, performance characteristics and tooling, number. Alternatively, for connectors with fewer pins,
such as pressure testing equipment. Full guidance for the identification will read, C014--FM3100--B/G/S.
both electrical self diagnosis and conventional This is broken down as follows:
diagnosis is contained within this section.
C014 Connector number
Trouble--shooting and fault finding should always be FM3100 Front Main harness, circuit number
carried out in a logical and planned sequence, many 3100
apparent faults associated with electronic components B/G/S Wire colour
are often hastily diagnosed and result in the
replacement of expensive components. An extra few Reference will have to be made to the wiring chapter of
minutes confirming the apparent fault will result in a Section 55 to correctly identify the pin in question.
more positive and cost effective repair.

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 4
Where the fault finding procedure requires checks for
continuity a visual inspection of the wiring should be
made prior to conducting tests to ensure that obvious
‘mechanical’ damage has not occurred to the harness
or the connectors.

A good quality multi--meter is an essential item to

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high range
and work downwards to avoid damaging the TA60--21--014
instrument. 1

IMPORTANT: Care should be used when using the

multi--meter, only use the instrument as instructed to
avoid damage to the internal elements of the
micro--processor. When checking the continuity of
wiring, sensors or switches it is necessary to isolate the
electronic micro--processor and ensure the keystart is
turned off to prevent possible further damage. The
keystart should only be switched on and the processor
connected where specifically instructed in the fault
finding procedure.

If it is found necessary to clean the connectors a

contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS. Do
not use a cleaner that contains Trichloro--ethylene, this
solvent will damage the plastic body of the connector.
It is preferable to use a cleaner with a Freon T.F. base.

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 4
CLUTCH AND SYNCHRONISER CALIBRATION

The Hi--Lo transmission has wet multi--plate clutches

that require periodic calibration to compensate for
wear. Calibration should only be necessary if a
deterioration in gear shift quality is noted.
NOTE: During the calibration procedure the electronic
management system detects precisely the point at
which the clutches start to engage . The engagement
is detected by a reduction in engine speed. During
calibration it is essential that no action is taken to to
cause the engine speed to vary. Be sure that the air
conditioner and all electrical equipment is switched off. 1
Do not operate the PTO or any hydraulic lever or move
the hand or foot throttle.
There are two methods to enter the calibration mode:
(i) Through the diagnostic connector, using special tool
No. 4FT.950 and menu mode H1, or,
(ii) By depressing both Hi and Lo buttons on the shift
lever during start up.
Tractor Preparation

NOTE: The clutches should be adjusted when the

transmission oil is at a temperature of 20°C (68°F) or
over.
2
Park the tractor on level ground, away from obstacles
(in case of unexpected tractor movement).

Apply handbrake, switch off all electrical equipment

and air conditioning if fitted. Stop the engine and place
remote levers in neutral and lower hydraulic equipment
to the ground.

Place all the shift levers in neutral. Block the wheels,

front and rear.

Either, (i) Install tool 4FT.950 into the diagnostic plug 3

and select H1 by depressing the diagnostic switch
once or (ii) press and hold both the Hi and Lo buttons
and start the engine.

‘‘CAL‘ will appear in the transmission display, (release

Hi and Lo buttons).

Set engine speed to 1200 ERPM ±100.

Select forward, first gear, high range (C) and release

the clutch.

The transmission is now ready for calibration. 4

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 4
Press and hold upshift button to calibrate clutch Hi.

If the start up procedure was incorrect a ‘‘U” code will

appear. See ‘Error Codes’.

5
After a few seconds the displayed Hi is replaced by a
number which increases during calibration.

Hold the upshift button until the engine speed

decreases by 50 RPM and the number stops
increasing.

6
Press the down shift button to calibrate the Lo clutch in
the same manner as the Hi clutch.

Synchroniser Calibration

To calibrate the synchroniser, at any stage after initial

tractor preparation, press both the Hi and Lo buttons 7
and hold.

‘‘SOC” appears during calibration.

‘‘END” displays to signify completion.

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 4
PRESSURE TESTING
Transmission Clutches A and B

1. Prepare the tractor for pressure testing:

(i) Remove the instrument console side covers, lift and

remove cab rubber mat and remove the floor pan.

(iii) Ensure the handbrake is fully applied and wheels

chocked.

(iv)Disconnect a range switch connector and install TA6021012

Special Tool 4FT.951 (bypass connector) into the
2
harness, (1) Figure 2.

(v) Start and run the tractor to warm the transmission

oil to a minimum temperature of 50°C (122°F).

2. Install suitable pressure gauges, (0--40 bar, 0--600

lbf.in2), Figure 3,
1. Pressure gauge, FT8503A, with adaptor
FT8503--8
2. Adaptor, NH.35--102 (10--1.00mm x 7/16
JIC)
3. Hose, (Finis Code 3936707)

Into clutch A and B pressure test points. Figure 4.

TA6021011

4
21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 4
3. Start the engine, engage 1st GEAR, and shuttle to
FORWARD, leaving the RANGE IN NEUTRAL.
Increase engine speed to approx 1200 rev/min.

4. Using the Hi--Lo buttons on the main shift lever,

switch between Hi and lo drive and observe the
gauges.
TA6021005
5

Each clutch should obtain 16--18 bar (235--261 [Link])

maximum pressure, when fully engaged and zero
pressure when disengaged.

TA6021007
6

During the swapping of clutches there is an overlap

period where both clutches have approximately 5 bar
(75 [Link]) at the crossover point.

When the clutch pedal is depressed a gradual reducing 7

of pressure should be seen and when the clutch pedal
switch has operated, zero pressure should be
indicated on the gauge. When releasing the clutch the
opposite of disengaging should be seen with a gradual
and smooth increase of pressure up to maximum
pressure.

21- 6 8
SECTION 21 -- TRANSMISSION -- CHAPTER 4
Shuttle Synchroniser Operating Piston Pressure
Testing

NOTE: Due to the operating characteristics of the R F

synchroniser it is not possible to accurately pressure
test the synchroniser operating piston during normal
tractor operation. The synchroniser will only take the
required pressure to move and then the pressure will
be cut. This would be seen only as a momentary blip on
a pressure gauge. Therefore the following procedure,
using the calibration mode, should be used to
determine if full pressure is being achieved.

1. Prepare the tractor as described for testing the A

TA6021010
and B clutches.
9
NOTE: If only pressure testing the synchroniser piston
it is not necessary to install the range switch bypass
connector, tool number 4FT.951.

2. Install the pressure gauges, adaptors and hoses

into the test points located in the top cover, Figure
9.

3. Enter the calibration mode for the synchroniser:--

(i) Press and hold engaged, both the Hi--Lo shift

buttons on the main lever. With the buttons
depressed start the engine.

(ii) ‘CAL’ will be displayed on the instrument panel.

Release the buttons.

(iii) Press and hold in both the Hi--Lo shift buttons

again. After a few seconds ‘SOC’ will be displayed
and the synchroniser calibration will commence.

The table (Figure 11) shows the synchroniser

calibration stages and at what stage pressure can be
10
expected to be seen.

Pressures
Stage Forward (F) Reverse (R)
1 NO NO

2 NO YES

3 B CLUTCH PRESSURISED

4 NO NO

5 YES NO

11
21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 4
LIMP HOME
1

WARNING
Care should be taken when operating the tractor
with the limp home harness connected. Clutch
engagement will be harsher than normal. Do not
leave the limp home harness connected when the
operation has been completed.
2
In the unlikely event of an electrical fault developing
within the transmission that renders the tractor
immobile, for example, failure of the supply voltage to
the PWM valves, the emergency ‘Limp Home 12
Harness’, Special Tool No. NH.21--100 for
Power/Range/Dual Command transmissions, is
available to enable the tractor to be driven onto a
transporter or hard standing, in order that the repair
can be carried out in a suitable location. The Limp
Home device is not and must not be used as a means
to continue operating the tractor in its work
environment.

To engage and operate the ‘Limp Home Harness’

proceed as follows:--

1. Apply the parking brake.

2. Stop the engine and turn keystart off. 13

3. Remove the electronic draft control panel.

4. Locate and disconnect the rear main harness

access connector, Figure 13, enabling the
connection of the limp home harness connector,
marked with ‘HARNESS’, Figure 12, into the rear
main harness of the tractor, Figure 15.

5. Connect the other connector of the Limp Home

harness Figure 12, marked ‘DIAGNOSTIC’, to the
‘BLACK’ diagnostic plug, Figure 15.

6. Start the vehicle.

7. Select forward or reverse using the switch, (2)

14
Figure 12, on the Limp home harness control box.

8. Operate the momentary switch, (1) Figure 12, of the

Limp Home Harness to move the vehicle. If
necessary, depress the foot throttle to increase
engine speed.

9. When the tractor has been delivered to the repair

area, disconnect the Limp Home Harness and
reconnect the limp home access connector of the
rear main harness and proceed with diagnosing and
repairing the fault.

21- 8 15
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES --DUAL COMMAND
ERROR DISPLAY LOGIC
1. Errors are displayed on the right hand liquid crystal
display of the AIEC panel or the centre display of
EIC panels and are prefixed with an ‘‘E”.
2. Error codes always flash.
3. There are four types of errors: Disabling, “N”, “CP”,
and Hidden.
4. Disabling errors disable the transmission
permanently (until the next power-up).

10
5. Disabling and hidden errors are accompanied by a
steady alarm for 5 seconds. After 5 seconds, the
error code continues flashing on the LCD, but the
alarm stops. If the error clears during the 5 second
period, the alarm will stop when the error clears,
and the LCD will return to normal display.
6. If there are multiple disabling or hidden errors to
display, they will be displayed sequentially.
Example, for codes E11, E17 and E21:
LCD: | E11------ |E17------ | E21------ | E11 | E17 |
E21 |
Time: | 5 sec | 1 s | 5 sec | 1 s | 5 sec | 1s | 5 sec
| 5 sec | 5 sec | 5 sec | etc...
Alarm: |steady |off|steady |off|steady |off|
11
off--------------------------------------
NOTE: The display sequence may not always start
with the lowest error number, and the errors may not
be displayed in numerical order at first. There is some
“randomness” depending on the exact timing and
sequence of events.
7. “N” and “CP” errors are accompanied by a pulse
alarm and require action from the driver. The alarm
will continue and the transmission is disabled until
the driver takes action.
“CP” can be cleared by cycling the clutch pedal. In
some cases, “CP” can also be cleared by cycling
the shuttle lever.
“N” can be cleared by shifting the shuttle lever to
neutral. 12

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 4
“N” and “CP can result from improper action by the
driver, or they can result from faults in the system
which require action from the driver to re-start
operation.
8. Normal error display mode:
If there are any disabling errors, only disabling
errors will be displayed.
If there are no disabling errors and at least one “N”
error is active, “N” will flash.
If there are no disabling errors and no “N” errors,
and at least one “CP” error is active, “CP” will flash.
Hidden errors will not be displayed.
13
9. Hd in the diagnostic menu will enable “display all
errors” mode. Also, a new module (or an old
module after the memory has been reset using H8)
will automatically be in “display all errors” mode
until there are no errors to display for 6 minutes.
The six minutes must be during one power-on
cycle, i.e. turning off the key switch zeros the timer.

14
If there are any disabling errors. ALL errors will be
displayed sequentially. “N” and “CP” will not be
displayed; instead, the error codes associated with
the “N” or “CP” fault will be displayed.
If there are no disabling errors and there is at least
one “N” error, the first “N” error will be displayed.
The display will alternate at one second each
between “N” (to tell the driver what to do) and the
associated error code (to assist with trouble
shooting).

15
If there are no disabling errors or “N” errors, and
there is at least one “CP” error, the first “CP” error
will be displayed. The display will alternate at one
second each between “CP” (to tell the driver what
to do) and the associated error code (to assist with
trouble shooting).
If there are no disabling errors, “N” errors, or “CP”
errors, any hidden errors will be displayed
sequentially.

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 4
A new module, or an old module after the memory
has been reset using H8, will automatically be in
”display all errors” mode until there are no errors to
display for 6 minutes. The six minutes must be
during one power-on cycle, i.e. turning off the key
switch zeros the timer. After six minutes with no
errors, the module switches automatically to
normal error display mode, and all stored error
codes are erased.

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 4
Error Code Listing

ERROR TRANS.
ERROR DESCRIPTION PRIORITY DISPLAY MODE
CODE STATUS

E21 Chassis harness disconnected 1 Disable Latched

E34 Fuse 14 Blown 2 Disable Latched
E36 Dump solenoid open circuit 3 Enabled Latched
E32 Clutch hydraulic pressure detected 4 Disable Latched
E53 5 volt reference failed, shorted to 12 volts 5 Disable Latched
E54 5 volt reference failed short to ground 6 Disable Latched
E12 Clutch pedal potentiometer signal too high 7 Disable Latched
E11 Clutch pedal potentiometer signal too low 8 Enabled Latched
E61 Synchroniser potentiometer signal too high 9 Disable Latched
E62 Synchroniser potentiometer signal too low 10 Disable Latched
E46 Fuse 21 blown 11 Enabled Latched
E33 Clutch pressure switch, open or short circuit 12 Enabled Latched
E39 High clutch solenoid open circuit 13 Enabled Latched
E38 High clutch solenoid short circuit 14 Enabled Latched
E41 Low clutch solenoid open circuit 15 Enabled Latched
E40 Low clutch solenoid short circuit 16 Enabled Latched
E66 Reverse solenoid open circuit 17 Enabled Latched
E68 Reverse solenoid short circuit 18 Enabled Latched
E65 High solenoid open circuit 19 Enabled Latched
E67 High solenoid short circuit 20 Enabled Latched
E37 Clutch disconnect switch open circuit 21 Enabled Latched
E24 Synchroniser not calibrated 22 Enabled Latched
E70 Unable to initialise synchroniser during start--up 23 Enabled Latched
E47 Clutch disconnect switch misadjusted high 24 Enabled Latched
E48 Clutch disconnect switch short circuit/misadjusted 25 Enabled Latched
E51 Transmission temperature sensor open circuit 26 Enabled Latched
E52 Transmission temperature sensor short circuit 27 Enabled Latched
E24 Both clutches not calibrated 28 Enabled Latched
E64 Synchroniser failed to engage reverse 29 Enabled Latched
E63 Synchroniser failed to engage high 30 Enabled Latched
E59 Forward/neutral/reverse switch disagreement 31 Enabled Latched
CP Depress clutch pedal to enable transmission 32 Disable Latched
EHi Hi clutch not calibrated 33 Enabled Latched
ELo Lo clutch not calibrated 34 Enabled Latched
E55 Forward switch failed to +8V or +12V 35 Enabled Latched

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 4

ERROR TRANS.
ERROR DESCRIPTION PRIORITY DISPLAY MODE
CODE STATUS
E56 Forward switch failed to earth or open circuit 36 Enabled Latched
E57 Reverse switch failed to +8V or +12V 37 Enabled Latched
E58 Reverse switch failed to earth or open circuit 38 Enabled Latched
E13 Up and downshift switches both on 39 Enabled Temporary
E49 Wheel speed sensor circuit open or short circuit 40 Enabled Temporary
E26 ERPM speed too high 41 Enabled Temporary
E27 ERPM speed too low 42 Enabled Temporary

Clutch Spring Pressure Calibration Error Codes

ERROR
ERROR DESCRIPTION
CODE
U20 Correct start up procedure not used
U21 Engine rev/min too low
U22 Engine rev/min too high
U23 Forward/reverse shuttle lever not in forward
U24 Main shift lever is not in gear
U25 Range lever not in gear
U26 Clutch pedal not fully released
U27 Hi Clutch calibration is too low
U28 Hi Clutch calibration is too high
U29 Lo Clutch calibration is too low
U30 Lo Clutch calibration is too high
U31 Wheel motion detected during calibration
U37 Synchroniser shuttle mode calibration
U38 Synchroniser Hi--Lo mode calibration

21- 13
SECTION 21 -- TRANSMISSION -- CHAPTER 4

ERROR CODE
E21 -- CHASSIS HARNESS DISCONNECTED
EFFECT -- Transmission disabled

Inspect main harness connectors

ERROR CODE
E24 -- SYNCHRONISER AND CLUTCHES NOT CALIBRATED
EFFECT -- Transmission disabled

Has a new processor been installed or

Perform calibration
H8 used without performing calibration
procedures
after installation?

Calibration values have corrupted in

processor. Attempt calibration. If error
occurs again replace processor.

ERROR CODES;
E11 -- CLUTCH PEDAL POTENTIOMETER SIGNAL TOO LOW
E12 -- CLUTCH PEDAL POTENTIOMETER SIGNAL TOO HIGH
EFFECTS -- Transmission disabled
Wiggle test potentiometer
Using Diagnostic ‘H’ menu, select H9, Channel 0, wiring whilst in H9, Channel
(clutch pedal position mode). Is the clutch operaion 0. If readings become
within the typical values of 91 released and 26 erratic trace and repair fault
depressed? in wiring. If no fault evident
install new processor.

Disconnect potentiometer. Check operation using

suitable multi--meter. Is potentiometer O.K.? Replace potentiometer

Check for short to earth or Check for short to +12V

open circuit between or +8V between
C077--CM7430--Y/R/B C077--CM7430--Y/R/B
and C128--19 (E11) and C128--19 (E12)

21- 14
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E13 -- UP AND DOWNSHIFT SWITCHES BOTH ON
EFFECTS -- No shift triggered

Operator error -- Tractor functioning

Both switches pressed together? normally

Wiggle test switch wiring

Use Diagnostic menu mode H5, are switches
whilst in H5 mode. If
functioning correctly?
readings become erratic
trace and repair fault in
wiring. If no fault evident
install new processor.

Disconnect switch connector from harness.

Check operation of switches using a suitable multi--meter. Replace switch
Is a switch fault indicated?

Check for a short circuit in harness wiring. Disconnect

C128 from processor and check between C128--24 and
C128--5 for a short circuit or a short to +12V on either
C128--24 or C128--5.

ERROR CODE
E26 -- ERPM TOO HIGH
EFFECTS -- Poor shift quality and possibly unable to perform calibration

Has engine exceeded 3,500 rev/min for three seconds Tractor functioning
or longer? normally

Check output from alternator. Is approximately 7 volts Replace/repair

measured at alternator speed output terminal? alternator

Inspect wiring from alternator through to C128--34

for intermittent open/short circuit repair as
necessary.

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E27 -- ERPM TOO LOW
EFFECTS -- Poor shift quality and possibly unable to perform calibration

Has engine operated at less than 500 rev/min for Tractor functioning
longer than three seconds? normally

Is the alternator drive belt broken? Replace or refit drive belt

Check output from alternator.

Is approximately 7 volts measured at Alternator faulty.
speed output terminal? Repair/replace as required

Inspect wiring from alternator through to C128--34

for a short to earth or +12V or open circuit.
Repair as necessary.

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E32 -- CLUTCH HYDRAULIC PRESSURE DETECTED WHEN NOT COMMANDED
(SHUTTLE LEVER IN NEUTRAL)
EFFECTS -- Transmission disabled
Pressure test clutches A & B to determine area of
fault.

Remove PWM solenoid valve assembly Tractor OK. Discard old

affected. Inspect and clean/replace. PWM if replaced.
Is the error cleared?

With the cab floor removed and engine

running, shuttle lever in neutral. Possible top cover fault
WARNING: Ensure wheels are chocked allowing hydraulic oil to
and handbrake applied. clutch
Is voltage indicated at the PWM solenoid,
C161 or C162?

Replace processor with one of known

performance

ERROR CODE
E33 -- CLUTCH PRESSURE SWITCH OPEN/SHORT CIRCUIT
EFFECTS -- Disables the dump logic software and also displays E32. Transmission remains
operative.

Remove pressure switches from transmission top Replace faulty

cover and check operation. Are switches functioning switch
correctly?

Disconnect processor connectors. Check

wiring between C128--4 (7900--TQ/K/B) and
switch connectors, C159 and C160, for
open/short circuit repair/replace wiring as
necessary.

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E34 -- FUSE 14 BLOWN
EFFECTS -- Transmission disabled.

Replace with correctly rated

Inspect Fuse 14, has fuse failed? fuse. Operate tractor, does Tractor
fuse fail again? Okay.

Disconnect Connector C127. Is

+12V available at pins 34 and 35, Substitute processor
with keystart ON?

Check continuity of wiring

from Fuse 14 to C127--34
and C127--35. Trace and
repair open circuit in wiring
as necessary.

ERROR CODE
E36 -- DUMP SOLENOID OPEN CIRCUIT
EFFECTS -- No effect during normal driving. No dump facility available though if pressure is
sensed in both A and B clutches.

With the cab floor removed, disconnect connector

C163 to the dump solenoid. With a suitable Replace solenoid
multi--meter check the solenoid for open/short circuit.
Is a solenoid fault indicated?

Disconnect processor connectors. Check for

short to ground (earth) or an open circuit
between C127--10 and the solenoid harness
side connector, C163. Repair/replace wiring as
necessary.

C019--27 C163
C123--13
1 2
C127--10
RM--7003--U/G/B RM--7003--U/G/B
(Y25)

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E37 -- CLUTCH PEDAL SWITCH OPEN CIRCUIT
EFFECTS -- Transmission disabled.

Is the clutch pedal switch adjusted correctly. Adjust switch

Using Diagnostic Menu Mode H5 (switch Wiggle test the

diagnostics), operate clutch, is switch wiring while in H5
functioning correctly? mode. Listen for
intermittent fault.
Wiggle test the wiring while in H5 mode. Is
contact made indicating switch okay?

Disconnect the clutch pedal switch, connector

Replace switch
C076. Using a suitable multi--meter, is the
and adjust
switch functioning OK?

Disconnect processor connectors and check

for an open circuit between C127--30 and the
neutral switch (shuttle lever), C075--4 Repair/replace
(7420--Y/P/B). Is an open circuit indicated? wiring as
NOTE: Clutch pedal switch must be connected necessary
and pedal released.

Clutch pedal switch may still be

at fault, performing sluggishly,
especially in cold weather.
Replace switch.

21- 19
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E38 -- CLUTCH ‘B’ SOLENOID (HIGH/REVERSE) SHORT CIRCUIT
E39 -- CLUTCH ‘B’ SOLENOID OPEN CIRCUIT
EFFECTS -- Transmission disabled.
With the cab floor removed, disconnect connector
C162 to Clutch B (Y24). With a suitable multi--meter Replace solenoid
check the solenoid for open/short circuit. Is a solenoid
fault indicated?

Disconnect processor connectors. Check for

short to ground (earth) or an open circuit
between C127--17 and C127--12 and the
solenoid harness side connector, C162.
Repair/replace wiring as necessary.

ERROR CODES;
E40 -- CLUTCH ‘A’ (LOW) SOLENOID SHORT CIRCUIT
E41 -- CLUTCH ‘A’ SOLENOID OPEN CIRCUIT
EFFECTS -- Transmission disabled.
With the cab floor removed, disconnect connector
C161 to Clutch A (Y23). With a suitable multi--meter Replace solenoid
check the solenoid for open/short circuit. Is a solenoid
fault indicated?

Disconnect processor connectors. Check for

short to ground (earth) or an open circuit
between C127--18 and C127--26 and the
solenoid harness side connector, C161.
Repair/replace wiring as necessary.

21- 20
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E46 -- FUSE 21 OPEN CIRCUIT
EFFECTS -- Transmission disabled

Replace with correctly rated

Inspect Fuse 21, has fuse failed? fuse. Operate tractor, does Tractor
fuse fail again? Okay.

Disconnect Connector C128. Is

+12V available at pin 6, with Substitute processor
keystart ON?

Check continuity of wiring

from Fuse 21 to C128--6
(2050--G). Trace and repair
open circuit in wiring as
necessary.

ERROR CODE
E47 -- CLUTCH PEDAL SWITCH SET TOO HIGH
EFFECTS -- Inching jerky and high pedal position

Is the clutch pedal switch

adjusted correctly? Adjust switch

Possible failed switch or open circuit

Is Error Code E37 displayed when
between neutral switch, C075--4
pedal is released?
(7420A--Y/P/B) and C127--30. See
Error E37.
Switch possibly sluggish,
particularly in cold weather.
Replace switch and adjust.

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E48 -- CLUTCH PEDAL SWITCH SET TOO LOW
EFFECTS -- Tractor performs normally but clutch pedal will not cut off power to clutch
solenoids.
Is the clutch pedal switch adjusted
Adjust switch
correctly.

Disconnect switch from harness.

Using a suitable multi--meter, does the switch Replace switch
function OK?

With the ignition on, and switch disconnected,

is +12V indicated at switch harness Trace and repair short
connector, C076--3 (7050--R/G/B)? circuit in wiring

Possible fault with processor, substitute

with one with known performance.

ERROR CODE
E49 -- WHEEL SPEED SENSOR SHORT OR OPEN CIRCUIT
EFFECTS -- Shift quality generally poor
Enter Diagnosic Menu Mode H9 (voltmeter), Wiggle test wiring for
Channel 20. Is a value of 64±5% displayed? possible intermittent fault

Disconnect processor connector, C128 and C127

and disconnect the wheel speed sender connector. Trace and
Test the wiring between C127--6 and wheel speed repair/replace
connector, C046--RM5135--TQ wiring
Is a short or open circuit indicated.

With the sender installed, check for a short to

Replace sender if either
earth on each sender terminal or for an open
condition is indicated.
circuit of the sender. Is a fault indicated?

Replace processor

21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E51 -- TEMPERATURE SENDER OPEN CIRCUIT
E52 -- TEMPERATURE SENDER SHORT CIRCUIT
EFFECTS -- Slow shifting and clutch pedal higher than normal during inching.

Warm or cool oil

Is the oil temperature below --30_C, E51 or above
to remove error
130_C, E52?
code

Using diagnostic Menu Mode H9, Channel 2, with the Wiggle test wiring for
oil at approximately 40°C, is a value of 75 displayed? possible intermittent fault

Remove the cab floor. Disconnect the temperature

sender connector. Using a multi--meter on the sender, Replace sender
is an open or short circuit indicated?

Disconnect processor connectors and

check between sender harness Trace fault and repair/replace
connector and C128--18 for open/short wiring as required.
circuit. Is a fault indicated?

Possible processor fault.

Replace processor.

ERROR CODES;
E53 -- 5 VOLT REFERENCE FAILED HIGH (SHORT TO (+8V or +12V)
E54 -- 5 VOLT REFERENCE FAILED LOW (SHORT TO EARTH)
EFFECTS -- Transmission disabled.
Short to +8V or +12V (E53) or short to ground (E54)
between +5V processor output terminal, C127--5
(5020--LN) and one of the following components: Repair/replace
D Clutch pedal potentiometer wiring as
D Synchroniser potentiometer required
D Forward/reverse switches
Inspect harness from each component.
Is a fault indicated?

Fault may be in the electrical components of

the hydraulics. Repair as detailed in
Refer to hydraulic section. Hydraulic Section
Is a fault found in Hydraulic Electrics?

Substitute
processor for one
of known
performance
21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E61 -- SYNCHRO POTENTIOMETER SIGNAL TOO HIGH
E62 -- SYNCHRO POTENTIOMETER SIGNAL TOO LOW
EFFECTS -- The synchroniser is disabled
Remove floor pan and disconnect synchroniser
potentiometer connector.
Using a suitable multi--meter, is either a short to Trace and repair
+12V/+8V or to earth indicated between fault in wiring
potentiometer harness connector (7960--P/K/B) and
processor connector C128--17?

Check potentiometer operation. Replace

Is a short circuit indicated? potentiometer

Substitute
processor with one
of known
performance.

ERROR CODES;
E63 -- SYNCHRONISER NOT FULLY ENGAGING HI--LO (FORWARD) POSITION
E64 -- SYNCHRONISER NOT FULLY ENGAGING SHUTTLE (REVERSE) POSITION
EFFECTS -- If the previously engaged mode can be reselected, the error is cleared and the
shift can be re--attempted. If synchroniser cannot be engaged only lo--forward drive will be
possible.

Remove the floor pan. Is the potentiometer Repair or replace

linkage OK? as required

Disconnect linkage to potentiometer.

Enter menu mode H9, Channel 27. Replace
Turn potentiometer manually and observe cluster display. potentiometer
Is the potentiometer functioning correctly?

Suspect a faulty PWM

Pressure test the synchroniser operating piston.
solenoid valve.
Is the pressure approximately 16 bar when actuated?
Clean/replace and retest

Suspect mechanical fault within transmission.

Possible synchroniser failure or sticking piston.
Remove top cover and inspect.

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E65 -- HI/LO (FORWARD DRIVE) SOLENOID OPEN CIRCUIT
E66 -- SHUTTLE (REVERSE DRIVE) SOLENOID OPEN CIRCUIT
EFFECTS -- Transmission disabled.

Remove floor pan and disconnect affected solenoid.

Test across solenoid terminals with a suitable Replace solenoid
multi--meter. Is an open circuit indicated?

Disconnect processor connectors.

Test for an open circuit between C127--11 and
C157--RM8030--LG, and between C127--36
and C157--RM8035--P/LG/S, for E65.
Test for an open circuit between C127--13 and
C156--RM8045--P/LN/S, for E66.
Trace fault and repair/replace wiring as
required.

ERROR CODES;
E67 -- HI--LO (FORWARD) SOLENOID SHORT CIRCUIT
E68 -- SHUTTLE (REVERSE) SOLENOID SHORT CIRCUIT
EFFECTS -- Transmission disabled.

Remove floor pan and disconnect affected solenoid.

Test across solenoid terminals and from each terminal Replace solenoid
to earth with a suitable multi--meter.
Is a short circuit indicated?

Disconnect processor connectors.

Test for a short circuit between C127--11 and
C157--RM8030--LG, and between C127--36
and C157--RM8035--P/LG/S, for E67.
Test for a short circuit between C127--13 and
C156--RM8045--P/LN/S, and between
C127--14 and C156--RM8040--LG, for E68.
Trace short in harness and repair/replace
wiring as required.

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
CP -- GEAR SELECTED WITHOUT CLUTCH PEDAL DEPRESSED
EFFECTS -- Transmission disabled.

Cycle the clutch pedal or shuttle lever to clear error

code.

ERROR CODE
EHI -- CLUTCH B NOT CALIBRATED
EFFECTS -- Transmission disabled

Was clutch ‘B’ calibrated after a change of processor

or after using H8 (memory clear) mode?

Perform calibration Replace processor with

to clear error code one of known performance

ERROR CODE
EL0 -- CLUTCH A NOT CALIBRATED
EFFECTS -- Transmission disabled

Was clutch ‘A’ calibrated after a change of processor

or after using H8 (memory clear) mode?

Perform calibration Processor possibly

to clear error code corrupted. Replace with
one of known performance

ERROR CODE
E70 -- UNABLE TO INITIALISE SYNCHRONISER DURING START UP PROCEDURE
EFFECTS -- Transmission operable in ‘Low Forward’ only.

Remove floor pan. Repair linkage

Is linkage to synchroniser potentiometer OK?

Disconnect linkage to potentiometer.

Enter menu mode H9, channel 27, and Replace potentiometer
manually operate potentiometer.
Is the potentiometer functioning correctly?

Suspect fault within transmission.

Remove top cover. Inspect synchroniser and
operating piston.

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E55 -- FORWARD SWITCH FAILED TO +8V OR +12V
E56 -- FORWARD SWITCH FAILED TO EARTH OR OPEN CIRCUIT
EFFECTS -- Transmission enabled

Using diagnostic Menu Mode H5 (switch Suspect intermittent fault. Wiggle

diagnostics), operate forward switch, is test wiring from the forward switch
switch functioning okay? to the processor.

Disconnect FNR switch connector C075. From

C075--2 (7250--S/R/B), with the ignition ‘ON’, Trace and repair
is +8V or +12V indicated (E55) or, fault in wiring
with the ignition ‘OFF’, is a short to earth indicated
(E56)?

With the Keystart OFF, disconnect processor

connector, C128. Check for an open circuit Trace and repair
between C128--20 and C075--2 (7250--S/R/B), fault in wiring
Is an open circuit indicated?

Substitute FNR switch assembly for one of

known performance.

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODES;
E57 -- REVERSE SWITCH FAILED TO +8V OR +12v
E58 -- REVERSE SWITCH FAILED TO EARTH OR OPEN CIRCUIT
EFFECTS -- Transmission enabled

Using diagnostic Menu Mode H5 (switch Suspect intermittent fault. Wiggle

diagnostics), operate reverse switch, is test wiring from the reverse switch
switch functioning okay? to the processor.

Disconnect FNR switch connector, C075. From

C075--3 (7260--S/U/B), with the ignition ‘ON’. is +8V or
+12V indicated (E57) or, Trace and repair
with the ignition ‘OFF’, is a short to earth indicated fault in wiring
(E58)?

Disconnect processor connector C128.

Check for an open circuit between C128--7 Trace and repair
and C075--3 (7260--S/U/B). fault in wiring
Is an open circuit indicated?

Substitute FNR switch assembly for one of

known performance.

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 4
ERROR CODE
E59 -- FORWARD/NEUTRAL/REVERSE SWITCH
DISAGREEMENT (MORE THAN ONE SWITCH OR NO SWITCHES APPLIED)
EFFECTS -- Transmission enabled

Using diagnostic Menu Mode H5 (switch Suspect intermittent fault. Wiggle

diagnostics), operate shutttle lever, are test wiring from the shuttle lever
switches functioning okay? switch to the processor.

Disconnect shuttle switch assembly connector, C075

and processor connector, C128. Trace and repair
Is an open circuit indicated between C075--4 fault in wiring
(7420A--Y/P/B) and C128--27?

Clean/replace the switch assembly

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 4
CLUTCH CALIBRATION ERROR CODES

U20 -- CORRECT START UP PROCEDURE WAS NOT USED

Depress and release clutch pedal and proceed

with clutch calibration

U21 -- ENGINE REV/MIN TOO LOW

Adjust to 1200 rev/min  100 rev/min

U22 -- ENGINE REV/MIN TOO HIGH

Adjust to 1200 rev/min  100 rev/min

U23 -- FORWARD/REVERSE SHUTTLE LEVER IS NOT IN FORWARD

Position lever into forward mode

U24 -- MAIN SHIFT LEVER IS NOT IN GEAR

Position main range lever into 1st gear

U25 -- RANGE LEVER NOT IN GEAR

Position range lever into high range

U26 -- CLUTCH PEDAL NOT FULLY RELEASED

Release clutch pedal and/or check pedal

operation

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 4

U27 -- HI (B) CLUTCH CALIBRATION IS TOO LOW

(ENGINE REV/MIN DROPPED TOO SOON)

Check PWM valve for sticking or dirt ingress.

Clean or replace valve.

If PWM is not faulty, suspect mechanical fault

within Clutch ‘B’ assembly.

U28 -- HI (B) CLUTCH CALIBRATION IS TOO HIGH. (MAX. ALLOWED CALIBRATION

VALUE EXCEEDED WITHOUT DROPPING ENGINE REV/MIN.)

Check PWM valve for sticking or dirt ingress

Check hydraulic pressure in Clutch ‘B’

If hydraulics OK, suspect mechanical failure,

possibly synchroniser fault not connecting
transmission to engine.

U29 -- LO (A) CLUTCH CALIBRATION IS TOO LOW

(ENGINE REV/MIN DROPPED TOO SOON)

Check PWM valve for sticking or dirt ingress.

Clean or replace valve.

If PWM is not faulty, suspect mechanical fault

within Clutch ‘A’ assembly.

U30 -- LO (A) CLUTCH CALIBRATION IS TOO HIGH. (MAX. ALLOWED CALIBRATION

VALUE REACHED WITHOUT DROPPING ENGINE REV/MIN.)

Check PWM valve for sticking or dirt ingress

Check hydraulic pressure in Clutch ‘A’

If hydraulics OK, suspect mechanical failure,

possibly synchroniser fault not connecting
transmission to engine.
21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 4

U31 -- WHEEL MOTION DETECTED DURING CALIBRATION

Ensure handbrake is fully applied and that
high range is selected.

Was calibration too low causing wheel

movement prior to lugging engine.

Mechanical fault within transmission.

Gear movement without wheel movement.

U37 -- SYNCHRONISER SHUTTLE (REVERSE) MODE CALIBRATION

Synchroniser potentiometer feedback outside

limits

Check potentiometer linkage and

potentiometer operation

U38 -- SYNCHRONISER HI--LO (FORWARD) MODE CALIBRATION

Synchroniser potentiometer feedback outside

limits

Check potentiometer linkage and

potentiometer operation.

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 5
SECTION 21 -- TRANSMISSION

Chapter 5 -- Shuttle Command (Mechanical Transmission)

CONTENTS

Section Description Page

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21 114 Mechanical Transmission Housing Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . 13

21 000 --SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed with constant--mesh gears and
synchronisers on all speed gears
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helically toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 forward ranges and 4 reverse ranges
for a total of 16 forward and 16 reverse
speeds
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helically toothed
-- Reduction ratios:
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 15) : (46 x 55) = 1 : 7.03
Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 26) : (46 x 40) = 1 : 2.95
Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (24 x 29) : (46 x 37) = 1 : 2.45
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed and range shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent, by two hand levers
located at the operator’s right side
Speed and range gear lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced--fed by a gear pump (same as
the power steering circuit pump)
Speed driven gear (10, page 8) inner diameter . . . . . . . . . . . . mm 60.060 to 60.090
Bush (11) outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Speed output shaft (13) diameter . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush (11) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055
Range (8) driven gear inner diameter . . . . . . . . . . . . . . . . . . . . mm 60.060 to 60.090
Bush (9) outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 59.981 to 60.000
Gears to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 to 0.109
Range output shaft (7) diameter . . . . . . . . . . . . . . . . . . . . . . . . mm 49.375 to 49.391
Bush (9) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.400 to 49.430
Shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.009 to 0.055

(to be continued)

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 5
(continued)
PTO drive shaft (3, page 8) diameter (at the bushings) . . . . . mm 31.950 to 31.975
Press--fit bush (1) inner diameter . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 to 32.085(o)
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . mm 0.015 to 0.135
Speed input shaft rear bearing (2) thrust washer . . . . . . . . . . mm 2.950 to 3.000
Range input shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 48
Range input shaft (4) adjust shims . . . . . . . . . . . . . . . . . . . . . . mm 1.70 --1.75 -- 1.80 --1.85 -- 1.90 --1.95 --
2.00 -- 2.05 -- 2.10 -- 2.15 -- 2.20 -- 2.25
-- 2.30 --2.35 -- 2.40 -- 2.45 -- 2.50 --
2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 -- 2.80
-- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.10 --
3.20 -- 3.30
Range output shaft bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . see page 48
Range output shaft (5) adjust shims . . . . . . . . . . . . . . . . . . . . . mm 1.70 --1.75 -- 1.80 --1.85 -- 1.90 1.95 --
2.00 -- 2.05 -- 2.10 -- 2.15 -- 2.20 -- 2.25
-- 2.30 --2.35 -- 2.40 -- 2.45 -- 2.50 --
2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 -- 2.80
-- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.10 --
3.20 -- 3.30
Implement pressure regulating valve spring (8, page 11):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
-- Compressed length under a load of 278 to 304 N (28.4 to 31 kg) 102.5
Implement working pressure . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 to 17.6 (17 to 18)
Lubrication pressure regulating valve spring (7, page 11):
-- --Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 42
-- Compressed length under a load of 84 to 90 N (8.6 to 9.2 kg) 24.5
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 6.8 to 8.3 (7 to 8.5)

(o) Final dimension to be obtained without reaming.

SPEED AND RANGE GEARS (40 KPH OPTION)

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--speed with constant--mesh gears and
synchronisers on all speed gears
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helically toothed
Range gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 forward ranges and 4 reverse ranges
for a total of 20 forward and 16 reverse
speeds
For other values not shown herein refer to the previous table: SPEED AND RANGE GEARS

CREEPER GEARS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic spur gears
Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through a lever located at the
operator’s left side
Thickness of thrust washers (6, page 8) between driven gears and
creeper support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.465 to 1.535

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 5
SHUTTLE GEARS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, with helically toothed
gears, assembled as a standard
Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through a synchroniser
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (43 x 37 x 39) : (37 x 39 x 44) = 1 : 1.02
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever in right hand console
Driven gear bearing adjust shims (12, page 8) . . . . . . . . . . . . mm 2.55 -- 2.60 -- 2.65 -- 2.70 -- 2.75 -- 2.80
-- 2.85 -- 2.90 -- 2.95 -- 3.00 -- 3.05 --
3.10 -- 3.15
Driven gear bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 46

TIGHTENING TORQUES
Torque
DESCRIPTION Thread size
Nm kgm
Bolts and nuts, speed clutch/transm housing to engine . . . . . . . . . (see C and C, page 2, Sec. 18)
Bolts, speed clutch/transm housing to rear axle housing . . . . . . . . M14 x 1.5 176 18
Setscrew, clutch release fork lever (C1, page 4) ............. M16 x 1.5 157 16
Bolts, transmission housing cover (C2) . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5
Screws, range rear bearing retaining plate (C3) . . . . . . . . . . . . . . . M10 x 1.25 49 5
Nut, range output shaft (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M47.5 x 1.5 294 30
Screw, solenoid valve pin (C5) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 47 to 54 4.8 to 5.5
Screw, solenoid valve (C6) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 5.4 to 8.1 0.55 to 0.83
Screws, range and transmission control lever support (C7) . . . . . M10 x 1.25 49 5
Fitting, transmission control lever support inlet (C8) . . . . . . . . . . . . M22 x 1.5 83 8.5
Plug, lubrication pressure regulating valve(C9) . . . . . . . . . . . . . . . . M18 x 1.5 49 5
Screws, creeper gear fixed plate (C10) . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 54 5.5
Screws, clutch housing front cover (C11) . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4
Nut, transmission output shaft (C12) . . . . . . . . . . . . . . . . . . . . . . . . . M45 x 1.5 490 50
Bolts, transmission input shaft support cover . . . . . . . . . . . . . . . . . M8 x 1.25 23 2.4
Screws, range rear bearing support plate . . . . . . . . . . . . . . . . . . . . M14 x 1.5 142 14.5
Bolts, cab to rubber mounts SILENT BLOCK . . . . . . . . . . . . . . . . . -- 340 to 420 34.7 to 42.8
Bolts, cab support bracket (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 114 to 148 11.6 to 15.1
Bolts, cab support bracket (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 250 to 309 25.5 to 31.5

(*) Apply a couple of drops of New Holland Thread Sealant 82995768.

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 5

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 5
SPECIAL TOOLS 293972 Transmission overhaul rear bracket
(use with tool no. 290090)
CAUTION
293343 Output shaft nut spanner
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL X 293805 Input shaft puller (use with tool no.
tools marked with the identification code (X). 50062) or output shaft retaining tool
To work safely and achieve the best technical results X 293808 Output shaft retaining tool
with additional savings of time and effort, these 292313 Reverse idler gear pin puller adapter
mandatory tools should be used in conjunction with the
292927 Slide hammer
suggested special tools listed below and integrated
with the self--made ones for which you will find the 292176 Range input and output shaft end play
necessary construction drawings and specifications test tool (use with tools nos. 50013 and
directly on this Manual. 50018)
291051 Range input shaft bearing and gear
List of special tools necessary to carry out the different puller
operations described in this Section. 291525 Transmission and rear axle housing
295027 Cab lifting adapter (use with tool no. alignment pins
290740) X 293869 Output shaft bearing installer
290740 Cab lifting hook (use with tool no. X 293992 Installer for assembling bushes on the
295027) PTO drive shaft (use with tool no.
291215 Range control lever spring hook 293800)
290090 Overhaul rotary stand X 293993 Installer for assembling the shuttle input
292320 Tractor separation stand shaft to PTO shaft seal (use with tool no.
293800)
291517 Transmission housing lifting hook
293800 Handle
293971 Transmission overhaul front bracket
(use with tool no. 290090) 294000 PTO drive shaft bush puller
295049 Range output shaft retaining tool

2
Tool to be fabricated for range input and output shaft bearing adjustment (Mark tool with no. 50018 -- Dimensions in
mm).
Fabricate tool using Aq 42 material.

21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 5
Tool to be fabricated for range input shaft bearing
assembly (Mark tool with no. 50060 -- Dimensions in
mm).
Fabricate tool using UNI C30 material.

3
Tool to be fabricated for input shaft bearing
removal(Mark tool with no. 50062 --
Dimensions in mm).
Fabricate tool using UNI Fe 42 C material.

25849

4
Tool to be fabricated for range output shaft bearing
assembly (Mark tool with no. 50061 -- Dimensions in
mm).
Fabricate tool using UNI C30 material.

21- 6
SECTION 21 -- TRANSMISSION -- CHAPTER 5

6
Tool to be fabricated for range input shaft taper bearing assembly (Mark tool with no. 50013 -- Dimensions in mm).
Fabricate tool using UNI C40 material. -- Use only part (a)

7
Tool to be fabricated to adapt the transmission overhaul front bracket (tool no. 293971). (Mark tool with no. 50110
--Fabricate tool using UNI Fe 42 C material.

8
Tool to be fabricated for location and alignment during engine/transmission housing installation. (Mark tool with no.
50117 -- Dimensions in mm). Fabricate tool using UNI C40 material. Make 2

21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 5

9
Longitudinal Views -- 40 KPH Transmission with 5th Speed and Creeper Gears
1. PTO shaft centring bushes 7. Range output shaft
2. Transmission input shaft rear bearing thrust washer 8. Range driven gears
3. PTO drive shaft 9. Range driven gear bushes
4. Range input shaft bearing adjust shims 10. Speed driven gears
5. Range output shaft bearing adjust shims 11. Speed driven gear bushes
6. Thrust washers between driven gears and creeper 12. Shuttle driven gear bearing adjust shims
gears support 13. Transmission output shaft

21- 8
SECTION 21 -- TRANSMISSION -- CHAPTER 5

10
Longitudinal View -- 40 KPH Transmission with 5th Speed and Range Gears
1. Seal 16. High and medium--high range engagement
2. Seal synchroniser
3. O ring 17. 1st and 2nd gear synchroniser
4. Circlip 18. 3rd and 4th gear synchroniser
5. Circlip 19. Shuttle driven gear
6. Taper bearing 20. Spacer
7. Shuttle synchroniser 21. Circlip
8. Circlip 22. Transmission output shaft
9. Circlip 23. Taper bearing
10. Seal 24. 5th speed driven gear
11. Transmission input shaft 25. 5th speed drive gear
12. Seal 26. 5th gear synchroniser
13. Range input shaft 27. Circlip
14. Range output shaft 28. Shuttle input shaft
15. Low and medium--low range engagement sleeve

NOTE: During installation apply sealant on surfaces marked with an X as detailed on page 45.

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 5

25853

11
Transmission Control Lever Support Longitudinal Views and Transmission Cross Sections
1. Shuttle control fork 8. O ring
2. Shuttle control inner lever 9. O ring
3. O ring 10. Range control idler lever
4. Fork detent (1) 11. Speed control idler lever
5. Retaining ring 12. Actuating balls and springs
6. Reverse pin 13. Actuating balls and springs
7. Shuttle reverse idler gear

NOTE: During installation apply sealant on surfaces marked with an X as detailed on page 45.

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 5

12
Speed and Range Control Lever Support Cross Section and Solenoid Valve Arrangement
1. PTO brake solenoid control valve 7. Lubrication pressure regulating valve spring
2. PTO solenoid control valve 8. Implement pressure regulating valve spring
3. Diff lock solenoid control valve 9. Solenoid valve pin
4. Inlet fitting 10. Solenoid valve
5. Implement pressure regulating valve 11. FWD engagement solenoid valve.
(16.7 to 17.6 bar -- 17 to 18 kg/cm2)
6. Lubrication pressure regulating valve
(6.8 to 8.3 bar -- 7 to 8.5 kg/cm2).

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 5
DESCRIPTION AND OPERATION
Standard transmission (30 KPH) Optional transmission (40 KPH)
The standard transmission is fitted with range and The 40 KPH option transmission is fitted with range
shuttle gears and provides a total of 16 forward and 16 and shuttle gears and provides a total of 20 forward and
reverse speed gears or ratios. Transmission controls 16 reverse speed gears or ratios. Transmission
consist in three different levers, as follows: controls consist in three different levers, as follows:
The main shift lever selects four speed ratios through The main shift lever selects five speed gears or ratios
synchronised engagement sleeves. through a synchronised engagement sleeve.
The range lever shifts through the low and Refer to the previous description above for the range
medium--low ranges by means of a non--synchronised and shuttle lever operation.
engagement sleeve and through the high and This transmission differs from the standard version
medium--high ranges by means of a synchronised described above in the addition of the 5th speed ratio.
sleeve.
NOTE: With the 5th speed gear engaged, an interlock
The shuttle lever selects the direction of movement device prevents the shuttle lever to be moved to the
of the tractor. reverse position.

TROUBLESHOOTING -- TRANSMISSION AND RANGE GEARS

Problem Possible Cause Correction
Noisy operation with range lever in 1. Input and output shaft support Remove transmission housing and
neutral and main lever engaged.
g g bearing misadjusted adjust bearings (see page 48).
2. Failed or defective inner Remove housing, overhaul
component transmission and replace faulty
parts.
3. Internal component seizure due Overhaul transmission and top up
to poor lubrication oil to correct level.
Noisy operation with tractor 1. Faulty clutch plate springs Replace clutch plate.
stationary, idling engine and
transmission in neutral
Self--disengagement of speed, 1. External linkage and levers Adjust correctly.
range
g and shuttle gears
g misadjusted.
2. Failed control rail retaining Replace springs.
springs
3. Damaged synchroniser Remove transmission housing and
engagement teeth replace synchroniser.
4. Partial engagement travel Correct reasons for problem and
restore full travel.
Difficult engagement of speed, 1. External linkage and levers Adjust correctly.
range
g and shuttle gears
g misadjusted.
2. External levers or linkage stiff or Check pivot points and lubricate.
seized.
3. Central clutch drags See page 4, Section 18.
4. Faulty synchroniser Remove transmission housing and
replace synchroniser.
5. Internal control items (rails, forks Overhaul control items
and sleeves) slide with difficulty

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 5
MECHANICAL TRANSMISSION HOUSING DANGER
Lift and handle all heavy components using lifting
Removal -- Installation (Op. 21 114 10) equipment of appropriate [Link] that units or
parts are supported by suitable slings or [Link]
that no--one is in the vicinity of the load to be lifted.

Remove the mechanical transmission housing as

follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Connect the engine hood to a hoist using a nylon
cable (1) and disconnect the hood struts (2) (one
on the LH side and one on the RH side).

2
4. Loosen the screws (3) which retain engine hood to
engine, disconnect front light electrical connectors
and remove hood using the hoist. Ensure that the
hood is displaced without obstructions and that no
other components are interfering.

23353

21- 13
SECTION 21 -- TRANSMISSION -- CHAPTER 5
5. Unscrew the retaining screws and remove side
panels (1) (one on each side).

4
6. Jack up rear tractor and place two suitable stands
(2) under the final drive cases to raise the wheels
off the ground. If necessary, detach lift rods from
lower links.

5
7. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the left wheel.

6
8. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect tool to a hoist using hook tool no. 290740
and keep hook tensioned.

21- 14
SECTION 21 -- TRANSMISSION -- CHAPTER 5
9. Detach connectors at the washer motor. Detach
washer bottle (1) lines and remove bottle.

8
10. Remove the clip and detach the creeper gear
control idler lever (2). Loosen the parking brake
control cable retaining screw (3).

9
11. Remove pin securing the fork (4) to the parking
brake actuator lever. Loosen the nut securing the
cable to the fork (4) and release cable.

10
12. Loosen the attaching nut and detach the ground
cable (5) between the cab and rear axle.

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 5
13. Release the clamp (1) and detach the main tank
breather tube.

12
14. Detach the ground synchronised PTO control
cable (2) from the rail.

13
15. Detach the two connectors (3 and 4) located under
the cab floor.

14
16. Detach both engine to cab connectors (5 and 6).

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 5
17. Disconnect radar and fuel filter connectors (4 and
3, respectively). Remove protection and
disconnect connectors (1 and 2) from starting
motor.

16
18. Detach light connector (5) located on the handrail
(repeat for both tractor sides).

17
19. Detach heater to engine connecting lines (6)
located under the right hand front side of the cab.

18
20. Loosen the nut and detach the throttle control cable
(7) from injection pump.

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 5
21. Detach connectors (1) from brake master
cylinders.
22. Loosen fittings (2) and detach brake control hoses.
23. Detach the brake master cylinder lines to the
reservoir.

20
24. Loosen the power steering motor connecting lines
(4) to the steering pump.

21
25. Detach the power steering motor connecting lines
(5) to the steering cylinders.

22
26. Loosen fittings and detach the air conditioning lines
(6).

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 5
27. Loosen the locknut, slide out the cotter pin and
detach the PTO control cable (1).

24
28. Remove pins (2), loosen retaining screws (3) and
detach the auxiliary valve control cables, right hand
side.
29. If auxiliary valves are fitted also on left hand side,
repeat step 28 for left hand side auxiliary valves.

25
30. Loosen the screw attaching the steps (6) to the
bracket.

26
31. Loosen the screw attaching the steps (1) to the cab
platform.
32. Repeat steps 30 and 31 on opposite side and
remove steps.

21- 19
SECTION 21 -- TRANSMISSION -- CHAPTER 5
33. Raise the cab mat (2) and loosen the cab mounting
bolt while holding the locknut under the cab floor.
Retrieve bolt and washer. Repeat for both tractor
sides.

28
34. Loosen the rear cab bolts (on both sides).
35. Slowly raise the cab taking care that no
components are connected, hooked or interfering.
Remove the cab and lower it on a suitable support
base.

29
36. Loosen the plug (3) and drain oil from the rear axle
and transmission housing into a suitable container.

30
37. Drain fuel tanks, then loosen the clamp (1)
retaining the connecting line between the main and
auxiliary tanks.

21- 20
SECTION 21 -- TRANSMISSION -- CHAPTER 5
38. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
39. Detach the fuel return line (2) from the injection
pump to the auxiliary tank. Remove auxiliary tank.

32
40. Loosen the clamp and detach the injection pump
supply line (5). Detach connectors (4), then
unscrew and remove the fuel level sensor
assembly.

33
41. Loosen the nut of the metal strap (6) securing the
main tank. Remove the strap and tank.

34
42. Loosen the retaining screws and remove the cab
and fuel tank support bracket (1). (Repeat on both
sides of the transmission housing).

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 5
43. Loosen the retaining screws and remove the main
tank support bracket (2).

36
44. Loosen the attaching screws and remove the radar
unit and mounting bracket (3).

38
46. Loosen the clamps and separate the rear axle oil
cooler hoses (1) from tubes.

21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 5
47. Detach and remove the range and speed control
cables (1) from the rails (2) and brackets (3).

40
48. Detach all connectors from the solenoid valves in
the range and speed control assembly.
NOTE: Before detaching connectors from the control
assembly, mark each connector and respective
solenoid valve.

41
49. Detach the shuttle control cable (1) and bracket.

42
50. Loosen the retaining screws and remove the
propshaft guard.
51. Remove circlip (4) and slide out sleeve (5). Repeat
for transfer box circlip and sleeve.

21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 5
52. Loosen the bearing--support (3) retaining screws
at the transmission housing, detach and remove
the front diff lock control line (2).

44
53. Place stand tool no. 292320 with one of the two
trolley jacks (6) under the engine and the other
under the transmission housing.
54. Place two wooden wedges (one each side)
between the front axle support and front axle to
prevent engine oscillation.

45
55. Loosen the retaining screws and remove starting
motor (1).

46
56. Remove the transmission housing to engine
attaching bolts.

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 5
57. Loosen the metal spacer retaining screw (2) at the
transmission housing.
58. Separate the engine from the transmission
housing.

48
59. Loosen and remove two bolts from the
transmission housing upper cover (3), screw in
chains of hook tool no. 291517 to the housing and
keep them tensioned using a hoist.
60. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool no.
292320 under the rear axle housing.
61. Remove the transmission housing retaining bolts
and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.
49
62. Reinstall the transmission housing to the rear axle
housing and engine observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 61 back to step 1.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 26 and on page 13 of Section 18.
-- Tighten to correct torques as detailed on page
3.

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 5

20270

50
Pattern for application of sealant during installation of the speed clutch--transmission housing to rear axle housing.

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 5
PLATFORM

Removal--Installation (Op. 90 110 36)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the platform as follows:

1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Using a hoist, raise rear tractor, place two
stationary stands (1) under the final drive cases,
lower the tractor, loosen retaining bolts and remove
rear wheels.

2
4. Detach the parking brake control cable (1) from the
rail (3) and support bracket (2).

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 5
5. Loosen the retaining clamp and detach the
breather hose (1) from the tube.

4
6. Detach the auxiliary valve control cables (1).

5
7. Detach the lift control levers (1) and the Lift control
cable (2).

6
8. Detach the range and speed control cables (1)
from the rails (2) and brackets (3).

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 5
9. Detach the shuttle control cable (1) and fastening
bracket.

8
10. Disconnect the two electrical connectors (1)
located under the platform in correspondence with
the range and speed control rail assembly.

9
11. Release retaining screws and remove side panels
(1) (one on each side).

10
12. Detach connectors (1) from brake master
cylinders.
13. Loosen fittings (2) and detach brake control hoses.
14. Detach the brake master cylinders lines to the
reservoir.

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 5
15. Detach the power steering supply and return lines
(1) (at the fittings under the platform).

12
16. Detach the steering cylinder control lines (5).

13
17. Disconnect all electrical connections (1) between
the platform and engine.

14
18. Disconnect electrical cables (1) from starting
motor.

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 5
19. Unscrew the locknut and detach throttle control
cable (7) from injection pump.

16
20. Detach the clutch release control line (1) from the
pump.

17
21. Loosen the screws (1) securing the hood support
to the instrument panel support.

18
22. Sling the platform and connect it to a hoist. Loosen
front retaining bolts (1).

21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 5
23. Loosen rear platform retaining bolts (1).

20
24. Remove the platform using a hoist.
25. Reinstall the platform observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 23 back to step 1.
-- Tighten to correct torques as detailed on page
3.

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 5
MECHANICAL TRANSMISSION

Removal--Installation of Speed and Range Gears

(Op. 21 114 85)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To overhaul the mechanical transmission, it is

necessary to remove the transmission housing
following the procedure detailed on pages 13 to 26.
Then proceed as follows:
1. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets, tools
nos. 293971 (1) and 293972 (2), respectively.

1
2. Loosen retaining bolts and remove upper cover
(1).

2
3. Loosen the cover (1) retaining bolts, position tool
no. 295049 (2) on the transmission housing,
loosen the output shaft locknut using spanner tool
no. 293343 (3) and retrieve cover (1).

21- 33
SECTION 21 -- TRANSMISSION -- CHAPTER 5
4. Remove retaining screws and detach the range
input and output shaft rear bearing support (1).

4
5. Using puller tool no. 291051 (1) and a suitable
insert (2) remove the gear (3) along with the
bearing and bush. Take care to keep the input shaft
bearing off.

5
6. Loosen the plugs (1) and retrieve the actuating
balls and springs. Remove plug (2).

6
7. Withdraw roll pins (1) securing the low and
medium--low range control fork. Withdraw the roll
pins (7) from the two range selector dogs.

23383

21- 34
SECTION 21 -- TRANSMISSION -- CHAPTER 5
8. Remove the fork (1) along with the engagement
sleeve, slide out the rail (2) and retrieve the
selector dog (3).

8
9. Slide out the control rail (1) and safety pin (2) of
both rails (1) and (2, Fig. 9).

9
10. Slide out the medium--low and medium--high
range gears (1 and 2, respectively) along with the
inner bushes and thrust pad (3).

10
11. Remove synchroniser (1) (if fitted) or the
engagement sleeve along with the control fork and
output shaft (2).

21- 35
SECTION 21 -- TRANSMISSION -- CHAPTER 5
12. Remove the range input shaft (1).

12
13. Assemble tool no. 293805 (1) using two 20 mm
shims (2) to support the transmission input shaft.

13
14. Withdraw the bearing spring retainer (1) (on both
sides).

14
15. Retrieve clutch engagement bearing (1).

21- 36
SECTION 21 -- TRANSMISSION -- CHAPTER 5
16. Loosen the screw (1) attaching the fork to the lever.

16
17. Withdraw the control lever (2) and retrieve the fork
(1).

17
18. Loosen all cover (1) retaining bolts (2).

18
19. Screw in three of the screws (1, Fig. 19) into the
threaded holes to separate the cover (1) from the
transmission housing.

21- 37
SECTION 21 -- TRANSMISSION -- CHAPTER 5
20. Loosen the plug (1) and retrieve springs and
actuating pawl.

20
21. Partially punch out the roll pin until releasing the
control lever (3) from the fork (1). Remove control
lever and fork.

21
22. Using a puller withdraw the bearing (1) from the
shuttle input shaft.

22
23. Loosen retaining screws and remove cover (1).
Slide out circlip, seals and locating dowel from the
shaft.

21- 38
SECTION 21 -- TRANSMISSION -- CHAPTER 5
24. Remove circlip (1), seals and locating dowel.

24
25. Remove the circlip and using adapter tool no.
292313 (1) and slide hammer tool no. 292927
remove the reverse idler gear pin. Leave gear in
place.

25
26. Using a brass punch, push on the rear of reverse
control gear.

26
27. Withdraw the input shaft (1) along with the reverse
gear and shuttle synchroniser from the front side.

21- 39
SECTION 21 -- TRANSMISSION -- CHAPTER 5
28. Remove circlip (1) from the transmission input
shaft.

28
29. Remove tool no. 293805 from rear side, set the
housing upright and withdraw the input shaft (1).
Retrieve the gear (2), reverse idler gear and
bearing.

29
30. Remove tool no. 293805 from rear side, set the
housing upright and withdraw the input shaft (1).
Retrieve the gear (2), reverse idler gear and
bearing.

30
31. Loosen the stop plugs (5), slide out both selector
dog (6) roll pins and the fork internal retaining
spring pin.

21- 40
SECTION 21 -- TRANSMISSION -- CHAPTER 5
32. Slide out the rails from rear side and retrieve forks
and selector dog.

32
33. Remove the safety pawl (1).

33
34. Loosen the fitting and retaining screw, remove the
output shaft lubrication tube (1).

34
35. Install tool no. 293808 (1) on transmission output
shaft and insert a spanner (2) to hold the shaft in
place.

21- 41
SECTION 21 -- TRANSMISSION -- CHAPTER 5
36. Unstake the transmission output shaft locknut (1).

36
37. Loosen the transmission output shaft locknut and
retrieve the bush.

37
38. Using an aluminium punch from the front side,
release shaft from bearing.

38
39. Position the transmission housing upright,
withdraw the output shaft (1) and retrieve the group
of gears.

21- 42
SECTION 21 -- TRANSMISSION -- CHAPTER 5
40. Reinstall the mechanical speed and range gears
into the transmission housing observing the
following:
-- Reinstallation follows the removal procedure in
reverse, from step 39 back to step 1.
-- Refer to figures on pages 8 to 11 for correct
orientation of the different parts.
-- Ensure the housing is thoroughly cleaned
(especially inner compartments).
-- Check seals and replace if damaged.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 45
-- Tighten to correct torques as detailed on page
3.
-- Consider the following operations and perform
adjustments as detailed on pages 46 to 49.
41. After removing the circlip and thrust washer,
disassemble the transmission input shaft bearings
using tools nos. 293805 (1) and. 50062 (2) (see on
page 6). Heat the bearings, reinstall them and
settle using a brass punch. 40
42. Mount retaining tool no. 293808 (1) on the
transmission output shaft and insert a spanner (3)
to hold it in place. Support tool (1) using tool no.
293805 (2) attached to the housing.

41
43. Install front bearing (2) on to the transmission
output shaft using tool no. 293869 (1).

21- 43
SECTION 21 -- TRANSMISSION -- CHAPTER 5
44. Withdraw the PTO shaft seal using puller tool no.
294000 (2) and slide hammer (1).

43
45. Install the seal using tool no. 293993 (3) and
handle tool no. 293800 (1).

44
46. Withdraw the bush (3) as per step 44. Install the
bush (3) using tool no. 293992 (2) and handle tool
no. 293800 (1).

45
47. Remove the range input shaft bearing (2) using two
suitable pullers and an insert (1).

21- 44
SECTION 21 -- TRANSMISSION -- CHAPTER 5
48. Heat and Install the bearing (3) on to the input shaft
using tool no. 50060 (2) shown on page 6. Using
tool no. 50013 (1) (see on page 7), keep the
bearing properly seated during cooling.

47
49. Heat and Install the bearing (1) on to the output
shaft using tool no. 50061 (2) shown on page 6.
Using tool no. 50018 (3) (see on page 5) keep the
bearing properly seated on the gear during cooling.
NOTE: Remove tools nos. 50060 (2, Fig. 48) and
50061 (2, Fig. 49) when bearings (1 and 3) have
completely cooled down.

48
Pattern for application of sealant during
installation of control rail support (1), upper cover
(2) and front cover (3) to the transmission housing

21- 45
SECTION 21 -- TRANSMISSION -- CHAPTER 5
MECHANICAL TRANSMISSION HOUSING

Shuttle Gear Bearing Adjustment

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
50. Remove the circlip (5) and slide out adjust shim (4),
front bearing (3), spacer (2) and rear bearing (1).

50
51. Reassemble all parts without the adjust shim.
Ensure the assembly is bottoming. Measure
distance (L1) from the top of gear (2) to the bearing
outer race (1). L1

51
52. Place the gear on a suitable bush (1) to raise the
inner assembly. Ensure also the circlip is raised.

21- 46
SECTION 21 -- TRANSMISSION -- CHAPTER 5
53. Measure distance (L2) from the top of gear (2) to
the bearing (1) outer race. Adjust shim (2, Fig. 53)
to be added is given by:
S = L1 -- L2 -- 0.05 mm
where:

L2
S = Adjust shim(2).
L1 and L2 = Readings on the gear
0.05 mm = Decrease necessary to compensate for
bearing increased load deriving from tightening of
the transmission output shaft locknut.
If necessary, round off the value (S) to the previous
0.05 mm.
Example:
Reading L1 = 10.25 mm. 53
Reading L2 = 7.33 mm.
Adjust shim:
S = 10.25 -- 7.33 -- 0.05 = 2.87 mm.
Adjust shim to be assembled is 2.85 mm.
NOTE: Available adjust shims for the shuttle driven
gear are listed on page 3
54. Remove circlip (1), assemble adjust shim (2) as
previously found and lock the assembly reinstalling
circlip (1).

21- 47
SECTION 21 -- TRANSMISSION -- CHAPTER 5
MECHANICAL TRANSMISSION HOUSING

Range Input and Output Shaft Taper Bearing

Adjustment
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
55. Install cover (2) without the adjust shim. Install tool
no. 50013 (1) (see page 7) on to the input shaft.

55
56. Screw installer tool no. 292176 (2) on tool no.
50013 (3). Place a dial indicator (1) with the stylus
touching the bearing inner race. Turn the shafts to
settle the bearing rollers, reset gauge to zero
ensuring that the assembly is bottoming.
Through the lever of installer tool no. 292176 (2), bring
the assembly to touch the cover (4) and read the travel
(L) on the dial indicator.
Adjust shim to be added is given by:
S = L-- (0 to 0.06 mm)
where:
S = Adjust shim.
L = Travel reading.
0 to 0.06 mm = input shaft bearing end play. 56
NOTE: Available adjust shims for the range input shaft
bearings are listed on page 2.
57. Dismantle tools (2 and 3), remove cover (4),
assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 56 to
check end play is to specification, 0 to 0.06 mm.
Remove tools (2 and 3).

21- 48
SECTION 21 -- TRANSMISSION -- CHAPTER 5
58. Install disc (1) with a test shim (Sp). Remove
output shaft lubrication [Link] tool no.
50018 (4) (see on page 5), installer tool no. 292176
(3) and dial indicator (2). Ensure the indicator
stylus is located on the bearing inner race.

Turn the shafts to settle the bearing rollers and

reset gauge to zero ensuring that the assembly is
bottoming.
Using the lever of installer tool no. 292176 (3) bring
assembly to touch the disc (1) and read travel (H)
on the dial indicator.
Shim to be added is given by:
S1 = H + Sp -- (0 to 0.06 mm) 57
where:

S1 = Adjust shim.
Sp = Test shim.
H = Travel reading.
0 to 0.06 mm =Output shaft bearing end play.
NOTE: Available adjust shims for the range output
shaft bearings are listed on page 2.
59. Dismantle tools (3 and 4), remove disc (1), replace
test shim (Sp) with adjust shim (S1), reinstall disc
(1) and tools (3 and 4). Repeat step 58 to check end
play is to specification, 0 to 0.06 mm. Remove tools
(3 and 4) and screw in the output shaft lubrication
plug.

21- 49
SECTION 21 -- TRANSMISSION -- CHAPTER 5
MECHANICAL TRANSMISSION HOUSING

Removal--Installation of 5th Speed Gears (Op. 21

140 14)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

To overhaul the 5th speed gears, it is necessary to

remove the transmission housing following the
procedure detailed on pages 13 to 26. Then proceed
as follows:
1. Fix the transmission housing on the rotary stand
tool no. 290090 using front and rear brackets, tools
nos. 293971 (1) and 293972 (2), respectively.

1
2. Loosen the retaining bolts and remove the upper
cover (1).

2
3. Slide out the bearing spring retainer (1) (on both
sides)

21- 50
SECTION 21 -- TRANSMISSION -- CHAPTER 5
4. Retrieve the clutch engagement bearing (1).

4
5. Loosen the screw (1) attaching the fork to the
clutch control lever.

5
6. Withdraw the control lever (2) and retrieve the fork
(1).

6
7. Loosen all cover (1) retaining bolts (2).

21- 51
SECTION 21 -- TRANSMISSION -- CHAPTER 5
8. Screw in three of the screws (1, Fig. 8) into the
threaded holes to separate the cover (1) from the
transmission housing.

8
9. Loosen the screw (1) and retrieve spring and
actuating ball.

9
10. Withdraw the bearing (1) from the shuttle input
shaft using a puller.
11. Remove the control and safety selector dog roll
pins from the 5th speed rail. Withdraw the control
fork along with the rail from the front side. Retrieve
selector dogs.

10
12. Remove circlip (1).

21- 52
SECTION 21 -- TRANSMISSION -- CHAPTER 5
13. Retrieve the synchroniser assembly (1), the 5th
speed drive gear along with thrust washer and
seal.

12
14. Loosen the fitting and retaining screw, remove the
output shaft lubrication tube (1).

13
15. Install tool no. 293808 (1) on to the transmission
output shaft and insert a spanner (2) to hold the
shaft in place.

14
16. Unstake the transmission output shaft locknut(1)

21- 53
SECTION 21 -- TRANSMISSION -- CHAPTER 5
17. Loosen the transmission output shaft locknut and
retrieve the 5th speed driven gear.
NOTE: If it is necessary to disassemble the entire
transmission and range gears, perform also previous
steps from 9 to 13 during the disassembly procedure
detailed from page 33 to page 45.
18. Reinstall the 5th speed gear assembly into the
housing observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 17 back to step 1.
-- Refer to figures on pages 8 to 11 for correct
orientation of the different parts.
-- Ensure the housing is thoroughly cleaned
(especially inner compartments). 16
-- Check seals and replace if damaged.
-- Before reassembling the 5th speed gear
assembly, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the
figure on page 45.
-- Tighten to correct torques as detailed on page
3.

21- 54
SECTION 21 -- TRANSMISSION -- CHAPTER 5
SPEED AND RANGE CONTROL RAIL
ASSEMBLY

Removal -- Installation (Op. 21 130 30)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the mechanical speed and range control rail

assembly as follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Raise rear tractor, place a stationary stand (1)
under the RH final drive case and remove RH
wheel.

2
Disconnect speed and range control cables (1) from
rails (2) and supports (3).

21- 55
SECTION 21 -- TRANSMISSION -- CHAPTER 5
4. Detach all electrical connectors (1) from solenoid
valves and sensors.
NOTE: Before detaching connectors from the control
assembly, mark each connector and respective
solenoid valve as well as each connector and
respective sensor to assist reassembly and avoid
reversal of connections.

4
5. Loosen all lines (1) from the speed and range
control rail assembly.

5
6. Loosen two retaining screws and insert two
alignment pins (1) into the holes. Loosen all
retaining screws and remove control assembly.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

7. Reinstall the mechanical speed and range control

rail assembly to the transmission housing
observing the following:
-- Reinstallation follows the removal procedure
in reverse, from step 7 back to step 1.
-- Before reassembling the speed and range
6
control rail assembly thoroughly clean and
degrease mating surfaces and apply a 2 mm.
bead of sealant following the pattern shown in
the figure on page 45.
-- Tighten to correct torques as detailed on page
3.

21- 56
SECTION 21 -- TRANSMISSION -- CHAPTER 5
CREEPER GEARS

Removal -- Installation (Op. 21 160 50).

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

1. To overhaul the creeper gear assembly it is

necessary to remove the transmission housing 1
2
following the procedure detailed on pages 13 to 26.

2. Fix the transmission housing on the rotary stand

tool no. 290090 using front and rear brackets, tools
nos. 293971 (1) and 293972 (2), respectively.
3. Remove the circlip (1).

24519

1
4. Retrieve the driven gear assembly (1).

24520
1
2

24521

21- 57
SECTION 21 -- TRANSMISSION -- CHAPTER 5
5. Loosen retaining screws and remove the creeper 1
gear housing (1).
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

6. Reassemble the creeper gear assembly observing

the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 5 back to step
1.
-- Refer to figures on page 8 to 11 for correct 24522
orientation of different components.
4
-- Tighten to correct torques as detailed on pages
3.
-- Ensure the creeper housing (1, Fig. 4) does
not disturb the input shaft bearing cover.
-- After reassembling the transmission housing
to the rear axle housing, but before installing
the fuel main tank, carry out the following
adjustment:

CREEPER GEAR ASSEMBLY

Creeper External Control Lever Travel

Adjustment
7. Prior to this adjustment, it is necessary to reinstall
the transmission housing to the rear axle housing,
but the fuel main tank should not be installed.
Then proceed as follows:
8. Loosen the locknut (1) and loosen the bolt (2)
almost completely. Move the external lever (3) 1
backwards to end of travel.
9. Tighten the screw (3) until touching the external 2
lever (1). Then, screw it in a further 1 1/2 turn and
lock using the locknut (2).
Loosen the locknut (4) and screw in the screw (5)
until obtaining a distance (L) = 57 mm between this 3
screw and screw (3). Tighten the locknut (4). 24523

5
2

4
3
24524

21- 58
SECTION 21 -- TRANSMISSION -- CHAPTER 6
SECTION 21 -- TRANSMISSION

Chapter 6 -- Power Command Transmission

CONTENTS

Section Description Page

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Description and Operation and Power Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transmission Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Transmission Overhaul -- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Component Disassembly -- Clutch Pack Exploded Views and Adjustments
Oil Manifold Bushes, Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Upper Speed Shaft End Float Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Clutch Pack Exploded Views and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Transmission Overhaul -- Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clutch Testing During Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Output Shaft End Float Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Medium Range clutch assembly, End Float Adjustment . . . . . . . . . . . . . . . . . . . . . . 82
Clutch Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Error Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Limp Home Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

21- 1
SECTION 21 -- TRANSMISSION -- CHAPTER 6
21 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS
-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS -- FULL POWERSHIFT TRANSMISSION

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 forward and 6 reverse gears,

controlled by nine hydraulically
engaged clutches via processor
driven PWM valves
Gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical toothed, constant mesh
-- Reduction ratios:
Forward 1 (F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (62/28) : (53/14) = 1 : 8.383
Forward 2 (F2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (65/28) : (51/41) = 1 : 2.888
Forward 3 (F3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Speed shift controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by two buttons located on the
control lever
Transmission lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced--fed by a gear pump (same
as the power steering circuit pump)
Number of driven discs--Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
-- Thickness of driven discs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . mm 2.65 -- 2.75
Number of drive discs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
-- Thickness of drive discs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch A thickness under a load of 163 kg (1600 N) . mm 23.5 -- 23.7
Number of Belleville springs -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Free spring length -- Clutch A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32
-- Compressed spring length under a load of 215 kg (2108 N) . . . mm 23

21- 2
SECTION 21 -- TRANSMISSION -- CHAPTER 6
SPECIFICATIONS -- FULL POWERSHIFT TRANSMISSION
continued
Number of driven discs--Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
-- Thickness of driven discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . mm 2.65 -- 2.75
Number of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
-- Thickness of drive discs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . mm 1.80 -- 2.00
Multi--pack clutch B thickness under a load of 163 kg (1600 N) . mm 23.5 -- 23.7
Number of Belleville springs -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
-- Free spring length -- Clutch B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 32
-- Compressed spring length under a load of 215 kg (2108 N) . . mm 23
Number of driven discs--Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Thickness of driven discs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . mm 2.70 -- 2.80
Number of drive discs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Thickness of drive discs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . mm 1.5--1.7
Multi--pack clutch C thickness under a load of 163 kg (1600 N) . mm 26.2 -- 26.4
Number of Belleville springs -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Free spring length -- Clutch C . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 54.7
-- Compressed spring length under a load of 182 kg (1784 N) . . . mm 46
Number of driven discs--Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Thickness of driven discs -- Clutches D--E . . . . . . . . . . . . . . . . . . mm 2.70 -- 2.80
Number of drive discs -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Thickness of drive discs -- Clutches D--E . . . . . . . . . . . . . . . . . . . mm 1.5--1.7
Multi-pack clutches D--E thickness under a load of 163 kg (1600 N) mm 26.2 -- 26.4
Number of Belleville springs -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . 6
-- Free spring length -- Clutches D--E . . . . . . . . . . . . . . . . . . . . . . . . mm 4.1
-- Compressed spring length under a load of 182 kg (1784 N) . . . mm 3.22
Number of driven discs--Fast Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
-- Thickness of driven discs -- Fast Clutch . . . . . . . . . . . . . . . . . . . . mm 2.70 -- 2.80
Number of drive discs -- Fast Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
-- Thickness of drive discs -- Fast Clutch . . . . . . . . . . . . . . . . . . . . . mm 1.5--1.7
Multi--pack Fast clutch thickness under a load of 163 kg (1600 N) mm 42.9--43.1
Number of Belleville springs -- Fast Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 8
-- Free spring length -- Fast Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.4
-- Compressed spring length under a load of 4820 N . . . . . . . . . . mm 24.4

21- 3
SECTION 21 -- TRANSMISSION -- CHAPTER 6
SPECIFICATIONS -- FULL POWERSHIFT TRANSMISSION
continued
Number of driven discs -- Slow Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
-- Thickness of driven discs -- Slow Clutch . . . . . . . . . . . . . . . . . . . mm 2.70 -- 2.80
Number of drive discs -- Slow Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
-- Thickness of drive discs -- Slow Clutch . . . . . . . . . . . . . . . . . . . . mm 1.5--1.7
Multi--pack Slow clutch thickness under a load of 163 kg (1600 N) mm 55.1--56.9
Number of Belleville springs -- Slow Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 12
-- Free spring length -- Slow Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . mm 57.6
-- Compressed spring length under a load of 4820 N . . . . . . . . . . mm 36.6
Number of driven discs -- Clutches Medium & Reverse . . . . . . . . . . . . . . . 12
-- Thickness of driven discs -- Clutches Medium & Reverse . . . . . mm 2.70 -- 2.80
Number of drive discs -- Clutches Medium & Reverse . . . . . . . . . . . . . . . . 12
-- Thickness of drive discs -- Clutches Medium & Reverse . . . . . . mm 1.5--1.7
Multi--pack clutches Medium & Reverse thickness under a load of 51.5--51.7
163 kg (1600 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Number of Belleville springs -- Clutches Medium & Reverse . . . . . . . . . . . 12
-- Free spring length -- Clutches Medium & Reverse . . . . . . . . . . . mm 57.6
-- Compressed spring length under a load of 4820 . . . . . . . . . . . . mm 36.6
PTO drive shaft (7) diameter at the bushing . . . . . . . . . . . . . . . . . . mm 31.950 -- 31.975
Press--fit bush inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 31.990 -- 32.085 ( ° )
PTO drive shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . mm 0.015 -- 0.135
Medium Clutch Bearing Shims (rolling resistance adjustment) . . mm 8.900 to 9.650 in 0.025 steps
‘C’ Clutch Bearing Shims (rolling resistance adjustment) . . . . . . . mm 9.800 to 10.700 in 0.025 steps
Upper speed shaft assembly shims . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.80 to 4.80 in 0.05 steps
Output shaft and Medium clutch assembly endfloat shims . . . . . . mm 1.50 to 3.40 in 0.05 steps
3.95 -- 4.00
Transmission output shaft thrust washer . . . . . . . . . . . . . . . . . . . . . mm
Low pressure regulation valve spring
-- Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 127
-- Compressed spring length under a load of 278 to 304 N
(28.4 to 31 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 107.4--101.2
Low pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 16.7 -- 17.6 (1.7 -- 1.8)
Lubrication pressure regulation valve spring :
-- Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.5
-- Compressed spring length under a load of 37 to 41 N
(3.8 to 4.2 kg) . mm 26--25
Lubrication pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (kg/cm2) 3.0--3.7 (29.5--36.5)

(°) Final dimension to be obtained without grinding

21- 4
SECTION 21 -- TRANSMISSION -- CHAPTER 6
SPECIFICATIONS -- SEMI--POWERSHIFT TRANSMISSION AND RANGE GEARS
continued

SPECIFICATIONS -- CREEPER GEARS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic spur gear set
-- Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 : (20+100) = 1:6
Control type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through a lever on LH side of the
driver’s seat
Creeper housing and driven gear thrust washer thickness . . . . . . mm 1.465 to1.535

TIGHTENING TORQUES
Tightening Torques
Thread Torque
size
Bolts and nuts, clutch/transmission housing to engine . . . . . . . . . . . . . . . . (see C3 and C4, page 2, Sec. 18)

Bolts, clutch/transm housing to rear axle housing . . . . . . . . . . . . . . . . . . . . M14 x 1.5 176 18

21- 5
SECTION 21 -- TRANSMISSION -- CHAPTER 6

21- 6
SECTION 21 -- TRANSMISSION -- CHAPTER 6

21- 7
SECTION 21 -- TRANSMISSION -- CHAPTER 6

21- 8
SECTION 21 -- TRANSMISSION -- CHAPTER 6

21- 9
SECTION 21 -- TRANSMISSION -- CHAPTER 6
SPECIAL TOOLS
297612 Transmission end casing lifting hook 3
CAUTION
off).
Operations described in this Section of the Manual 297613 Medium clutch shaft adaptor (for lifting
must be performed using the following ESSENTIAL and endfloat adjustment)
tools marked with the identification code (X). 297614 Medium and ’C’ clutch hub bearing
To work safely and achieve the best technical results setting tool
with additional savings of time and effort, these 297615 Manifold bush removal tool
mandatory tools should be used in conjunction with the 293343 Output shaft spanner (65mm).
suggested special tools listed below and integrated
with the self--made ones for which you will find the
295027 Cab lifting tool.
necessary construction drawings and specifications
290740 Lifting hooks
directly on this Manual.
292176 Range input and output shaft end play
test tool (use with tools nos. 50013 and
List of special tools necessary to carry out the different 50018).
operations described in this Section: X 293869 Output shaft bearing installer (use with
tool no. 50108).
290090 Overhaul rotary stand. 292927 Slide hammer.
292320 Tractor separation stand. 295021 Clutch spring compressor.
291517 Transmission housing lifting hook. 294035 Pressure test kit (use with tool no.
297616 Transmission overhaul brackets (use 295024).
with stand tool no. 290090). 295024 Fitting (kit no. 294035).

5
Tool to be fabricated for range input and output shaft bearing adjustment
(Mark tool with no. 50018 -- Dimensions in mm).
Fabricate tool using Aq 42 material.

21- 10
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Tool to be fabricated for input and output shaft bearing
assembly (Mark tool with no. 50108 -- Dimensions in
mm).
Fabricate tool using UNI C40 material.

25291

6
Alignment pins to be fabricated for engine and speed
clutch/transmission housing removal/installation
(Mark tool with no. 50117 -- Dimensions in mm).
Fabricate tool using UNI C40 material.

25292

7
Adapter to be fabricated for reverse idler gear pin
removal (Mark tool with no. 50143 --
Dimensions in mm).
Fabricate tool using UNI C40 material.

25280
8

21- 11
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Transmission Locking Tool
(Manufacture locally)

------------------------------

POWER COMMAND TRANSMISSION COMPONENTS

1. Input shaft seal 14. Output shaft endfloat adjustment shims
2. Flywheel 15. Slow (S) range clutch
3. Flywheel to transmission damper 16. Medium range clutch assembly, endfloat adjustment
4. Clutch housing cover shims
5. Clutch ’A’ 17. Medium clutch hub bearing preload shims
6. Clutch ’B’ 18. Medium (M) range clutch
7. Top shaft adjustment shim 19. Medium clutch driven gear (meshes with reverse
8. Reverse clutch driven gear (meshes with medium clutch driven gear)
clutch driven gear) 20. Clutch ’E’
9. Reverse (R) clutch 21. Clutches ’C’ and ’D’
10. Transmission end housing 22. Clutch ’C’ hub bearing preload shims
11. Slow speed idler gear 23. Four wheel drive shaft
12. Power Take Off driveshaft 24. Lube oil transfer tube
13. Transmission output shaft

21- 12
SECTION 21 -- TRANSMISSION -- CHAPTER 6

NOTES

21- 15
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DESCRIPTION AND OPERATION
The power command transmission is available in an
18x6 (40 Km/h) or a 17x6 (30 Km/h) configuration. An
optional creeper unit is available providing an
additional 10 forward and 6 reverse ratios. The
transmission is also specified with four wheel drive or
less four wheel drive.
The transmission consists of 9 multi--plate hydraulic
clutch assemblies each controlled by a PWM (Pulse
Width Modulated) valve, via an electrical signal
supplied from an electronic control Module.

9
The pressure oil to engage the clutches is supplied
from the low pressure hydraulic circuit, which is
maintained at 16--18 bar by the low pressure regulating 1
valve (1), located in the transmission top cover.

10
Transmission lube oil is supplied via the low pressure
regulating valve and is controlled to a maximum
pressure of approximately 7 bar by the lube relief valve,
located in the front section of the transmission.

11
An oil cooler by--pass valve (1), located in the
transmission top cover, ensures that excessive oil
pressure, generated at cold start up, or if the cooler
becomes blocked, bypasses the cooler until the oil
warms up and the pressure drops.

21- 16
SECTION 21 -- TRANSMISSION -- CHAPTER 6
The low pressure system also incorporates a hydraulic
accumulator, located on the right hand side of the
transmission. This provides instant additional oil to fill
possible voids when transmission shifts involving
multiple clutches are performed.

13
The transmission clutches can be broken down into
three groups and described as follows:--
A and B clutches -- Located at the front of the
transmission and providing a high ratio and low ratio
output.

14
C, D and E clutches -- Located in the central part of the
transmission and each providing a single speed. Using
either the A or B clutch with any of the C, D and E
clutches provides six speeds:
F (fast), S (slow), M (medium) and R (reverse)
clutches, located at the rear of the transmission
provide a further 3 forward ranges and 1 reverse range,
enabling the transmission to provide 18 forward and 6
reverse ratios.

15
RANGE S M F R
SPEED
AC 1 7 13 R1

BC 2 8 14 R2

AD 3 9 15 R3

BD 4 10 16 R4

AE 5 11 17 R5

BE 6 12 18 R6
16

21- 17
SECTION 21 -- TRANSMISSION -- CHAPTER 6

BSB0247A

17
Power Command Transmission Power Flows

Transmission Output Drive Drive after A or B clutch

Clutch pack engaged Drive from B clutch when B engaged

Drive out of C,D or E clutch, Drive in from Engine

depending on ratio selected

A = Clutch A
B = Clutch B
C = Clutch C
D = Clutch D
E = Clutch E
F = Fast Range Clutch
S = Slow Range Clutch
M = Medium Range Clutch
R = Reverse Range Clutch

21- 18
SECTION 21 -- TRANSMISSION -- CHAPTER 6

A B

F S

C D E

BSB0243A

18
1st Gear Selected

A B

F S

C D E

BSB0244A

19
10th Gear Selected

21- 21
SECTION 21 -- TRANSMISSION -- CHAPTER 6

A B

F S

C D E

BSB0245A

20
16th Gear Selected

A B

F S

C D E

BSB0246A

21
Reverse 5th Selected
The engagement of the clutches is controlled by inputs from various sensors and switches:--
21- 22
SECTION 21 -- TRANSMISSION -- CHAPTER 6
INPUT SENSORS

DESCRIPTION FUNCTION LOCATION

Engine Torque/RPM Sensor Measures engine speed and torque
by means of flywheel damper spring
deflection. Depending on the torque
being transmitted will assist in
determining when a gear shift will
occur

Transmission Output speed and Measures transmission output

Mid--speed sensors speed and speed of the
transmission at the input to the
range section. The speeds are
compared to assist in determining
clutch engagement times

Transmission oil temperature Measures temperature of the oil to

sensor provide compensation for hot/cold
oil conditions.

Foot throttle potentiometer Determines a preset throttle

position, only functional when in
Auto function mode to assist in
determining auto shifts.

Clutch pedal disconnect switch Disengages power to range

clutches (fast/slow/med/rev) PWM
valves, thereby disengaging drive.

Clutch pedal potentiometer Provides operator controlled

engagement of the feathering
(range) clutches.

Shuttle lever Provides information to the

processor,via switches, for forward,
reverse and neutral transmission
drive selection.

21- 23
SECTION 21 -- TRANSMISSION -- CHAPTER 6
INPUT SENSORS

DESCRIPTION FUNCTION LOCATION

Gear shift switches Allows the operator to shift ratios via
push buttons switches sending a
signal to the processor.

Footbrake switches Informs the processor of when the

brakes are being applied to assist in
ratio shifts during auto function
operation.

Handbrake switch To be applied during calibration,

error code if not applied. Tractor will
drive if handbrake applied but
audible alarm sounds.

Pressure switches for These monitor for possible stuck

fast/slow/med/rev clutches valves. If pressure is indicated in
more than one circuit drive will be
shut down and an associated error
code will be displayed.

Creeper engaged switch Informs the processor when creeper

has been engaged, preventing
selection of certain higher ratios.

Alternator Provides a secondary engine speed

to the processor. Will only be used if
the engine torque/speed sensor
becomes inoperative.

Seat switch Seat switch must be operated, ie,

operator seated, before the
processor allows engagement of
forward or reverse drive. (Note, a
faulty switch can be over ridden by
the clutch pedal). Also prohibits
start--up and transmission
calibration if not engaged.

21- 24
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DESCRIPTION FUNCTION LOCATION
Auto Function Select Switch Sends a signal to the processor to
select the auto shift functions

OUTPUT DEVICES

DESCRIPTION FUNCTION LOCATION

Clutch PWM valves, A,B,C,D,E and Controls oil to the clutches to
fast/slow/med/rev engage/disengage the clutches via
a signal from the processor.

PTO lube solenoid During feathering (inching) the

solenoid is closed, allowing
additional oil to the transmission
clutches. 10 seconds after the
completion of feathering the
solenoid opens allowing lube oil to
the PTO. This provides 2 functions,
to increase lube during feathering
and then reduce oil (less drag)
during normal driving.
Gear Display Unit Provides operator information as to
which ratios are selected and
pre-selected, whether auto mode is
selected and error code information.

CONTROL DEVICE --

DESCRIPTION FUNCTION LOCATION

MICRO PROCESSOR The transmission is controlled by a
micro processor, located at the front
of the right hand console. The
processor has 3, 36 way connectors
and in addition to controlling the
transmission also controls the
Electronic hydraulic lift system. The
processor has an inbuilt diagnostic
facility which can interpret a number
of system faults and display an error
code on the gear display unit. A full
description of error codes and fault
finding can be found later in this
Chapter.

Driving the Tractor -- Figure 22 Start the engine with the shuttle lever in neutral and the
clutch pedal depressed. The LCD on the instrument

21- 25
SECTION 21 -- TRANSMISSION -- CHAPTER 6
panel and adjacent to the Powershift control will
display ‘N’ (for neutral) and ‘7’. (When the tractor is
initially started, the electronic control will automatically
select 7th. gear, for a smooth pull away).
NOTE: Neutral start switches prevent operation of the
starting motor unless the shuttle lever is in neutral and
the clutch pedal depressed.

22
Figure 23
For forward travel, with the engine idling, pull the
shuttle lever (1) toward the steering wheel, against light
spring-pressure, and move it up.

23
Figure 24
Once moving, select the required ratio with the upshift
button (2) or downshift button (1), as previously
described. An example of the display that you will see
is shown at (3), where ‘F’ indicates forward and ‘10’
indicates that 10th. gear is selected. The LED for 10th.
gear will also be illuminated.
Once moving, select the required ratio with the upshift
button (2) or downshift button (1) as previously
described.
NOTE: An alternative lower or higher ratio may be
preselected before pulling away. However, if a ratio
higher than 12 is selected then the electronic control
will select 12, this being the highest ratio permissible 24
when pulling away from a standstill. If, for example,
15th. gear is selected before pulling away, the 15th.
gear LED will flash and the 12th. gear LED will be
steady. The tractor will pull away in 12th. gear and
change up, sequentially, to the selected gear as engine
load, engine speed and road speed are optimised. The
LED’s for 13th. and 14th. gear will illuminate, as these
ratios are automatically selected, then the 15th. gear
LED will stop flashing and become steady as that gear
is reached.

21- 26
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Figure 25
To reverse the direction of travel, reduce engine speed,
pull the shuttle lever (1) toward the steering wheel, then
move it down.
NOTE: When changing from forward to reverse travel,
the nearest available ratio will be selected. As only six
ratios are available in reverse, the ground speed in
reverse gear may be different to the speed in the
selected forward gear. For example, if F15 is selected
in forward travel, then the nearest reverse ratio, R6, will
be selected when the shuttle lever is moved to the
reverse travel position.

25
Figure 26
When performing shuttle operations, the transmission
will ‘remember’ the previously selected gear. For
example, if travelling forward in F15 and the shuttle
lever is moved to the reverse position, the transmission
will select the highest available ratio in reverse (R6).
When the shuttle lever is moved forward again, the
LED for ratio F15 will flash, but the nearest ratio (F12)
will be selected and the F12 LED will glow. The
transmission will then automatically change,
sequentially to F13, F14 and then F15, at which point
the F15 LED will stop flashing and become steady .

21- 27
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Auto Shift Function
Engaging the auto shift mode permits automatic gear
changing in the forward ratios. Two automatic ranges
are available:
Road range -- ratios 12 -- 17 (30 km/h transmission)
or 12 -- 18 (40 km/h transmission)
Field range -- ratios 1 -- 11

Auto Shifting in Road Range -- Figure 27

While travelling forward in 12th. gear or higher, press
and release the AUTO switch (1) on the right-hand ‘B’
pillar.

27
Figure 28
The gear ratio currently selected will already be
displayed and the appropriate LED illuminated. When
AUTO shift is engaged an ‘A’ will appear in the LCD
display.
When in AUTO shift, the tractor will automatically
select lower or higher gears, within the range of 12 to
18, as dictated by engine torque and speed, use of
brakes, etc.

28
Figure 29
To disengage AUTO shift and return to normal shifting,
press and release the AUTO switch (1).
Alternatively, the auto mode may be cancelled by
pressing either of the up/down buttons or by using the
shuttle lever to select reverse.

21- 28
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Auto Shifting in Field Range -- Figure 30
While travelling or operating in any forward gear
between 1 and 11, press and release the AUTO switch
(1) on the right-hand ‘B’ pillar. The transmission will
make automatic shifts within a span of 5 gears.

30
Figure 31
The gear ratio currently selected will already be
displayed and the appropriate LED illuminated. When
AUTO shift is engaged an ‘A’ will appear in the LCD
display.
When in AUTO shift, the system will automatically set
an operating range of plus or minus two gears from that
currently selected. Automatic changes will occur within
this range, dependent upon load and speed.
Example: While operating in 7th. gear, ‘7’ is displayed
and the 7th. gear LED is illuminated. If the AUTO
switch is pressed, the LED’s for 5th. and 9th. gear will
flash to indicate that automatic changing will occur
between 5th. and 9th. gears. 31

Changing the Gear Span -- Figure 32

The range of plus or minus two gears may be
expanded both up and down on the move, using the
downshift and upshift buttons (1) and (2).
Example 1: Upshifting: When operating in AUTO
mode in 7th. gear, as described above, the LED’s for
5th. and 9th. gear will flash. On reaching 9th gear press
the upshift button (2) once to select 10th gear. When
the tractor has upshifted to 10th, press the button again
to select 11th gear. AUTO shifting will now be provided
between 5th and 11th gears. The LED for 5th will
continue to flash identifying the lowest automatic gear
selected.
Example 2: Downshifting: Assuming 5th has been 32
selected as the lowest AUTO ratio, slow the tractor
until this gear has been engaged. Then, using the
downshift button (1), select 4th gear and further reduce
speed until 4th gear engages. 3rd gear may now be
selected if required. Applying this technique it is
possible to select gears 1 to 11 in the AUTO range.

21- 29
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Go To Mode
An additional feature of AUTO shift is the ‘Go To’ mode.
The ’Go To’ system can be programmed to downshift
to a lower gear below that of the working gear
whenever the implement is raised. This feature can be
further enhanced by selecting the field AUTO shift
function whereby the tractor will also automatically
upshift again on lowering the implement.
To programme ‘go to’ mode, proceed as follows:

Figure 33
Press and hold the AUTO function switch (1) on the ‘B’
pillar.

33
Figure 34
With the engine running, press and release the top of
the fast raise switch (1) to raise the implement. The
auto field LED will illuminate on the transmission
display. Continue to hold in the AUTO function switch.

34
Figure 35
With the AUTO function switch still depressed, select
the required ‘Go To’ gear using the upshift button (2) or
downshift button (1). The LED for the ’Go To’ gear
selected will flash. Release the AUTO switch. Lower
the implement by pressing and releasing the fast raise
switch.
NOTE: Auto shift in the field range is disengaged every
time the implement is raised and re-engaged when it
is lowered.

21- 30
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Figure 36
To disengage ’Go To’ mode and return to normal
shifting, press and hold the AUTO switch (1). Move the
fast raise switch (1) Figure 36, to raise or lower the
implement.
NOTE: With AUTO shift selected in conjunction with
the ’Go To’ mode, the lowest gear in the AUTO function
becomes the ’Go To’ gear.

36
Speed Matching
When travelling on the road in the road range (ratios
12--18) the transmission will automatically downshift to
match engine speed to road speed if the following
method is adopted:
Decrease engine speed, depress the clutch pedal,
simultaneously increasing engine speed by pressing
the foot throttle further down.
When the clutch pedal is released, the transmission
will automatically select a lower gear ratio (provided
the lowest speed is not already selected) to
approximately match engine speed to road speed.

21- 31
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Programming Reverse Gear Ratios
When changing from forward to reverse, the
transmission will normally select the same ratio in
reverse as was selected for forward travel.
For special shuttle shift applications, Power Command
transmission offers the advantage of automatically
changing the reverse gear ratio up to three ratios
higher or lower than the currently engaged forward
gear ratio.
To programme an alternative reverse gear, proceed as
follows:

Figure 37
• Turn the key-start switch off.

37
Figure 38
• Move the shuttle lever (1) to the reverse gear
position.

38
Figure 39
• Press and hold down the upshift button (2).
• While holding down the upshift button, turn on the
key-start switch (but do not start the engine). The
digital display should show ‘0’ (unless the
transmission has previously been programmed to
select a higher or lower reverse gear.)
• Release the upshift button. The transmission is
now in the programming mode.

21- 32
SECTION 21 -- TRANSMISSION -- CHAPTER 6
To programme a higher reverse ratio --
Figure 40:
• Press the upshift button (2) one, two or three times,
as required. The display will show ‘1’, ‘2’ or ‘3’. This
indicates that when reverse is selected the gear
will be one, two or three ratios higher than the
forward gear ratio.

40
To programme a lower reverse ratio -- Figure 41:
• Press the downshift button (1) one, two or three
times, as required. The display will show ‘--1’, ‘--2’
or ‘--3’. This indicates that when reverse is selected
the gear will be one, two or three ratios lower than
the forward gear ratio.

41
To exit the programme -- Figure 42:
• Turn the key-start switch off. The transmission is
now programmed.
NOTE: Remember that only six reverse gears are
available. Consequently, if travelling forward in ratios
F13 -- 18, the transmission will always behave as if ratio
F12 (the highest ratio in the field range) is selected.
Therefore, if the transmission has been programmed
to select 2 ratios lower in reverse, then R4 will be
selected.
Conversely, if travelling forward in ratios F1 -- 6, the
transmission will always behave as if ratio 7 is
selected. Therefore, if the transmission has been
programmed to select 2 ratios higher in reverse, then 42
R3 will be selected.

21- 33
SECTION 21 -- TRANSMISSION -- CHAPTER 6
POWER COMMAND (FULL POWERSHIFT)
TRANSMISSION HOUSING

Removal -- Installation (Op. 21 113)

Remove the transmission housing from the tractor as

follows:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Connect the engine hood to a hoist using a nylon
cable (1) and disconnect the struts (2) (one on the
LH side and one on the RH side).

23353

21- 34
SECTION 21 -- TRANSMISSION -- CHAPTER 6
5. Unscrew the retaining screws and remove side
panels (1) (one on each side).

4
6. Jack up rear tractor and place two suitable stands
(2) under the final drive cases to raise the wheels
off the ground. If necessary, detach lift rods from
lower links.

5
7. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the left wheel.

6
8. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect tool to a hoist using hook tool no. 290740
and keep hook tensioned.

21- 35
SECTION 21 -- TRANSMISSION -- CHAPTER 6
9. Detach connectors at the washer motor. Detach
windscreen washer bottle (1) lines and remove
tank.

8
10. Remove the clip and detach the creep gear control
idler lever (2). Loosen the parking brake control
cable retaining screw (3).

9
11. Remove the pin and withdraw the pin securing the
fork (4) to the parking brake actuator lever. Loosen
the nut securing the cable to the fork (4) and
release cable.

10
12. Loosen the attaching nut and detach the ground
cable (5) between the cab and rear axle.

21- 36
SECTION 21 -- TRANSMISSION -- CHAPTER 6
13. Release the clamp (1) and detach the main tank
bleeding line.

12
14. Detach the ground synchronised PTO control
cable (2) from the rail.

13
15. Detach the three electrical connectors (1, 2, and 3)
located under the cab floor.

14
16. Disconnect radar and fuel filter connectors (4 and
3, respectively). Remove protection and
disconnect connectors (1 and 2) from starting
motor.

21- 37
SECTION 21 -- TRANSMISSION -- CHAPTER 6
17. Detach light connector (5) located on the handrail
(repeat for both tractor sides).

16
18. Detach heater to engine connecting lines (6)
located under the right hand front side of the cab.

17
19. Loosen the nut and detach the throttle control cable
(7) from injection pump.

18
20. Disconnect the brake reservoir to brake master
cylinder tubes (1).

21- 38
SECTION 21 -- TRANSMISSION -- CHAPTER 6
21. Loosen the power steering valve connecting lines
(4) to the control pump.

20
22. Detach the power steering valve connecting lines
(5) to the steering cylinders.

21
23. Loosen fittings and detach the air conditioning lines
.

22
24. Loosen the locknut, slide out the cotter pin and
detach the PTO control cable (1).

21- 39
SECTION 21 -- TRANSMISSION -- CHAPTER 6
25. Loosen the outer cable sleeve pinch bolt (1) and
remove the pin (2) securing the cable to the valve.
26. If auxiliary valves are fitted also on left hand side,
repeat step 28 for left hand side auxiliary valves.

24
27. Loosen the screw attaching steps (6) to the
bracket.

25
28. Loosen the screw attaching steps (1) to the cab
platform.
29. Repeat steps 30 and 31 on opposite side and
remove steps.

26
30. Raise the cab mat (2) and loosen the cab mounting
bolt while holding the locknut under the cab floor.
Retrieve bolt and washer. Repeat for both tractor
sides.

21- 40
SECTION 21 -- TRANSMISSION -- CHAPTER 6
31. Loosen the rear cab bolts (on both sides).
32. Slowly raise the cab taking care that no
components are connected, hooked or interfering.
Remove the cab and lower on a suitable support
base.

28
33. Loosen the plug (3) and drain oil from the rear axle
and transmission housing into a suitable container
(see specified quantity on page 6, Section 00).

29
34. Drain fuel tanks, then loosen the clamp (1)
retaining the connecting line between the main and
auxiliary tanks.

30
35. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
36. Detach the fuel return line (2) from the injection
pump to the auxiliary tank. Remove auxiliary tank.

21- 41
SECTION 21 -- TRANSMISSION -- CHAPTER 6
37. Loosen the clamp and detach the injection pump
supply line (5). Detach connectors (4), then
unscrew and remove the fuel level sensor
assembly.

32
38. Loosen the nut of the metal strap (6) securing the
main tank. Remove the strap and tank.

33
39. Loosen the retaining screws and remove the cab
and fuel tank support bracket (1). (Repeat on both
sides of the speed clutch--transmission housing).

34
40. Loosen the retaining screws and remove the main
tank support bracket (2).

21- 42
SECTION 21 -- TRANSMISSION -- CHAPTER 6
41. Loosen the attaching screws and remove the radar
unit and mounting bracket (3).

36
42. Loosen the attaching screws and remove the brake
control line bracket (4).
NOTE: Do not bend the brake control tubes sharply
when moving them away from the transmission
housing to avoid damages.

37
43. Loosen the clamps and separate the rear axle oil
cooler hoses (1) from tubes.

38
44. Detach and remove the accumulator (2) tubes,
loosen the retaining screws and remove
accumulator.

21- 43
SECTION 21 -- TRANSMISSION -- CHAPTER 6
45. Detach all connectors from the side control valve
assembly, the top cover and speed sensors.
NOTE: Before detaching connectors from both control
valve housings, mark each connector and respective
solenoid valve to assist reassembly and avoid reversal
of connections.

40
46. Disconnect all the hydraulic pipework between the
transmission and rear axle and the pipework to the
front of the unit.

41
47. Loosen the retaining screws and remove the
propshaft guard.
48. Remove circlip (4) and slide out sleeve (5). Repeat
for transfer box circlip and sleeve.

42
49. Loosen the bearing--support (3) retaining screws
at the transmission housing, detach and remove
the front diff lock control line (2).

21- 44
SECTION 21 -- TRANSMISSION -- CHAPTER 6
50. Place stand tool no. 292320 with one of the two
trolley jacks (6) under the engine and the other
under the transmission housing.
51. Place two wooden wedges (one each side)
between the front axle support and front axle to
prevent engine oscillation.

44
52. Loosen the retaining screws and remove starting
motor (1).

45
53. Remove the transmission housing to engine
attaching bolts.

46
54. Loosen the metal spacer retaining screw (2) at the
transmission housing.
55. Separate the engine from the transmission
housing.

21- 45
SECTION 21 -- TRANSMISSION -- CHAPTER 6
56. Loosen two bolts from the transmission housing
top cover (3), screw in chains of hook tool no.
291517 to the housing and keep them tensioned
using a hoist.
57. Place a stationary stand under the draft sensing
unit bracket. Place the trolley jack of stand tool no.
292320 under the rear axle housing.
58. Detach the transmission housing retaining bolts
and remove the housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.
48
59. Reinstall the transmission housing to the rear axle
housing and engine observing the following:
-- Reinstallation follows the removal procedure in
reverse, from step 67 back to step 1.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant
following the pattern shown in the figure on
page 29 and on page 13, Section 18.
-- Tighten to correct torques as detailed on page
3.

21- 46
SECTION 21 -- TRANSMISSION -- CHAPTER 6

20270

49
Pattern for application of sealant during installation of the speed clutch--transmission housing to rear
axle housing.

21- 47
SECTION 21 -- TRANSMISSION -- CHAPTER 6
TRANSMISSION OVERHAUL

Disassembly--Reassembly (Op.21 155)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Prior to servicing the Power Command transmission,

it is necessary to remove the transmission housing
following the procedure detailed previously.

1. Fix the transmission housing on the rotary stand

tool no. 290090 using front (1) and rear (2)
brackets, tools no. 297616.

1
2. Remove the top cover and the 3 oil transfer tubes
and “O” rings.

2
3. Remove the “A” clutch supply pipe the PWM valve
manifold and 5 PWM manifold oil tubes.

21- 48
SECTION 21 -- TRANSMISSION -- CHAPTER 6
4. Remove the 2 speed sensors.

4
5. Remove Reverse, Medium, Fast and Slow range
pressure test couplers, ( Medium range test
coupler at bottom of transmission ).

5
6. Remove “A” clutch supply coupling and tube from
A/B clutch housing.

6
7. Remove Reverse clutch circlip from end cap and
remove the cap using an 10x1.5mm coarse
threaded bolt screwed into the end of it.

21- 49
SECTION 21 -- TRANSMISSION -- CHAPTER 6
8. Insert a suitable tool through the speed sensor
orifice to lock the Reverse shaft. Unlock tabs on the
nut at the front end of the Reverse shaft and
unscrew the nut using a 55mm socket.

8
9. With the transmission still in the horizontal position,
remove the A/B clutch housing.

9
10. Remove the circlip retaining the B clutch, clutch
plates and remove the plates from the housing.

10
11. Using special tool No.295021, to compress the
belleville washers, remove the circlip and washers
from the B clutch housing.

21- 50
SECTION 21 -- TRANSMISSION -- CHAPTER 6
12. Remove the oil manifold.

12
13. Remove the 4 oil supply tubes and “O” rings from
behind the manifold.

13
14. Remove the speed section upper front shaft.

14
15. Remove the circlip from the front end of the upper
speed shaft.

21- 51
SECTION 21 -- TRANSMISSION -- CHAPTER 6
16. Remove the gear, shim and spacer from the upper
speed shaft.

16
17. Ensure that the transmission still locked using the
special tool in the reverse clutch speed sensor
hole.

17
18. Release the tabs on nut at the front end of the lower
speed shaft and unscrew the nut using a 60mm
socket. Remove the holding tool.

18
19. Remove the belleville washer, clutch manifold, the
2 O--rings from the end of the shaft and the shaft
support bearing.

21- 52
SECTION 21 -- TRANSMISSION -- CHAPTER 6
20. Rotate the transmission so that the rear end is at
the top. Remove the 8 transmission end plate
screws and end plate.

20
21. Unlock tabs on the nut at the rear end of the
Fast/slow range shaft and unscrew, lock the
transmission with the locking tool inserted through
the mid--speed sensor hole. Remove the nut using
either special tool No. 293343 or a 65mm socket.
NOTE: The nut has a left hand thread.
22. Remove shims from the end of the shaft.

21
23. Remove the circlip and shims from the rear end of
the Medium range shaft.

22
24. Remove end casing bolts and lift off the end casing
using the three special lifting hooks, tool No.
297612, spaced equally around the end casing.

21- 53
SECTION 21 -- TRANSMISSION -- CHAPTER 6
25. Install the gear locking tool through the reverse
speed sensor hole. Unlock the tabs on the nut at
the rear end of the Medium range shaft and loosen
the nut using a 70mm socket.

24
26. Remove the oil splash plate baffle.

25
27. Install the lifting adaptor tool, 297613, into the
medium clutch assembly.

26
28. Fit the special lifting hooks to the end of the 3 range
shafts, using M14x1.5 bolts to secure.

21- 54
SECTION 21 -- TRANSMISSION -- CHAPTER 6
29. Remove Fast / Slow shaft assembly.

28
30. Remove the circlip from the fast clutch hub and
remove the hub.

29
31. Remove the Reverse shaft assembly.

30
32. Remove the Medium range shaft assembly.

21- 55
SECTION 21 -- TRANSMISSION -- CHAPTER 6
33. Remove the oil supply pipes for Fast and Slow
clutches and the lubrication pipe.

32
34. Knock the upper speed shaft out from the front of
the transmission and remove from the rear. Lift the
cluster gear out from the top of the transmission.

33
35. Withdraw the lower shaft from the rear of the
transmission.

34
36. Rotate the transmission to position the rear
uppermost and remove the washer from the lower
shaft support.

21- 56
SECTION 21 -- TRANSMISSION -- CHAPTER 6
37. Remove the “E” clutch pack

36
38. Remove the “D” clutch output hub and gear.

37
39. Remove the “C/D” clutch assembly and remove
the clutch bearing shim and spacer.

38
40. Unscrew the lubrication relief valve nut from the
front of the transmission and remove the valve and
pipe. Note location of the 2 copper washers.

21- 57
SECTION 21 -- TRANSMISSION -- CHAPTER 6
41. Remove the lubrication pipes and T piece.

40
42. Remove the lower oil baffle plate.

41
43. Remove the fuel tank cross--over tube retaining
bolt on the right hand side of the transmission and
remove the tube.

21- 58
SECTION 21 -- TRANSMISSION -- CHAPTER 6
TRANSMISSION COMPONENTS
DISASSEMBLY

Oil Manifold Bush, Removal and Installation

The procedure for removal and installation of the
medium clutch, reverse clutch or fast/slow clutch oil
manifold bushes is very similar and should be
performed as follows.
NOTE: The bushes are extremely tight, only use the
special tool to attempt removal/installation. Attempting
to drift the bushes out or in will result in damage to
either bush or casing.

43
1. Install Special tool, number, 297615, into the bush
to be removed and locate the four bolts into the
oilway holes.
2. Fabricate a suitable flat metal bar, approximately
13mm thick x 375mm long with a 17mm hole
through the centre and obtain a 16mm, 8.8 graded
bolt approximately 225mm long with two suitable
flat washers.

44
3. Install the bolt through the rear of the tool and
position the flat bar over the bolt and across the
casing as shown in Figure 44.
4. Install and tighten the nut gradually to withdraw the
bush from the casing.

45
Installation
NOTE: Due to the tightness of the bushes it is
recommended that the bush is cooled for
approximately one hour in a suitable cooling device, (a
domestic fridge/freezer will suffice). If the special tool
is installed onto the bush and placed into the fridge with
the bush this will also aid installation.
5. Position the bush and tool correctly in the housing.
Gently tap the tool to ensure the bush is square in
the housing.

21- 59
SECTION 21 -- TRANSMISSION -- CHAPTER 6
6. Locate the bolt through the front of the tool, with the
flat bar across the casing at the rear. Tighten the
nut to pull the bush into the housing, Figure 47.
The bush is correctly installed when it contacts the
raised lip in the housing.

47
Transmission Upper Speed Shaft End Play
Adjustment
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Proceed as follows:
1. Place the transmission input shaft (1) on a bench,
slide on the gear (6), spacer (5), a 3.5 mm test shim
(4), gear (3). Lock the assembly with a circlip (2).
2. Settle the assembly. Using a feeler gauge (7),
measure the end play between the circlip (2) and
gear (3).
3. Shim to be assembled is given by the measured
dimension plus the test shim minus the specified
end play.

Example:

Gauge reading:= 0.90 mm

Test shim:= 3.50 mm 48
Specified end play= 0 to 0.15 mm
Shim to be assembled: = 0.90 + 3.50 -- 0.10 = 4.30
mm.
NOTE: Available adjust shims are detailed on page 2.
4. Remove circlip (2), withdraw the gear (3) and test
shim (4). Add shim (8) as previously found, gear (3)
and lock the assembly with the circlip (2).
5. Settle the assembly. Using a feeler gauge (7)
check that end play is to specification.

21- 60
SECTION 21 -- TRANSMISSION -- CHAPTER 6
CLUTCH ’A’ DISASSEMBLY
1. Remove the retaining ring (1), the bearing inner
lock ring and retrieve the hubs of the clutches A
and B along with the bearing and clutch A discs and
centering springs.

50
2. Remove seal (3).

51
3. Remove the outer (4) and inner circlips from the
outside of clutch A (5), withdraw clutch A from the
cover. Retrieve the bearing.

52
4. Position tool no. 295021 (2) and puller tool no.
292651 (1) having a length of 300 mm and
complete with extraction brackets no. 292655
having a length of 300 mm on clutch A (5), turn the
tool bolt to compress the clutch release Belleville
springs and remove the retaining ring.
Disassemble tool no. 295021 (2) and puller (1) and
retrieve Belleville springs.

21- 61
SECTION 21 -- TRANSMISSION -- CHAPTER 6
5. Place the clutch A housing on the cover (2), blow
compressed air into the control oil inlet hole and
remove the piston (1).
6. The piston seals should be carefully removed
using a small screwdriver. Install new seals onto
the piston, using fingers only. To install the piston,
apply a generous coating of petroleum jelly to the
piston seals and housing bore and using a suitable
adaptor over the piston, tap the piston into the
housing. Ensure that the piston remains square to
the housing bore during installation.

55
Clutch ’A’ Assembly
1. Seal 12. Circlip
2. Bearing Outer Circlip 13. Steel Drive Plate, 5 off
3. Housing Shaft Circlip 14. Friction Plate, 5 off
4. Bearing 15. Plate separator spring, 5 off
5. Bearing Inner Circlip 16. Hub
6. Sealing Rings 17. Washer
7. Clutch Housing 18. Bearing
8. Piston 19. Circlip
9. Piston, Inner and Outer Seals 20. Circlip
10. Dished Washers, 7 off 21. Hub
11. Circlip Cup 22. Circlip

21- 62
SECTION 21 -- TRANSMISSION -- CHAPTER 6

56
Clutch ’B’ Assembly
1. Circlip 7. Housing
2. End Drive Plate 8. Piston, Inner and Outer Seals
3. Friction Plate, 5 off 9. Piston
4. Plate Separator Spring, 5 off 10. Dished Washers, 7 off
5. Steel Drive Plate, 5 off 11. Circlip Cup
6. Sealing Rings 12. Circlip

NOTE: Piston seal replacement and the procedure for disassembling and reassembling the multi plate clutches
is the same for each clutch. Refer to the clutch ’A’ disassembly and the exploded view of the relevant clutch.

21- 63
SECTION 21 -- TRANSMISSION -- CHAPTER 6

57
Clutch ’C’ Assembly
1. Circlip 9. End Plate
2. Circlip Cup 10. Circlip
3. Dished Washers, 8 off 11. Hub
4. Flat Washer 12. Bearing
5. Piston, Inner and Outer Seals 13. Spacer
6. Piston 14. Bearing pre--load Shim
7. Housing 15. Bearing
8. Clutch Plates, 8 off each

21- 64
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Clutch ’C’ Hub Taper Bearing Adjustment
1. Assemble the ’C’ clutch hub to the special tool,
No297614, complete with bearings, spacer and
original shim. Tighten the bolt of the special tool to
140 Nm.

58
2. Wrap a length of string around the smaller of the
two gears and attach to a suitable spring balance.
Measure the rolling resistance of the bearings
during rotation, not at the point where rotation
begins.
3. The rolling resistance should equate to 0.5--0.8Kg
on the spring balance. If outside the specification
install a thinner shim to increase the resistance or
install a thicker shim to reduce the resistance.

21- 65
SECTION 21 -- TRANSMISSION -- CHAPTER 6

60
Clutch ’D’ Assembly
1. Clutch Plates, 6 off each 8. Circlip
2. End Plate 9. Circlip Cup
3. Circlip 10. Dished Washers, 6 off
4. Hub 11. Flat Washer
5. Bearing 12. Piston, Inner and Outer Seals
6. Circlip 13. Piston
7. Bearing 14. Housing

21- 66
SECTION 21 -- TRANSMISSION -- CHAPTER 6

61
Clutch ’E’ Assembly
1. Clutch Plates, 6 off each 8. Circlip
2. End Plate 9. Circlip Cup
3. Circlip 10. Dished Washers, 6 off
4. Hub 11. Flat Washer
5. Bearing 12. Piston, Inner and Outer Seals
6. Circlip 13. Piston
7. Bearing 14. Housing

21- 67
SECTION 21 -- TRANSMISSION -- CHAPTER 6

62
Fast (F3) Clutch Assembly
1. Circlip 7. Piston, Inner and Outer Seals
2. End Plate 8. Flat Washer
3. Clutch Plates 9. Dished Washers, 8 off
4. Hub (retained to top shaft) 10. Circlip Cup
5. Housing 11. Circlip
6. Piston 12. Bearing

End Bearing (item 12) Removal

In order to remove the dished washers and piston it is
necessary to remove the end bearing.

21- 68
SECTION 21 -- TRANSMISSION -- CHAPTER 6

64
Slow (F1) Clutch Assembly
1. Housing 10. Bearing
2. Piston 11. Spacer
3. Piston Inner and Outer 12. Bearing
4. Flat Washer 13. Hub and Gear Assembly
5. Dished Washers, 12 off 14. Seal
6. Circlip Cup 15. End Plate Outer Circlip
7. Circlip 16. End Plate Inner Circlip
8. Washer 17. End Plate
9. OIl Baffle Washer 18. Clutch Plates, 13 off each

End Bearing (item 10) Removal

In order to remove the dished washers and piston it is
necessary to remove the end bearing.

21- 69
SECTION 21 -- TRANSMISSION -- CHAPTER 6

66
Medium (F2) Clutch Assembly
1. Bearing 12. Nut
2. Sealing Rings 13. Bearing
3. Housing 14. Hub Bearing
4. Piston 15. Hub
5. Piston, Inner and Outer Seals 16. Seal
6. Flat Washer 17. Shim
7. Dished Washers, 12 off 18. Hub Bearing
8. Circlip Cup 19. Washer
9. Circlip 20. Friction Plate, 12 off
10. End Plate Circlips 21. Steel Drive Plate, 12 off
11. End Plate

End Bearing (item 13) Removal

In order to remove the dished washers and piston it is
necessary to remove the end bearing.

21- 70
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Medium Clutch Hub Taper Bearing Adjustment
1. Assemble the Medium clutch hub to the special
tool, No.297614, complete with bearings, spacer
and original shim. Tighten the bolt of the special
tool to 140 Nm.

68
2. Wrap a length of string around the gear and attach
to a suitable spring balance. Measure the rolling
resistance of the bearings during rotation, not at
the point where rotation begins.
3. The rolling resistance should equate to 0.7--1.2Kg
on the spring balance. If outside the specification
install a thinner shim to increase the resistance or
install a thicker shim to reduce the resistance.

21- 71
SECTION 21 -- TRANSMISSION -- CHAPTER 6

70
Reverse Clutch Assembly
1. Sealing Rings 12. Bearing
2. Housing 13. Chamfered Washer (Chamfer towards hub)
3. Piston 14. Spacer
4. Piston, Inner and Outer Seals 15. Oil Baffle Washer
5. Flat Washer 16. Bearing
6. Dished Washers, 12 off 17. Spacer
7. Circlip 18. Hub
8. Circlip Cup 19. Seal
9. End Plate Circlips 20. Bearing
10. End Plate 21. Washer
11. Shaft 22. Clutch Plates, 12 off each

21- 72
SECTION 21 -- TRANSMISSION -- CHAPTER 6
TRANSMISSION REASSEMBLY
1. Apply Vaseline to the contact surfaces between the
fuel cross pipe and the transmission casing and
install the pipe from the right side of the
transmission. Secure with the retaining bolt.

71
2. Install the lower splash plate with the 4 Allen key
bolts and spacers using New Holland Thread lock
and Seal adhesive, (Part No.82995773) on the
bolts.

72
3. Replace the lubrication pipes and Tee--piece.

73
4. Install the lubrication relief valve and tighten the nut
to 68–84 Nm. Ensure copper washers are correctly
located either side of the tube.

21- 73
SECTION 21 -- TRANSMISSION -- CHAPTER 6
5. Rotate the transmission so that rear is uppermost.
With the front bearing shim and spacer removed,
install the C/D clutch assembly ( including “C”
clutch gear cluster) into the transmission ensuring
that the oilway alignment marking on the clutch is
visible.
NOTE: Prior to installation of the C/D clutch assembly
it is necessary to check that the taper bearing rolling
resistance is within specification, as described in the
‘COMPONENT DISASSEMBLY’ section.

75
6. Install the “D” clutch output hub and gear.

76
7. Install the “E” clutch pack ensuring that the oilway
marking is in line with those on the C/D clutch
assembly.

77
8. Carefully push the lower speed shaft down through
the clutch packs ensuring that the marking hole is
in line with the markings on the clutch packs.

21- 74
SECTION 21 -- TRANSMISSION -- CHAPTER 6
9. Rotate the transmission to the horizontal position
and install the upper speed shaft from the rear of
the transmission, pushing it through the gear
cluster which is inserted through the top of the
transmission.
NOTE: Prior to installation of the upper shaft it is
necessary to check that the upper shaft component
end play is within specification, as described in the
‘COMPONENT DISASSEMBLY’ section.

79
10. Install the spacer, shims and gear and retain with
the circlip, through the front of the transmission.

80
11. Install the upper speed shaft bearing retaining
plate, using the two lower bolts only at this stage,
at the rear of the transmission. Tighten the bolts to
22--25 Nm.
NOTE: Use New Holland thread lock and seal
adhesive, Part No.82995773, on the bolts.

81
12. Rotate the transmission to the vertical position and
install the oil supply pipes for Fast & Slow clutches
and lubrication pipe.

21- 75
SECTION 21 -- TRANSMISSION -- CHAPTER 6
13. Install Medium range shaft assembly
NOTE: Prior to installation of the medium clutch
assembly it is necessary to check that the taper
bearing rolling resistance is within specification, as
described in the ‘COMPONENT DISASSEMBLY’
section.

83
14. Install Reverse shaft assembly.

84
15. Install Fast clutch hub and refit circlip.

85
16. Install Fast / Slow shaft assembly and remove the
lifting eyes from the three shafts.

21- 76
SECTION 21 -- TRANSMISSION -- CHAPTER 6
17. Install splash plate baffle.

87
18. Lock the transmission with the special locking tool
located in the reverse speed sensor hole. Replace
the nut at the rear end of the Medium range shaft
and tighten to 467 – 515Nm using a 70mm socket.
Lock tabs on nut.

88
19. Clean mating faces of end case and transmission
case and apply silicone sealant. Use Vaseline to
hold the clutch manifold slip rings in position and
using guide dowels, lower the end case into
position. Tighten end case bolts to 187 -- 210 Nm.

89
20. Install Fast/Slow end bearing race and replace the
Fast / Slow range shaft end nut and tighten to
300Nm, using either special tool No.293343 or a
65mm socket. Use the special locking tool in the
medium speed sensor hole.
NOTE: The nut has a left hand thread.

21- 77
SECTION 21 -- TRANSMISSION -- CHAPTER 6
21. Install Medium range end bearing race and spacer.

91
22. Lock the transmission with the special locking tool
located in the reverse speed sensor hole.

92
23. Install spacer, shims and bearing in C clutch gear
cluster and fit shaft support bearing ensuring inner
race is fitted first followed by outer race. Fit the
washer with the chamfer facing towards the
manifold.
NOTE: Take care not to damage the brown plastic
bearing ring when refitting.

93
24. Replace the 2 O--rings on the end of the lower
speed shaft and apply petroleum jelly to the shaft.
25. Push the manifold back onto the shaft, gently
tapping with a rubber faced hammer if necessary.
Replace the belleville washer ensuring the outer
edge is in contact with the manifold and inner edge
in contact with the nut.

21- 78
SECTION 21 -- TRANSMISSION -- CHAPTER 6
26. Replace the nut and tighten to 467 – 515Nm using
a 60mm socket. Form tabs on nut to prevent
loosening. Remove special locking tool.

95
27. Install speed section upper front shaft.

96
28. Install 4 x oil supply tubes and “O” rings from
behind manifold and install the manifold. Tighten
the manifold bolts to 24Nm.

97
29. Install B clutch components ensuring that the slip
ring joints are in line with each other and that
petroleum jelly is applied to help hold them in
position.
NOTE: To avoid damaging the slip rings, the joints
should be lined up with the area of the manifold where
there is no oil gallery before the clutch is pushed into
position.

21- 79
SECTION 21 -- TRANSMISSION -- CHAPTER 6
30. Clean the mating faces of the A/B clutch housing
and apply silicone sealant. Install the oil transfer
tube from the lube relief valve.

99
31. Install the A/B clutch housing and tighten the bolts
to 21 – 26 Nm.

A,B,C,D and E Clutch Testing

32. At this stage it is advisable to test the A,B,C,D and
E clutch packs using compressed air.
33. Obtain from parts two, 5162184, tubes and two,
5135733, ‘O’ rings. Obtain locally a valve and
gauge.

100
34. Also obtain locally, suitable fittings to connect into
the workshop air line hose. Assemble the valve
and gauge with fittings to connect into the
workshop air line and to have a fitting after the
gauge to allow connection of the tubes. Braze/weld
onto the straight ends of the 5162184 tubes fittings
to connect into the valve and gauge assembly.
35. On one of the tubes cut off the end to provide a
straight tube, clean the end to provide a smooth,
chamfered finish. This tube is used to test the ‘A’
clutch, Figure 101.

101
36. To test the clutches, Figure 102, ensure the valve
is closed and install the valve, gauge and tube onto
the air line. Locate the tube into the relevant clutch
test port. Quickly open and close the valve and
observe the drop off in pressure on the gauge and
listen to the escaping air.
37. A good clutch will see a smooth and continuous
drop off of pressure on the gauge. A clutch with
poor sealing will show an immediate drop in
pressure when the air is turned off and the sound
of escaping air will also be heard.

102

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SECTION 21 -- TRANSMISSION -- CHAPTER 6
Output Shaft (fast/slow) End Float Adjustment
38. Insert test shims until they are flush with the
machined face of the casing. Measure the test
shim pack (Sp). Install end plate and tighten bolts
to the specified torque, ensuring that the belleville
washers have their outer edge against the end
plate.

103
39. Rotate the transmission several times using the
special tool in the end of the Medium range shaft.
Between turns tap the end of the output shaft with
a rubber faced hammer to ensure the shaft is fully
settled in the transmission.

104
40. Install the special tool, NH21--104 (3), over the
output shaft, with the double ended threaded bar
(2), screwed into the output shaft. Attach the lever
assembly, tool 292176 (1), to the threaded bar.
Position a suitable DTI gauge onto the end housing
with the stylus on the face of the output shaft nut.
Ensure the operating arm of the DTI is as vertical
as possible and zero the gauge.
41. Lift the output shaft using special tool 292176. The
DTI reading should be between 0.04 and 0.09mm
which is the endfloat on the shaft.
42. Calculate the shim required:--
S1 = H + Sp -- (0.065mm)
Where: 105
S1 = Final shim size
Sp = Test/initial shim
H = DTI travel reading
0.065 mm = Mid range of endfloat specification
43. Recheck endfloat until within specification. Torque
end plate bolts to 35Nm ([Link]).

21- 81
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Medium Range Shaft End Float Adjustment
44. Install test shims and circlip on rear end of the
Medium range shaft. Measure the test shim pack
(Sp).
45. Rotate the transmission several times using the
special tool in the end of the Medium range shaft.
Between turns tap the end of the special tool in the
medium range shaft with a rubber faced hammer
to ensure the shaft is fully settled in the
transmission.

106
46. Install the special tool, NH21--104 over the special
tool installed in the medium range shaft, with the
double ended threaded bar screwed into the
medium shaft tool. Attach the lever assembly, tool
292176, to the threaded bar. Position a suitable
DTI gauge onto the end housing with the stylus on
the lower face of the tool installed into the medium
range shaft. Ensure the operating arm of the DTI
is as vertical as possible and zero the gauge.

107
47. Lift the medium range shaft using special tool
292176. The DTI reading should be between 0.04
and 0.09mm which is the endfloat on the shaft.
48. Calculate the shim required:--
S1 = H + Sp -- (0.065 mm)
Where:
S1 = Final shim size
Sp = Test/initial shim
H = DTI travel reading
0.065 mm = Mid range of endfloat specification
49. Recheck endfloat until within specification.

108
50. Rotate the transmission into the horizontal
position. Insert a suitable tool through the speed
sensor orifice to lock the Reverse shaft. Tighten
Reverse shaft end nut to 467 – 515 Nm using a
55mm socket. Lock tabs on the nut. Install
Reverse clutch assembly end cap and fit circlip.

109

21- 82
SECTION 21 -- TRANSMISSION -- CHAPTER 6
51. Install “A” clutch supply coupling and tube from A/B
clutch housing.

110
52. Install Reverse, Medium, Fast and Slow range
pressure test couplers.

111
53. Install 2 x speed sensors

112
54. Install 5 x PWM manifold oil tubes and install the
PWM valve manifold and“A” clutch supply pipe.

113

21- 83
SECTION 21 -- TRANSMISSION -- CHAPTER 6
55. Install 3 oil transfer tubes and “O” rings

114
56. Install top cover and tighten bolts to 50 Nm.

115

21- 84
SECTION 21 -- TRANSMISSION -- CHAPTER 6
CLUTCH CALIBRATION
The Full powershift transmission has 9 clutch packs
that require periodic calibration to compensate for
wear. Calibration should only be necessary if a
deterioration in gear shift quality is noted.
NOTE: During the calibration procedure the electronic
management system detects precisely the point at
which the clutches start to engage . The engagement
is detected by a reduction in engine speed. During
calibration it is essential that no action is taken to to
cause the engine speed to vary. Be sure that the air
conditioner and all electrical equipment is switched off.
Do not operate the PTO or any hydraulic lever or move
the hand or foot throttle.
116
There are two methods to enter the calibration mode:
(i) Through the white diagnostic connector, using
special tool No. 4FT.950 and menu mode H1, or,
(ii) By depressing both up/down shift buttons together
during start up.

117
Tractor Preparation
NOTE: The clutches should be adjusted when the
transmission oil temperature is between 60°C and
105°C.

118
Park the tractor on level ground, away from obstacles
(in case of unexpected tractor movement).
Apply handbrake, switch off all electrical equipment
and air conditioning if fitted. Stop the engine and place
remote levers in neutral and lower hydraulic equipment
to the ground.
Place the shuttle in neutral.
Either, (i) Install tool 4FT.950 into the diagnostic plug
or (ii) press and hold both Up/down shift buttons and
start the engine. Select H1 by depressing the
diagnostic switch once.

119

21- 85
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Release the buttons. The display will change to show
transmission temperature. Press the up or downshift
button to proceed.
If the temperature is less than 10°C Error Code ‘U19’
will be displayed. If the temperature is between 10°C
and 60°C ‘‘CL” will be displayed. If the temperature is
to high, above 105°C, ‘‘CH” will be displayed.
If ‘U19’ is displayed calibration will not be possible and
the oil will have to be warmed before proceeding.

120
If ‘CL’ or ‘CH’ are displayed after 4 seconds the display
will return to oil temperature and the tractor may be
operated to obtain the correct transmission oil
temperature. If it is not practical to wait for the oil
temperature to change press either of the up or down
shift buttons while ‘CL’ or ‘CH’ is being displayed. The
display will then show an ‘A’ and calibration can
proceed.
Move the shuttle lever to forward and release the
clutch pedal.
Set engine speed to 1200 ERPM ±100.

121
The transmission is now ready for calibration.
Press and hold the downshift button to calibrate clutch
A.
If the start up procedure was incorrect a ‘‘U” code will
appear.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

122
Release the downshift button, the display will change
to ‘b’, indicating that clutch B is ready for calibration.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

123

21- 86
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Repeat the above steps for clutches C, D, E and F1(S),
F2(M), F3(F) and R. After clutch R has been calibrated,
release the downshift button and the display will
change to F.
Turn the key start switch off for at least 2 seconds to
store the calibration values.
NOTE: Transmission output speed, seat switch, hand
brake switch and clutch pedal position are constantly
monitored. Calibration cannot proceed unless the
tractor is stationary and the clutch pedal released.
Repeatedly depressing the upshift button will cycle
through each clutch mode, enabling a particular clutch
to be calibrated several times if required.
124
AUTOMATIC CALIBRATION SEQUENCE
MODE:
When the tractor is set up correctly for the calibration
sequence, ie, H1 selected or upshift and downshift
buttons applied simultaneously, forward selected and
the display showing ’A’, (to calibrate clutch A), pressing
the AUTO FUNCTION pushbutton will start the
automatic calibration sequence.
Both the FIELD and TRANSPORT indicator lamps will
flash while in this mode. The clutches will be calibrated
one by one without the need to keep the downshift
button depressed.

125
If an error occurs while in auto mode the sequence is
stopped and the relevant code displayed. Press the
auto function pushbutton or the upshift/downshift
pushbuttons to clear the error.
NOTE: In ’automatic calibration sequence’ the seat
switch is constantly monitored, if the operator leaves
the seat the sequence will be stopped.
CAUTION
The tractor is drivable even if calibration has not been
completed. Pay attention in this condition as the tractor
could be jerky or sluggish. Always pull away using the
clutch pedal very carefully.

126

21- 87
SECTION 21 -- TRANSMISSION -- CHAPTER 6

CALIBRATION ERRORS

U19 Oil temperature below 20°C

U21 Engine RPM too low
U22 Engine RPM too high
U23 Shuttle lever is in neutral
U26 Clutch pedal is not released
U31 Output speed sensed -- tractor is moving
U33 Handbrake not applied
U34 Seat switch not activated
U36 Maximum allowed clutch calibration value
exceeded
U37 ERPM dropped too soon during clutch cal

CALIBRATION MESSAGES
CH Oil temperature above 50°C -- Press upshift
to proceed
CL Oil temperature between 10 and 20°C --
press upshift to proceed

21- 88
SECTION 21 -- TRANSMISSION -- CHAPTER 6
POWER COMMAND TRANSMISSION

PRESSURE TESTING
Transmission Clutches, A,B,C,D,E, F1, F2, F3
and R
Where F1 = Slow Range
F2 = Medium Range
F3 = Fast Range

127
1. Prepare the tractor for pressure testing:
(i) Ensure the handbrake is fully applied.
(ii) Install diagnostic switch (1), Tool No.4FT.950
into the white diagnostic plug of the tractor
harness.
(iii) Start and run the tractor to warm the
transmission oil to a minimum operating
temperature of 60°C (140°F).

128
2. Install suitable pressure gauges (0--40bar, 0--600
lbf.in2) with the appropriate New Holland quick
release couplers, nine if available, into each of the 2
clutch pressure test points. 1
Reference Figure 129 for gauge, hose and adaptor
details:
1. Pressure gauge, FT8503A, with adaptor 3
FT8503--8
2. Quick release adaptor, Pt No.291924
3. Adaptor, 297153 (7/16x20 JIC--1/4x18NPSF)
4
4. Hose, (Finis Code 3936707)

129
NOTE: Existing quick release fitting will need to be
A B
removed and a banjo fitting M14 x 1.5 mm to No. 7 E D C
UNF will be needed for the Slow, Medium and Reverse
clutch test ports.
3. (a) Located in the raised horizontal manifold, under
the right hand foot step are the test ports for
clutches A,B,C,D and E, Figure 130.

TA6021003
130

21- 89
SECTION 21 -- TRANSMISSION -- CHAPTER 6
(b) Mounted on the left hand side of the
transmission is the Medium Range Test Port (1)
with banjo fitting.

131
(c) Mounted on Right Hand side of the
transmission is the Reverse Range Test Port (1)
and clutches A to E test ports (2).

132
(d) Mounted on the top of the transmission is the
Slow Range Test Port (1), with banjo fitting and the
Fast Range Test Port (2).

133
4. Start the engine and enter HJ mode (1). Depress
the clutch pedal and move the shuttle lever into
forward. Release the clutch. The upper character
on the display will show ‘A’, indicating that clutch ‘A’
solenoid will be energised.

134

21- 90
SECTION 21 -- TRANSMISSION -- CHAPTER 6
5. To energise the solenoid press and hold the
downshift button and observe the pressure reading
on the gauge which should be 17±1 bar.
NOTE: The clutch pedal (1) should be depressed
before energising the solenoid. Once energised the
pedal should be released slowly to avoid harsh clutch
engagement.

135
6. The pressure can be controlled with the clutch
pedal. When the pedal is depressed the lower two
digits will change to a number 0--16 indicating the
approximate pressure in bars, as long as the clutch
pedal is correctly calibrated. With the pedal fully
released ‘FP’ will be displayed indicating Full
Pressure. Here clutch A is indicating
approximately 7 bar (3).
7. To select other clutches, repeatedly press the
upshift button (2) and then depress the downshift
button (1) to energise the solenoid.
8. If all gauges read low, suspect a fault in the low
pressure hydraulic system, refer to section 35.
9. If one or more gauges read correct and the other 136
gauges are low this indicates that the hydraulic
system is okay and that the fault lies within the
transmission assembly. Remove and inspect the
relevant solenoid valve assembly, if no fault is
found suspect an internal transmission fault. it will
be necessary to remove the transmission and
disassemble the relevant area to locate the fault.
NOTE: If pressure testing the transmission is
performed when not in the diagnostic mode HJ, it will
be observed that approximately 4 bar (58 [Link] 2) of
pressure is applied to clutches C, D and E when in
neutral. This is a design feature to prevent vehicle
creep while in neutral and is not indicative of a system
error. The pressures are released when a gear is
engaged.

21- 91
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Codes and Fault Finding Refer to Section 55 for complete wiring diagrams.
The transmission electronic management system has Where the fault finding procedure requires checks for
an inbuilt self diagnostic facility. This facility utilises the continuity a visual inspection of the wiring should be
digital display of the gear shift handle assembly to made prior to conducting tests to ensure that obvious
indicate, in coded format, any malfunction in the ‘mechanical’ damage has not occurred to the harness
electrical and electronic circuitry and in the or the connectors.
micro--processor. It should be noted that the self A good quality multi--meter is an essential item to
diagnostic capability is generally limited to diagnosis of perform fault finding. It should be capable of measuring
the electrical and electronic circuitry and related resistance of at least 20,000 ohms and measuring
components, however, there are some codes, which voltage and current. When using the multi--meter it is
can be generated if pressure switch circuits are not good practice to select a high range and work
closed because of an actual lack of hydraulic pressure. downwards to avoid damaging the instrument.
Any malfunction of the mechanical and hydraulic
IMPORTANT: Care should be used when using the
components must be diagnosed using conventional
multi--meter, only use the instrument as instructed to
techniques, performance characteristics and tooling,
avoid damage to the internal elements of the
such as pressure testing equipment.
micro--processor. When checking the continuity of
Trouble--shooting and fault finding should always be wiring, sensors or switches it is necessary to isolate the
carried out in a logical and planned sequence, many electronic micro--processor and ensure the keystart is
apparent faults associated with electronic components turned off to prevent possible further damage. The
are often hastily diagnosed and result in the keystart should only be switched on and the processor
replacement of expensive components. An extra few connected where specifically instructed in the fault
minutes confirming the apparent fault will result in a finding procedure.
more positive and cost effective repair.
If it is found necessary to clean the connectors a
With the use of micro--processors it is often that this contact spray should be used. DO NOT USE ANY
item is blamed for any malfunction but the real truth is OTHER METHOD FOR CLEANING TERMINALS. Do
that this item is usually sound and that the fault is due not use a cleaner that contains Trichloro--ethylene, this
to poor contacts in the associated connectors. solvent will damage the plastic body of the connector.
Each electrical connector illustrated and identified in It is preferable to use a cleaner with a Freon T.F. base.
the wiring diagrams in Section 55 and referred to in the
following fault finding procedure, has the same
identification reference. For example, the main
transmission processor connectors are referred to as
Connectors C100 and C101 in the illustration and also
referred to as C100 and C101 in the fault finding
procedure. Often in the fault finding flow chart the
connector and pin are abbreviated and will read, for
example, C100--21. The C100 refers to the connector
and the 21 to the pin number. Alternatively, for
connectors with fewer pins, the identification will read,
C014--FM3100--B/G/S. This is broken down as
follows:
C014 Connector number
TA60--21--014
FM3100 Front Main harness, circuit number 3100
B/G/S Wire colour 137

21- 92
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES -- POWER COMMAND
ERROR DISPLAY LOGIC
1. Errors are displayed on the liquid crystal display
portion of the gear shift and display assembly. A
Power Command transmission error code is
prefixed with an ‘F’.
2. Error codes always flash.
3. There are four types of errors: Disabling, “N”, “CP”,
and Hidden.
4. Disabling errors disable the transmission
permanently (until the next power-up).
TA11

138
5. Disabling and hidden errors are accompanied by a
steady alarm for 5 seconds. After 5 seconds, the
error code continues flashing on the LCD, but the
alarm stops. If the error clears during the 5 second
period, the alarm will stop when the error clears,
and the LCD will return to normal display.
6. If there are multiple disabling or hidden errors to
display, they will be displayed sequentially.
Example, for codes F2A, F2b and F2C:
LCD: | F2A------ | F2b------ | F2C------ | F2A | F2C
| F2A |
Time: | 5 sec | 1 s | 5 sec | 1 s | 5 sec | 1s | 5 sec
| 5 sec | 5 sec | 5 sec | etc... TA11
Alarm: |steady |off|steady |off|steady |off|
139
off--------------------------------------
NOTE: The display sequence may not always start
with the lowest error number, and the errors may not
be displayed in numerical order at first. There is some
“randomness” depending on the exact timing and
sequence of events.
7. “N” and “CP” errors are accompanied by a pulse
alarm and require action from the driver. The alarm
will continue and the transmission is disabled until
the driver takes action.
“CP” can be cleared by cycling the clutch pedal. In
some cases, “CP” can also be cleared by cycling
the shuttle lever.
“N” can be cleared by shifting the shuttle lever to MM7
neutral. 140

21- 93
SECTION 21 -- TRANSMISSION -- CHAPTER 6
“N” and “CP can result from improper action by the
driver, or they can result from faults in the system
which require action from the driver to re-start
operation.
8. Normal error display mode:
If there are any disabling errors, only disabling
errors will be displayed.
If there are no disabling errors and at least one “N”
error is active, “N” will flash.
If there are no disabling errors and no “N” errors,
and at least one “CP” error is active, “CP” will flash.
Hidden errors will not be displayed. TA11

141
9. Hd in the diagnostic menu will enable “display all
errors” mode. Also, a new module (or an old
module after the memory has been reset using H8)
will automatically be in “display all errors” mode
until there are no errors to display for 6 minutes.
The six minutes must be during one power-on
cycle, i.e. turning off the key switch zeros the timer.

142
If there are any disabling errors. ALL errors will be
displayed sequentially. “N” and “CP” will not be
displayed; instead, the error codes associated with
the “N” or “CP” fault will be displayed.
If there are no disabling errors and there is at least
one “N” error, the first “N” error will be displayed.
The display will alternate at one second each
between “N” (to tell the driver what to do) and the
associated error code (to assist with trouble
shooting).

143
If there are no disabling errors or “N” errors, and
there is at least one “CP” error, the first “CP” error
will be displayed. The display will alternate at one
second each between “CP” (to tell the driver what
to do) and the associated error code (to assist with
trouble shooting).
If there are no disabling errors, “N” errors, or “CP”
errors, any hidden errors will be displayed
sequentially.

144

21- 94
SECTION 21 -- TRANSMISSION -- CHAPTER 6
A new module, or an old module after the memory
has been reset using H8, will automatically be in
”display all errors” mode until there are no errors to
display for 6 minutes. The six minutes must be
during one power-on cycle, i.e. turning off the key
switch zeros the timer. After six minutes with no
errors, the module switches automatically to
normal error display mode, and all stored error
codes are erased.

145

21- 95
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code Listing
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
F11 Inching pedal potentiometer undervoltage 14 & Disabled Pulse
71 Enabled
F12 Inching pedal potentiometer overvoltage 13 & Disabled Pulse
70 Enabled
F21 Coils disconnected -- Limp home or harness error 1 Disabled
F23 Creeper engaged, speed or gear to high 35 Enabled
F24 All clutches need calibration 11 Disabled
F27 ERPM to low -- circuit open or short 60 Enabled
F37 Solenoid power switch circuit open 31 Disabled
F38 Disabled range selected by operator 25 & Enabled
16 & Disabled Pulse
15 Disabled Pulse
F47 Solenoid power switch misadjusted (clutch pedal) 69 Enabled
F48 Solenoid power switch circuit short to 12 volts 68 Enabled
F49 Wheel speed sensor circuit open 47 Enabled
F50 Wheel speed sensor circuit short 48 Enabled
F51 Temperature sensor circuit open 66 Enabled
F52 Temperature sensor circuit short to ground 67 Enabled
F53 Regulated 5/7 volts too high 7 Disabled
F54 Regulated 5/7 volts too low 8 Disabled
F59 Forward/reverse/neutral switch disagreement 12 Disabled Pulse
F60 Upshift input undervoltage 50 Enabled
F61 Upshift input overvoltage 51 Enabled
F62 Downshift input undervoltage 52 Enabled
F63 Downshift input overvoltage 53 Enabled
F64 Forward pressure switch, open circuit or short to ground Enabled
F65 Reverse pressure switch, open circuit or short to ground Enabled
F66 Forward input undervoltage 56 Enabled
F67 Forward input overvoltage 57 Enabled
F68 Reverse input undervoltage 58 Enabled
F69 Reverse input overvoltage 59 Enabled
F70 Torque Damper Fault Enabled
F71 Torque sensor circuit open Enabled
F72 Torque sensor circuit short to ground Enabled
F73 Mid speed sensor circuit open 79 Enabled
F74 Mid speed sensor circuit short to ground or 12V 80 Enabled
F75 Swapped mid and rear speed sensors 82 Enabled

21- 96
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
F76 Swapped ERPM Sensor with either mid or output sensor Enabled
F77 No signal from wheel speed sensor 49 Enabled
F78 No signal from mid speed sensor 81 Enabled
F79 Engine RPM >3000 34 Enabled Pulse
F80 Wheel speed too high for gear selected 33 Enabled Pulse
F81 Proper ratio not detected 30 Disabled Pulse
F82 Accelerator pedal potentiometer circuit short to +8v or +12v Enabled
F83 Accelerator pedal potentiometer circuit open or short to ground Enabled
F84 Pressure indicated on forward clutch pressure switches when Disabled
clutch solenoids are off
F85 Pressure indicated on reverse clutch pressure switch when Disabled
clutch solenoid is off
F1A Clutch A open or short to earth 36 Disabled
F1B Clutch B open or short to earth 37 Disabled
F1C Clutch C open or short to earth 38 Disabled
F1D Clutch D open or short to earth 39 Disabled
F1E Clutch E open or short to earth 40 Disabled
F1F PTO lube solenoid open or short to ground Disabled
F1H High range clutch open or short to ground Disabled
F1J Reverse clutch open or short to ground Disabled
F1L Low range clutch open or short to ground Disabled
F1U Mid range clutch open or short to ground Disabled
F2A Clutch A short to 12V 2 Disabled
F2B Clutch B short to 12V 3 Disabled
F2C Clutch C short to 12V 4 Disabled
F2D Clutch D short to 12V 5 Disabled
F2E Clutch E short to 12V 6 Disabled
F2F PTO lube solenoid short to 12V Disabled
F2H High range clutch short to 12V Disabled
F2J Reverse range clutch short to 12V Disabled
F2L Low range clutch short to 12V Disabled
F2U Mid range clutch short to 12V Disabled
FCA Clutch A not calibrated 61 Enabled
FCB Clutch B not calibrated 62 Enabled
FCC Clutch C not calibrated 63 Enabled
FCD Clutch D not calibrated 64 Enabled
FCE Clutch E not calibrated 65 Enabled Pulse

21- 97
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR ERROR DESCRIPTION PRIORITY TRANS. ALARM
CODE STATUS MODE
FCH High clutch not calibrated Enabled
FCJ Reverse clutch not calibrated Enabled
FCL Low clutch not calibrated Enabled
FCU Mid clutch not calibrated Enabled
CP Depress clutch pedal or select neutral to re--enable 32 Disabled
N Shift to neutral to re-enable transmission Disabled
CALIBRATION ERRORS
U19 Oil temperature below 20°C
U21 Engine RPM too low
U22 Engine RPM too high
U23 Shuttle lever is in neutral
U26 Clutch pedal is not released
U31 Output speed sensed -- tractor is moving
U33 Handbrake not applied
U34 Seat switch not activated
U36 Maximum allowed clutch calibration value exceeded
U37 ERPM dropped too soon during clutch cal
CALIBRATION MESSAGES
CF Calibration procedure completed successfully
CH Oil temperature above 105°C -- Press upshift to proceed
CL Oil temperature between 10 and 60°C -- press upshift to
proceed

21- 98
SECTION 21 -- TRANSMISSION -- CHAPTER 6
NOTES

21- 99
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DIAGRAM 11 -- Error Code F11

21- 100
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DIAGRAM 11 -- Error Code F11 -- Clutch potentiometer voltage below valid range
Key OFF
Key ON
In Mode H9 channel Recheck
Enter Diagnostic Mode 0. Does the value
H9 channel 0. Operate ever drop below 14 Inspect wiring
the clutch pedal. Is the during cycling of the for intermittent
value continuously less clutch pedal. fault whilst in
than 14? H9 mode
channel 0
Replace
Are the connectors to the potentiometer
potentiometer and processor
okay?

Reconnect/repair
as required
Disconnect processor connectors C100 &
C101 and potentiometer connector C077.
Check for continuity between the Repair wiring as
processor and potentiometer connectors required
as per the circuit diagram. Is continuity
correct for all wires?

With processor and potentiometer Locate and

connectors disconnected, is there repair short to
an open circuit to chassis between chasis
C077--1 and C100--1?

Check operation of potentiometer. Remove left hand

side panel below instrument cluster to expose
potentiometer and wiring. Disconnect plug to
potentiometer and check operation of potentiometer.
Between the orange and green wires. With pedal
released, is resistance 0.32kΩ, gradually changing to
2.5kΩ as the clutch pedal is depressed
and
Between the green and black wires. With pedal
released, is resistance 3.6kΩ, gradually changing to
1.5kΩ as the clutch pedal is depressed?

Replace
potentiometer

Remove, inspect and refit

processor connectors C101
and C100. If error still ocurs
replace processor.

21- 101
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DIAGRAM 12 -- Error Code F12

21- 102
SECTION 21 -- TRANSMISSION -- CHAPTER 6
DIAGRAM 12 -- Error Code F12 -- Clutch potentiometer voltage above valid range
Key OFF
Key ON
In Mode H9 channel Recheck
Enter Diagnostic Mode 0. Does the value
H9 channel 0. Operate ever rise above 95 Inspect wiring for
the clutch pedal. Is the during cycling of the intermittent fault
value continuously clutch pedal. whilst in H9
greater than 95? mode channel 0
Replace potentiometer
Disconnect potentiometer
connector C077. Between pin Locate and repair short
No. 1 and chassis. Is the between C077--1 and C100--1
voltage 0 volts?

Disconnect potentiometer
connector C077. Between pin Locate and repair short
No. 3 and chassis. Is the between C077--3 and C101--1
voltage 0 volts?

Check operation of potentiometer. Remove left hand side panel below instrument
cluster to expose potentiometer and wiring. Disconnect plug to potentiometer and
check operation of potentiometer:
Between the orange and green wires. With pedal released, is resistance 0.32kΩ,
gradually changing to 2.5kΩ, as the clutch pedal is depressed and
Between the green and black wires. With pedal released, is resistance 3.6kΩ,
gradually changing to 1.5Ω, as the clutch pedal is depressed?

Replace
potentiometer
With the key OFF is there Locate and repair
continuity between open circuit
C077--3 and chassis? between C077--3
and C101--1
Remove, inspect and refit
processor connectors C101
and C100. If error still ocurs
replace processor.

21- 103
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F21
TRANSMISSION EXTENSION HARNESS TO MAIN HARNESS DISCONNECTED.
EFFECT -- Transmission inoperable

Inspect harness connectors, C019 and C020.

Reconnect if necessary.

If harness connectors okay, check

connections to clutch solenoids, C024, C025,
C026, C027, C028, C031, C032, C039 and
C040.

21- 104
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F23
CREEPER ENGAGED IN A GEAR HIGHER THAN 10TH
EFFECT -- Upshifts are inhibited.

Downshift to 10th Gear (or lower)

[shifting to neutral or depressing Tractor
clutch will also cause transmission to Okay
downshift. ]

Does error code occur on less

creeper tractors or when creep is
disengaged?

Suspect creeper switch or wiring going

Replace processor for one of
open circuit. Use mode H5 to check switch
known performance
transition. Is a transition sensed in H5?

Check switch adjustment. If

Okay check switch operation.
If Okay check wiring from
C100--4 to switch,
C021--RM7460--W/O/B, for
open circuit and check other
side of switch for +12V with
Ignition on. Repair as
required.

ERROR CODE F24

ALL CLUTCHES & SYNCHRONISERS REQUIRE CALIBRATION
EFFECT -- Transmission is disabled.

Has a new
processor been Perform calibration -- Refer to Calibrations
installed

Calibration values have been

corrupted in processor. Attempt
calibration. If unable to maintain
calibration install a new
processor.

21- 105
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F27
ERPM SIGNAL NOT PRESENT
EFFECT -- No speed matching. Delay in upshifts after auto take off. Minor reduction in shift
performance (2,300 rpm assumed by processor)

Is the sensor Ensure the sensor is

connected to the correctly connected and
harness recheck for error

Check if sensor is correctly

installed. Remove the speed Remove and refit
sensor and re-install. Is the sensor correctly.
sensor installed correctly?

Swap the engine sensor with

either the trans mid or output
speed sensors. Recheck for Replace sensor.
error. Has F27 been replaced
by either F77 or F78?

Check for open circuit between

processor C101--11 and
C255--2 (W/N/B) speed sensor.
Repair/Replace wiring as
required.

21- 106
SECTION 21 -- TRANSMISSION -- CHAPTER 6
NOTES

21- 107
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code F37 displayed -- Clutch disconnect switch open circuit.

Check switch adjustment and switch operation.

If okay trace break in wiring (open circuit).

Error Code F48 displayed -- Clutch disconnect switch short circuit.

Check switch adjustment and switch operation.

If okay trace short circuit in wiring.

Error Code F47 displayed -- Clutch disconnect maladjusted high

Check switch adjustment and operation of switch.

NOTE: With each of these error codes also check that the clutch potentiometer operates over the full
range using Service mode HA. If the range is not 0--99 then refer to ’Clutch Potentiometer calibration’
Diagram 5.

21- 108
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F38
DISABLED RANGE SELECTED BY OPERATOR
(i) Reverse not selected from a gear higher than C1

NOTE: This error code will be displayed in conjunction with another error code,
F49, F50 or F77.

If reverse has been attempted in a gear higher than C1 when there was a wheel speed
sender error (F49, F50 or F77) reverse will not be selected. The transmission will be dis-
abled but can be recovered, to forward drive, by cycling the shuttle lever or clutch pedal.
Reverse cannot be obtained for 10 seconds. The processor then assumes that the tractor
has slowed sufficient to make the shift. Rectifying the wheel speed sender error will elimin-
ate the reoccurrence of F38.

Disconnect processor connectors C100 & C101 and disconnect

transmission output speed sensor connector, [Link] wiring for
open/short circuit to C101--3 and repair as required. If wiring checks
out OK test sensor.

With the sender installed in the transmission, check for a short to

earth on each sender terminal. Check resistance of the sender which
should be approximately 0.8--1.2KΩ at 20_C. Replace if outside
specification.

21- 109
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES;
F51 -- TEMPERATURE SENDER OPEN CIRCUIT
F52 -- TEMPERATURE SENDER SHORT TO GROUND
EFFECT -- Hot oil is assumed, if oil is cold sluggish shifting and a higher than normal clutch
pedal position will be apparent.

Disconnect processor connectors C100 & C101 and disconnect

temperature sender, C023. Test the wiring for open/short circuit to
C100--20 and repair as required. If wiring checks out OK test
temperature sender.

With the sender installed check for a short to earth, and an open
circuit from the terminal of the sender to the chassis.

21- 110
SECTION 21 -- TRANSMISSION -- CHAPTER 6
NOTES

21- 111
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES;
F53 -- 5 VOLT REFERENCE VOLTAGE TOO HIGH
F54 -- 5 VOLT REFERENCE VOLTAGE TOO LOW

21- 112
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES;
F53 -- 5 VOLT REFERENCE VOLTAGE TOO HIGH
F54 -- 5 VOLT REFERENCE VOLTAGE TOO LOW
EFFECT -- Transmission disabled

Disconnect the following components, one at a time, to

isolate area of fault.

Disconnect Clutch Pedal potentiometer, Replace potentiometer

C077, are F53/54 cleared?
NOTE: Should cause error F11 if
potentiometer is faulty

Disconnect forward/reverse connector,

Replace
C075, (under steering column shroud).
forward/reverse switch
Are F53/54 cleared?
NOTE: Should cause errors F66 and
F68 if switches are faulty.

Disconnect the upshift/downshift switches

Replace
connector, C103. Are F53/54 cleared?
upshift/downshift
NOTE: Should cause errors F60 and F62 if
switch assembly
switches are faulty.

Check wiring from each of the above

components back to processor connector Trace and repair
C101--12. Is either a short or open circuit faulty wiring
indicated?

Suspect faulty processor. Replace

with one of known performance

21- 113
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F59
FORWARD/REVERSE/NEUTRAL SWITCH DISAGREEMENT
(MORE THAN ONE SWITCH ENGAGED)
EFFECT -- Transmission is Disabled
Disconnect processor connectors C100 & C101. Trace and repair
Disconnect connector, C075, to FNR switch. Is an open wiring
circuit indicated between C100--5 and neutral switch?

Replace forward/neutral
reverse switch.

Disconnect processor (A010) connectors C100 & C101, and

disconnect connector, C103, to upshift/downshift/range shift
assembly S3. Using a suitable multimeter, check between Trace and repair
C100--23 & C103--3, CM7210--S/LG/B. For: (1) Open Circuit faulty wiring
(2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave up/down range switch

assembly disconnected with key start on. Check for voltage on
C103--3, CM7210--S/LG/B. Is +5v, +8v or +12V indicated?

Trace and repair Reconnect up/down/range

21- 114
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES;
F62 -- DOWNSHIFT SWITCH INPUT VOLTAGE LOW
F63 -- DOWNSHIFT SWITCH INPUT VOLTAGE HIGH
EFFECT -- Downshift switch will not function, lower gears cannot be selected.
NOTE: If required, key on and restart to select B1/R1.

Disconnect processor (A010) connectors C100 & C101, and

disconnect connector, C103, to upshift/downshift/range shift
assembly S3. Using a suitable multimeter, check between Trace and repair
C100--19 & C103--4, CM7200--S/K/B. For: (1) Open Circuit faulty wiring
(2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave up/down range switch

assembly disconnected with key start on. Check for voltage on
C103--4, CM7200--S/K/B. Is +5v, +8v or +12V indicated?

Trace and repair Reconnect up/down/range

21- 115
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Codes F64 and F65

Auto. sw.

Rev Hi Lo Med

21- 116
SECTION 21 -- TRANSMISSION -- CHAPTER 6

Error Code F64-- FORWARD PRESSURE SWITCH OPEN CIRCUIT OR SHORT TO GROUND

Error Code F65-- REVERSE PRESSURE SWITCH OPEN CIRCUIT OR SHORT TO GROUND
Effects: No effect to normal operation if a circuit failure. Loss of drive in a particular range if a faulty
PWM valve
Key OFF
Key ON
Recheck
Faulty range PWM valve.
Does the tractor drive in all forward
Determine faulty range and replace
ranges and reverse range?
the valve to that clutch

Circuit or switch fault.

Replace fuse and test
Inspect fuse 13.
tractor operaton
Fuse okay?

With the engine off remove the

floorpan and ensure that all
pressure switch connectors
(C243, C244, C245, C246) are Test drive tractor to ensure
fitted correctly. Clear error fault is not intermittent
code and start tractor, does
the error re--occur?

Suspect a faulty switch. Enter diagnostic mode HJ

(transmission pressure testing). Connect a multi--meter Replace faulty
across each switch in turn while selecting the switch as required
appropriate clutch, F1=low, F2=med, F3=hi, ,R=rev.
Does the switch close when the clutch is pressurised?

Disconnect the processor connectors,

C239 (for F64) or C100 (for F65). Repair or replace wiring as
Disconnect the connectors from the required. To determine the
pressure switches (C243, C244, C245, faulty harness, disconnect
C246). Using a suitable multi--meter is connector C020 and check for
continuity indicated between the continuity between the
processor connector, C239--8 (F64) or processor and either C020--45
C100--15 (F65) and each switch (F64) or C020--46 (F65).
connector, pin 2 ?

With the pressure switch connectors

disconnected check for a short to ground Trace and repair short to
at each switch connector terminal. Is a ground in harness
short circuit to ground indicated?

With the pressure switch connectors disconnected Trace and repair open
and the key start switch ON, check for +12V at each circuit between Fuse 13
switch connector pin 1(R/LG/B). Is +12V indicated? and switch connectors

21- 117
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES:
F66 -- FORWARD SWITCH INPUT VOLTAGE TOO LOW
F67 -- FORWARD SWITCH INPUT VOLTAGE TOO HIGH
EFFECT -- Tractor will operate normally, except there will be a short delay recognising that
forward has been selected.

Disconnect processor (A010) connectors C100 & C101, and

disconnect connector, C075 to forward/reverse/neutral
switch assembly S4. Using a suitable multimeter, check Trace and repair
between C100--21 & C075--5, CM7250--S/R/B. For: (1) faulty wiring
Open Circuit (2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

switch assembly disconnected with key start on. Check for voltage
on C075--CM7250--5 S/R/B. Is +5v, +8v or +12V indicated?

Trace and repair Reconnect

21- 118
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES;
F68 -- REVERSE SWITCH INPUT VOLTAGE TOO LOW
F69 -- REVERSE SWITCH INPUT VOLTAGE TOO HIGH
EFFECT -- Tractor will operate normally, except there will be a slight delay recognising that
reverse has been selected.

Disconnect processor connectors C100 & C101, and

disconnect connector, C075 to forward/reverse/neutral Trace and repair
switch assembly. Using a suitable multimeter, check faulty wiring
between C100--22 & C075--CM7260--S/U/B. For: (1) Open
Circuit (2) Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

switch assembly disconnected with key start on. Check for voltage
on C075--CM7260--S/U/B. Is +5v, +8v or +12V indicated?

Trace and repair Reconnect

21- 119
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES-- F70
TORQUE DAMPER FAULT
EFFECTS -- No automatic shifts, No. 6--7, 7--6, 12--13 or 13--12 Powershifts. These gear shifts
can be made by using the clutch pedal.

Is the torque sensor B32

installed correctly. Remove and reinstall

Suspect mechanical fault.

Dismantle and inspect flywheel damper
fingers.

ERROR CODES:
F71 -- TORQUE SENSOR CIRCUIT OPEN
F72 -- TORQUE SENSOR CIRCUIT SHORT TO GROUND

Is Torque Sensor connected to Reconnect connector C255

harness

Disconnect torque sensor (B32) connector

C255 from harness and disconnect
connectors C100 and C101 from
microprocessor (A010) with a suitable Trace and repair wiring
multimeter check from C101--11 to C255--2
-- 7760 W/N/B. For open/short circuit is fault
found?

With the torque sensor

installed check between the
sensor connector terminals for
open or short circuit within the
sensor. Replace the sensor if a
fault is indicated.

21- 120
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES:
F73 -- MID SPEED SENSOR OPEN CIRCUIT
F74 -- MID SPEED SENSOR SHORT CIRCUIT
EFFECT -- Centrifugal compensation assumes 2300 rpm for clutch B, minor shift performance
loss at other speeds. Gears affected 2, 4 and 6.

Is the mid speed sensor

Reconnect connector, C037
connected to harness

Disconnect mid speed sender B4

connector, C037, from harness and
disconnect C100 & C101 from the Trace and repair
processor (A010). With a suitable wiring fault
multimeter check wiring from C101--3 to
C037--3, RM7401--P/B/G. For open/short
circuit. Is fault found?

With the mid speed sensor installed,

check between the sensor connector
terminals for a short or open circuit
within the sensor. Replace the
sensor assembly if a fault is
indicated.

ERROR CODE F75

SWAPPED MID AND REAR SPEED SENSORS
EFFECT -- After error is detected the tractor will operate normally.
Swap speed sensor
connectors, C037 and C038.

21- 121
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F76
SWAPPED ERPM SENSOR WITH EITHER MID OR OUTPUT SENSOR.
EFFECT -- Transmission Disabled

Swap Connector C255

with either C037 or C038.

21- 122
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F77
NO SIGNAL FROM REAR WHEEL SPEED SENSOR.
EFFECT -- Upshifts in high range inhibited. Jerky or sluggish shuttle shifting and automatic
take off generally poor shifting.

Mechanical fault within

Is tractor moving transmission/rear axle
preventing drive.
Is the sensor installed
correctly? Remove and
reinstall correctly
Replace rear speed sensor
assembly.

ERROR CODE F78

NO SIGNAL FROM MID SPEED SENSOR.
EFFECT -- Centrifugal compensation assumes 2,300 rpm for Clutch B. Minor shift quality loss
at other speeds, only affect gears 2, 4 and 6.

Mechanical fault within

Is tractor moving transmission/rear axle
preventing drive.
Is the sensor installed
correctly? Remove and
reinstall correctly

Replace mid speed sensor.

ERROR CODE F79

ENGINE RPM EXCEEDS 3000 REV/MIN.
EFFECT -- General shift quality poor and/or delayed.

When engine speed reduced below 2,800 rev/min Tractor

does error code clear? operating OK

Check output from speed output terminal of NO Replace/repair alternator

alternator. Is voltage approx. 7 volts at idle?

Inspect wiring from the alternator to C100--17 of

the processor. Check for possible intermittent
short circuit to +12V. Repair as necessary.

21- 123
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE F80
TRANSMISSION OUTPUT REV/MIN TOO HIGH FOR SELECTED GEAR.
EFFECT -- None

Self clearing when speed OK

for gear selected.

ERROR CODE F81

CORRECT RATIO NOT DETECTED (OUTPUT SPEED TOO LOW FOR GEAR SELECTED)
EFFECT -- Transmission disabled.

Are connectors C027

and C028 to clutches A Refit connectors correctly
C028 & B C027 correctly
fitted?

Possible slipping clutch.

Pressure check clutches. Have all clutches
Are clutches ≐ 16 bar? low pressure?

Clutch discs worn. Low pressure Possible faulty

Dismantle transmission and hydraulic PWM valve or
inspect. system fault. piston seal leakage
Refer to or other leakage in
Hydraulic clutch showing low
Section. pressure.

21- 124
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODE CP
DEPRESS CLUTCH PEDAL TO RE--ENABLE TRANSMISSION
EFFECT -- Transmission disabled.
Depress clutch pedal or cycle shuttle switch to re--enable
transmission. If CP does not extinguish proceed.

Inspect for loose harness Inspect connector

connectors at C100, C101, and ensure a tight Test drive tractor to
C019 and C001. Are any fit. Is Error Code ensure code does
connections loose? eliminated? not re--appear

Check for an intermittent short to ground on the neutral start switch

wiring: Locate
With the keystart OFF and the FNR lever in either F or R, connect a and repair
continuity meter between connector C100--5 and ground. An open short
circuit should be indicated. Twist the harness from C100 to the circuit
shuttle switch. Is continuity indicated at any time?

Check for an intermittent short to ground on the shuttle switch wiring:

Locate
With the keystart OFF and the FNR lever in N, connect a continuity
and repair
meter between connector C100--5 and C075--4, CM7420--Y/P/B.
open
Continuity should be indicated. Twist the harness from C100 down to
circuit
C075. Is an open circuit indicated at any time?

Check for an intermittent fault in +12V supply to processor module. Locate and
Check for continuity between fuse 14 output and C101--19 and repair open
C101--20, C101--21 Is an open circuit indicated at any time? circuit

Check for an intermittent fault in ground wiring to processor module. Locate and
Check for continuity between C100--12 and C100--14 and ground. Is repair open
an open circuit indicated at any time? circuit

Remove and inspect the shuttle neutral switch. Replace with a Discard of
switch of known performance. Test drive tractor. Is Error Code removed
eliminated? switch

Substitute
processor with one
of known
performance

21- 125
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code F82

21- 126
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code F82 -- ACCELERATOR PEDAL POTENTIOMETER SHORT CIRCUIT TO +8V OR +12V

Effects: No upshift during engine braking while in transport auto--shift mode Key OFF
Key ON
Enter Diagnostic Mode Inspect wiring
Recheck
H9 channel 6. Operate for intermittent
the accelerator pedal. Is fault whilst in
the value continuously H9 mode
greater than 55? channel 6

Disconnect accelerator
potentiometer connector
(C256) and processor
Locate and repair
connector (C239).Is a
short circuit on wire
voltage greater than +5v
B/TQ/S between
indicated at C256--2 with
C256--2 and C239--15.
the ignition ON?

Check operation of potentiometer

(B33). Disconnect plug to
potentiometer and check operation
between pins 2 and 3. With pedal Replace
released, is resistance 0.9--1.0kΩ, potentiometer
gradually changing to 3.7kΩ as the
accelerator pedal is depressed, are
the values correct?

Remove, inspect and

refit all the connectors
in the circuit, if the fault
persists substitute the
processor.

21- 127
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code F83

21- 128
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Code F83 -- ACCELERATOR PEDAL POTENTIOMETER OPEN CIRCUIT OR SHORT TO
GROUND
Effects: No upshift during engine braking while in transport auto--shift mode Key OFF
Key ON
Enter Diagnostic Mode Inspect wiring
Recheck
H9 channel 6. Operate for intermittent
the accelerator pedal. Is fault whilst in
the value continuously H9 mode
less than 20? channel 6

Disconnect accelerator
potentiometer connector
Locate and repair
(C256) and processor
short to ground on wire
connector (C239).Is an
B/TQ/S between
open circuit indicated
C256--2 and C239--15.
between C256--2 and
ground?

With the accelerator potentiometer

connector (C256) and processor Locate and repair
connector (C239) still disconnected, open circuit on wire
Is continuity indicated between B/TQ/S between
C256--2 and C239--15? C256--2 and C239--15.

Check operation of potentiometer

Remove, inspect and

refit all the connectors
in the circuit, if the fault
persists substitute the
processor.

21- 129
SECTION 21 -- TRANSMISSION -- CHAPTER 6
Error Codes F84 and F85

Auto. sw.

Rev Hi Lo Med

21- 130
SECTION 21 -- TRANSMISSION -- CHAPTER 6

Error Code F84-- PRESSURE INDICATED ON FORWARD CLUTCH PRESSURE SWITCHES WHEN
CLUTCH SOLENOIDS ARE OFF

Error Code F85-- PRESSURE INDICATED ON REVERSE CLUTCH PRESSURE SWITCH WHEN
CLUTCH SOLENOID IS OFF

Effects: Transmission disabled

Key OFF
Key ON
Recheck
With the engine off remove the
floorpan and disconnect each
range pressure switch (F84) or
reverse range switch (F85). Replace the faulty switch
Using a suitable multi--meter,
is an open circuit indicated
across each switch?

With the switch or switches still

Trace and repair the short to a
disconnected, turn the ignition
+5v, +8v or +12v source
ON and check at the harness
between C100--15 (F85) or
connector of the switch. The
C239--8 (F84) and the
’O’ wire should be at zero
pressure switch connectors.
volts. Is the value correct?

Reconnect the pressure

switches and install pressure
gauges into the range clutch Suspect a faulty processor.
test ports, Section 21, Chapter Reinstall the correct level
6, page 89. Start the engine software into the processor
and with the transmission in using the PDT tool and
neutral observe the gauges. Is recheck. If error persists
pressure indicated at one of substitute the processor.
the clutches?

With the engine OFF, remove

and replace the PWM valve of
the clutch indicating pressure.

21- 131
SECTION 21 -- TRANSMISSION -- CHAPTER 6

ERROR CODES F1A THROUGH TO F2U

F1A -- CLUTCH A OPEN OR SHORT TO EARTH F1F -- PTO LUBE OPEN OR SHORT TO EARTH
F2A -- CLUTCH A SHORT TO 12V F2F -- PTO LUBE SHORT TO 12V
F1B -- CLUTCH B OPEN OR SHORT TO EARTH F1H -- HIGH CLUTCH OPEN OR SHORT TO EARTH
F2B -- CLUTCH B SHORT TO 12V F2H -- HIGH CLUTCH SHORT TO 12V
F1C -- CLUTCH C OPEN OR SHORT TO EARTH F1J -- REVERSE CLUTCH OPEN OR SHORT TO EARTH
F2C -- CLUTCH C SHORT TO 12V F2J -- REVERSE CLUTCH SHORT TO 12V
F1D -- CLUTCH D OPEN OR SHORT TO EARTH F1L -- LOW CLUTCH OPEN OR SHORT TO EARTH
F2D -- CLUTCH D SHORT TO 12V F2L -- LOW CLUTCH SHORT TO 12V
F1E -- CLUTCH E OPEN OR SHORT TO EARTH F1U -- MID CLUTCH OPEN OR SHORT TO EARTH
F2E -- CLUTCH E SHORT TO 12V F2U -- MID CLUTCH SHORT TO 12V

Error codes F1A through to F2U indicate either a short or open circuit in the wiring of one of the
PWM solenoids. Using a suitable multi--meter check the wiring from the PWM solenoid back to
the processor module. Locate the short/open circuit, repair or replace wiring as necessary.

If wiring is okay disconnect the PWM solenoid from the harness and check that the resistance
of the PWM coil is approximately 10Ω at 20_C. If not, replace the PWM solenoid.

If wiring and PWM solenoids are okay replace the micro processor with one of known
performance.

A B C D E LOW MED HIGH REV

21- 132
SECTION 21 -- TRANSMISSION -- CHAPTER 6
ERROR CODES:
FCA -- CLUTCH A NOT CALIBRATED FCH -- HIGH CLUTCH NOT CALIBRATED
FCB -- CLUTCH B NOT CALIBRATED FCJ -- REVERSE CLUTCH NOT CALIBRATED
FCC -- CLUTCH C NOT CALIBRATED FCL -- LOW CLUTCH NOT CALIBRATED
FCD -- CLUTCH D NOT CALIBRATED FCU -- MID CLUTCH NOT CALIBRATED
FCE -- CLUTCH E NOT CALIBRATED
EFFECTS -- Poor clutch performance of uncalibrated clutch.

Perform calibration procedure. Tractor Okay

Does the error clear?

Are any errors or messages Refer to calibration errors

displayed during calibration?

Remove PWM valve, clean and

reinstall or replace. Can calibration Tractor Okay
be performed successfully?

Pressure test clutch. Is pressure Possible clutch piston seal leakage

approximately 16 bar? or leakage to piston from PWM
valve

Mechanical fault within transmission.

Dismantle and inspect clutch pack
assemblies

21- 133
SECTION 21 -- TRANSMISSION -- CHAPTER 6

CALIBRATION ERRORS AND MESSAGES

U19 -- Oil temperature below 10_C

Warm oil to above 10_C before processing with calibration.

U21 -- Engine RPM too low

Increase engine RPM to 1200 100

U22 -- Engine RPM too high

Reduce engine RPM to 1200 100

U23 -- Shuttle lever is in neutral

Place shuttle lever in forward

U26 -- Clutch pedal not released

Release clutch pedal

U31 -- Output speed sensed -- tractor moving

U33 -- Hand brake not applied

Apply hand brake

U34 -- Seat switch not activated

Check seat switch in H menus (H5)

U36 -- Maximum allowed clutch calibration value exceeded

Current value exceeded without lugging engine down. Possible PWM valve faulty.
Low Hydraulic Pressure fault or a faulty synchroniser not transmitting drive.

U37 -- Engine RPM dropped too soon

Engine lugged down too soon. Possible PWM fault or
mechanical fault within transmission.

21- 134
SECTION 21 -- TRANSMISSION -- CHAPTER 6

CALIBRATION ERRORS AND MESSAGES (Continued)

CH -- Oil temperature above 105_C

Message for information only. Press upshift to proceed.

CL -- Oil Temperature between 10 and 60_C degrees

Message for information only. Press upshift to proceed.

21- 135
SECTION 21 -- TRANSMISSION -- CHAPTER 6
LIMP HOME 1
WARNING
Care should be taken when operating the tractor with
the limp home harness connected. Clutch engagement
will be harsher than normal. Do not leave the limp home
harness connected when the operation has been
completed.

In the unlikely event of an electrical fault developing 2

within the transmission that renders the tractor
immobile, for example, failure of the supply voltage to
the PWM valves, the emergency ‘Limp Home
Harness’, Special Tool No. NH.21--100 for all Power,
Range and Dual Command transmissions is available 146
to enable the tractor to be driven onto a transporter or
hard standing, in order that the repair can be carried
out in a suitable location. The Limp Home device is not
and must not be used as a means to continue
operating the tractor in its work environment.
To engage and operate the ‘Limp Home Harness’
proceed as follows:--
1. Apply the parking brake.
2. Stop the engine and turn keystart off.
3. Remove the electronic draft control panel.
4. Locate and disconnect the rear main harness
access connector, Figure 147, enabling the
connection of the limp home harness connector, 147
Figure 146, marked with ‘HARNESS’, into the rear
main harness of the tractor, Figure 149.
5. Connect the other connector of the Limp Home
harness, Figure 146, marked ‘DIAGNOSTIC’, to
the ‘WHITE’ diagnostic plug, Figure 149.
6. Start the vehicle.
7. Select forward or reverse by operating
forward/reverse switch, (2) Figure 146, for 2
seconds on the Limp home harness control box.
Return the switch to the centre position.
8. Operate the momentary switch, (1) Figure 146, of
the Limp Home Harness to move the vehicle. If
necessary, depress the foot throttle to increase
engine speed. 148
9. When the tractor has been delivered to the repair
area, disconnect the Limp Home Harness and
reconnect the limp home access connector of the
rear main harness and proceed with diagnosing
and repairing the fault.

149

21- 136
SECTION 23 -- DRIVE LINES -- CHAPTER 1
SECTION 23 -- DRIVE LINES

Chapter 1 -- Drive Lines

CONTENTS

Section Description Page

23 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

FWD ELECTRO--HYDRAULIC CLUTCH SPECIFICATIONS

Reduction Ratio:
Model TM165 W/Power Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48/58 = 1:1.208
Model TM165 W/Range Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46/61 = 1:1.326
Models TM135 and TM150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/57 = 1:1.14
Models TM115 and TM125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/55 = 1:1.08
FWD Shaft Bearing Adjust Ring Shims (5, page 4) . . . . . . . . . . . . mm 1.00--1.05--1.10--1.15--1.20--1.251.
30--1.35--1.40--1.45--1.50--1.551.6
0--1.65--1.70--1.75--1.80--1.851.90
--1.95--2.00--2.05--2.10--2.15--2.20
Clutch Reaction Disc Thickness (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1--7.3--7.5--7.7--7.9--8.1--8.3
8.5--8.7--8.9--9.1--9.3--9.5--9.7
9.9--10.1
Clutch Driven Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch Drive Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Driven Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.7÷1.8
Clutch Drive Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.45÷1.55 and 1.65÷1.75
Free Belleville Spring Height (one) . . . . . . . . . . . . . . . . . . . . . . . . . . mm 9.85÷10.10
Free Belleville Spring Height under a 19341 N or 1972 kg load . . mm 7.75

DRIVE SHAFT SPECIFICATIONS

Front Sleeve Positioning Adjust Ring Shims (2, page 4) . . . . . . . . mm 1--1.2--1.5--1.8--2--2.2--2.5--3--3.33.
7--4--4.3
Front Sleeve End--Play (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.2÷1.7

23- 1
SECTION 23 -- DRIVE LINES -- CHAPTER 1
TIGHTENING TORQUES

24653

1
DESCRIPTION Thread Size Tightening Torque
Nm kgm
Drive Shaft Main Bearing Attaching Screw (C1) . . . . . . . . . . . . . . . . . . M12 x 1.5 88 9
Transfer Box Attaching Screw (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 49 5

SPECIAL TOOLS 293996 Transfer box drive shaft puller

(M8x1.25) adapter (to be used with tool
CAUTION
no. 292927)
Operations described in this section of the Manual
must be performed using the following ESSENTIAL
292927 Puller (to be used with tool no. 293996)
tools marked with the identification code (X).
To work safely and achieve the best technical results X 293995 Transfer box drive shaft end--play
with additional savings of time and effort, these checking bracket
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated
with the self--made ones for which you will find the
necessary construction drawings and specifications
directly on this Manual.

23- 2
SECTION 23 -- DRIVE LINES -- CHAPTER 1
Tool to be fabricated to remove the
electro--hydraulic transfer box rear cup. (Mark tool
with no. 50067. Dimensions in mm.)
NOTE: Fabricate tool using F42 material.

2
Tool to be fabricated to remove the
electro--hydraulic transfer box reaction disc (Mark
tool with no. 50068. Dimensions in mm.)
NOTE: Fabricate tool using F42 material.

3
Tool to be fabricated to remove the
electro--hydraulic transfer box clutch assembly.
(Mark tool with no. 50069. Dimensions in mm.)
NOTE: Fabricate tool using F42 material.

23- 3
SECTION 23 -- DRIVE LINES -- CHAPTER 1

5
FWD Electro--Hydraulic Clutch Sectional Views
G = 1 to 1.2 mm. Release travel. 7. Driven gear
L = 1.2 to 1.7 mm. Sleeve (3) end--play. 8. Drive gear
1. Circlip 9. Clutch reaction disc
2. Sleeve (3) positioning adjust ring. 10. Drive discs
3. Front sleeve 11. Driven discs
4. Circlip 12. Control piston
5. FWD shaft bearing adjust shims. 13. Belleville spring
6. FWD shaft 14. Belleville spring reaction disc

NOTE: During installation apply sealer on surfaces marked with an X as detailed on page 19.

23- 4
SECTION 23 -- DRIVE LINES -- CHAPTER 1
TROUBLESHOOTING
Problem Possible Causes Correction
FWD does not engage 1. Faulty FWD engagement switch. Replace switch.
2. The electromagnet is not ener- Reset electrical connections and
gised: damaged or detached replace faulty parts.
connectors, faulty remote
switch.
3. FWD control solenoid valve Repair or replace solenoid valve.
stuck open.
4. Worn clutch discs . Replace clutch discs.
5. Bent Belleville springs. Repair clutch assembly.
FWD does not disengage 1. Low transmission oil. Reset oil level.
2. Blocked oil filter. Replace filter.
3. Faulty water pump. Overhaul or replace pump.
4. Faulty FWD engagement switch. Replace switch.
5. The electro--magnet is not ener- Reset electrical connections and
gised: damaged or detached replace faulty parts.
connectors, faulty remote
switch.
6. FWD control solenoid valve Repair or replace solenoid valve.
stuck open.
7. Oil leaks through the seals with Replace faulty oil seals.
consequent pressure drop: hub,
piston, inlet fitting, and transfer
box shaft seals
With the FWD electro--hydraulic 1. Faulty pump pressure switch. Replace pressure switch.
clutch disengaged, the FWD does
not engage when the brake pedals
are pressed.

DESCRIPTION AND OPERATION

The transfer box is located under the rear transmission The transfer box is controlled by a control gear located
housing and connects the rear transmission to the front on a bevel spur gear. This gear acts on the clutch and
axle by means of a shaft running along the central axis moves a gear splined to the FWD shaft.
of the tractor. Refer to pages 6 and 7 for the description of the transfer
box clutch operation.

23- 5
SECTION 23 -- DRIVE LINES -- CHAPTER 1

6
Exhaust oil

Lubrication oil

FWD ELECTRO--HYDRAULIC CLUTCH (FWD ENGAGED)

When the FWD is engaged by means of the switch FWD engagement takes place through the Belleville
located on the EMU panel, the oil within the control springs (2) which keep pressed the multi--pack clutch
piston (3) annular groove is open to sump. The (4) which transfers the drive reaching the front axle
solenoid valve is in the discharge position through the drive shaft (1).
(de-energised).

23- 6
SECTION 23 -- DRIVE LINES -- CHAPTER 1

7
Pressure oil

Lubrication oil

FWD ELECTRO--HYDRAULIC CLUTCH (FWD DISENGAGED)

When the switch located on the EMU panel is pressed, Under these conditions, the control clutch (4) is not
the solenoid valve opens and lets the oil flow from the compressed and the drive shaft (4) reaching the front
pump into the control piston (3) annular groove. axle can rotate freely as it is no longer integral to the
Pressure oil works against the action of the Belleville assembly.
springs (2) and moves the piston (3).

23- 7
SECTION 23 -- DRIVE LINES -- CHAPTER 1
DRIVE SHAFT AND BEARING

Removal -- Installation (Op. 23 101 20 -- 23 101 26)

Models Less Front Suspension

WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Proceed as follows:
1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

1
3. Loosen the retaining screws and remove the drive
shaft protection.
4. Remove circlip (4) and withdraw the sleeve (5).
Repeat for transfer box circlip and sleeve.

2
5. Loosen the screws retaining the bearing (3) to the
transmission and speed clutch housing and
recover the bearing as well as the drive shafts.
6. Reinstallation of the drive shaft follows the removal
procedure in reverse.

23- 8
SECTION 23 -- DRIVE LINES -- CHAPTER 1
DRIVE SHAFT REAR UNIVERSAL JOINT

Removal -- Installation

Models with Front Suspension

WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Proceed as follows:
1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

4
3. Place a trolley jack under the cast arm leading to
the rear swivel block of the front suspension.
4. Remove the four bolts securing the swivel block to
the transmission casing, and carefully lower the
swivel block, a pry bar may be required to release
the dowels.

5
5. Unscrew the coupling securing the universal joint
assembly to the shaft and remove the universal
joint assembly.
NOTE: In order to remove the complete driveshaft or
front universal joint it is necessary to remove the front
axle. Refer to Section 25.

23- 9
SECTION 23 -- DRIVE LINES -- CHAPTER 1
TRANSFER BOX SHAFT OIL SEAL

Replacement with the transfer box shaft removed

from the tractor. (Op. 23 101 32 -- 23 202 44)
The transfer box shaft oil seal can be replaced with the
transmission housing on a bench or installed into the
tractor(both in the mechanical and electro--hydraulic
clutch versions).

WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Proceed as follows:
1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.
3. If the transmission housing is installed on the
engine, drain oil from the rear transmission and
speed clutch housings and remove the drive shaft 1
reaching the front axle (see page 8).
4. Using a screw--driver or punch, remove dust ring
and oil seal to be replaced.

2
5. Install a new seal and settle it correctly into its seat
using the drift tool no. 293475 (1).
6. Install a new dust seal.
7. Assemble the drive shaft reaching the front axle, fill
transmission with specified oil, and connect the
negative cable to the battery.

23- 10
SECTION 23 -- DRIVE LINES -- CHAPTER 1
ELECTRO--HYDRAULIC CLUTCH TRANSFER
BOX
Removal -- Installation (Op. 23 202 46)
Removal and installation of the electro--hydraulic
clutch transfer box can be carried out with the
transmission housing on a bench or installed in the
tractor.
WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

1
4. Detach the supply line from the transfer box bottom
cover.

2
5. Remove the transfer box bottom cover.

23- 11
SECTION 23 -- DRIVE LINES -- CHAPTER 1
6. Remove the inner transfer box guard.

4
7. Remove the oil suction line.

5
8. Remove the dust ring, oil seal and circlip retaining
the transfer box shaft bearings.

6
9. Recover the transfer box shaft bearing adjust ring.
10. Fabricate on site the bracket tool no. 50069
following the instructions given in the drawing on
page 3.
11. Install the bracket tool no. 50069 on the
transmission housing to lock the FWD clutch.

23- 12
SECTION 23 -- DRIVE LINES -- CHAPTER 1
12. Using a puller tool no. 292927 (1) and adapter tool
no. 293996 (2) partially withdraw the transfer box
shaft.
NOTE: With the transmission installed on range
command and power command models screw a bolt in
the end of the shaft and lever out.

8
13. Complete transfer box shaft removal by hand and
ensure that the clutch is held in place by the bracket
tool no. 50069 (3).
NOTE: On models with power command or range
command transmissions it is not possible to remove
the transfer box shaft completely with the transmission
installed.

9
14. Remove the bracket tool no. 50069 and withdraw
the clutch complete with the FWD engagement
control device.
NOTE: The bracket tool no. 50069 is necessary to
remove the electro--hydraulic clutch transfer box when
the transmission housing is installed into the tractor. If
the transmission housing is placed on a bench proceed
as follows:

10
15. Using a puller tool no. 292927 (1) and adapter tool
no. 293996 (2) and partially withdraw the transfer
box shaft.

23- 13
SECTION 23 -- DRIVE LINES -- CHAPTER 1
16. With the housing in the upright position, complete
transfer box removal with one hand and hold the
FWD clutch in place with the other.

12
17. Remove the clutch complete with the FWD
engagement control device.

13
18. Remove the pipe section protecting the transfer
box shaft.
19. Overhaul the FWD electro--hydraulic clutch on the
bench as follows:
20. Fabricate on site the tools nos. 50067 and 50068
following the instructions given in the drawings on
page 3.
21. Place the clutch on a hydraulic press with the clutch
discs turned upwards.
22. Install the tool no. 50068, previously fabricated on
site, on the clutch.

14
23. Overcome the clutch spring resistance with the
press and remove the circlip retaining the clutch
discs.

23- 14
SECTION 23 -- DRIVE LINES -- CHAPTER 1
24. Release the hydraulic press and recover the clutch
discs together with the circlip, reaction and clutch
release discs.

16
25. Place the clutch assembly with the springs turned
upwards and install the tool no. 50067 on the
clutch. Overcome the spring action using the
hydraulic press and remove the two saddle rings
which retain the springs.

17
26. Release the hydraulic press and recover the
springs complete with the reaction disc.
27. Check the O rings for wear and replace if damaged.
28. Reinstallation of the clutch follows the removal
procedure in reverse.
29. Place the clutch complete with all details on the
press with the discs turned upwards.
30. Install the tool no. 50068, previously fabricated on
site, on the clutch.

18
31. Overcome the clutch spring action with the press
and using a feeler gauge measure the clearance
between the circlip and reaction disc. The
clearance should be 1 to 1.2 mm. If this is not the
case, replace the clutch reaction disc (9, page 4).
With a new reaction disc installed, use the press
again to check that the clearance between the
circlip and reaction disc is 1 to 1.2 mm.

23- 15
SECTION 23 -- DRIVE LINES -- CHAPTER 1
32. Install the pipe section protecting the transfer box
shaft ensuring that the split is turned upwards.

20
33. Install the clutch on the transmission housing and,
if the transmission housing is assembled on the
tractor, lock the clutch using the bracket tool no.
50069 (3). Install the transfer box shaft.
34. Remove the bracket tool no. 50069 and insert the
outer race of the transfer box shaft bearing in its
seat keeping it in contact with the rollers.

21
35. Install the circlip retaining the transfer box shaft
bearings.

22
36. Fix the screw of the tool no. 293995 (1) to the
transfer box shaft.

23- 16
SECTION 23 -- DRIVE LINES -- CHAPTER 1
37. Fix the tool no. 293995 (1) to the transmission
housing. (If necessary, loosen the threaded pin
nuts on the tool to align the transmission housing
holes.)

24
38. Install a lever gauge and fix it using to the
transmission housing (not to the tool) its magnetic
base. Position the gauge tip on the transfer box
shaft top.

25
39. With the lower nut completely loose, screw in
manually the upper nut of the tool no. 293995 until
it touches the upper spring cup. Then screw it in a
further 1 1/2 turns. When in this condition, reset
gauge to zero.

26
40. Loosen the upper nut of the tool no. 293995
completely and screw in by hand the lower nut until
it touches the lower spring cup. Then screw it in a
further 1 1/2 turns.
41. Read the transfer box shaft axial displacement (L)
on the lever gauge. The shim pack (5, page 4) to
be inserted between the circlip and bearing race
will be as follows:
S1 = L -- 0,05
where:
L = transfer box axial displacement read on the
gauge

23- 17
SECTION 23 -- DRIVE LINES -- CHAPTER 1
0,05 = necessary reduction to avoid bearing
pre--load.
Round off the value obtained to the lower value
within 0.05 mm.
42. Remove tool no. 293995 from the transmission
housing.
43. Remove the circlip retaining the transfer box shaft
bearings.

44. Insert shims (1) as previously computed.

45. Install the circlip retaining the transfer box shaft
bearings.

28
46. Install the oil seal and settle it down correctly using
a positioner tool no. 293475 (1). Last, install the
dust ring.

29
47. Install the oil suction line.
48. Install the inner transfer box protection.

23- 18
SECTION 23 -- DRIVE LINES -- CHAPTER 1
49. Thoroughly clean and degrease the transmission
housing and transfer box bottom cover mating
surfaces following the pattern shown in the figure.

31
50. Install the transfer box bottom cover and connect
the supply line to the cover.

23- 19
SECTION 23 -- DRIVE LINES -- CHAPTER 1
NOTES

23- 20
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
SECTION 25 -- MECHANICAL FRONT AXLE

Chapter 1 -- Mechanical Front Axle

CONTENTS

Section Description Page

25 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SECTIONAL VIEWS -- SPECIAL TOOLS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steering, stress--supporting,
centrally pivoted
Pinion and Crown Wheel -- Differential
Pinion to crown wheel reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/34 = 1:3.4
Pinion to crown wheel backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.18 -- 0.23
Cone point adjustment shims (8, page 7) . . . . . . . . . . . . . . . . . . . . mm 2.3 -- 2.4 -- 2.5 -- 2.6 -- 2.7 -- 2.8 --
2.9 -- 3.0 -- 3.1 -- 3.2 -- 3.3 -- 3.4 --
3.5
Pinion bearing adjustment shims (12) . . . . . . . . . . . . . . . . . . . . . . . mm 2.2--2.25--2.3--2.35--2.4--2.45--
2.5--2.55--2.6--2.65--2.7--2.75--
2.8--2.85--2.9--2.95--3.00--3.05--
3.10--3.15--3.20--3.25--3.3--
3.35--3.4--3.45

(to be continued)

25- 1
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
SPECIFICATIONS
(continued)
Crown wheel point adjustment shims (2) . . . . . . . . . . . . . . . . . . . . . mm 1 -- 1.1 -- 1.2 -- 1.3 -- 1.4 -- 1.5--
1.6 -- 1.7 -- 1.8 -- 1.9 -- 2
Side gear to differential gear backlash . . . . . . . . . . . . . . . . . . . . . . . mm 0.18
Differential gear thrust washer (5) thickness . . . . . . . . . . . . . . . . . . mm 1.470 -- 1.530
Side gear thrust washer (3) thickness . . . . . . . . . . . . . . . . . . . . . . . mm 1.4--1.5--1.6--1.7--1.8
Differential gear pin (6) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.939 -- 24.960
Pin bore diameter on differential gears (7) . . . . . . . . . . . . . . . . . . . . mm 25.040 -- 25.061
Pins to seats mounting clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.080 -- 0.122
Side gear hub (4) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.954 -- 51.000
Hub bore diameter on differential casing . . . . . . . . . . . . . . . . . . . . . mm 51.100 -- 51.146
Side gears to seats mounting clearance . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.192
Differential Lock Assembly (Dog Clutch)
Free spring length (1, page 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm approx. 87
Compressed spring length, under a load of 1888 -- 2035 N
(192.5 -- 207.5 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm approx. 48
Differential Lock Assembly (Multi Wet Plate Clutch)
Drive discs (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.75 -- 1.855
Drive discs (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . quantity 5
Driven discs (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.35 -- 2.45
Driven discs (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . quantity 6
Axle--Shafts and Swivel Assemblies
Outer axle--shaft (7, page 8) dia. at the bushings (8) . . . . . . . . . . . mm 44.975 -- 45.000
Press--fit bushing (8) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . mm 45.100 -- 45.175 (1)
Axle--shafts to bushings mounting clearance . . . . . . . . . . . . . . . . . mm 0.100 -- 0.200
Bushings to seats fitting interference . . . . . . . . . . . . . . . . . . . . . . . . mm 0.064 -- 0.129
Swivel pin bearing adjust shims (10) . . . . . . . . . . . . . . . . . . . . . . . . mm 0.10--0.15--0.20--0.25--0.30
Planetary Reduction Hubs
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16:(16+68) = 1:5.25
Planet gear thrust washer (9) thickness . . . . . . . . . . . . . . . . . . . . . . mm 0.77 -- 0.83
Front Axle Support Pillars
Axle housing to support pillars end play . . . . . . . . . . . . . . . . . . . . . . mm 0.3 -- 1.1
Max. wear end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2
Front support pillar (1) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 62.720 -- 62.740
Press--fit front bush (2) inner diameter . . . . . . . . . . . . . . . . . . . . . . . mm 62.80 -- 62.884 (1)
Pillar (1) to bush (2) mounting clearance . . . . . . . . . . . . . . . . . . . . . mm 0.060 -- 0.164
Rear bush (4) outer diameter (press--fit into pinion support) . . . . . mm 115.527 -- 115.585
Rear bush (5) inner diameter (press--fit into support pillar) . . . . . . mm 115.636 --115.711 (1)
Bush to bush mounting clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.051 -- 0.184
Axle front and rear thrust washer (3 and 6) thickness 4.90 -- 5.00
Supersteer Swivel Bearing
Torque required to rotate axle when correctly shimmed . . . . . . . . . . . . . . . 40--45 kgm
Supersteer swivel bearing shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.05 -- 1.90
in 0.05 increments
(1) final dimension without reaming

25- 2
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
TORQUE SPECIFICATIONS

25- 3
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
SPECIAL TOOLS X 293798 Front axle differential casing bearing
adjustment ring nut spanner (Class IV)
CAUTION
Operations described in this Section of the Manual
X 293880 Front wheel hub bearing ring nut
must be performed using the following ESSENTIAL
spanner (Class III)
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these X 293881 Front wheel hub bearing ring nut
mandatory tools should be used in conjunction with the spanner (Class IV).
suggested special tools listed below and integrated
with the self--made ones for which you will find the X 293882 Front axle hub bearing pulling aids (two)
necessary construction drawings and specifications
directly on this Manual. 292888 Front axle planetary reduction hub
alignment pins (M12x1.25)
List of special tools necessary to carry out the different
operations described in this Section. 293812 Front wheel removal/installation pins
(M16x1.25)
293460 Front axle overhaul stand
X 293857 Front axle swivel pin puller
291517 Front differential casing
removal--installation hook X 292161 Front axle swivel pin bearing outer race
puller
293743 Front axle differential casing overhaul
fixture X 292220 Front axle bearing rolling torque test tool

X 293878 Front axle drive pinion nut spanner 293889 Front axle--shaft to swivel housing
(Class III) mounting guide (Class III)

X 293879 Front axle drive pinion nut spanner 293888 Front axle--shaft to swivel housing
(Class IV) mounting guide (Class IV)

X 293391/ 292870 Front axle differential engagement oil

X 293438 Drive pinion bearing adjustment tool pressure test kit

X 293510 Drive pinion bearing adjustment gauge. LOCALLY FABRICATED TOOLS

Front pinion shaft holding tool -- fabricate from 4WD
X 292903 Pulling pliers shaft coupling.
-- Supersteer/suspended axle differential unit guides
X 293876 Front axle drive pinion retaining tool 2 x M16 x 1.5 bolts
(Class III)
-- Supersteer/suspended axle pinion flange holding
tool
X 293877 Front axle drive pinion retaining tool
(Class IV) -- Supersteer differential vice holding plate
-- Supersteer/suspended axle differential pinion
293400 Front axle drive pinion cone point adjustment tool spacer (use with 293391)
adjustment gauge -- Supersteer pivot bearing turning tool

X 293665 Front axle differential casing bearing

adjustment ring nut spanner (Class III)

25- 4
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
Locally fabricated tools

1 2

2 3
Pinion Shaft Tool Differential Vice Holding Plate
(Standard Axle) (Supersteer Axle)

4 5
Differential Casting Guide Bolts Differential Pinion Bearing Setting Spacer
(Supersteer and Suspended Axles) (Supersteer and Suspended Axles)

6
Pinion Shaft Holding Tool
(Supersteer & Suspended Axle)

25- 5
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

7
Supersteer Pivot Bearing Turning Tool

25- 6
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

8
Front Axle Cross--Sections

A. Dog Clutch Differential 6. Differential gear pin

B. Multi Wet Plate Clutch Differential 7. Differential gears
1. Spring 8. Pinion cone point adjustment shims
2. Crown wheel bearing adjustment shims 9. Clutch drive discs
3. Side gear thrust washer shims 10. Clutch driven discs
4. Side gears 11. Seal
5. Differential gear thrust washer shims 12. Pinion bearing adjustment shims

25- 7
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

9
Support Pillars and Planetary Reduction Hub Cross--Sections

1. Front support pillar 6. Rear thrust washer

2. Front support pillar bush 7. Outer axle--shafts
3. Front thrust washer 8. Bushings
4. Rear bush (press--fit into support pillar) 9. Driven gear thrust washers
5. Rear bush (press--fit into pinion support) 10. Swivel pin adjustment shims

DESCRIPTION AND OPERATION

The TM range of tractors are fitted with a centrally The differential assembly includes two planet gears.
pivoted front axle with support pillars and propshaft Drive is transferred to the epicyclic reduction gear hubs
parallel to the tractor centreline. by means of maintenance--free universal joints.

25- 8
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Front differential lock

disengaged

Front differential lock engaged

Trapped oil

Pressure oil

FRONT DIFFERENTIAL LOCK ASSEMBLY -- DOG CLUTCH

When the diff lock is not engaged, the solenoid valve When the switch on the instrument panel is activated,
is in the discharge position (not energised) and the solenoid valve opens and directs oil from the low
therefore the oil is free to return to sump. pressure circuit into the drive piston (1), where it
Under these conditions, the helix spring (2) keeps the overcomes the spring (2) force and moves the piston,
diff lock dog clutch teeth apart. locking the differential.

25- 9
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Front differential lock

disengaged

Front differential lock engaged

Trapped oil

Pressure oil

11
FRONT DIFFERENTIAL LOCK ASSEMBLY -- MULTIWET PLATE CLUTCH
When the diff lock is not engaged, the solenoid valve When the switch on the instrument panel is activated,
is in the discharge position (not energised) and the solenoid valve opens and directs oil from the low
therefore the oil is free to return to sump. pressure circuit into the drive piston (2)
Under these conditions, the clutch drive and driven Low pressure oil moves the piston locking the
discs remain separated and the differential lock is differential.
disengaged.

25- 10
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
TROUBLESHOOTING -- HYDRAULIC DIFFERENTIAL LOCK
Problem Possible Cause Correction
Differential lock not engaging. 1. Rear axle oil low. Top up to correct level.
2. Blocked oil filter. Replace filter.
3. Faulty hydraulic pump. Overhaul or replace pump.
4. Faulty diff lock switch Replace switch.
5. Power supply not reaching the Restore electrical connections and
solenoid valve: detached or replace faulty parts.
damaged connectors, faulty
remote switch.
6. Diff lock solenoid valve stuck on Repair or replace solenoid valve.
discharge.
7. Oil leaks through the seals with Replace faulty seals.
consequent pressure drop
(piston or supply line seals).
Multiwet plate clutch only.
8. Worn friction plates (multi wet Replace friction plates.
plate clutch)
Differential lock not disengaging 1. Diff lock solenoid valve stuck on Repair or replace solenoid valve.
delivery
2. Diff unlock spring broken (dog Replace spring.
clutch)
With differential lock engaged in 1. Faulty electronic management Repair or replace EMU.
auto function, the diff lock does not unit (EMU)
disengage when raising lift arms
using the FAST RAISE switch.
With differential lock engaged, the 1. Faulty brake pedal switch Replace switch.
diff lock does not disengage when (connected to the brake pump).
brake pedals are pressed.

25- 11
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
FRONT AXLE ASSEMBLY

Removal -- Installation (Op. 25 100 30)

STANDARD AXLE
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate [Link] that units or
parts are supported by suitable slings or [Link]
that no--one is in the vicinity of the load to be lifted.

Proceed as follows:
NOTE: The front axle assembly can be separated from
the tractor with either the propshaft removed from or
installed in the tractor. The following operations detail
how to remove the front axle assembly with the
propshaft still in the tractor. To remove the propshaft,
refer to that described in Section 23.
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. If front ballast is fitted, thread a nylon cable (1)
through the first row of ballast, unscrew support
plate (2) retaining screws and remove ballast using
a hoist.
4. Unscrew retaining screws of the second row of
ballast and slide them out, one at a time.

25- 12
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
5. Loosen the retaining screws and remove the
propshaft guard.
6. Remove the circlip (4) and slide out the sleeve (5).

3
7. Slightly raise tractor using a hoist and a nylon cable
(1) and place a stationary stand under the sump.

4
8. Lock the front axle relative to the engine using
wooden wedges. Loosen the attaching bolts and
remove the front wheels.

5
9. Detach the steering control cylinder lines (3). Mark
the lines and respective fittings to assist
reassembly.

25- 13
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
10. Detach the differential lock control line (1).

7
11. If fitted, disconnect the steering angle sensor
connector, located behind the alternator.

8
12. Loosen the front (3) and rear support pillar
attaching bolts and remove the front axle using a
hoist and two nylon cables (2) (one on each side).
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.
13. Reinstall the front axle assembly observing the
following:
-- Reassembly follows the disassembly
procedure in reverse, from step 11 back to step
1.
-- Tighten to correct torques as detailed on page
3. 9

25- 14
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
FRONT AXLE ASSEMBLY

Removal -- Installation (Op.25 100.35)

SUSPENDED AXLE
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate [Link] that units or
parts are supported by suitable slings or [Link]
that no--one is in the vicinity of the load to be lifted.

1. Open and raise the engine hood.

2. Detach the negative cable from the battery and
insulate.

1
3. If front ballast is fitted, thread a nylon cable (1)
through the first row of ballast. Unscrew support
plate (2) retaining screws and remove ballast using
a hoist.
4. Unscrew retaining screws of the second row of
ballast and slide them out, one at a time.

2
5. Disconnect the movement potentiometer linkage
and electrical connector.

25- 15
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
6. Disconnect the 2 steering tubes and the differential
lock tube from the right hand side.
NOTE: If front axle brakes are fitted, disconnect the
common brake pipe to the axle.

4
7. If fitted, disconnect the steering angle sensor
connector from behind the alternator and withdraw
the cable from the engine.

5
8. Disconnect the FWD driveshaft at the sliding
coupler joint.

6
9. Remove the brackets retaining the suspension
ram hydraulic pipes to the tee--bar casting.

25- 16
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
10. Raise the tractor using a suitable hoist and cable
at the front support, sufficient to remove the front
wheels, place stands under the axle for safety.

8
11. With the wheels removed, raise the tractor further
to allow a bar to go between the sump and fwd shaft
and support using stands either side of the engine.
Allow enough space between the stands to
withdraw the axle tee--bar from the front of the
tractor.

9
12. Using a suitable lifting jack, raise the right hand
side of the axle to gain access to the left hand pivot
pin. Remove the pin retaining plate and using a drift
knock the pin from the pivot from the front of the
tractor.

10
13. With the axle supported centrally at the front and
also under the Tee--bar, raise or lower until access
is gained to the right hand pin. Remove the right
hand pin retaining plate and drift out the pin from
the front of the tractor.

25- 17
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
14. With the tee bar supported, remove the four bolts
from the rear swivel assembly of the bar, slightly
lower the tee--bar and prise the rear swivel
assembly from the transmission dowels.

12
15. Ensuring that all pipes are disconnected and that
the axle casting can clear the front support,
carefully withdraw the axle, with the rear tee bar
supported away from the tractor.

13
16. Place the axle assembly onto a suitable stand.
Prise the yoke from its bearing surface, to gain
access to the tee--bar securing bolts.

14
17. Using a suitable hoist/lifting crane, support the
tee--bar. Remove the retaining bolts, noting the two
thin headed bolts at the top and bottom.

25- 18
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
18. Slightly withdraw the tee--bar casting and remove
the universal joint bolts and remove the propshaft.
Remove the tee--bar casting away from the axle.

16
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

19. Re--install the front axle assembly observing the

following:
-- Reassembly follows the disassembly
procedure in reverse from step 18 back to 1.
-- Tighten the bolts to the correct torques as
detailed on page 3.
-- If front axle brakes are fitted it will be necessary
to bleed the front braking system.
-- If necessary ensure that the axle and hub oil
levels are correct and that items requiring
grease lubrication are sufficiently lubricated.

25- 19
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
FRONT AXLE ASSEMBLY

Removal -- Installation (Op.25 100.33)

SUPERSTEER AXLE
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity. Ensure that units or
parts are supported by suitable slings or hooks. Ensure
that no--one is in the vicinity of the load to be lifted.

1. Open and raise the engine hood.

2. Detach the negative cable from the battery and
insulate.

1
3. If front ballast is fitted, thread a nylon cable (1)
through the first row of ballast. Unscrew support
plate retaining screws and remove ballast using a
hoist.
4. Remove the ballast support.

2
5. Remove the four wheel drive driveshaft guard and 1
loosen the driveshaft coupling at the splined joint.
Remove the bolts to the front U.J. and let the
driveshaft hang.

25- 20
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
6. Disconnect the hydraulic tubes for steering and
differential lock, located on both right and left hand
sides. Remove the transfer tubes and plate bolted
to the underside of the sump.

4
7. Raise the tractor using a suitable hoist and cable
around the axle housing, sufficient to remove the
front wheels, place stands under the axle for safety.
Support the tractor using a suitable flat bar under
the sump and stands either side of the engine.

5
8. If fitted disconnect the steering angle sensor
connector, located behind the alternator and
withdraw the cable from the engine.

6
9. Disconnect the steering arms from the supersteer
unit to the axle.

25- 21
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
10. Attach two nylon cables to either end of the axle
and connect to a suitable hoist. Remove the six
bolts from the supersteer swivel lower plate, note
the shims on either side and lower the axle
sufficient to remove it from the tractor.

8
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

11. Re--install the front axle assembly observing the

following:
-- Reassembly follows the disassembly
procedure in reverse from step 10 back to 1.
NOTE: It will be necessary to obtain the correct swivel
bearing pre--load setting for the supersteer unit, see
SuperSteer Swivel Bearing Adjustment.
-- Tighten the bolts to the correct torques as
detailed on page 3.
-- If necessary ensure that the axle and hub oil
levels are correct and that items requiring
grease lubrication are sufficiently lubricated.

Supersteer Swivel Bearing Adjustment

1. Fabricate locally a plate, to install onto the axle, see
Figure 7, under Special Tools, for dimensions.

25- 22
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
2. Assemble the axle onto the super steer unit, Install
the lower plate with original shims, and tighten the
six bolts to 373 Nm.
3. Install the locally fabricated plate to the front of the
axle (1).

10
4. Using a suitable torque wrench, rotate the axle
assembly on the nut of the fabricated plate. The
correct force to rotate the axle on the the swivel,
after initial breakaway, should be between
30--32Kgm.
NOTE: The steering cylinders should be disconnected,
the wheels off and the weight pack removed.

11
5. If the force required is incorrect adjust the shims (1)
to obtain the correct value. Shims are available
between 1.05mm and 1.90mm in increments of
0.05mm.
Increasing the shim thickness will decrease the
force required to rotate the axle assembly.
NOTE: If the correct value cannot be obtained with
equal size shims on each side, it is acceptable to raise
or lower one side by one shim increment to obtain the
correct value.

12
6. When the correct value is obtained remove the
fabricated tool and ensure the lower plate bolts are
correctly tightened to 373 Nm (275 [Link].).

25- 23
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
HUB CASSETTE SEALS -- ALL AXLE TYPES

Removal/Installation
1. Jack up tractor, support the front axle and remove
road wheel.
2. Position hub filler/drain plug at lowest point and
drain oil from hub.

13
3. Remove planetary carrier retaining bolts.
4. Using slide hammer remove planetary carrier from 1 2
hub.

25594

14
5. Remove the retaining ring and sun gear.
1 2

25595

15
6. Release the locking tab on ring gear locking nut.
IMPORTANT: Ensure the locking tab is fully released, 1 2
otherwise damage to the thread will occur when
removing nut.

25597

25- 24
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
7. Remove the ring gear locking nut using special
New Holland socket 1
Class 2 and 3 axles Tool No. 293880
Class 4 axles Tool No. 293881

25598

17
8. Remove ring gear and wheel hub.
1 2

25599

18
9. Remove seal using suitable extracting tool.

19
10. Position new seal onto seal installer.
Class 2 and 3 axles Tool No. NH.25--100
Class 4 axles Tool No. NH.25--101
Ensure seal is positioned on tool with spiral ring
visible.

25- 25
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
11. Position tool and seal over splines of swivel
housing and gently slide tool forward until seal
locates in housing.

21
12. Position a suitable tube on end of seal installer and
using soft faced hammer, drive seal into housing.
The seal installer is designed to accurately position
the seal in the housing at the correct depth.
NOTE: On class 2 and 3 axles the special socket can
be used when driving in seal. The tool will not be
damaged providing soft faced hammer is used.

22
13. Re-assemble hub using disassembly procedure in
reverse.
14. Install ring gear and locking nut.
Before installing locking nut, ensure there is no
swarf in threads on the nut or hub.
If locking nut threads are damaged install a new
nut, otherwise damage to the thread on the hub will
occur when tightening the nut.
Replacement ring gear locking nuts are available
under the following Part Numbers:
Class 2 and 3 axles Tool No. 5142020
Class 4 axles Tool No. 5141692

25- 26
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
15. Tighten ring gear locking nut to correct torque:
Class 3 axles 392 Nm
Class 4 axles 490 Nm
While tightening the nut, continue turning the wheel
hub to ensure the bearings are seated.

24
16. Deform the locking tab on the end of the nut and
check that the hub turns without binding.
1 2

25597

25
17. Prior to installation of the planetary cover,
thoroughly clean the mating surfaces and apply a
2 mm bead of flexible sealing gasket New Holland
Part No. 88299571.
18. Refill hub with oil to specification NH410B (AMBRA
MULTI G).

25- 27
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
FRONT AXLE OVERHAUL -- ALL OPTIONS
1. Unscrew plug (1) and drain off the oil from the axle
casing.

1
25588

27
2. Unscrew plug (1) on the left-hand epicyclic final
drive casing and drain the oil; repeat the same 1
operation on the right-hand casing.

25589

28
3. Remove the rear support (1) of the front axle;
remove the front support and retrieve the washer. 1

25590

29
4. Unscrew the two track rod retaining bolts (1).
1

25591

25- 28
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
Prior to removal of the track rod ensure that the hubs
will not rotate on their swivels, causing the axle to fall
from its stand.
5. Using a removal tool, withdraw the pins from their
bores in the stub axle housing, and remove the
track rod.

31
6. Remove the circlips (2) from the cylinder rod pivot
pins, unscrew the pin retaining bolts of the cylinder
(1), withdraw the pins and detach the two cylinders.
1 2
Recover the four pins, washers, spacers and
cylinders complete with hoses.

25593

32
7. Unscrew the retaining bolts of the left--hand final
drive casing cover (1). Screw in the two studs
292888 (2) and, using a slide hammer screwed into
1 2
the oil drain plug, detach the cover (1) from the
casing.

25594

33
8. Remove the outer circlip (1) securing the driving
gear (2) and remove the gear.
1 2

25595

25- 29
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
9. Remove the inner circlip (1).
1

25596

35
NOTE: If desired it is possible to remove the hub and
swivel housing together, without the need to remove
1 2
the wheel hub bearing lock nut.
10. Remove the staking (1) on the wheel hub bearing
lock nut (2).

25597

36
11. Remove the wheel hub bearing lock nut using
special tool 293880, for class III axles and special 1
tool 293881 for class IV axles.

25598

37
12. Remove the wheel hub (1) with the ring gear (2).
1 2

25599

25- 30
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
13. Unscrew the three retaining bolts (1) of the lower
pin of the stub axle housing. Recover the lower
pivot pin and the adjustment shims.
1

39
14. Unscrew the four retaining bolts (1) of the
mudguard bracket (2) and remove the bracket.

40
15. If fitted, remove the sensor pin retaining screw (1)
and remove the sensor pin (2) from the swivel pin.

41
16. Unscrew the three retaining bolts of the upper pivot
pin.
2
17. Withdraw the upper pivot pin (1) and detach the 1
stub axle housing (2).
18. If fitted and if necessary, remove the steering angle
sensor from the casing. Using a pair of long nosed
pliers pull out the red locking tab from the centre of
the connector, then using a small screwdriver or
pointed instrument, remove each pin from the plug
and slide the protective conduit off the wire.

25- 31
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
19. Remove as much sealant as possible from around
the potentiometer and wires from the axle casing.
1 2
Remove the remainder of the sealant from the axle
and clean.
20. Unscrew the retaining bolt (2) of the axle shaft (1).

43
21. Remove the axle shaft from the casing.
22. To disassemble the right--hand final drive unit,
follow the same procedure as the left hand final
drive unit.

44
23. Unscrew two of the bolts fixing the bevel
drive--differential support to the axle casing. Screw
in the two dowels 292888 (1). Supersteer Axles
1 2 3
require larger diameter dowels. These can be
manufactured from two M16 x 1.5 mm bolts.
Remove the remaining bolts and separate the
differential support from the axle casing. Attach a
hoist (2) to the support and remove the differential
support (3) from the axle casing.

25606

45
24. Install tool 293743 (1) in the vice on the work
bench. Bolt the differential support on to the tool 1
detach the lifting hoist.
2
The Supersteer Axle requires a new plate to be
manufactured to secure the unit in the vice.
25. Unscrew bolt (2) and remove the ring nut lock tab
3
(3). Remove the internal diff. lock control pipe.

25607

25- 32
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
The Supersteer Axle requires a new plate to be
manufactured to secure the unit in the vice, see
Special Tools, page 5 Figure 3.

25- 33
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
DOG CLUTCH DIFFERENTIAL LOCK
DISASSEMBLY/REASSEMBLY
26. Remove the two bolts securing the external bell
housing (1) of the diff. lock, and fit in their place two
bolts with minimum length 70 mm. Gradually
unscrew the four remaining bolts from the external
bell housing of the diff. lock so as to allow the diff.
lock release spring to gradually extend.
NOTE: It is necessary to fit two bolts because the
normal bell housing bolts are not sufficiently long to
allow the spring to extend to its full free length.

48
27. Unscrew the last two 70 mm bolts. Remove the bell
housing (1), the helical spring (2) and the diff. lock 1 2
piston.

25609

49
28. Remove circlip (2) and remove the diff. lock sleeve.
1 2

25610

50
29. Remove the circlip securing the diff. lock piston,
and recover the sliding sleeve with the two thrust
washers.

25- 34
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
30. Gently tap the piston out of the clutch bell housing.

52
1. Differential assembly
2. Shim (Backlash)
3. Circlip
4. Dog clutch
5. Lock ring

53
1. Dog clutch
2. Thrust washer
3. Return spring
4. Piston ‘O’ rings ×2
5. Hub
6. Lock ring
7. Circlip

25- 35
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
MULTI--PLATE DIFFERENTIAL LOCK
CLUTCH -- DISASSEMBLY/REASSEMBLY

Overhaul (Op. 25 104 34)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

With the pinion and crown wheel carrier placed on the

fixture tool no. 293743.
Proceed as follows:
1. Remove the retaining ring (3), bell housing (2),
4
clutch disc (4) hub retaining ring (1).

25819

1
2. Remove the circlip (1), disassemble the reaction
ring (2) along with the clutch discs (3) and clutch
disc hub (4).

2
3. Remove the thrust washer (1), washer (2) and
release bearing (3).

25- 36
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
4. Blow compressed air into the oil inlet fitting and
drive out the diff. clutch lock piston (1).

4
5. Remove the attaching bolts (1) and diff. lock
support plate (2). Retrieve oil seal.
6. Check all hydraulic cylinder sliding surfaces are
free from scuffs and in perfectly good condition.
7. Check clutch discs for abnormal wear or
imperfections. Replace if damaged.
8. Reinstall the differential lock assembly observing
the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 5 back to step
1.
-- Refer to figures on page 7 for correct
orientation of the different parts.
5
-- Check seals and replace if damaged.
-- Tighten to correct torques as detailed on page
3.

25- 37
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
CROWN WHEEL DIFFERENTIAL --
DISASSEMBLY/REASSEMBLY -- ALL 1 2
OPTIONS
1. Remove the crown wheel-differential assembly (2)
from the housing (1).

25613

6
DIFFERENTIAL COMPONENT DRAWINGS --
DOG CLUTCH

1. Differential assembly
2. Bearing Cup
3. Adjuster Ring
4. Support Cup

7
DIFFERENTIAL GEAR SET UP
In case of differential assembly overhaul it is necessary
to adjust the backlash between the teeth of the planet
pinions and side gears.
Proceed as follows:
1. Thoroughly clean the components of the
differential to remove any traces of oil which would
otherwise prevent accurate backlash
measurement.
2. Install the two side gears without thrust washers.
3. Fit the planet gears complete with thrust washers
and pins and screw the pin retaining bolts in by a
few turns to hold the pins in place.
8
4. Position a dial gauge on the differential housing.
5. Move the left--hand the side gear to bring it into full
contact with the planet pinion and then push it up
against the differential housing, reading the
endfloat (Gs) on the dial gauge.

25- 38
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
6. Repeat the above operations to measure the
endfloat on the right--hand side gear (Gd).
The endfloat should be 0.25 mm.
Therefore the shims to be inserted in the
differential housing are given by:
S L.H. = Gs -- 0.25 mm for the left--hand side gear;
S L.H. = Gd -- 0.25 mm for the right--hand side gear.
7. Install shims as near as possible to the calculated
value, and, using a dial gauge and following the
procedure described above, check that the
endfloat of the left and right--hand side gears is
approximately 0.25 mm.
9
PINION SHAFT ADJUSTMENTS
1. This is the same procedure for all differential
options. See Pinion Shaft Adjustment Section.

PINION SHAFT REMOVAL -- ALL OPTIONS

1. Straighten the locking tab on the splined shaft lock 1
nut (1).

10
2. To loosen the pinion nut it is necessary to
manufacture a tool to hold the pinion shaft. This 1 2
can be manufactured by welding a suitable 20 mm
nut to the end of a drive shaft coupling 81873108.

Locally Manufactured Pinion Shaft Tool

1. Coupler Part No 81873108
2. 20 mm Nut

25- 39
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
3. Supersteer and Suspended Axle Pinion nut
removal. Prevent rotation with suitable lever
(protect threads).

12
4. Unscrew the nut using wrench 293878 class III
axles or tool 293879 class IV axles, (1) while
1
holding the bevel drive pinion shaft against rotation
with the locally fabricated tool.

13
5. Remove the locking ball from the sleeve.
NOTE: Not applicable for Supersteer or Suspended
Axle Assemblies.

14
6. Withdraw the pinion shaft (1) from the rear of the
casing and remove the spacer, the adjustment
1
shims and the bearing.

25- 40
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
7. Remove the dust seal, the oil seal (1) and the rear
bearing. 1

25- 41
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
PINION SHAFT ADJUSTMENTS
INSTALLATION -- ALL OPTIONS

Pinion Bearing Preload Shimming

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

Proceed as follows.
1. Remove bearing from pinion.
2. Clamp tool 293391 (293438 for Class IV axles), (1)
in the vice, fit the inner races of the bearings (2 and
4) and the bearing spacer (3) and secure the nut on
the tool.

17
NOTE: The pinion of all the supersteer/suspended
assembly is shorter and tool 293391 and 293438
requires a spacer to be inserted under the lower
bearing (4). The spacer can be manufactured locally
using the dimensions shown in Figure 5, page 5, under
Special Tools.

18
3. Using a depth micrometer, measure distance (H1)
between the upper surface of the tool and the 1
7.5 = H1
central threaded pin of tool 293391/293438 (1).
4. Disassemble the above parts, lubricate the
bearings with oil and then re--assemble the parts,
excluding the bearing spacer, in the differential 2
housing. Hold the differential housing in the vice
using tool 293743, not applicable to
3
Supersteer/Suspended axles.
4

25- 42
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
5. Tighten a nut of tool 293391/293438 (1), while
turning the tool to ensure that the bearings are 1
seated correctly. H2
6. Install spacer for supersteer suspended axle.
7. Using a depth micrometer, measure distance (H2).
8. The thickness of the adjustment shim required is
calculated by:
Shim S1 = H2 -- H1 + 0.05 mm
If necessary, round the value thus obtained up to the
nearest 0.05 mm.
Leave tool in differential housing for pinion depth
measurement. 1

20
Pinion To Crown Wheel Shimming Procedure
The pinion to crown wheel shimming procedure
calculates the thickness of shims S2, positioned
beneath the shoulder of the pinion gear to ensure that
the theoretical conical point of the pinion aligns with the
centre of the differential crown wheel.

Pinion Shimming Dimensions

H4 Dimension from Pinion Bearing to Centre line
of Differential Casing
H3 115 mm Manufacturers Pinion DimensionC
(Correction Factor) or 122.5 mm ±C for class IV
axles
S2 Shim Thickness 21
The dimension H4 necessary in the calculation of the
shim thickness can be determined using either New
Holland pinion adjustment tool 293400 or VL Churchill
tool FT3135.
Both procedures are explained as follows.

Pinion Shimming using New Holland Pinion

Adjustment Tool 293400
1. Install pinion bearings in differential support
housing and clamp in position using New Holland 1 2
Tool No 293391/293438 as used when
determining thickness of shims for bearing
preload.

1. Pinion Measuring Gauge Tool No 293400

2. Pinion Bearing Clamp. Use Tool No 293391/293438 or
alternative clamp 50048 as shown
3. Pinion Bearings
4. Micrometer (Part of Tool No 293400)
4 3
22

25- 43
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
2. Install New Holland Pinion Setting Tool No 293400
complete with bearing cup and adjusting rings.
Tighten bearing caps to 113 Nm (83 lbf).
If New Holland Tool No 293391 as described in
pinion bearing shimming procedure is not available
the Bearing Clamp Tool No 50048 may be used to
clamp the bearings.
3. Adjust the cones of the tool so that the depth
micrometer tip touches the inner race of the
bearing and measure the dimension (H4).

23
4. Determine the thickness of shims to be installed
beneath the pinion gear as follows:
Shim thickness S2 = H4--H3
Where:--
H4 = Dimension measured using pinion
micrometer tool
H3 = 115 mm±C
115 mm is the nominal manufacturing dimension
from rear face of pinion gear to conical point of
pinion. (Supplied by Manufacturer)
C = Manufacturing correction factor stamped on
face of pinion. 1
Example H4 = 118.27
C = +0.1 mm
H3 = 115 + 0.1
= 115.1 mm 7 +0.1
S2 = H4 --H3
= 118.27 -- 115.1
Shim Thickness S2 = 3.17 mm

25- 44
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
Pinion Shimming using VL Churchill Tools
FT.3135
1. Install bearing caps (less bearing cup) and tighten
to a torque of 113 Nm (83 lbf).
2. Measure internal dimension of bearing bore and
call this dimension ‘A’.

25
3. Install pinion bearings in the differential support
housing and clamp in position with Tool No FT
3135.
NOTE: Tighten the clamp so that the bearing cones
can just be turned by hand.
4. Locate the bar gauge, part of Tool No FT3135, H4
across bearing bore and measure dimension ‘B’.
1. Depth Gauge
2. Bar Gauge -- Part Of Tool No FT.3135
3. Pinion Shaft Bearings
4. Pinion Setting Gauge -- Tool No FT.3135
5. Differential; Support Casing

26
5. Calculate Dimension ‘H4’ using Formula
H4 = B -- 25* + A
2
NOTE: *FT 3135 Bar Gauge is 25 mm diameter.
6. Determine the thickness of shims S2 to be installed
beneath the pinion gear as follows:
S2 = H4 -- H3
Where:--
H4 = Dimension Calculated in Step 5 above.
H3 = 115 mm ±C
115 mm is the nominal manufacturing dimension
from rear face of pinion gear to conical point of
pinion. (Supplied by Manufacturer)
C = Manufacturing correction factor stamped on
face of pinion.
Example A = 95 mm
B = 95.77 mm
H4 = B --25* + A
2
H4 = 95.77--25* + 95
2
H4 = 118.27
C = 0.1 mm
H3 = 15 + 0.1
= 115.1
Shim Thickness S2 = 118.27 -- 115.1
= 3.17 mm

25- 45
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
Pinion Shim and Bearing Installation
1. Install shim selected in pinion to crown wheel
shimming procedure between pinion head and
bearing. Ensure the chamfer on the shim faces
towards the pinion head.

27
2. Install bearing onto pinion

28
NOTE: The use of a electronic induction heater will
assist in the installation of the bearings without the
need for a press.

25- 46
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
Pinion Bearing Preload Rolling Torque
The pinion bearing preload is measured as the torque
or force required to rotate the pinion. The shim selected
in the Pinion Bearing preload shim adjustment
procedure on page 37 ensures that the correct preload
is achieved when the pinion nut is tightened to a torque
of 294 Nm (217 lbf ft).
NOTE: If the special tool required to determine the
thickness of preload shim is not available install the
same shim as removed during disassembly.
1. Install the inner pinion bearing onto the pinion and
locate the pinion into the differential carrier. Hold
the pinion in position with a universal puller.
30
2. Install the spacer and shims onto the pinion shaft.
Lubricate and install the pinion outer bearing.

1 2 3 4

5
16

14 13 12 11 10 9 8

32
Drive Pinion Components (Standard Steer Axle)
1. Shim 5. Nut 9. Sleeve 13. Shim
2. Bearing 6. Dust Cap 10. Bearing 14. Spacer
3. Bearing Cup 7. Seal 11. Bearing Cup 15. ‘O’ Ring
4. Housing 8. Ball (N/A Supersteer) 12. Shim 16. Pinion

25- 47
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

33
Suspended and Supersteer Pinion Components
1. Pinion 7. Coupling
2. Pinion depth shim 8. Dust shield
3. Bearing 9. Seal
4. Spacer 10. O-ring
5. Shim 11. O-ring carrier
6. Nut 12. Bearing

25- 48
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
3. Install the sleeve. ball and pinion nut. Do not install
the ‘O’ ring, oil seal and dust shield at this stage.
4. Tighten the pinion nut to a torque of 294 Nm
(217 lbf ft).

34
5. Screw an M12 bolt into end of the pinion shaft or
use the locally fabricated pinion holding tool. Using
a suitable low value torque meter measure the
rolling torque of the pinion A1.
The rolling torque should be 0.5--1.0 Nm
(4.5--8.5 lbf in) excluding breakaway torque.
6. If the values recorded during the adjustment
procedure are outside the specification adjust the
thickness of shim and recheck bearing preload.

35
7. When the correct shim thickness has been
established remove the pinion nut, sleeve and ball
and install the ‘O’ ring and pinion oil seal.
8. Carefully reinstall the sleeve, ball and pinion nut.
NOTE: Attempting to fit the oil seal with the sleeve
installed may damage the oil seal lip.
9. Tighten the pinion nut to a torque of 294 Nm
(217 lbf ft) and deform the locking tab.
Measure and record the pinion and seals
rolling resistance A1.

25- 49
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
CROWN WHEEL ADJUSTMENTS -- ALL OPTIONS

Adjustment of the crown wheel bearings and the

backlash between the pinion and crown wheel

Hydraulic Dog Clutch

1. Install the differential assembly complete with
crown wheel and inner crown wheel bearing rings
in the differential housing.

36
2. Insert the outer bearing rings in the differential
housing, fit the differential support caps, ensuring
correct orientation of the threaded adjustment ring
(3), smooth edge facing outwards. Tighten the
bolts to a torque of 59 Nm, then slacken them off
and re--tighten to a torque of 20 Nm.

37
3. Measure the thickness SP the adjustment shim (2)
which was previously removed during the axle
overhaul procedure. Refit the shim and circlip.

38
4. With the bearings lubricated, rotate the crown
wheel and at the same time tighten the threaded
adjustment ring using wrench 293665 to a torque
of 39 -- 59 Nm to take up the axial play between the
components.

25- 50
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
5. Measure the backlash between pinion and crown
wheel, using a dial gauge perpendicular to the
outer edge of a tooth on the crown wheel.
6. Repeat the measurement in a further two positions
120° apart and compare the average of the three
values (Gm) with the specification backlash:
0.15--0.20 mm, with an average of 0.18 mm.

40
If the measured backlash exceeds the
prescribed value, fit a thinner adjustment shim.
The thickness of the adjustment shim to be fitted in the
differential housing is given by:
Shim S = Sp -- {(Gm -- 0.18 ) x 1.35}
where:
Sp = thickness of test shim installed in the differential
housing. i.e. original shim used as a test shim.
Gm = average backlash measured between the pinion
and crown wheel
If the backlash measured is less than the
prescribed value, fit a thicker adjustment shim,
the value being given by: 41
Shim S = Sp + {( 0.18 -- Gm) x 1.35}
Recheck the backlash and adjust shim if necessary.

DIFFERENTIAL BEARING PRELOAD -- ALL

OPTIONS
The differential bearing preload is checked by
measuring the combined rolling torque of the crown
wheel and pinion assembly and comparing it to the
pinion and seals rolling torque value.
1. Attach a torque meter to the pinion shaft and
measure the rolling torque to rotate the pinion and
crown wheel A2.

25- 51
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
2. Subtract from the rolling torque reading A2
described above, the pinion only rolling torque A1.
1 2
The difference between the two values should be
1 to 1.5 Nm, (9 -- 13 lbf in).
3. If the rolling torque of the pinion and differential
assembly is not to specification adjust the ring
3
‘opposite’ the crown wheel to increase or reduce
differential bearing preload. Recheck the rolling
torque as detailed above.
Refit the lock tabs to secure the adjusting ring(s).

43
EXAMPLE
Rolling torque of Pinion and Differential
A2 = 2.1 Nm (19 lbf in)
Rolling torque of Pinion
A1 = 0.7 Nm (6 lbf in)
Calculated Rolling Torque of Differential
= 2.1 -- 0.7 Nm (19 -- 6 lbf in)
=1.4 Nm (13 lbf in)

25- 52
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
SWIVEL PIN AND POTENTIOMETER
DISASSEMBLY/REASSEMBLY

STEERING SWIVEL PINS AND BEARINGS

Replacement (Op. 25 108 46 or 25 108 47)

In the event that the steering swivel pins prove difficult
to remove, proceed as follows.
1. Remove the grease nipples and the steering swivel
pin retaining bolts.
2. Fit the bolts (1) of tool 293857.
3. Fit the plate (2) of the tool and fix it to the three bolts
with nuts (5).
4. Fit the central tie bolt (4) screwing it fully into the
grease nipple bore on the pin (6).
5. Screw in the nut (3) to drive the pin out of its bore.

1
6. Using extractor tool 292161 (1) remove the
steering swivel bearings.
1
7. Re--install the steering swivel bearings using a
suitable drift.

25- 53
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
STUB AXLE ADJUSTMENT
WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

Install the front axle on stand 293460 and proceed as

follows.
1. Smear grease AMBRA GR 75MD on the outer
races of the bearings and fit the upper cover,
without the shims, and with tool 292220 (2) 1 2
attached. Tighten the retaining bolts.
NOTE: To facilitate installation of the swivel pin, we
recommend that guide 293889 (1) is installed on the
axle shaft.

3
2. Fit the lower cover without shims, lubricate the
three retaining bolts with engine oil.
3. Gradually,tighten the lower cover bolts equally
whilst rotating the casing to allow the excess
grease to escape.

25- 54
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
4. Using a torque wrench and tool 292220 (1), check
that the torque required to rotate the casing is 15 1
-- 25 Nm. Adjust the three lower bolts until the
correct torque is achieved.
5. Measure the gap (H) created between the lower
cover and the casing in three places.

5
6. Calculate the average of the three values
measured. The total thickness of the adjustment
shims to be fitted under the lower cover is Shim
S3= H -- 0.20 mm .
If necessary, round up the value to the next 0.05
mm.
7. Insert shims under lower swivel cover. Torque to
113 Nm.

8. After having rotated the casing a few times to allow

the components to bed down, check that the torque
necessary to rotate the casing is 118 -- 147 Nm.
9. If the torque value measured is greater than the
prescribed value, increase the thickness of the
shims, if it is less than the prescribed value, reduce
the thickness of the shims.
10. Remove tool 292220, fit the grease nipples in the
upper and lower covers and grease the assembly.

25- 55
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
STEERING ANGLE POTENTIOMETER
REPLACEMENT
-- Feed the new wires of the potentiometer
through the front axle and install the
potentiometer ensuring that it is correctly
located on the pins. Apply setting silicone
around the potentiometer and along the wires
where it contacts the axle beam.
-- Fit the stub axle, the adjustment shims, the
upper and lower pivot pins.
-- Position the wheels in the straight ahead
position. Install the potentiometer drive pin
carefully into the top swivel until it locates in the
‘D’ section of the potentiometer. When the pin 7
locates it will be approximately 45 degrees
from the fixing hole screw. Rotate the pin
against spring pressure to enable the retaining
screw to be installed.
NOTE: Calibration of the steering angle sensor must
then be carried out using the procedure described in
Section 55, Chapter 2.

25- 56
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
AXLE COMPONENT REASSEMBLY -- ALL
OPTIONS
Refit the differential assembly to the axle casing after
having carefully cleaned and degreased the mating
surfaces and applied a bead of gasket sealer approx.
2mm wide along the line shown in the figure below.

9
-- Install the axle shafts and securing bolt.
-- Fit the wheel hub, the ring gear of the final drive
unit and the lock ring and tighten to the
prescribed torque value, whilst turning the
wheel hub to ensure that the bearings are
correctly seated.
NOTE: It is recommended that a new lock ring is
installed and the stub axle thread cleaned before
installation.
-- Fit the securing and stop circlips, the driving
gear and the cover of the final drive unit.
-- Fit the pins, washers, spacers and steering
cylinders.
-- Fit the track rod, the front and rear supports 10
and the oil drain plugs.
-- Refill with oil.

Gasket sealer application diagram for assembly

of bevel drive unit and epicyclic final drive unit.
The types of gasket sealer to use are listed in Section
00.

25- 57
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
CHECKING THE ALIGNMENT OF
STEERING--DRIVE WHEELS (Op. 44 511 80)
When travelling forward in a straight path, the wheels
of four--wheel drive tractors must be parallel to the
longitudinal axis of the tractor, alternatively a slight
toe--in of the front wheels is permissible up to a
maximum of 6 mm as measured at the edges of the
wheel rims.
To check the exact value of the toe--in setting of
four--wheel drive tractors, proceed as follows.
1. Inflate the front tyres to the prescribed pressure.
2. Position the steering at half--lock with a
straight--edge along the longitudinal axis of the
tractor.
3. Check that the wheels are parallel to the
longitudinal axis of the tractor.
4. Measure the distance (1) between the front
inside edges of the wheel rims, at the height of the
wheel hub centres.
5. Turn both front wheels through 180o then measure,
again at the height of the wheel hub centres, the
distance (2) between the rear inside edges of the 1
wheel rims, checking that this new measurement
is equal to or greater than the distance (1) by a
maximum or 6 mm. The rotation of the wheels
through 180o is necessary to eliminate the effect on 2
the measurement of any wear of the rims.

1
6. If it is necessary to correct the wheel alignment,
remove nut (2) and pull the track rod end (1) out of 1
its housing. Slacken off locknut (3) and screw the
track rod end (1) in or out to increase or decrease
the distance (2, fig. 1).
Reposition the track rod end (1) in its housing and
re--check alignment as described in points 4 and 5.
After having adjusted the alignment to within the
prescribed limits, tighten locknut (3) to a torque of
180 Nm (183 kgm) and nut (2) to 100 Nm
(10.2 kgm).
3 2
NOTE: Self--locking nut (2) must be renewed each time
24667
it is removed or partially unscrewed.
2

25- 58
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
SECTION 25 -- FRONT AXLE

Chapter 2 -- Terraglide (Front Axle Suspension)

CONTENTS

Section Description Page

25 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 000 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 000 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Block Component Locations / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Terraglide Operation -- Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terraglide Operation -- Axle Levelling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
25 000 Automatic Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
25 000 Error Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
25 000 Error Code retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
25 000 Clearing Stored Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
25 000 H9--Vehicle Sensor and Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
25 000 Error Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
25 100 Suspended Front Axle Assembly--Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 62
25 100 Suspension Cylinder Removal and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
25 000 Suspension Control Valve Assembly--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

25- 1
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
23 000 -- SPECIFICATIONS
System Relief Valve (Rod End) 210bar
System Relief Valve (Piston End) 210bar
Shock Valve (30bar differential pressure)

23 000 -- TIGHTENING TORQUES

25- 2
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
23 000 -- DESCRIPTION AND OPERATION

2
Terraglide Front Suspension System
1. Suspension/Damping Cylinder 4. Lockout/Suspension Activation Switch
2. Control Valve Assembly 5. Suspension Arm
3. Microprocessor 6. Panhard Rod

INTRODUCTION
Terraglide is an optional electronically controlled conditions could make the tractor unstable. This is
hydraulic suspension feature fitted to the front axle especially important where the tractor is operating with
which allows the axle to raise and lower to absorb minimal front axle loads while transporting heavy 3
shock loads and maintain the tractor in a level plane point hitch implements.
when variations in weight are applied to the front Terraglide is automatically engaged each time the
wheels. tractor is started however when the tractor is
The Terraglide system reduces pitching, keeps the stationary or travelling at less than 1.5kmh the
front wheels in contact with the ground and improves system is automatically ‘‘Locked Out’’ for safe
stability during fast road speeds when ground mounting of implements or ballast.

25- 3
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
At speeds between 1.5--12kmh the operator can turn
the suspension off using the switch (1) on the cab pillar.
This is ideal for instances where accurate depth control
is required with implements mounted on the front
linkage or for grading with a front loader.
At speeds above 12kmh the system is automatically
engaged.

3
The control valve assembly which supply oil to the
Terraglide suspension/damping system is located on
the right hand side of the transmission.

4
The microprocessor which electronically controls the
hydraulic control valve is located beneath the
electronic draft control panel on the right hand side of
the operator.
On tractors with Power Command transmissions the
microprocessor controls only the Terraglide system,
however on tractors with Range Command
transmissions the microprocessor also contains the
software which controls the Electronic Draft Control
System.

5
To assist in diagnosing faults and achieving optimum
performance the microprocessor has an inbuilt self
diagnostic facility and electronic calibration procedure.
All information regarding error codes and calibration
data is displayed on the electronic instrument cluster.
Full details on error codes and calibration procedures
are described later in this Chapter.

25- 4
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

6
Front Axle Installation--Terraglide Suspension
1. Front Support 5. Potentiometer
2. Hydraulic Cylinder 6. Pivot Arm (Panhard Rod)
3. Axle 7. Fulcrum Point
4. Axle Pivot Point
The Terraglide suspension system connects the axle The vertical movement of the axle in relation to the
(3) to the tractor front support (1) through a pivot arm front support is measured by the potentiometer (5)
(4) referred to as a “Panhard Rod” and the single which transmits a signal to the controlling
hydraulic cylinder (2). microprocessor.
Whenever the front axle is subjected to shock loads, Dependant on the shock loading subjected to the
vibration or front end weight changes the Panhard rod system and the amount of vertical axle movement
pivots about the fulcrum point (7) while at the same detected by the microprocessor the hydraulic system
time the axle oscillates about the pivot point (4). This responds to absorb the shock loads and adjust the
movement causes the front axle to move up or down vertical position of the axle so that the tractor continues
in relation to the tractor front support. to operate on a level plane.

25- 5
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Hydraulic Control System
The hydraulic control system can be considered as two The potentiometer (5) Figure 6 measures the vertical
separate systems. position of the front axle in relation to the front support
A Ride Control System and is linked to the microprocessor. Whenever the
microprocessor detects that the vertical height of the
B Levelling System
axle in relation to the front support is away from the
The “Ride Control System” controls the suspension operating parameters set within the software in the
damping and absorbs shock loads from the front axle microprocessor, hydraulic oil is directed through the
when the tractor is being driven over rough surfaces. control valve to the hydraulic cylinder to adjust the
The “Levelling System” controls the height of the front height of the axle accordingly.
axle in order to maintain that the tractor operates on a NOTE: Ride control and the levelling system only
level plane by compensating for:-- operate when the Terraglide suspension is switched on
The addition or removal of weight from the tractor. and the tractor is being driven at speeds above 1,5kph.
Loss of cylinder oil to the reservoir through the Operation of the Terraglide system for various working
system relief valve due to shock pressures above situations is described on the following pages.
210 bar in the system. The location of those specific components referenced
Internal or external system leakage. in the circuit diagrams which are externally visible on
the control valve are identified in Figure 9.

Terraglide Hydraulic Circuit

1 Raising Solenoid 16 Check Valve
2 Lowering Solenoid 16a Orifice
3 Shuttle Valve 18 Orifice
4 Pilot Operated Check Valve 19 Orifice
5 Pilot Operated Check Valve 24 Lockout Valve (Piston End)
6 Relief Valve 20bar 25 Shock Valve (30bar differential pressure)
7 System Relief Valve (Piston End) 210bar 26 Lockout Valve (Rod End)
8 Check Valve 28 Check Valve
9 Orifice 29 Check Valve
11 Check Valve 30 Latch Valve
12 Orifice 31 Latch Valve
13 Shock Valve (30bar differential pressure) 32 Pressure Compensated Flow Control Valve
14 Load Sensed Unload Valve 33 Pressure Compensated Flow Control Valve
15 Check Valve 34 System Relief Valve (Rod End) 210bar
15a Orifice 35 Check Valve

P To Piston End of Cylinder AP Piston End Accumaltor

R To Rod End of Cylinder AR Rod End Accumaltor

25- 6
A B

1
25 4 18

32 28

9 14
15a 15
3

16a 16

24 30

2
35 19

13
6

25- 7
5

26 31

11
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

BS B0670B

Terraglide Hydraulic Circuit 7

A. Ride Control System B. Levelling System

AP
29

1
4 18
25
P

32 28

9 14
15a 15
3

16a 16

24 30

2
35 19

R
13

6 5

25- 8
33

26 31
34

AR
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

BS B1141A

Terraglide Hydraulic Circuit (Engineering Schematic) 8

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

9
Hydraulic Control Valve Assembly
A. Load Sense Line C. Pump Pressure In
B. Return to Reservoir

1 Raising Solenoid 24 Lockout Valve (Piston End)

2 Lowering Solenoid 25 Shock Valve (30bar differential pressure)
4 Pilot Operated Check Valve 26 Lockout Valve (Rod End)
5 Pilot Operated Check Valve 30 Latch Valve
6 Relief Valve 20bar 31 Latch Valve
7 System Relief Valve (Piston End) 210bar 32 Pressure Compensated Flow Control Valve
13 Shock Valve (30bar differential pressure) 33 Pressure Compensated Flow Control Valve
14 Load Sensed Unload Valve 34 System Relief Valve (Rod End) 210bar

25- 9
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Terraglide Control System Switched OFF
When the Terraglide system is ‘OFF’ oil in the piston excess pressure to reservoir. Make up oil for the rod
end of the cylinder is trapped by the lockout valve (24) end of the cylinder is then supplied from the
and piston end relief valve (7). accumulator through the check valve (11).
Oil in the rod end of the cylinder is trapped by the The same principal is true for the rod end of the cylinder
lockout valve (26) and the rod end relief valve (34) with the relief valve (34) protecting the system and
Because there is no flow/pressure differential across make up oil being supplied by the piston end
orifice (9) the shock valve (25) remains closed and accumulator through the check valve (32).
check valve (8) is also closed. If oil continues to be lost through the system relief valve
Providing the axle is not subjected to a shock loading (7) the front of the tractor will lower until the reading on
e.g. the front wheel hits a large obstruction the system the potentiometer reaches the maximum limit allowed
relief valve (7) remains closed. by the processor. At this point the microprocessor will
direct oil through the control valve and into the front
If the front wheels hit a large obstruction causing
axle hydraulic cylinder piston end to raise the front of
pressure in the piston end of the cylinder to exceed
the tractor back to the specified operating band.
210bar the pressure relief valve will open venting the

25- 10
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Terraglide Control System Switched OFF 10

Trapped Oil Return To Reservoir

25- 11
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Operation Of Terraglide Ride Control
--Wheel Hits Small Bump
When the Terraglide system is ‘ON’ and tractor speed Because the raise accumulator has absorbed the oil
is above 1.5 kmh the lockout valves 24 and 26 are displaced from the piston end of the cylinder a
energised to allow oil flow through the valves. corresponding volume of oil must be added to the rod
NOTE: Check valves (4) and (5) in the levelling system end. This is supplied by the rod end accumulator which
circuit B, Figure 7, prevent oil flowing from the cylinder forces oil through the check valve (11) and into the rod
and back through the levelling system to reservoir. end of the cylinder.
When the tractor hits a small bump there is a Once over the bump the shock loaded pressure in the
corresponding increase in pressure in the piston end piston end of the cylinder reduces and oil is forced back
of the hydraulic cylinder as the shock load moves the by the diaphragm in the piston end accumulator past
ram upwards. At the same time there is a reduction in the check valve (8) and into the piston end of the
pressure on the rod end of the cylinder cylinder.
Oil displaced due to the increased pressure in the At the same time oil in the rod end of the cylinder is
piston end flows from the cylinder through orifice (9), forced back through orifice (12), lock out valve (26) and
the lockout valve (24) and the latch valve (30) to the latch valve (31) to the rod end accumulator to restore
raise accumulator. the balance between the piston and rod ends of the
cylinder.
Because the tractor has only hit a small bump the
differential pressure across the orifice (9) and shock This controlled flow of oil to and from either side of the
valve (25) is less than 30bar and insufficient to allow cylinder from the accumulators produces the damping
the valve to open. effect which absorbs the shock loads when the tractor
hits a small bump.

25- 12
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Operation of Terraglide Ride Control System--Wheel Hits Small Bump 11

Piston End OIl Rod End Oil

Reduced Pressure Piston End Return To Reservoir

25- 13
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Operation Of Terraglide Ride Control
--Wheel Hits Medium Size Bump
When the tractor hits a medium size bump oil pressure The accumulator absorbs the oil displaced from the
in the piston end of the hydraulic cylinder increases piston end of the cylinder and make up oil from the rod
quickly. end accumulator flows through the check valve (11)
Due to this rapid increase in pressure oil flows from the into the rod end of the cylinder.
cylinder through orifice (9), the lockout valve (24) and Once over the bump the shock loaded pressure in the
latch valve (30) to the piston end accumulator. piston end of the cylinder reduces and oil is fed back
Because the pressure rise in the cylinder is more rapid from the piston end accumulator past the check valve
than when the tractor hits a small bump the pressure (8) into the piston end of the cylinder.
differential across the orifice (9) and shock valve (25) Excess oil in the rod end of the cylinder returns through
is correspondingly larger. Under this condition the orifice (12) lock out valve (26) and latch valve (31) to
shock valve (25) opens allowing oil flow directly from the rod end accumulator to restore the balance
the piston end of the cylinder through the shock valve between the piston and rod ends of the cylinder and
to the piston end accumulator. absorb the shock loads.

25- 14
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Piston End Oil Rod End Oil

Reduced Pressure Piston Oil Return To Reservoir

25- 21
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Axle Levelling System 16

High Pressure Pump Oil Return To Reservoir

Trapped Oil

Axle Levelling System

When the height of the axle is within the required Oil from the piston and rod ends of the cylinder is
specification the raise (1) and lower (2) solenoids are trapped by the check valves (4) and (5).
not energised and high pressure system oil from the
hydraulic pump is prevented from flowing into the
Terraglide levelling circuit B.

25- 22
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Axle Levelling System ON--Lowering (Figure 1 off 2) 17

High Pressure Pump Oil Return To Reservoir

Trapped Oil

Axle Levelling System On The processor energises the lowering solenoid (2) and
Lowering pump oil at system pressure flows through the lowering
The height of the front axle in relation to the front solenoid and past the pilot check valve (5) to the rod
support is measured by the potentiometer and end of the cylinder.
monitored by the microprocessor. Oil also flows through check valve (16) to the load
When the Terraglide system is ‘ON’ and the sensed unload valve where it is dead headed.
microprocessor detects from the reading of the Piston end oil is prevented from returning to reservoir
potentiometer that the vertical position of the axle in by pilot check valve (4) and load sensed unload valve
relation to the front support is away from the required (14).
operating limits the axle levelling system is activated. The load sense line senses the pressure in the levelling
If the vertical position of the axle needs to be lowered system and applies the pressure to the shuttle valve
the following sequence of events takes place:-- (3), load sense unload valve (14) and the load sensing
circuit of the hydraulic pump.

25- 23
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Axle Levelling System ON--Lowering (Figure 2 off 2) 18

High Pressure Pump Oil Return To Reservoir

Discharge Oil

The load sensed signal opens the unload valve (14) cylinder being controlled by orifice (18) and gallery
allowing oil to flow through the valve to reservoir. within the raise solenoid (1) to reservoir.
Because oil can now flow to reservoir a pressure drop When the axle reaches the correct height as measured
is created across the orifices 15a and 16a which allows by the potentiometer (5) Figure 6, the lowering
the pilot check valves (4) and (5) to open. solenoid is switched OFF.
Oil, can now flow through the pilot check valve (4) from If the pressure in the rod end circuit exceeds 20bar the
the piston end of the cylinder, the rate of flow into the relief valve (6) will open venting the excess pressure oil
to reservoir.

25- 24
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Axle Levelling System ON--Raising 19

High Pressure Pump Oil Return To Reservoir

Discharge Oil (20 bar)

Axle Levelling System On

Raising
If the vertical position of the axle needs to be raised the Oil from the rod end of the cylinder flows through pilot
following sequence of events takes place. check valve (5) to check valve (35) and relief valve (6).
The raise solenoid (1) is energised and pump oil flows The relief valve opens when the back pressure in the
past check valve (28), through the raise solenoid (1), circuit reaches of 20bar and controls the flow of oil from
check valve (29) and pilot operated check valve (4) to the rod end of the cylinder back to reservoir thereby
the piston end of the cylinder. preventing cavitation within the system.

25- 25
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

NOTES

25- 26
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
AUTOMATIC CALIBRATION PROCEDURE
The suspension system must be calibrated when
either a new suspension valve, front axle
potentiometer or EDC/Suspension control module has
been fitted.
Depending on the type of failure to the suspension
system the automatic calibration procedure will have to
be repeated up to three times in order to vent all of the
air out of the hydraulics.
7. Disconnect all implements from the tractor.
8. Park the vehicle on level ground.
9. Move shuttle lever to neutral.
10. Stop engine
11. Engage handbrake
12. Connect Tool (1) No 295041 to the diagnostic
connector (black) located beneath electronic draft
control operator panel.

20
13. Turn key start switch to ON and start engine.
14. The instrument panel will display “HH” to indicate
that the menu has been activated.

21
15. Select “H1” by depressing the diagnostic tool
button once.

25- 27
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
16. The instrument panel EDC area will change and
display CAL.

23
NOTE: On tractors fitted with the analogue instrument
panel the information displayed is the same as that for
the electronic instrument panel but is displayed in the
upper right hand display as shown.

24
17. Set engine speed to 1200 erpm+/--50 erpm
18. Operate the Terraglide supspension lockout switch
3 times within a 4 second period.

25
19. The automatic calibration procedure will now
operate. “ACP” will be displayed and the light in the
suspension rocker switch will flash. The
suspension will immediately drop to the bottom of
travel.
NOTE: For safety reasons the ACP will only function
when the axle speed=0 kph. Check that the instrument
cluster is displaying the correct ground speed before
starting ACP.
WARNING
If the automatic calibration needs to be stopped press
the suspension rocker switch once.

25- 28
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
The ACP will activate the raise and unload levelling
valves until the front axle reaches the maximum
height for a period of 4 seconds. The hydraulic
pump will now reach ‘‘High Pressure Standby’’ and
the maximum value of the potentiometer is
displayed on the instrument panel and stored in the
processor.

27
ACP will now automatically activate the unload
levelling valve until the front axle reaches the
minimum height for a period of 4 seconds. Once
again the hydraulic pump will reach ‘‘High Pressure
Standby’’ and the minimum value of the
potentiometer is dispalyed on the instrument panel
and stored in the processor.

28
ACP will now automatically activate both the raise
and unload levelling valves until the front axle
reaches the nominal operating position.
The Automatic Calibration Procedure is now
complete and ‘‘END’’ is displayed on the
instrument cluster.

29
20. Set engine speed to low idle.
21. Turn OFF keystart switch to store calibration
values.
NOTE: If an error occurs in ACP mode a ‘‘U’’+ number
(ACP error code) will be displayed and the automatic
calibration procedure must be repeated.
NOTE: Refer to Error codes and Fault Finding for
further details.

25- 29
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
ERROR CODES AND FAULT FINDING
The Terraglide suspension system has an inbuilt self
diagnostic facility and uses the insrument cluster to
display the codes.
The suspension software provides two different types
of error codes:
‘‘U’’ Codes which are errors generated during the
Automatic Calibration Procedure ‘‘ACP’’

30
‘‘L’’ Codes which are related to the normal operational
checks on the valves and sensors of the Terraglide
suspension system.

31
ERROR CODES RETRIEVAL
A maximum of 10 Front suspension error codes can be
stored and are displayed in sequence with the most
recent displayed first
Error codes are retrieved using the Hb routine as
follows:--
1. Connect Tool No 295041 to the diagnostic
connector (black) located beneath Electronic Draft
Control operator panel.

32
2. Turn key start ON and instrument panel will display
“HH” to indicate that the “H” menu has been
activated.

25- 30
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
3. Repeatedly depress the button on the diagnostic
tool untill “Hb” is displayed.

34
4. If there are any error codes stored in the
microprocessor “Hb” will change to display the first
code.

35
5. To view the number of hours since the error last
occured press and hold the lockout/suspension
switch.

36
6. The EDC panel of the instrument cluster will:_
First display the number of hours since the error
last occured.

25- 31
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Then display the number of times the error has
occured.

38
7. To display the next error code momentarily press
the lockout/suspension switch.
8. Press and hold the switch to display the hours and
occurences for this error code

39
CLEARING STORED ERROR CODES
To clear stored error codes depress diagnostic switch
button until “HC” appears in the display.

40
The display will then change from “HC” to “EE” to “HH”
indicating that stored error codes have been cleared.
NOTE: “HC” will clear all types of error codes.

25- 32
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
H9-- VEHICLE SENSOR AND VOLTAGE
TESTS
The H9 diagnostic mode is a test routine to verify the
operating voltages of systems within the tractor.
The H9 menu system now incorporates channels to
enable those voltages applicable to the Terraglide
suspension system to be measured.
The following procedure describes the method for
using the Terraglide Suspension H9 channels and
should be used alongside the fault finding diagnostic
charts to help determine the cause of a failure.
1. Connect Tool No 295041 to the diagnostic
connector (black) located beneath Electronic Draft
Control operator panel. 42
2. Turn key start ON and instrument panel will display
“HH” to indicate that the “H” menu has been
activated.
3. Repeatedly depress the button on the diagnostic
tool untill “H9” is displayed.
4. After approximately four seconds the display will
change to “0”.

43
5. Repeatedly depress the lockout suspension switch
untill the required channel is displayed on the
instrument panel.

44
6. In Figure 45 Channel 39 has been selected.

25- 33
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
7. The channel number will then change and show, as
a percentage value, the voltage of the front axle
height potentiometer. Turning the potentiometer
through its full range of travel will cause the display
to show values of approximately 12 to 84 which
indicate that the potentiometer is operating
correctly.

46
H9 Channel Numbers

25- 34
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
ERROR CODE LISTING and FAULT FINDING
CHARTS
DANGER
The fault finding charts on the following pages describe
the procedure for identifying possible causes of
malfunction in the Terraglide suspension system.
Exercise extreme caution when working on the front
suspension system.
Where it is necessary to disconnect hydraulic pipework
or disassemble the suspension hydraulic control valve
assembly ALWAYS ensure that the suspension
system is depressurised and that the axle is resting on
the support stops. Refer to Page 69 for details on
depressurising the system.
Always ensure all personnel stand clear of the axle
when performing the auto calibration procedure.

25- 35
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
ERROR CODE LISTING

ERROR CODE ERROR DESCRIPTION PAGE

L01 LOCKOUT VALVE RAISING SOLENOID NOT WORKING 39
L02 RAISING SOLENOID NOT WORKING 39
L03 LOWERING SOLENOID NOT WORKING 39
L04 FRONT AXLE POTENTIOMETER RAISE VALUE IS 41
HIGHER THAN SET LIMIT
L05 FRONT AXLE POTENTIOMETER LOWER VALUE IS 41
LOWER THAN SET LIMIT
L06 THE SUSPENSION IS NOT CALIBRATED 43
L07 FRONT AXLE WEIGHT HAS BEEN REDUCED BUT THE 43
SUSPENSION IS UNABLE TO RESET NOMINAL HEIGHT
L08 FRONT AXLE WEIGHT HAS BEEN INCREASED BUT THE 43
SUSPENSION IS UNABLE TO RESET NOMINAL HEIGHT
L09 LOCKOUT VALVE LOWERING SOLENOID NOT WORKING 43

U01 FRONT AXLE POTENTIOMETER OPEN CIRCUIT 45

U02 FRONT AXLE POTENTIOMETER RAISE VALUE IS 47
HIGHER THAN SET LIMIT
U03 FRONT AXLE POTENTIOMETER SHORT CIRCUIT 49
U04 FRONT AXLE POTENTIOMETER LOWERING VALUE IS 49
LOWER THAN SET LIMIT
U05 SUSPENSION IS NOT REACHING ITS 51
MINIMUM/MAXIMUM POSITION DURING AUTO
CALIBRATION PROCEDURE
U06 NOT USED --
U07 SUSPENSION IS STATIONARY DURING THE RAISE 53
COMMAND IN THE AUTOCALIBRATION PROCEDURE
U08 SUSPENSION IS UNABLE TO REACH MAXIMUM HEIGHT 55
WITHIN 20 SECONDS
U09 SUSPENSION IS STATIONARY DURING THE LOWERING 57
COMMAND IN THE AUTOCALIBRATION PROCEDURE
U10 SUSPENSION UNABLE TO REACH MINIMUM HEIGHT 57
WITHIN 25 SECONDS
U11 UNABLE TO CALIBRATE SUSPENSION 59
U12 AUTO CALIBRATION PROCEDURE STOPPED BECAUSE 61
VEHICLE NOT STATIONARY

25- 36
25- 37
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Terraglide Suspension System Wiring Diagram 47

B34 Axle Height Sensor Y27 Suspension Lower Solenoid
H32 Front Suspension Engaged Lamp Y28 Suspension Lower Lockout Solenoid
S58 Suspension Switch Y29 Suspension Raise Lockout Solenoid
Y30 Suspension Raise Solenoid
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Codes L01, L02, L03,

25- 38
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Code L01 -- Lockout Valve Raising Solenoid Not Working

97mm

25- 40
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Code L04 -- Front Axle Potentiometer threshold is higher than set limit

Error Code L05 -- Front Axle Potentiometer threshold is lower than set limit
Key OFF
Key ON
Recheck
Perform the Auto Calibration
Procedure (ACP) and record the
higher and lower potentiometer
values displayed on the
instrument panel.
Are values greater than 970 and
less than 150?

Is length of potentiometer Adjust linkage and

linkage 97mm perform auto calibration
procedureI

Is potentiometer linkage Check for short and

damaged open circuits between
C253--1 and C127--5 Locate
C253--2 and C242--32 and repair
Repair C253--3 and C127--32? damage in
linkage/replace Check that connector harness
potentiometer located behind
Perform the Auto alternator is connected.
Calibration Procedure Is the wiring Okay?
(ACP)

Disconnect
potentiometer and enter
H9 Diagnostic Mode
Channel 39.
Turn potentiometer fully
clockwise and counter
clockwise. Does the
reading on instrument
panel change from
approximately 12 to 84?

Replace
potentiometer and
perform the Auto
Calibration
Procedure (ACP)

25- 41
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Codes L07, L08, L09

97mm

25- 42
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Code L06 -- The suspension is not calibrated

Key OFF
Key ON
Recheck
Perform the Auto Calibration
Procedure (ACP)

Error Code L07 -- Front Axle Weight has been reduced but the suspension is unable to
reset nominal height
Error Code L08 -- Front Axle Weight has been increased but the suspension is unable to
reset nominal height

Key OFF
Key ON
Perform the Auto Calibration Recheck
Procedure (ACP) and check for
error codes
Are their any “U” Error codes

Refer to “U” Error code fault

finding chart and check
potentiometer linkage

Error Code L09 -- Lockout Lower Solenoid Not Working

Key OFF
Key ON
Recheck
Is solenoid connected to harness
(connector C250 identified with Connect Solenoid
black band)?

Locate and
Is continuity of wiring harness
repair damage
between
in harness
C250--1 and C242--27
C250--2 and C242--23 okay?

Replace Solenoid

25- 43
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Codes U01

C253

3. 7570 B
2. 3120 O
1. 3220 O

25- 44
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Code U01 -- Front Axle Potentiometer Open Circuit

Key OFF
Key ON
Check for open circuits between Recheck
Locate and
C253--1 and C127--5
repair damage
C253--2 and C242--32
in harness
C253--3 and C127--32?
and check
Check that connector located
connector C001
behind alternator is connected

Enter diagnostic
Perform the Auto Calibration Procedure
mode H9 and
(ACP) and record the higher and lower
check values for
potentiometer values displayed on the
channel 5.
instrument panel.
Values away from
Are values less than 150?
specification?

Perform auto
calibration
procedure

25- 51
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Codes U07

25- 52
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Error Code U07 -- Suspension is stationary during the raise command in the auto
calibration procedure
Key OFF
Key ON
Recheck
Is raise solenoid connected to
harness (connector identified with Connect Solenoid
red band)?

Are tractor
hydraulic lift and Investigate high
remote valves pressure
operating hydraulic circuit
satisfactorily fault

Is the continuity of wiring harness Locate and

between repair damage
C251--1 and C242--28 in harness
C251--2 and C242--22 okay?

Is front axle, Disconnect Depressurise

Is front axle, hydraulic

cylinder or potentiometer
linkage damaged

Repair and Perform

the Auto Calibration
Procedure (ACP)

25- 59
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Error Codes U12

25- 60
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

Error Code U12 -- Autocalibration procedure stopped/vehicle not stationary

Key OFF
Key ON
Recheck

Has Handbrake been applied

Enter H9 diagnostic mode Check stored error codes

Channel 43. for a recent occurence of
Is wheel speed at 0 Mph? F49 or F50. Is either error
code displayed?

Refer to Section 21,

Transmissions, Chapter 2,
Range command, or
Chapter 6, Power
Command

Enter H9 diagnostic mode

Channel 20. Inspect the wiring to the
Is ground speed input speed sensor (C038) ,
value approximately 50? repair as necessary

Replace the rear axle

speed sensor on Range
Command tractors or the
transmission output speed
sensor on Power
Command tractors

25- 61
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
SUSPENDED FRONT AXLE ASSEMBLY
Removal -- Installation (Op.25 100.35)

DANGER
DO NOT remove any pipes from the suspension
cylinder or valve block unless the system has been
depressurised. The system remains under pressure
even when the tractor engine is off.
Lift and handle all heavy components using lifting
equipment of appropriate [Link] that units or
parts are supported by suitable slings or [Link]
that no--one is in the vicinity of the load to be lifted.

1. Open and raise the engine hood.

2. Detach the negative cable from the battery and
insulate.

1
3. Depressurise the suspension system. Locate the
screw of the load sense unload valve, on top of the
valve block and rotate clockwise, allow the tractor
to lower completely onto the stops then rotate the
screw anti--clockwise to return to normal operation.
NOTE: It is advisable to remove the hydraulic filter
located above the suspension valve block to gain
access to the depressurising screw.

2
4. If front ballast is fitted, thread a nylon cable (1)
through the first row of ballast. Unscrew support
plate (2) retaining screws and remove ballast using
a hoist.
5. Unscrew retaining screws of the second row of
ballast and slide them out, one at a time.

25- 62
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
6. Disconnect the movement potentiometer linkage
and electrical connector.

4
7. Disconnect the 2 steering tubes and the differential
lock tube from the right hand side.
NOTE: If front axle brakes are fitted, disconnect the
common brake pipe to the axle.

5
8. If fitted, disconnect the steering angle sensor
connector from behind the alternator and withdraw
the cable from the engine.

6
9. Disconnect the FWD driveshaft at the sliding
coupler joint.

25- 63
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
10. Remove the brackets retaining the suspension
ram hydraulic pipes to the tee--bar casting.

8
11. Raise the tractor using a suitable hoist and cable
at the front support, sufficient to remove the front
wheels, place stands under the axle for safety.

9
12. With the wheels removed, raise the tractor further
to allow a bar to go between the sump and fwd
shaft and support using stands either side of the
engine. Allow enough space between the stands to
withdraw the axle suspension arm from the front of
the tractor.

10
13. Using a suitable lifting jack, raise the right hand
side of the axle to gain access to the left hand pivot
pin. Remove the pin retaining plate and using a drift
knock the pin from the pivot from the front of the
tractor.

25- 64
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
14. With the axle supported centrally at the front and
also under the suspension arm, raise or lower until
access is gained to the right hand pin. Remove the
right hand pin retaining plate and drift out the pin
from the front of the tractor.

12
15. With the tee bar supported, remove the four bolts
from the rear swivel assembly of the bar, slightly
lower the tee--bar and prise the rear swivel
assembly from the transmission dowels.

13
16. Ensuring that all pipes are disconnected and that
the axle casting can clear the front support,
carefully withdraw the axle, with the rear tee bar
supported away from the tractor.

14
17. Place the axle assembly onto a suitable stand.
Prise the yoke from its bearing surface, to gain
access to the tee--bar securing bolts.

25- 65
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
18. Using a suitable hoist/lifting crane, support the
tee--bar. Remove the retaining bolts, noting the two
thin headed bolts at the top and bottom.

16
19. Slightly withdraw the tee--bar casting and remove
the universal joint bolts and remove the propshaft.
Remove the suspension arm casting away from
the axle.

17
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

20. Re--install the front axle assembly observing the

following:
-- Reassembly follows the disassembly
procedure in reverse from step 18 back to 1.
-- If front axle brakes are fitted it will be necessary
to bleed the front braking system.
-- If necessary ensure that the axle and hub oil
levels are correct and that items requiring
grease lubrication are sufficiently lubricated.

25- 66
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
FRONT AXLE COMPONENTS

Suspension Arm and Pivot Assemblies

18
1. Suspension arm 11. Retaining plate
2. Bolt 12. Bolt
3. Pin 13. Washer
4. Seal 14. Grease fitting
5. Bearing 15. Pin
6. Circlip 16. Pivot Arm (Panhard rod)
7. O--ring 17. Bearing
8. Grease fitting 18. O--ring
9. Circlip 19. Grease fitting
10. O--ring

25- 67
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Potentiometer Components

97mm

19
1. Potentiometer Harness 9. Clip
2. Bracket 10. Nut
3. Potentiometer 11. Rod
4. Circlip 12. Guard
5. Nut 13. washer
6. Washer 14. Bolt
7. Operating arm 15. Nut
8. Link rod 16. Harness retainer

25- 68
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
Cylinder Installation

20
1. Cylinder 10. Lower pin
2. Circlip x2 11. Grease fitting
3. Connector 12. Spacer
4. O--ring 13. Upper pin
5. Seal 14. Washer
6. Connector 15. Bolt
7. O--ring 16. Retaining plate
8. Seal 17. Washer
9. Bearing 18. Bolt

25- 69
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
SUSPENSION CYLINDER REMOVAL
DANGER
Exercise extreme caution when performing tasks on
the front suspension system. ALWAYS ensure that the
system is depressurised and that the axle is at rest on
the support stops.

1. Disconnect the battery to prevent accidental

tractor start up.

21
2. Depressurise the suspension system. Locate the
screw of the load sense unload valve, on top of the
valve block and rotate clockwise, allow the tractor
to lower completely onto the stops then rotate the
screw anti--clockwise to return to normal operation.
NOTE: It is advisable to remove the hydraulic filter
located above the suspension valve block to gain
access to the depressurising screw.

22
3. Place a suitable oil collecting container under the
pipe connections and disconnect the pipes from
the cylinder.

23
4. If necessary use a suitable hoist and cable around
the front support and raise the tractor until access
is gained to the lower pin. Remove the retaining
plate and drift the pin out from the front of the
tractor.

25- 70
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
5. Remove the bolt from the top pin and using a
suitable slide hammer with an M10 thread, remove
the top pin and lower the cylinder assembly away
from the tractor.

Installation
Installation is the reversal of removal, noting the
following points:
• Ensure the O--rings are installed on the O--Ring
Face Seal connectors of the cylinder.
• Lubricate the rod end bearings with the specified
grease after installation.

25
SUSPENSION CYLINDER OVERHAUL
Fully stroke the piston several times to remove as
much oil as possible and ensure that the cylinder is
cleaned externally before overhaul.
1. Remove the outer circlip. Push the rod gland into
the cylinder and remove the retaining ring from the
cylinder bore.

26
2. Pull the rod assembly from the cylinder.

27
3. Using the flats on the rod end, secure the rod in a
vice. Using a suitable bar, remove the rod end.
NOTE: The rod end has a thread locking compound
applied and will require considerable force to loosen.

25- 71
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
4. Remove the gland assembly from the rod.

29
5. If necessary, the rod end bearing can be replaced.
Remove the two circlips and using a suitable press,
press the bearing from the rod end.

30
Inspection
Inspect the cylinder bore, if scored or damaged in any
way replace the cylinder.
Inspect the rod for scoring and ensure that it is perfectly
straight, replace if damaged.
It is recommended at this stage to obtain a seal kit and
replace the seals prior to reassembly.

Reassembly
Reassembly is the reversal of the disassembly
procedure, noting the following points:
• Coat all seals with clean hydraulic oil prior to
assembly.
• Apply New Holland Thread Lock and Seal, Part
No.82995773, to the rod end and tighten to 200Nm
([Link]).

25- 72
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

31
Front Suspension Cylinder Assembly
1. Cylinder 10. Rod wiper*
2. Rod and piston 11. Retaining ring
3. Guide ring* 12. Bearing
4. Slipper seal* 13. Rod end
5. Guide ring* 14. Retaining ring
6. Dual ring seal* 15. Circlip
7. Step seal* 16. Gland retaining ring
8. O--ring* 17. Gland
9. Seal*
NOTE: Items Marked with an ( * ) are supplied in a service seal kit.

25- 73
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
SUSPENSION VALVE BLOCK REMOVAL
DANGER
Exercise extreme caution when performing tasks on
the front suspension system. ALWAYS ensure that the
system is depressurised and that the axle is at rest on
the support stops.

1. Disconnect the battery to prevent accidental

tractor start up.

32
2. Depressurise the suspension system. Locate the
screw of the load sense unload valve, on top of the
valve block and rotate clockwise, allow the tractor
to lower completely onto the stops then rotate the
screw anti--clockwise to return to normal operation.
NOTE: It is advisable to remove the hydraulic filter
located above the suspension valve block to gain
access to the depressurising screw.

33
3. Disconnect the wiring to the solenoids. Tag the
connectors for reassembly.

34
4. Place a suitable oil collecting container under the
pipe connections and disconnect the pipes to the
valve. Make a note of each connection for
reassembly.

25- 74
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2
5. Place a trolley jack under the valve assembly,
remove the 2 vertical bolts into the valve block and
carefully lower the complete valve assembly away
from the tractor.

36
SUSPENSION VALVE BLOCK OVERHAUL
It should be noted that due to the complexity of the
valve block that only the following major external items
are serviced:
• Ride control valve block section complete (1)
• Levelling system control valve block section
complete (2)
1. Ensure the valve block is clean.
2. Remove the four cap head screws from the end of
the ride control valve block section. Carefully pull
the sections apart. On replacement of a section
install new O--ring seals between the valve
sections. Tighten the screws to 9.5Nm ([Link]).
37
• Electrical solenoids
1. Ensure the area around the solenoids is clean.
2. Remove the outer nut and withdraw the solenoid
coil, then Unscrew and remove the solenoid valve.
3. Installation is the reversal, install the solenoid
valve ensuring that the O--ring is located under the
nut followed by the solenoid coil.

38
• Hydraulic accumulators
1. Ensure the area around the accumulators is clean.
2. Unscrew the accumulator counter clockwise to
remove and clockwise to install.

25- 75
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 2

40
Hydraulic Control Valve Assembly
A. Load Sense Line C. Pump Pressure In
B. Return to Reservoir

1. Raising Solenoid 25. Shock Valve (30bar differential pressure)

2. Lowering Solenoid 26. Lockout Valve (Rod End)
4. Pilot Operated Check Valve 30. Latch Valve
5. Pilot Operated Check Valve 31. Latch Valve
6. Relief Valve 20bar 32. Pressure Compensated Flow Control Valve
7. System Relief Valve (Piston End) 210bar 33. Pressure Compensated Flow Control Valve
13. Shock Valve (30bar differential pressure) 34 System Relief Valve (Rod End) 210bar
14. Load Sensed Unload Valve
24. Lockout Valve (Piston End)

NOTE: Some earlier versions had item ’34’, rod end 34

system relief valve, mounted on the outside of the
valve block as shown in Figure 41.

25- 76
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE

Chapter 1 -- Mechanical Rear Wheel Drive

CONTENTS

Section Description Page

27 000 --SPECIFICATIONS -- TIGHTENING TORQUES -- TOOLS -- SECTIONAL VIEWS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING

PINION, CROWN WHEEL AND DIFFERENTIAL -- SPECIFICATIONS

Pinion and crown wheel ratio:
TM165 w/range command and all
TM115, 125, 135 and 150 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/43 = 1:4. 30
TM165 w/power command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/43=1:3.91
Pinion to crown wheel backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0. 20 to 0. 28
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--pinion
Differential lock control:
-- Dog type clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acting through front--meshing,
hydraulically operated gears
-- Multi-plate clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acting through a hydraulically
controlled multi--pack clutch in oil
bath
Number of clutch discs:
-- Driven discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. 7
-- Drive discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n. 7
-- Driven disc thickness (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2. 85 to 2. 95
-- Drive disc thickness (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 1. 75 to 1. 85
Differential pinion bore dia. (5, figures 7 and 8) . . . . . . . . . . . . . . . . . . mm 28. 04 to 28. 061
Differential pinion journal dia. (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 27. 939 to 27. 960
Differential pinion running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . » 0. 080 to 0. 122
Side gear hub seat in differential
Casing dia. (4, figures 7 and 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 65. 0
Side gear hub dia. (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 62. 8 to 63. 0

(continued)

27- 1
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
PINION TO CROWN WHEEL AND DIFFERENTIAL -- SPECIFICATIONS
(cont)
Cone point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See pages 47, 48, 50 and 51
Cone point shimming (5, Figure 6):
-- model with dog clutch diff. lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1. 40--1. 45--1. 50--1. 55--1. 60--1.
65--1. 70--1. 75--1. 80--1. 85--1. 90--1.
95--2. 00--2. 05--2. 10--2. 15--2. 20--2.
25--2. 30--2. 35--2.
-- model with multi-plate clutch diff. lock . . . . . . . . . . . . . . . . . . . . . . . . mm 40--2. 45--2. 50--3. 0--3. 1--3. 3--3.
4--3. 5--3. 6--3. 7--3. 8--3. 9--4. 0
Pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See pages 49 and 52
Pinion bearing shimming (3, Fig. 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4. 40--4. 50--4. 60--4. 70--4. 80--4.
85--4. 90--4. 95--5. 00--5. 05--5. 10--5.
15--5. 20--5. 25--5. 30--5. 35--5. 40--5.
45--5. 50--5. 55--5. 60--5. 65--5. 70--5.
75--5. 80--5. 85--5. 90--5. 95--6. 00--6.
05--6. 10--6. 15--6. 20--6. 30--6. 40--6.
50--6. 60
Crown wheel bearing and backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . See pages 53, 54, 55 and 56
shims available (item 21, Figure 7 and item 25, Figure 8) . . . . . . . . mm 0. 15--0. 20--0. 50
Differential gear and pinion backlash . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0. 20
Differential gear thrust washer thickness
(item 20, Figure 7 and item 24, Figure 8) . . . . . . . . . . . . . . . . . . . . . . » 2. 80--2. 85--2. 90--2. 95--3. 00--3.
053. 10--3. 15--3. 20--3. 25--3. 30
Differential gear end play (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 0. 30
Differential gear end play adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . see pages 61 and 62

FINAL DRIVES -- SPECIFICATIONS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Epicyclic, with three planetary spur
gears
Reduction ratios:
-- Models TM115 and TM125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:(14+70)=1:6
-- Models TM135 and TM150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12:(12+63)=1:6.25
-- Model TM165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:(14+88)=1:7.28
Thickness of planetary gear thrust washers (8 and 10, Figures 7 and 8 )
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1
Thickness of planetary gear roller bearing spacer (9) . . . . . . . . . . . . » 4.90 to 4.95
Adjustment of drive wheel shaft tapered roller bearings . . . . . . . . . . . see page 72

27- 2
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
TIGHTENING TORQUES
DESCRIPTION Thread Torque
size Nm kgm
Nut, bevel pinion shaft (C1, Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M45x1. 5 490 50
Nut, final drive case (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M14x1. 5 176 18
Nut, wheel disc to wheel rim (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 294 30
Nut, steel wheel disc to wheel hub (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 255 26
Capscrew, wheel hub on dual wheel axle shaft (C5) . . . . . . . . . . . . . . . . . M16x1.5 294 30
Capscrew, RAIL disc on dual wheel axle shaft (C7) . . . . . . . . . . . . . . . . . . M16x1.5 294 30
Capscrew, drive wheel shaft (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 88 (*) 9 (*)
Capscrew, crown wheel and differential caps (C9) . . . . . . . . . . . . . . . . . . . M10x1.25 54 5.5
Self--locking nut, crown wheel (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12x1.25 137 14
Nut, RAIL disc block (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M20x2.5 245 25
Nut, RAIL disc to wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5 314 32
Nut, weight screw to steel wheel disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 294 30
Attaching screws, wheel weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 211 21.5
Allen screw, wheel weights to cast iron disc . . . . . . . . . . . . . . . . . . . . . . . . M16x1.5 186 19
Capscrew, pump and filter support( C2 pag 3 , sez.35, cap 3 ) . . . . . . . . M12x1.5 83 8.5

(*) see adjustment procedure on page 72

27- 3
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

25272

25273

27- 4
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
SPECIAL TOOLS X 293977 Spacer (to be used with 293510 or
CAUTION 293975)
Operations described in this Section of the Manual
X 293976 Spacer (to be used with 293510 or
must be performed using the following ESSENTIAL
293975)
tools marked with the identification code (X).
To work safely and achieve the best technical results
293400 Universal pinion installer
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated X 293994 Crown wheel--differential lifting hook
with the self--made ones for which you will find the
necessary construction drawings and specifications 292870 Universal differential lock pressure test
directly on this Manual. kit

List of special tools necessary to carry out the different X 293986 Differential planetary gear adjustment
operations described in this Section. tool

290090 Rotary stand X 293811 Reduction gear assembly lifting hook

292320 Tractor separation stand 292400 Rear wheel lifting hook.

291517 Rear axle housing lifting hook 291221 Differential overhaul stand.

293972 Front bracket for rear axle overhaul (to 292927 Slide hammer.
be used with 290090)
X 295026 Spacer and bushing (to be used with
293973 Rear bracket for rear axle overhaul (to 293975 or 293510).
be used with 290090)
X 295026 Spacer and bushing (to be used with
X 294168 Nut wrench (60mm) and for checking 293975 or 293510).
pinion rolling torque
295048 Spacers, two (to be used with 293975).

X 293975 Pinion bearing adjustment tool

27- 5
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

2
Tool to be fabricated to disassemble--assemble the final drives (Mark tool with no. 50091 --
-- Dimensions in mm).
Fabricate tool using Aq 42 [Link]
1. Make 2 legs in C 40 H&T material

Tool to be fabricated to disassemble--assemble the

final drives (Mark tool with no. 50078
-- Dimensions in mm).
Fabricate tool using 38 NCD 4 material.
1. Make from one male eyebolt M12 DIN 580
2. Apply New Holland Stud Lock 82995772

27- 6
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Tool to be fabricated to remove the hydraulic
pump idler gear pivot pin (Mark tool with no.
50143 -- Dimensions in mm)
NOTE: Fabricate tool using UNI C 40 material.

4
Tool to be fabricated to remove the hydraulic
pump idler gear journal setscrew(Mark tool with
no. 50140 -- Dimensions in mm)
NOTE: Fabricate tool using UNI C 40 material.

27- 7
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

6
Rear Axle Longitudinal Sectional View
1. Bevel pinion shaft 6. Tapered roller bearing
2. Tapered roller bearing 7. Crown wheel.
3. Bevel pinion bearing adjusting shim 8. Differential gear hub
4. Phonic wheel 9. Differential gear
5. Cone point adjusting shim

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on pages 35 and 36.

27- 8
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

7
Rear Axle Cross--Section (with dog clutch type differential lock).
1. Crown wheel bearing cap 12. Wheel axle shaft
2. Differential output half--shaft 13. Seal
3. Side gears 14. Seal
4. Differential casing 15. Planetary carrier
5. Differential gears 16. Differential output half--shaft
6. Differential gear hub (5) 17. Differential lock control piston
7. Crown wheel bearing cap 18. Seal
8. Thrust washer 19. Crown wheel
9. Planetary gear (11) bearing spacer 20. Side gear end play adjuster rings
10. Thrust washer 21. Pinion to crown wheel backlash and bearing adjuster
11. Planetary final reduction gears rings

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on pages 35 and 36

27- 9
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

8
Rear Axle Cross--Section (with multi-plate clutch differential lock)
1. Crown wheel bearing cap 14. Seal.
2. Differential output half--shaft 15. Planetary carrier
3. Side gears 16. Differential output half--shaft
4. Differential casing 17. Final drive case spacer
5. Differential gear 18. Drive discs
6. Differential gear hub (5) 19. Driven discs
7. Crown wheel bearing cap 20. Differential lock control piston
8. Thrust washer 21. Crown wheel
9. Planetary gear (11) bearing spacer 22. Seal
10. Thrust washer 23. Side gear end play adjuster rings
11. Planetary final reduction gears 24. Differential lock control line
12. Wheel axle shaft 25. Pinion to crown wheel backlash and bearing adjuster
13. Seal. rings

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on pages 35 and 36.

DESCRIPTION AND OPERATION

The rear axle assembly transfers drive from the Refer to pages 10 and 11 for the descriptions of
transmission to the epicyclic final drives through a operation of both types of differential lock.
bevel pinion and crown wheel coupling. The bevel The epicyclic final reduction gear sets are controlled by
gears are spiral type and are supported by tapered the bevel pinion and crown wheel output half--shafts,
roller bearings. which also control the brakes.
The differential is fitted with four planetary gears and
hydraulic differential lock. The differential lock being
either a dog clutch or multi-plate type.

27- 10
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Rear differential lock disengaged Rear differential lock engaged

Return to dump
Low pressure oil

REAR DIFFERENTIAL LOCK ASSEMBLY (Dog type clutch where fitted)

When it is not necessary to lock the differential, the The pressure applied to the piston (1) larger surface is
differential lock is kept disengaged by the pressure oil considerably stronger than the one acting on the
acting on the surface of the control piston smaller smaller surface of same piston (1) and consequently
annular groove (1). the piston (1) moves, engages the front toothed
When the switch on the instrument panel is activated, sleeves and locks the differential.
the solenoid valve opens and directs oil from the pump
into the drive piston main annular groove (1).

27- 11
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Rear differential lock disengaged Rear differential lock engaged

Return to dump
Low pressure oil (16--18 bar)

REAR DIFFERENTIAL LOCK ASSEMBLY (Multi-plate clutch where fitted)

When the switch on the instrument panel is activated, The pressure applied over the piston (1) surface
the solenoid valve opens and directs oil from the pump compresses the multi--pack clutch drive and driven
into the control piston (1) annular groove. discs and locks the differential.

27- 12
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
TROUBLESHOOTING -- PINION, CROWN WHEEL AND DIFFERENTIAL
Problem Possible Cause Correction
Noisy rear axle when the tractor is 2. Pinion and/or crown wheel bear- Remove rear axle housing and
moving, and also with transmission ing misadjustment adjust pinion and crown wheel
in neutral (not originating from final bearings correctly (page 47).
drives)
3. Worn or misadjusted side and Remove rear axle housing, replace
planetary gears worn parts and adjust the
differential gear backlash (page 61).
4. Excess differential side gears to Remove rear axle housing and
half--shaft spline backlash replace damaged parts.
Noisy rear axle with tractor under 1. Excess bevel pinion to crown Remove rear axle housing and
load and upon release wheel backlash adjust bevel pinion and crown
wheel bearings correctly (page 47).
2. Faulty or defective inner compo- Remove rear axle housing, replace
nent. worn parts and adjust differential
gear backlash correctly (page 61).
Noisy rear axle with over--heating 1. Insufficient pinion and/or crown Remove rear axle housing and
wheel bearing backlash adjust bevel pinion and crown
wheel bearings correctly (page 47)
2. Insufficient bevel pinion to crown Remove rear axle housing and
wheel tooth backlash adjust crown wheel bearings
correctly (page 53).

TROUBLESHOOTING -- FINAL DRIVES

Problem Possible Cause Correction
Noisy final drives when the tractor 1. Wheel axle shaft bearing misad- Remove final drive case and adjust
is movingg and also with justment. bearings (page 72).
t
transmission
i i in i neutral
t l
2. Faulty or defective inner compo- Remove final drive case and
nent. replace damaged parts.
3. Excess wheel axle shaft to final Remove final drive case and
drive spline backlash replace damaged parts.

27- 13
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
TROUBLESHOOTING -- HYDRAULIC DIFFERENTIAL LOCK
Problem Possible Cause Correction
Differential lock not engaging. 1. Low rear axle oil level. Top up to correct level.
2. Blocked oil filter. Replace filter.
3. Faulty hydraulic pump. Overhaul or replace pump.
4. Faulty diff lock switch Replace switch.
5. Power supply not reaching sole- Restore electrical connection and
noid valve: detached or dam- replace faulty [Link] or
aged connectors, faulty remote replace solenoid valve.
switch.
6. Diff lock control solenoid valve Overhaul or replace solenoid valve.
stuck on discharge.
7. Oil leaks through the seals with Replace faulty seals.
consequent pressure drop: cylin-
der piston oil supply line seals.
Differential lock not disengaging 1. Faulty diff lock--unlock switch Replace switch
2. Power supply not reaching sole- Restore electrical connection and
noid valve: detached or dam- replace faulty parts.
aged connectors, faulty remote
switch.
3. Diff lock control solenoid valve Overhaul or replace solenoid valve.
stuck on delivery.
4. Oil leaks through the seals with Replace faulty seals.
consequent pressure drop: cylin-
der piston or supply line seals.
With differential lock engaged and 1. Faulty diff lock switch (con- Replace switch.
control switch on automatic mode, nected to the Fast Raise switch).
the diff lock does not disengage
when raising lift arms using the
Fast Raise switch.
With differential lock engaged, the 1. Faulty diff lock switch (con- Replace switch.
diff lock does not disengage when nected to the brake pressure
brake pedals are pressed. switches/foot pedal switches).

27- 14
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
REAR AXLE HOUSING DANGER
Lift and handle all heavy components using lifting
Removal -- Installation (Op. 27 100 10) equipment of appropriate capacity. Ensure that units or
parts are supported by suitable slings or hooks. Ensure
that no--one is in the vicinity of the load to be lifted.

Remove the rear axle housing as follows:

1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.

1
3. Attach engine hood to a hoist using a nylon cable
(1) and disconnect the hood struts (2) (one on each
side).

2
4. Unscrew hood to engine attaching screws (3),
detach electrical connector to headlights and
remove the hood using the hoist. Ensure that there
are no obstacles or interference against other
components.

23353

27- 15
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
5. Unscrew the retaining screws and remove side
panels (1) (one on each side).

4
6. Jack up the rear of the tractor and place two
suitable stands (2) under the final drive cases in
order that the wheels are off the ground. If
necessary, detach the lift rods from the lower links.

5
7. Sling the wheel using a nylon cable (3), unscrew
retaining nuts and remove the wheel. Repeat for
the left wheel.

23556

6
8. Loosen the two bolts on the cab roof and fix tool no.
295027 (4) using two appropriate bolts. Connect
the tool to a hoist using the hook tool no. 290740
and keep hook tensioned.

27- 16
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
9. Detach connectors from the washer motor and
tubes from the washer tank (1). Remove tank.

8
10. Remove the cotter pin and detach creeper gear
control idler lever (2), loosen the screw (3) retaining
the parking brake control cable.

9
11. Remove the lockpin and withdraw the pin attaching
the fork (4) to the parking brake control lever.
Loosen the nut attaching the cable to the fork (4)
and release the cable.

10
12. Loosen the retaining nut and detach the ground
cable (5) between the cab and the rear axle.

27- 17
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
13. Unscrew the clamp (1) and detach the breather
tube from the main tank.

12
14. Disconnect the ground synchronised PTO control
cable (2) from the rail.

13
15. Detach the two connectors (3 and 4) located under
the cab floor.

14
16. Detach the two connectors (5 and 6) connecting
the engine to the cab.

27- 18
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
17. Detach radar connector (4), fuel filter connector
(3), remove protection and detach connectors (1
and 2) from starter motor.

16
18. Detach light connector (5) located on the handrail
(repeat for both tractor sides).

17
19. Detach lines (6) connecting heater to the engine,
which are located under the front cab right side.

18
20. Loosen the retaining nut and detach throttle control
cable (7) from injection pump.

27- 19
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
21. Detach connectors (1) from brake master cylinders
and brake fluid reservoir.
22. Loosen the fittings (2) and detach brake control
hoses.
23. Unscrew the hoses connecting the brake master
cylinder to the reservoir.

20
24. Unscrew the lines (4) connecting the hydrostatic
steering motor to the pump.

21
25. Detach lines (5) connecting the hydrostatic
steering motor to the steering cylinders.

22
26. Unscrew the fittings and remove air conditioning
lines (6).

27- 20
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
27. Loosen the retaining nut, slide out the cotter pin
and detach the PTO control cable (1).

24
28. Remove pins (2), unscrew retaining screws (3) and
detach auxiliary valve control cables on right side.
29. If auxiliary valves are fitted also on left side, repeat
step 28 for these valves.

25
30. Loosen the screw attaching the steps (6) to the
mounting bracket.

26
31. Loosen the screw attaching the steps (1) to the cab
floor.
32. Repeat steps 30 and 31 to remove steps on
opposite side.

27- 21
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
33. Raise the floor mat (2) inside the cab and loosen
the cab mounting bolt while holding the nut under
the cab floor. Recover the bolt and washer. Repeat
for both cab sides.

28
34. Loosen the rear cab mounting bolts (on both
sides).
35. Slowly lift the cab taking care that no components
are still connected, hooked or interfering. Remove
the cab and lower it onto a suitable base.

29
36. Loosen the plug (3) and drain oil from speed
clutch--transmission and rear axle housings into a
suitable container.

30
37. Drain fuel tanks, then loosen the clamp (1)
retaining the fuel lines between the main and
auxiliary tanks.

27- 22
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
38. Loosen the clamp and detach the tube (3) between
the main and auxiliary tanks.
39. Detach the fuel return line (2) from the pump to the
auxiliary tank. Remove the auxiliary tank.

32
40. Loosen the clamp and detach the injection pump
supply line (5). Detach connectors (4), then
unscrew and remove the fuel level sensor
assembly.

33
41. Loosen the nut of the metal strap (6) securing the
main tank. Remove the strap and tank.

34
42. Loosen the retaining screws and remove the cab
and fuel tank support bracket (1). (Repeat on both
sides of the transmission housing).

27- 23
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
43. Loosen the retaining screws and remove the main
tank support bracket (2).

36
44. Loosen the attaching screws and remove the
guard of the drive shaft to the front axle.
45. Remove the circlip (4) and withdraw the sleeve (5).
Repeat for transfer box circlip and sleeve.

37
46. Loosen the screws attaching the support bearing
(3) to the transmission housing, detach and
remove the front diff lock control line (2).

38
47. Slide out the hinge pin (1) and remove the top link
rod.

27- 24
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
48. Hook the tow hitch support (1) to a hoist, loosen the
attaching bolts and remove the support.

40
49. Loosen the retaining screws and remove the cab
rear brackets (2) (on both sides).

41
50. Loosen the retaining screws and remove the
telescopic stabiliser hinge brackets (3) (on both
sides).

42
51. Loosen all line fittings (1) at the auxiliary valves,
EDC valve, variable displacement pump, trailer
brake valve and remove line.

27- 25
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
52. Loosen and detach fittings (1 and 2) from the EDC
valve.

44
53. Loosen and remove outlet line (3) fitting from the
variable displacement pump filter.

45
54. Release clamps and withdraw the sleeve (4) from
the outlet line (3).

46
55. Loosen the retaining screws and remove the two
valves (5) together with the line (2) and bracket.

27- 26
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
56. Detach the multi--pole socket (1) and trailer brake
line terminal (2) from the bracket.

48
57. Loosen the retaining screws and remove the
multi--pole socket and trailer brake line bracket (3).

49
58. Loosen the retaining nut and remove the oil filler
tube (4) to the rear axle housing.

50
59. Remove the attaching screws and detach the
auxiliary valves (5), inlet and outlet lines and
bracket.

27- 27
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
60. Detach the EDC valve connector (1).

52
61. Detach lines (2, 3, and 4) from the hydraulic lift
valve, lift housing fitting and trailer brake valve,
respectively.

53
62. Remove the retaining screws and detach the EDC
valve (5).

54
63. Detach lines (6 and 7) from the variable
displacement pump assembly and lines (8) from
the rear axle housing.

27- 28
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
64. Loosen the retaining screws and remove the trailer
brake valve (1), bracket and lines disconnected at
step 63.

56
65. Detach the following connectors: (2) for PTO
speed sensor, (3) for draft sensor connection, and
(4) for lift arm max. height.

57
66. Detach the following connectors: (5) for
synchronised PTO speed sensor, (6) for speed
sensor, and (7, 8, and 9) from the variable
displacement pump assembly. Remove the cotter
pin and remove the synchronised PTO drive rail
(10).

58
67. Detach and remove hydraulic lift and PTO
lubrication lines (11, 12, and 14). Remove the
retaining screw (13) of the brake line bracket.

27- 29
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
68. Loosen and remove the hydrostatic steering
supply line (1).

60
69. Detach and remove the accumulator (2) to pump
connecting line.

61
70. Loosen and remove the differential unlock control
line (3).

62
71. Connect the variable displacement pump
assembly to a hoist, loosen the attaching bolts and
remove the assembly.

27- 30
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
72. Slide out the hinge pins and detach the lift rods (1).

64
73. Detach the oil supply line (2), withdraw the pivot
pins (3 and 4) and remove the assist ram.

65
74. Detach the PTO speed sensor wire tie--strap.

66
75. Connect the chain tool no. 291517 (6) to the lift and
hoist, unscrew lift attaching bolts and remove lift.

27- 31
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
76. Loosen the retaining screws and remove the lift
arm max. height sensor (1).

68
77. Remove the retaining screws, slide out the draft
sensor (2) with its protection (4) and mounting plate
(3). Recover the lower link (5). (Repeat for both
sides).

69
78. Disconnect the PTO clutch control line (6).

70
79. Attach a metal sling to a hoist and the PTO
assembly (7), loosen the attaching bolts (8) and
remove PTO assembly (7).

27- 32
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
80. Using two suitable studs, connect the draft sensor
support (1) to a nylon cable. Attach the nylon cable
to a hoist, loosen the attaching bolts and remove
the support.

72
81. Disconnect and remove the creeper control rail (2)
and parking brake control cable (3).

73
82. Detach the differential lock, FWD engagement,
PTO control, and PTO brake lines from the
solenoid support (4) and rear axle housing and
remove lines.

74
83. Loosen and detach brake control lines (5) from rear
axle housing.

27- 33
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
84. Place the stand tool no. 292320 with the stationary
trolley under the transmission housing and the two
mobile trolleys under the rear axle housing.
85. Fix tool no. 50091 (1) to the final drive case,
connect it to a hoist, loosen attaching bolts and
remove the entire final drive complete with the
outer ring gear, spacer, brake disc, and brake
control piston. (Repeat for the final drive case on
the other side).

76
86. Connect the chain tool no. 291517 (2) to the rear
axle housing and hoist, tension the chain, loosen
the attaching bolts (3) and detach the rear axle
housing from the transmission housing.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

87. Reinstall the rear axle housing assembly to the

speed clutch--transmission housing observing the
following:
-- Reassembly follows the disassembly
procedure in reverse, from step 86 back to step
1. 77
-- Check seals and replace if damaged.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a bead of liquid gasket of
approx. 2 mm. of diameter following the
patterns shown in the figures on pages 35 and
36.
-- Tighten to correct torques as detailed on pages
2 and 3.
88. To assist reinstallation of the final drive case, we
advise to position the half--shaft (4) into its seat on
the differential and brake disc.
78

27- 34
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

20270

20273

79
Patterns for application of liquid gasket during reinstallation of: (a) speed clutch--transmission housing to rear axle
housing; (b) final drive cases to rear axle housing.

27- 35
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
f
e
d
c
b
a

20272

Patterns for application of liquid gasket during reinstallation of: (a) hydraulic pump mounting plates; (b) hydraulic
lift; (c) PTO housing; (d) flex bar support; (e) parking brake bracket; (f) rear axle housing bottom cover.

27- 36
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
REAR AXLE HOUSING
Replacement (Op. 27 100 85)
WARNING
Handle all components with the greatest [Link] not
insert hands or fingers between the [Link]
suitable protection clothing, including goggles, gloves
and footwear.

To replace the rear axle housing it is necessary to

detach the rear axle housing from the transmission
housing first. Then proceed as follows:
1
1. Remove the hydraulic pump drive gear locking
circlip (1).

24361

1
2. Withdraw the hydraulic pump drive gear (1) and
recover the spacer.
1

24362

2
3. Remove the PTO shaft bearing retaining circlip.

24363

27- 37
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
4. Withdraw the PTO drive shaft and bearing (1).

24364

4
5. Place the rear axle housing on the rotary stand tool
no. 200090 using the front bracket tool no. 293972 1
(1) and rear bracket tool no. 293973 (2).

24365

5
6. Loosen the attaching bolts and remove the parking
brake control assembly (1).

1
24366

6
7. Loosen the differential lock control lines (1).

24367

27- 38
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
8. Withdraw the differential lock control lines (1).

24368

8
9. Loosen the retaining screws and recover the
transfer box bottom cover.

9
10. Straighten the locking tabs, unscrew the bolts and
remove the transfer box inner guard.

10
11. Loosen the hinge pin and withdraw the flex bar
draft idler unit (1)
1

24369

27- 39
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
12. Remove the ground synchronised PTO drive gear
(1) retaining snap ring (2).

24370

12
13. Using a suitable tool, push the lever (1) to the side
and release the mentioned gear (2, Fig. 12).
Remove the gear.

24371

13
14. Remove the snap ring (1) and slide out the ground
synchronised PTO drive shaft (2) and bearing. 1 2

24372

14
15. Withdraw the roll pin and remove the ground
synchronised PTO control lever (1).

1
24373

27- 40
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
16. Loosen the setscrew using adapter tool no. 50140
(1, see on page 7) and install the slide hammer tool 1
no. 292927.

25293

16
17. Using adapter tool no. 50143 (1, see on page 7)
and slide hammer tool no. 292927, withdraw the
pin and recover gear, bearings and adjustment
shim.

24375

17
18. Remove the spring (2) using a suitable hook (1).

24376

18
19. Detach the locking clip (1) .

24377

27- 41
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
20. Remove the roll pins, withdraw the lever (1) and
recover the fork.

24378

20
21. Set the rear axle housing upright, fix tool no.
293994 (1) on the crown wheel and hook it to a
suitable lifting equipment.

1 1

24379

21
22. Loosen the attaching bolts, remove the crown
wheel/differential support (1) on both sides,
1
recover the crown wheel and remove the inner
metal guard.

24380

22
23. Remove the brake drive piston (1) using
compressed air and recover clips on both sides.

24381

27- 42
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
24. Disassemble the oil suction tube.

24
25. Remove dust ring, seal and transfer box shaft
bearing retaining snap ring.

25
26. Recover the transfer box shaft bearing adjust ring.

26
27. Using a slide hammer tool no. 292927 (1) and
adapter tool no. 293996 (2) partially withdraw the
transfer box shaft.

27- 43
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
28. Remove the transfer box shaft with one hand while
holding the FWD engagement clutch with the other.

28
29. Remove the FWD engagement clutch assembly.

29
30. Remove the transfer box drive shaft guard.

30
31. Unstake the crushed nut, hold the pinion steady
and loosen the nut using the wrench tool no.
293343 (1).

24382

27- 44
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
32. Using a universal puller (1), partially withdraw the
1
bevel pinion.

24383

32
33. Disassemble the universal puller and remove front
bearing (1).
1

24384

33
34. Slide out the pinion and recover the inner parts
through the parking brake compartment.

24385

34
35. Slide out the bearing (1) from pinion using a drive
puller and a hydraulic press.

24386

27- 45
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
36. Remove the pinion rear bearing cup (1) from front
end using a driver tool, and recover adjustment
shim (S) . S1
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

37. Reinstall all components into the rear axle housing

observing the following:
-- Thoroughly clean the housing, especially the 1
inner compartments.
-- Reassembly follows the disassembly 24387

procedure in reverse, from step 36 back to step

36
1.
-- Refer to figures on pages 8, 9, and 10 for
correct positioning and orientation of the
different parts.
-- Tighten to correct torques as detailed on pages
3 and 4.
-- Before reassembling housings, supports and
covers, thoroughly clean and degrease mating
surfaces and apply a bead of liquid gasket of
approx. 2 mm. of diameter following the
patterns shown in the figures on pages 35 and
36.
-- During bevel pinion installation, carry out the
adjustments as detailed on pages 47 to 52.
-- During crown wheel installation, carry out
operations described from step 63 on page 53
to adjust tapered roller bearings and for pinion
to crown wheel correct mating.
-- During installation of the hydraulic pump drive
idler gear assembly, adjust tapered roller
bearings as detailed on page 57.
-- Install and adjust transfer box bearings as
detailed on pages 16, 17, 18, Section 23,
Chapter 1.
-- Refer to Section 21, Chapter 1 to adjust the
creeper control lever.

27- 46
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
REAR AXLE ADJUSTMENTS

A
D

C E

(A and B) -- Left and right hand differential side gear shims. Adjusts pre--load on differential gear assembly.

(D) -- Pinion shaft pre--load shim. Adjusts the pre--load on the pinion shaft bearings and components.

(E and F) -- Left and right hand crown wheel backlash and differential support bearing pre--load shims. Adjusts the
horizontal position of the crown wheel relative to the pinion gear. This affects the backlash depending on which side
the shims are fitted. Also affects the pre--load on the differential support bearings, effected by the total shims, E+F.

(G) -- Hydraulic pump idler gear shim. Adjusts the pre--load on the two conical bearings within the hydraulic pump
idler gear.

27- 47
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
PINION AND CROWN WHEEL ADJUSTMENTS
1

Pinion shaft position adjustment, shim C, 2

Figure 37, using special tool no. 293975.
Proceed as follows:
38. Assemble tool no. 293976, for small bearing
pinion, or 295026, for large bearing pinions (1)
complete with the pinion rear bearing outer cup (2)
on the rear axle housing.

24388

38
39. Assemble special tool no. 293975 (1) complete
with the bearings on the rear axle housing. Lock the
nut while turning the bearings.
NOTE: Place the second part of tool 295026 between
the inner part of the bearing and tool 293975. 1

24395

40
40. Assemble universal tool no. 293400 (2) on crown
wheel caps (1) complete with the bearing outer 1
cups.
41. Bring the rod of tool no. 293400 (H) to contact
bearing inner cup and measure dimension (H1).
42. Determine correct nominal dimension, H2 (2)
between the crown wheel centreline and pinion
larger base:
H2 = H 3 ± C 2
where:

24396

27- 48
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
H3 = 180 mm. Nominal dimension between crown
wheel centreline and pinion larger base for tractors
fitted with mechanical or dual command
transmissions. (small pinion bearing)
H3 = 183 mm. Nominal dimension between crown
wheel centreline and pinion larger base for tractors
fitted with range command or power command
transmissions. (large pinion bearing)
C = Correction factor stamped on the pinion,
expressed in mm and prefixed by + or -- if other
than 0, to be added to or subtracted from the
nominal dimension (H3), depending on the sign.
43. Pinion position shim thickness (S) is given by:
S1 = H1 + 35 -- H2
where
H1 = Depth gauge reading
35 mm = Thickness of bushing no 293976 (1,
fig. 38).
H2 =Correct nominal dimension between crown
wheel centreline and pinion larger base.
If necessary, round off the value (S) to the next 0.05
mm.
Examples:
-- Depth gauge reading: H1 = 146,9 mm
-- Thickness of bushing no. 293976 (1, fig. 38) = 35
mm
-- Nominal dimension between crown wheel
centreline and pinion larger base: H3 = 180 mm

Example 1:
-- Correction factor: C = -- 0.1 mm
-- Correct nominal dimension:H2 = 180 -- 0.1 = 179.9
mm
-- Shim thickness:
-- S1 = 146.9 + 35 -- 179.9 = 2.0 mm

Example 2:
-- Correction factor: C = +0.1 mm
-- Correct nominal dimension:: H2 = 180 + 0.1 = 180.1
mm
-- Shim thickness:
-- S1 = 146.9 + 35 -- 180.1 = 1.8 mm

Example 3:
-- Correction factor: C = 0 mm
-- Correct nominal dimension: H2 = H3 = 180 mm
-- Shim thickness:
-- S1 = 146.9 + 35--180 = 1.9 mm

44. Remove universal tool No. 293400.

27- 49
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
PINION AND CROWN WHEEL ADJUSTMENTS
1
Pinion Bearing Pre--Load Adjustment, shim D,
Figure 37, using special tool no. 293975.

Proceed as follows: H6
45. Using a depth gauge, measure dimension (H6)
between the end of tool no. 293975 (1) and the end
of the inner screw.
46. Remove tool no. 293975 from rear axle housing.

24397

42
47. Fix tool no. 293975 into a vice, assemble all parts
on it including a test shim (P) and spacer no.
293977 (1).
48. Screw in tool nut to lock the tool and using a depth H7
gauge measure dimension (H7) between tool end
and end of the inner screw.
49. Shim thickness (S2) is given by:
S2 = H6 + P + S1 -- H7 +0.2
where: P
P=Test shim
S1= Cone point adjustment shim, as found in the 1
previous paragraph. 24398

0.2 mm=Increase necessary to compensate for 43

bearing increased preload deriving from tightening
of the pinion shaft locknut
If necessary, round off the value (S2) to the next
0.05
mm
Example
-- Cone point adjustment shim, found in the previous
paragraph: S1= 1.8 mm
-- Depth gauge reading: H6=13.60mm
Test shim:P=2mm
Depth gauge reading:H7=12.10 mm
Shim thickness.
S2 =13.60+2+1.8--12.1+0.2=5.5 mm

27- 50
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
PINION AND CROWN WHEEL ADJUSTMENTS

Adjustment of crown wheel bearing pre--load and S1

crown wheel to pinion backlash, shims E & F
Figure 37.

Proceed as follows:
50. Assemble rear bearing outer cup (1) and shim (S1)
as determined in the previous procedures.
1

24387

44
51. Assemble pinion (1) complete with all components
and respective bearing pre--load shim (3, page 8)
as found during previous adjustments. If 1
necessary, hold the pinion in place using a suitable
tool.
NOTE: Cone point and pinion bearing shims (3 and 5,
page 8) are listed on page 1.

24399

45
52. Using the wrench tool no. 294168 tighten the nut
(C1, page 3) to 490 Nm (50 kgm) and while turning
the pinion shaft to settle the bearings. Remove
pinion tool.
53. Check if the rolling torque necessary to turn the
pinion shaft is 1.0 to 2.0 Nm (0.1 to 0.2 kgm) by
1
measuring it at the end of the shaft using the
wrench tool no. 294168 (1) and a suitable torque
wrench (2). Crush the nut (C1, page 3). 2
NOTE: Decrease the bearing adjustment shim pack
(S2), (3, page 8) if the rolling torque is lower than
specified, or increase it if higher.
24400

46
54. Assemble the crown wheel -- differential assembly
to the rear axle housing, insert the RH cap (2)
complete with a test shim (1.5mm), (1) and fix with 1
three screws. Tighten the screws to 54 Nm (5.5
kgm).

2
24401

27- 51
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
55. Measure LH cap thickness (D1).

24402

48
56. Assemble the LH cap without shims using three
lubricated screws (1) arranged at 120°.
57. Tighten alternatively and gradually the three
screws (1) until 6 to 9 Nm (0.6 to 0.9 kgm) while
turning the crown wheel to settle the bearings.

24403

49
58. Using a depth gauge, measure dimension (D2) at
the two recesses in the LH cap. Calculate the
average of the two readings.
59. The total shim pack (S) to be inserted beneath the
RH and LH caps is given by:
S = D2 -- D1 + A + 0.3
where:
A = Test shim = 1.5 mm
D1 = LH cap thickness, in mm. D2
D2 = Dimension measured in Figure 50, in mm.
0.3 mm =Increase necessary to diminish the
bearing preload deriving from the screws (1).
24404
If necessary, round off the value (S) to the next 0.05
mm. 50
60. Using a dial gauge, measure the backlash (G)
between the crown wheel and pinion teeth (take
three measures at 120° and take the average of the
readings).
61. Normal crown wheel to pinion backlash is 0.20 to
0.28 mm, with an average of 0.24 mm.
62. To compensate for possible backlash values
higher or lower than specified, a ratio of 1:1.34
corresponds between the radial movement
(backlash) and the horizontal movement of the diff
assembly.

24405

27- 52
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Therefore, the horizontal movement (Z)
necessary to restore specified backlash is:
Z = (G -- 0.24) x 1.34
Adjustment shim packs (Sd and Ss) to be inserted
on the RH and LH caps are given by:
Sd = A ± Z
Ss = S -- Sd
where:
S = Total shim pack value
Z = Crown wheel horizontal movement, found
above.
A = Test shim = 1.5 mm

63. Assemble the shim packs determined above on the

caps and tighten the screws (1) at the specified
torque.

24403

52
64. Check if the rolling torque necessary to turn the
crown wheel and pinion assembly is:
Rp + (1.25 to 2.0 Nm)
or Rp + (0.125 to 0.2 kgm)
by measuring it at the end of the pinion shaft using
the wrench tool no. 294168 (1) and a suitable 1
torque wrench (2).
where: 2
Rp = Rolling torque measured for the pinion only
(see page 51).
Example:
-- Measure of LH cap thickness (D1)= 14.00 mm 24400

-- Test shim A = 1.5 mm 53

-- Measure of clearance of D2 between LH cap and
its seat on the rear axle housing
14.15 mm; 14.25 mm.
D2 =Mean value (14.15 + 14.25):2 = 14.20 mm

27- 53
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
-- Total shim thickness
S = 14.20--14.00 + 1.5 + 0.3 = 2.00 mm

-- Measured backlash: 0.13 mm; 0.12 mm; 0.14 mm;

G = Mean value= (0.13 + 0.12 + 0.14): 3 = 0.13
mm
-- Horizontal movement (Z) necessary to restore
specified backlash.
Z = (0.13 -- 0.24) x 1.34= -- 0.11 x 1.34 ≅ − 0.15

-- Shim thickness to be inserted on the RH cap is:

Sd = 1.5 -- 0.15 = 1.35 mm
-- Shim thickness to be inserted on LH cap is:
Ss = 2.00 --1.35 = 0.65 mm

1 2 3 4 5

12 11 10 8 7
TIA35073

54
Pump Drive Gear Assembly
1. Spacer 7. Locking Tab
2. Bearing 8. Plate
3. Drive Gear 9. Sleeve
4. Spacer 10. ’O’ Ring
5. Bearing 11. Pin
6. Bolt 12. Shaft

27- 54
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
HYDRAULIC PUMP IDLER GEAR BEARING
ADJUSTMENT, (G), FIGURE 37.
65. When installing new bearings it will be necessary
to calculate the thickness of spacer (4) to obtain the
correct bearing preload. The spacer is available in
various thickness of 11.80--12.60 mm in steps of
0.025 mm.
66. Measure thickness of each bearing and record as
B1 and B2.

55
67. Place bearings in drive gear and measure
dimension ’A’.
68. Calculate thickness of spacer as follows.
Shim Thickness = A--(B1+B2)--0.15 mm
Example
B1 = 15.95 mm
B2 = 15.95 mm
A = 44.45 mm

TIA35075

56
Spacer Thickness
= 44.45--(15.95+15.95)--0.15 1 2
= 44.45--31.9--0.15
= 12.45 mm
69. Install gear (1), bearings (2) and selected
spacer (3).

3
TIA35076
57
70. Insert shaft retaining pin with lubrication groove
positioned horizontally.

27- 55
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
71. Install locking bolt and tighten to a torque of 50 Nm
(33 lbf ft). Turn idler gear to settle bearings, then 1 2
loosen bolt and re torque to 30 Nm (22 lbf ft) and
bend over locking tab.

TIA35069
59
72. Wrap a piece of cord around the idler gear and
using a spring balance check if the pull required to
turn the idler gear is 0.150--0.400 Kg. If pull is away
from specification recalculate thickness of spacer
required.

27- 56
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
HYDRAULIC LOCK DIFFERENTIAL ASSEMBLY
Removal--Installation (Op. 27 106 37)
With the assembly removed from the rear axle
housing, proceed as follows.
WARNING
Handle all components with the greatest care
Do not insert hands or fingers between the partWear
suitable protection clothing, including goggles, gloves
and footwear.

1. Loosen the crown wheel attaching bolts.

24406

1
2. Detach the crown wheel (1) from the differential
1
casing (2).

24407

2
3. Remove the side gear (1) from the differential
casing.

24408

27- 57
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
4. Remove the locking pins (1) of the differential gear
pivot pins.

24409

4
5. Slide out the pivot pins (2) and recover the
differential gears from both sides. We advise to 1
keep the pivot pin and side gear matched as they
removed.

2
24410

5
6. Withdraw the pivot pin (2), recover the pivot pin
holder (1) and side gears. 1

24411

6
7. Remove differential lock control gear retaining ring
(1). 1

24412

27- 58
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
8. Using suitable pullers, remove the bearing from the
crown wheel.
9. Remove the bearing from the differential casing as
indicated at step 8.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS. 1

10. Reinstall all the components of the differential

assembly observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 9 back to step 24413
1.
8
-- Refer to figures on pages 9 and 10 for correct
orientation of the different parts.
-- Tighten to correct torques as detailed on pages
3 and 4.
-- Consider the following operations and carry
out the adjustment detailed below.
11. Assemble the bearing (1) on the crown wheel and
differential casing using a suitable hammer.

Side gear end float adjustment (Shims A and B

Figure 37).
NOTE: Adjust the LH side carrier end float as indicated
for the RH side gear.
12. Assemble side gears, pivot pins and retaining pins.
13. Place the side gear (3) complete with a test shim
(2) on tool no. 293986 (1). 1

24414

1 2

24415

27- 59
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
14. Assemble the side gear and attached tool no.
293986 on the differential casing, place the crown
wheel above it and fix the crown wheel with three
bolts (1). Turn the assembly to settle.
1

24416

11
15. Place a dial test indicator gauge with the stylus on
the tool screw (1), press the tool and set gauge to
zero.

24417

12
16. Pull the tool (1) upwards and read the travel (H) on
the gauge.
17. Adjuster ring thickness to be inserted on RH side
gear is given by: 1
Rd = (B + H) -- 0,05 -- 0.30
where:
Rd=Adjustment shim to be inserted on RH side
gear.
B = Test shim = 3.00 mm
H = Travel measured using the gauge
0.05 mm =Half end play of differential gears in
relation to their pivot pins 24418

0.30 mm =Specified side gear end play. 13

Example
-- Travel measured using the gauge H = 0.50 mm
-- Test shim B = 3.00 mm
-- Thickness of the ring to be inserted on the RH side
gear is
Rd = (3.00 + 0.50) -- 0.05 -- 0.30 = 3.15 mm
18. Once determined the shim packs for LH and RH
side gears, reassemble the whole unit and tighten
the crown wheel to differential casing attaching bolt
nuts at 137 Nm (14 kgm).

27- 60
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
HYDRAULIC DIFFERENTIAL LOCK CONTROL
UNIT (Dog type clutch)
Removal--Installation (Op. 27 110 44)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

1. With the assembly detached from the rear axle

housing, proceed as follows. Place the assembly 1
(1) on a clean bench.

24419

1
2. Act on the piston (1) to release the retaining ring.

24420

2
3. Remove the retaining ring (1).

24421

27- 61
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
4. Withdraw the lock control unit (1) from its case.

24422

4
5. Remove circlip (1).

24423

5
6. Disassemble the unit, inspect all components and
seals, replace worn or damaged parts.
7. Reinstall all the components of the differential lock
control unit observing the following
-- Reassembly follows the disassembly
procedure in reverse, from step 6 back to step
1.
-- Refer to figures on page 9 for correct
orientation of the different parts.
-- Lubricate all details with AMBRA MULTI G oil.

24424

27- 62
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
WARNING
HYDRAULIC DIFFERENTIAL LOCK CONTROL
Handle all components with the greatest care.
UNIT (multi-plate clutch)
Do not insert hands or fingers between the parts.
Removal--Installation (Op. 27 110 42)
Wear suitable protection clothing, including goggles,
gloves and footwear.

With the crown wheel/pinion and differential assembly

on the bench, proceed as follows:
1. Loosen the bolts (1) retaining the differential lock
(2) and differential casings (3).
2. Detach the differential lock case (1) and recover
the multi--plate clutch (2).

1
3. Using a depth gauge, check if the clearance (3)
between the differential casing and the multi--pack
clutch (2) is 1.35 to 3.1 mm. If this is not the case,
replace clutch discs.
4. Reinstall all the components of the differential lock
control unit observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 3 back to step
1.
-- Refer to figures on page 10 for correct
orientation of the different parts.
-- Lubricate all components with AMBRA
MULTI--G oil.
2

27- 63
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
FINAL DRIVE CASE (LEFT OR RIGHT HAND)
Removal--Installation (Op. 27 120 10 -- 27 120 20)
WARNING
Lift and handle all heavy components using lifting
equipment of appropriate capacity.
Ensure that units or parts are supported by suitable
slings or hooks.
Ensure that no--one is in the vicinity of the load to be
lifted.

Remove the final drive case as follows:

1. Open and raise engine hood.
2. Disconnect negative cable (1) from battery and
insulate.

1
3. Loosen the plug (3) and drain oil from rear axle and
speed clutch/transmission housings into a suitable
container.

2
4. Jack up rear tractor and place a stationary stand
under the rear axle housing and a stationary pillar
under the LH steps to the cab.
5. Sling the wheel using a nylon cable (3), loosen
retaining nuts and remove the wheel. Repeat for
left wheel.

27- 64
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
6. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect the tool to a hoist using the hook tool no.
290740 and keep hook tensioned.

4
7. Loosen and remove the bolts attaching the cab to
rear brackets (on both rear mounts).

5
8. Detach the telescopic stabiliser, loosen the
attaching bolts and remove cab bracket (2) and
telescopic stabiliser bracket (3).
9. Reinstall bolt and nut on the rear RH mount.

6
10. Loosen the mounting screws and remove the draft
sensor wire protection (5).

27- 65
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
11. Place tool no. 50091 (1) and connect it to a hoist
using a rope. Loosen the final drive case to rear
axle housing retaining nuts.

8
12. Remove the final drive assembly (2) from the rear
axle housing together with the half--shaft (3)

9
13. Detach the piston from the spacer (5), recover
outer ring gear (4), spacer and friction plate (6).
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

14. Reinstall the final drive assembly to the rear axle

housing observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 13 back to step
1. 10
-- Refer to figures on pages 9 and 10 for correct
orientation of the different components.
-- Before reassembling the final drive case,
thoroughly clean and degrease mating
surfaces and apply a bead of liquid gasket of
approx. 2 mm. of diameter following the
patterns shown in the figures on page 35.
-- Tighten to correct torques as detailed on pages
3 and 4.
-- To assist final drive case reinstallation, locate
the half--shaft (4, Fig. 8) into its seat on the
differential and brake disc.

27- 66
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
DRIVE WHEEL SHAFT
Removal--Installation (Op. 27 120 34)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

With the final drive case removed from the rear axle
housing, proceed as follows:
1. Position the final drive case (1) on a rotary stand.

24608

1
2. If necessary, remove the locking plate (1) by
slightly turning it

24609

2
3. Loosen the screw attaching the planetary carrier
(1) to the drive shaft.

24610

27- 67
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
4. Slide out the planetary carrier (1).

1
24611

4
5. Recover the thrust washer (1).

24612

5
6. Using a suitable puller, remove the drive shaft (1).

6
7. Remove the seal (1) and recover the bearing inner
cup from the wheel side.

24614

27- 68
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
8. Using an expansion puller and a slide hammer,
remove the bearing outer cup from the wheel side.

8
9. Using an expansion puller and a slide hammer,
remove the bearing outer cup (1) from the final
drive side.

24616

9
10. Remove the seal (1).
WARNING
1
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

11. Reinstall all the components of the drive wheel

shaft assembly observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 10 back to step
1.
-- Refer to figures on pages 9 and 10 for correct
orientation of the different parts. 24617
12. Install the outer bearing cups and seals on the 10
housing using suitable drifts.
13. After installing all components on the final drive
case, adjust the drive wheel taper bearings.

27- 69
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
Drive wheel taper bearing adjustment
14. Tighten the screw (C3, page 3) to 196 Nm (20 kgm)
while turning the shaft to settle the assembly.
15. Loosen the screw (C3, page 3) then tighten it again
to 88 Nm (9 kgm) while turning the shaft to settle
the bearings properly.
16. Insert the safety plate and lock it screwing in or out
the screw (C3) until reaching the next notch
NOTE: Screw in or out to a max. angular variation of
15°.
17. Turn the shaft by hand and check if it turns freely,
with no end float, nor excess resistance
18. Using the grease nipple, fill the inner recess with
grease AMBRA GR 75 MD (several grease gun
strokes are needed). If a plug is fitted instead of the
grease nipple, remove plug and replace with a
grease nipple.

24619

27- 70
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
PLANETARY GEAR SET
Removal--Installation (Op. 27 120 32)
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

With the assembly removed from the case, proceed as

follows:
1. Remove retaining ring (1).

2. Slide out the pivot pins and recover the gears

complete with the needle bearings. Remove the
thrust washer (1).
3. Reinstall all components of the planetary gear set
observing the following:
-- Reassembly follows the disassembly
procedure in reverse, from step 2 back to step
1.
-- Insert the thrust washer (1) first on the driven
gear holder.

24621

27- 71
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1
NOTES

27- 72
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
SECTION 31 -- POWER TAKE--OFF

Chapter 1 -- Power Take--Off

31 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS
TM115--125-- TM165
135 and 150
540/1000 rpm PTO: fully independent
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . of tractor ground speed
or
synchronised with tractor gearbox
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through an electro--hydraulic
clutch pack in oil bath
Rotation (looking from tractor rear end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever located at the
operator’s RH side
Engine Speed at 540 rpm PTO Speed . . . . . . . . . . . . . . . . . . . . . . . rpm 1969
Engine Speed at 1000 rpm PTO Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2120
PTO Speed at Engine Max. Power Rating:
-- 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 603 631
-- 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 1038 1085
Transmission Synchronised PTO Speed
Synchro--Command
-- 540 rpm (TM115 & TM125) revs/wheel rev 13.9
-- 540 rpm (TM135 & TM150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 14.4
-- 1000 rpm (TM115 & TM125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 23.8
-- 1000 rpm (TM135 & TM150) .......................... » 24.8
Dual, Range and Power Command
-- 540 rpm (TM115 & TM125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 15.4
-- 540 rpm (TM135 & TM150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 16.0
-- 1000 rpm (TM115 & TM125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 26.5
-- 1000 rpm (TM135 & TM150) .......................... » 27.6
(continued overleaf)

31- 1
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
SPECIFICATIONS
(cont’d)

TM115--125-- TM165
135 and 150
Splined Output Shaft Diameter:
-- 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8” (6 splines) or
13/4” (6 splines) (optional)
-- 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8” (21 splines)
Driven Gear Bush OD (9, pages 4 and 5) . . . . . . . . . . . . . . . . . . . . mm 54.910 to 54.940
Driven Gear ID (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 55.060 to 55.106
Gears to Bushes Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 0.120 to 0.196
Driven Shaft Diameter. (11, pages 4 and 5) . . . . . . . . . . . . . . . . . . . mm 44.366 to 44.391
Bush ID (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 44.400 to 44.425
Shaft to Bushes Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 0.009 to 0.059
540/750/1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to previous description for
540/1000 rpm PTO except the
following
Engine speed at 750 rpm PTO speed . . . . . . . . . . . . . . . . . . . . . . . rpm 2148
PTO speed at engine max. power rating . . . . . . . . . . . . . . . . . . . . rpm 768 803
Splined output shaft dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8” (6 splines)
Transmission Synchronised PTO Speed:
Synchro--Command
-- TM115 & TM125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . revs/wheel rev 17.6
-- TM135 & TM150 . . . . » 18.4
Dual, Range and Power Command
-- TM115 & TM125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . revs/wheel rev 19.6
-- TM135 & TM150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 20.4
PTO Engagement Clutch
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulically actuated clutch pack
in oil bath
Number of Clutch Discs:
-- Drive Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8
Drive Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.45 to 1.55 1.45 to1.55
-- Driven Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8
Driven Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.35 to 2.40 2.35 to 2.40
Number of Clutch Engagement Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulically controlled brake
band acting on the clutch bell
housing
Control Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . same as for the power steering
circuit
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge type
Oil Filter Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . at pump inlet

31- 2
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
TIGHTENING TORQUES
Tightening Torque
Nm kgm
PTO case mounting bolts (C1, page 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 211 21,5
PTO output shaft retaining self--locking nut (C2) . . . . . . . . . . . . . . . . . . . M 12 x 1.25 137 14
PTO shaft retaining nut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 32 x 1.5 294 30
PTO clutch brake connecting plug (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . M 35 x 1.5 83 8,5
Spring retaining plug (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 49 5
Support bearing retaining screws (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 88 9
Solenoid valve retaining screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 5.4 to 8.1 0.55 --
0.83
Solenoid valve pin retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 47 to 54 4.8 to 5.5

SPECIAL TOOLS
CAUTION
Operations described in this section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated
with the self--made ones for which you will find the
necessary construction drawings and specifications
directly on this Manual.

List of special tools necessary to perform service

operations covered by this section of the Manual:

292870 Hydraulic clutch pressure test kit.

X 293997 Clutch drive shaft roller bearing installer
(with tool no. 293800)
X 293836 Clutch drive shaft seal protection
X 293993 Clutch drive shaft seal installer (with tool
no. 293800)
X 290785 Clutch drum seal mounting protection
X 294000 Cup and shaft bush removal pliers
293812 PTO guide pins
293800 Attachment (for tools nos. 293993 and 1
293997) PTO hydraulic clutch spring cup tool (Mark tool with
no. 50063. Dimensions in mm.)
293998 Clutch shaft cup installer Fabricate tool using Fe42C material.
293999 Clutch brake plunger puller adapter
50063 Clutch spring cup tool (use with tools no.
292651 and 292654) to be fabricated on
site, see fig. 1.

31- 3
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

2
(540 -- 750 -- 1000 rpm) PTO Sectional Views
C1. PTO case retaining screws 8. Driven gears
C2. PTO output shaft retaining nut 9. Driven gear support bushes
C3. PTO shaft retaining nut 10. Engagement sleeves
11. Driven shaft
C4. PTO clutch brake plug
12. Seal
C5. Spring retaining plug
13. Seal
C6. Support bearing retaining screws 14. Drive piston
1. Drive discs 15. Brake operating piston
2. Driven discs 16. Brake band
3. Clutch engagement spring 17. ‘O’ ring seals
4. Clutch body 18. Clutch control lines
5. Return spring 19. PTO speed selector lever
6. Metal seal rings 20. Speed selector fork
7. Drive gear
NOTE: During installation apply liquid gasket on surfaces marked with an X.

31- 4
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

b
3
PTO Sectional Views
a. Two--speed PTO sectional view (540--1000 rpm) 7. Drive gear
b. Two--speed PTO sectional view (540--1000 rpm) with 8. Driven gears
speed selection by replacement of the splined output 9. Driven gear support bushes
shaft 10. Engagement sleeves
C1. PTO case retaining screwss 11. Driven shaft
C2. PTO output shaft retaining nut 12. Seal
C3. PTO shaft retaining nut 13. Seal
1. Drive discs 14. Drive piston
2. Driven discs 15. Speed selector pin
3. Clutch engagement spring 16. Speed selector lever
4. Clutch body 17. Speed selector fork
5. Return spring 18. Return spring
6. Metal seal rings
NOTE: During installation apply liquid gasket on surfaces marked with an X .

31- 5
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4
Transmission Synchronised PTO Sectional View
1. Snap ring 6. Control gear
2. Engagement sleeve 7. Engine--controlled PTO drive shaft
3. Snap rings 8. Snap rings
4. Drive shaft support bearing 9. Idle gear
5. Trans. synchronised PTO drive shaft

DESCRIPTION AND OPERATION

The power take--off (P.T.O.) transfers engine power The PTO drive shaft runs through the transmission
directly to mounted, semi-mounted or trailed upper shafts. The PTO drive shaft front end is directly
equipment via a splined shaft at the rear of the tractor. splined to the engine flywheel, the rear end is
connected to the PTO control clutch.

31- 6
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
The Electronic Management Unit/Touch Panel
processor provides the control of the rear P.T.O. The
processor receives input from the P.T.O. ON/OFF
switches, (in cab and fender), P.T.O. speed sensor,
brake, soft start and ground speed interlock switches
and then provides the output signals to the P.T.O.
clutch engagement solenoid or P.T.O brake solenoid
and the P.T.O. ON/Overspeed warning lamp. If the
correct conditions are met, ie, speed parameters and
switch engagements then the P.T.O. is allowed to start.
Four types of rear P.T.O. system are available,
dependent upon tractor model and country.
a) Two--speed P.T.O. (North America only) with
inter-changeable output shafts. 5
b) Two--speed or three--speed, shiftable P.T.O.
(except North America) with inter-changeable
output shafts and the option of fender-mounted
switches for stationary P.T.O. work.
c) Three--speed ground drive P.T.O., available in
conjunction with three speed shiftable P.T.O.
above. (except North America).

Figure 6
The P.T.O. is engaged and disengaged by means of a
knob (2) on the right-hand console. The adjacent
warning light (1) will illuminate when the P.T.O. is
engaged.

6
Figure 7
A ‘soft start’ facility is provided on all models to permit
easy start up of heavy, high inertia, P.T.O.--driven
equipment. Soft start is engaged by means of a rocker
switch (1), on the right-hand B--pillar.
Soft start ‘feathers’ the P.T.O. clutch over the first 5
seconds of engagement to provide a slower, gradual
take up of the drive.
NOTE: Soft start only operates at engine speeds of
1800 rev/min and below. Above this speed, normal
P.T.O. engagement will occur, even if the switch is
actuated.

31- 7
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
Figure 8
With shiftable P.T.O., a range lever is provided. The
lever is used to select one of two or three P.T.O. speed
ranges to provide power or economy. The range lever
(1), is located at the rear of the right-hand console.
Ground drive P.T.O. is available, in conjunction with
3--speed, shiftable P.T.O., on all models except the
TM165. As suggested by the name, ground drive
P.T.O. speed is directly related to rotation of the rear
wheels rather than engine speed. When ground drive
P.T.O. is installed, a second lever (2) is provided.
Three ground speed ranges are provided, selected by
means of the P.T.O. range lever (1). The lever (2) is
used to select ground drive. 8

IMPORTANT: An automatic P.T.O. brake is installed to

stop shaft rotation quickly when the P.T.O. is
disengaged. To avoid overstressing the P.T.O. brake,
slow down the implement by reducing engine speed
before disengaging the P.T.O. This is particularly
important with implements having a high inertia. Such
implements should, ideally, be fitted with an overrun
clutch. To avoid damage to the brake when operating
high inertia implements, hold down the switch (1), to
disengage the brake and allow the implement to come
to rest naturally.
DANGER
To avoid inadvertent movement of the implement,
disengage the P.T.O. after each use. 9

31- 8
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
EXTERNAL P.T.O. CONTROLS (except N.
America) -- Figure 10
An optional, fender-mounted P.T.O. switch (1), may be
installed on the outer surface of both rear fenders to aid
alignment of the P.T.O shaft splines with equipment
and facilitate stationary P.T.O. operations.
With the engine running, touch the switch momentarily
to cause the P.T.O. shaft to index round to align the
shaft splines. If the switch is pressed for less than 5
seconds, the shaft will stop turning when the switch is
released.
Press and hold in the switch for more than 5 seconds
and the P.T.O. will operate continuously. Press the
switch again to stop the P.T.O. Alternatively, the P.T.O. 10
may be stopped by means of the in-cab controls, as
previously described.
NOTE: The warning light, on the P.T.O. control panel,
will illuminate when the P.T.O. is engaged, momentarily
or permanently.
NOTE: The P.T.O. may be engaged or
disengagedfrom the fender switch, whether the in-cab
control is in the on or off position.
NOTE: Simultaneous operation, within two seconds,
of in cab and external P.T.O. controls will result in error
code P38 showing. A 10 second delay will also occur
before P.T.O. control operation will recommence.
NOTE: The soft start function, if selected, will operate
irrespective of whether the P.T.O. is engaged from
inside the cab or from a fender switch.

31- 9
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
CAUTION
Before leaving the tractor to operate the external
Power Take Off switches:
• Move the gearshift levers to neutral.
• Disengage the P.T.O.
• Apply the parking brake.
With the engine running, move the hand throttle lever
to the low idle position (fully rearwards).

Figure 11
The operator must only activate the external Power 1
Take Off switches (1) while standing to the side of the
tractor (outboard of the rear tyres). To aviod damage to
implement or tractor, operation of the in cab and
external P.T.O. switches should not be carried out
simultaneously.
WARNING
Before using the external Power Take Off switches,
ensure that no person or object is in the area of the
implement, 3-point linkage or [Link].
Never operate the external switches while standing:
• Directly behind the tractor or tyres. 11
• Between the lower links.
• On or near the implement.
• Never extend arms, legs, any part of the body or
any object into the area near the 3-point linkage,
P.T.O. shaft or implement while operating the
external switch.
• Never have an assistant working the opposite set
of controls.
• When moving to the opposite set of controls, move
around the tractor or implement.
• Do not cross between the implement and tractor.

31- 10
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

Return to reservioir oil

Lubrication pressure oil

PTO CONTROL CLUTCH DISENGAGED

When the PTO is not in use, the oil is returned to An annular groove on the lubrication control valve (1)
reservoir and without pressure as the solenoid valve is guarantees the passage of enough oil to lubricate the
in the discharge position (de--energised). PTO drive shaft roller bearing (3).
Under these conditions, the spiral spring (5) keeps the When the clutch is being disengaged, the ball (2)
control clutch (4) disengaged. moves and allows control oil to flow inside the bore of
the clutch discharging plunger.

31- 11
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

Return to reservoir oil

Lubrication pressure oil

PTO CONTROL CLUTCH ENGAGED

When the switch on the right hand console is pressed, In this way, drive is transferred from the PTO drive shaft
the solenoid valve opens and deviates oil from the (2) to the PTO driven shaft (6).
pump into the piston (3) annular groove, where it Furthermore, pressurised oil moves the lubrication
overcomes the spring action (5) and compresses the control valve (1) and allows passing oil to lubricate and
control clutch pack. wash the entire clutch assembly.

31- 12
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

Pressure oil

PTO CLUTCH BRAKE

The band type clutch brake operates automatically. It valve is in the discharge position (de--energised) and
applies when the PTO clutch is being disengaged consequently there is no operation of the actuation
(braking start) and stops braking when the clutch is piston (1) onto the band operating lever (2), the piston
completely engaged. (1) being returned by the spring (5).
When working with high inertia implements it is When the PTO control clutch is being disengaged, the
possible to keep the brake disengaged by pressing the solenoid valve is energised and opens, deviating oil
switch located on the right hand console near the PTO from the pump onto the piston (1). The piston contacts
control handle. When the PTO clutch is engaged, the the lever (2) and band (4) is tightened against the
brake control oil is returned to reservoir as the solenoid housing (3) to brake the assembly.

31- 13
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
TROUBLESHOOTING

The table below details some possible displayed on the instrument cluster. The PTO
mechanical/hydraulic faults. The Electronic generated error codes are listed overleaf, for full details
management Unit/Touch panel processor will also refer to the Electronic Management Unit, Section 55,
generate error codes related to the PTO system. The Chapter 2.
error codes are prefixed with the letter ‘P’ and

Problem Possible Causes Correction

The PTO does not operate 1. Low transmission oil level. Reset correct level.
2. Blocked oil filter. Replace filter.
3. Faulty hydraulic pump. Repair or replace pump.
4. Faulty PTO engagement switch Replace switch.
5. Lack of power supply to the sole- Reset electrical connections and
noid valve: detached or dam- replace faulty parts.
aged connectors, faulty remote
switch.
6. PTO control solenoid valve stuck Repair or replace solenoid valve.
open.
7. Oil leakage through the seals Replace damaged seals.
with consequent pressure drop:
manifold or control plunger seals
The PTO remains engaged. 1. Faulty PTO engagement switch. Replace switch.
2. Lack of power supply to the sole- Reset electrical connections and
noid valve: detached or dam- replace faulty parts.
aged connectors or faulty remote
switch.
3. PTO control valve stuck open Repair or replace solenoid valve.
The PTO control clutch drags. 1. Faulty brake engagement switch Replace switch.
2. Lack of power supply to the sole- Reset electrical connections and
noid valve: detached or dam- replace faulty parts.
aged connectors or faulty remote
switch.
3. Brake control valve stuck closed. Repair or replace solenoid valve.
4. Worn PTO brake Replace brake.

31- 14
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
Electronic Management Unit / Touch Panel PTO Generated Error Codes
PRIORITY ERROR ERROR DESCRIPTION
(1 = Highest) CODE
1 P01 Rear PTO brake solenoid stuck off (circuit shorts to ground or module failure)
2 P02 Rear PTO brake solenoid stuck on (circuit shorts to +12V or module failure)
3 P03 Rear PTO brake output open circuit
4 P04 Rear PTO brake driver over temperature (circuit shorts to +12V or module failure)
7 P07 Rear PTO solenoid stuck off (circuit shorts to ground or module failure)
8 P08 Rear PTO solenoid circuit overcurrent (circuit shorts to ground)
27 P27 PTO speed sensor open circuit
33 P33 Rear PTO cab switch momentary contact open circuit
34 P34 Fender mounted rear PTO switch (if fitted) open circuit or short to ground
35 P35 Fender mounted rear PTO switch (if fitted) input short to +12V or short across
fender switch wires
36 P36 PTO failure to start
37 P37 Rear PTO cab momentary switch stuck closed (longer than 30 seconds)
38 P38 Cab and fender rear PTO controls operated within 2 seconds for each other
39 P39 Incorrect voltage on fender mounted rear PTO switch input (if fitted)
40 P40 PTO relay coil short to +12V or open circuit
41 P41 PTO relay coil short circuit to ground

31- 15
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
POWER TAKE OFF (PTO)

Removal -- Installation
(Op. 31 114 20 -- 31 116 20)
WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the PTO and hydraulic clutch as follows:

1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

1
3. Unscrew plug (3) and drain oil from transmission
and rear axle housings. Collect oil in a suitable
container.

2
4. Loosen retaining screws and remove the PTO
guard (1).
5. Loosen retaining screws and detach the hitch pin.
6. Remove the adjust tie--rod from the top link.

31- 16
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
7. Loosen the screws retaining the speed sensor (2),
detach connector (1) and recover the speed
sensor. Withdraw support (3).

4
8. Detach clutch control lines (1) and PTO rotation
speed selector lever (2).
1

24475 24476

5
9. Loosen the PTO assembly retaining screws (1).

24474

6
10. Using a hoist and a suitable hook detach the PTO
assembly (1) from the rear axle housing.

1
24477

31- 17
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

11. Reinstall the PTO case to the rear axle housing

taking the following into consideration:
-- Rassembly follows the disassembly procedure
in reverse, from step 10 back to step 1.
-- Before reinstalling the PTO case, thoroughly
clean and degrease mating surfaces and apply
a bead of liquid gasket of approx. 2 mm of
diameter following pattern shown in the figure
below.
-- Tighten to correct torques as detailed on page
3.

Pattern for application of liquid gasket between

the PTO case and rear axle housing.

31- 18
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
POWER TAKE OFF

Removal--Installation 540/750/1000 rpm PTO (Op.

31 114 46 -- 31 114 47 -- 31 114 48 -- 31 114 60 -- 31
1
116 46 -- 31 116 47 -- 31 116 48).
WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

Proceed as follows:
24478
1. Place the PTO assembly (1) on a rotary stand. 1
2. Remove the split pin (2) retaining the brake band
(1) and slide the brake band from the housing.

2
3. Remove the snap ring (2) and recover the drive
gear (1). 1 2

24479

3
4. Remove the driven and drive disc assembly (1)
together with the inner gear (2). 1 2

24480

31- 19
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
5. Reinstall the snap ring (2) using a puller (1) and
1
special tool 50063 (4, page 3). Screw in the puller
until releasing and removing the retaining ring (3). 2
Remove the snap ring (1).

4 3

24481

5
6. Recover the washer (1), spring (2), lower washer
1 2
(3), and Belleville spring (4).

24482

6
7. Using the special tool no. 29400 (1) and slide puller
292927 remove the cup (2) and inner bearing (3).
1
3
2
1

24483 24484

7
8. Using compressed air, remove clutch control
plunger (1).

24486

31- 20
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
9. Loosen the clutch control lines (1) and remove.

1 1

24487 24488

9
10. Loosen the driven shaft retaining nut (1).

24490
1
10
11. Remove the selector fork detent assembly, ball (1),
spring (2) and cap (3).

11
12. Unscrew the screws (2) retaining the drive shaft
support plate (1). 1

24491

31- 21
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
13. Remove the support plate (1) together with the
drive shaft.
1

13
14. Remove the pawl retaining pin (1) and recover the
1 2
pawl (2).

14
15. Loosen the nut (1), slide out the shaft (3) and 2
1
remove the entire assembly of the driven gears (2)
complete with forks and rod.

24496

15
16. Remove the seal (1).
1

24497

31- 22
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
17. Remove the snap ring (2) and recover the bearing 1 2
(1).

17
18. Withdraw the upper bearing (1) using a slide puller
equipped with a ring expander.

24499

18
19. Withdraw the spring pin (1) and remove the lever
complete with the selector control.

2
1

24500 24501

19
20. Remove the snap ring (1).

24502

31- 23
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
21. Loosen the screws (1) which retain the hydraulic 1
clutch control manifold (2).

24503

21
22. Withdraw the thrust washer (1), bearing inner race 1 2
(2), gear (4), manifold (3) with particular care to the
metal seal rings (1, fig. 23).
4

24504

22
23. Unhook and remove the metal rings (1).
1

24505

23
24. Remove the snap ring (1) and slide out the gears 3
(2) and thrust washer (3).

1 2
2

24506 24507

31- 24
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
25. Place the support plate (2) on two wooden blocks
and drive out the shaft (1) using a brass drift and a
hammer.

1
2

24508

25
26. Open the snap ring (2) and remove bearing (1).
27. Reassemble all details into the PTO case taking
the following into consideration:
-- Reassembly follows the disassembly
procedure in reverse, from step 24 back to step 1
1.
2
-- Check all seals and replace if necessary.
-- Tighten to correct torques as detailed on page
3.
-- Refer to figures on pages 4 and 5 to orient the
components.
-- Consider the following steps. 24509

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

28. Install the upper bearing (1) using a suitable

installer. 1

24510

27
29. Install the seal (1).

31- 25
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
30. Install the bearing (2) on the PTO drive shaft (1).

24512

29
31. Position the drive shaft (1) complete with its
1
bearing on the support plate (3) and lock it in place
using the snap ring (2).

3
2

24513

30
32. Insert the driving shaft (2) into the clutch case (1)
and keep it in place using a suitable support until 1
complete mounting.
2

24514

31
33. Install the seal (2) using the protection tool no.
290785 (1).
NOTE: Wait at least 15 minutes before mounting the
plunger (3). 1

24516
24515

31- 26
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1
34. Install the bearing (1) using the special tool no.
293997 (1) and attachment tool no. 293800.

24517

33
35. Position the cup (2) using the special tool no.
293998 (1) complete with an hex head bolt
M14x1.5 of suitable length.

24518

34
Ground Drive PTO Interlock Switch Adjustment
1. Position the ground drive PTO lever (1), into the
engaged position. Figure 35.
The lever should not be touching the switch.

35
2. Adjust the position of the switch, by slackening the
two nuts (1) on the switch bracket, to achieve a
12mm gap between the switch and pivot assembly.
3. After the correct gap is set, verify the operation of
the switch with a suitable multimeter. With the lever
engaged (ground drive selected) the switch should
be open circuit, with the lever disengaged (engine
speed PTO selected) the switch should be closed
and the resistance approximately 4Ω.
NOTE: The cab and operating lever are removed from
Figure 36 for clarity.

31- 27
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

NOTES PAGE

31- 28
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
SECTION 31 POWER TAKE--OFF

Chapter 2 -- Hydraulic Front Lift and Power Take--Off

CONTENTS

Section Description Page

31 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation
35 162 Front Hydraulic Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
31 146 Front P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overhaul
35 162 Front Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
31 142 Front P.T.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic and Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

31- 1
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
SPECIFICATIONS
Lubrication Relief Valve Setting (Open) 3.5bar 50 lbf/in2
P.T.O. Circuit Operating Pressure 16--18bar 232--261 lbf/in2
Clutch Friction Plate Thickness (new) 2.4mm 0.0945 in
Clutch Disc Thickness--Steel (new) 1.5mm 0.059 in

TORQUES

31- 2
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
DESCRIPTION AND OPERATION
Tractors with four wheel drive may be fitted with an
engine driven P.T.O. (1) and double acting front
hydraulic lift system (2).
If required the front hydraulic lift assembly can be
supplied without the front P.T.O. option.
Both systems operate independently.
When tractors are installed with the front hydraulic lift
they must also be fitted with engine side rails for
additional support to the transmission drive line
components.

2
Front Hydraulic Lift
The front hydraulic lift consists of an adjustable top link
(1) and a pair of folding lower links (2 and 3). The top
and lower links have open claws that permit rapid
coupling and uncoupling of implements. The claws are
equipped with self locking latches to ensure positive
retention of the tractor linkage to the implement.
Two double acting hydraulic cylinders are used to raise
and lower the hydraulic lift.

3
The front lift is operated by diverting the oil flow from
the No1 hydraulic remote valve to the hydraulic lift.
This process therefore allows the lift to be raised and
lowered using the No 1 remote valve controls.

4
Maximum height of the front lift is controlled using the
height limit control (1).

31- 3
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

6
Hydraulic Schematic Front Hydraulic Lift
1. Height Limit Control 5. Accumulator
2. No 1 Remote Control Valve Lever 6. Lift Arm Position Sensing Potentiometer
3. Diverter Valve 7. Front Hydraulic Lift
4. Remote Control Valve No 1 8. Solenoid Valve
When operating the front hydraulic lift the open/shut When the lift reaches the set height the solenoid valve,
diverter valve (3), must be opened allowing oil supply connected in the supply line to the front lift raise port of
from the number 1 remote valve (4) to be diverted to the cylinders and located on top of the transmission top
the front lift via the solenoid valve (8) and accumulator cover, is de--energised blocking the supply to the
(5) whenever the remote control valve lever is cylinders and preventing the lift from raising any
operated. further.
The hydraulic schematic shows the diverter valve The lowering function of the double acting cylinders is
installation for open centre remotes. The installation provided by connecting the flexible hose from the
and operation for closed centre remotes is however retract port of the lift cylinders into the lowering coupler
similar. of the number one remote valve.
The height limit control works in conjunction with the lift When the lift is lowered oil from the lower port of the
arm potentiometer (6) mounted underneath the front remote valve is directed through the retract ports of the
lift. lift cylinder to provide controlled lowering of the lift.

31- 4
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
Front P.T.O.
The electro hydraulically operated front P.T.O. (1) is
mounted directly below the front support and driven
from the engine crankshaft pulley.
The assembly can be supplied with either a 6 or 21
spline shaft.

7
The front P.T.O. is operated by pressing in the central
button (3) and pulling up the selector knob (2) on the
right hand control console inside the cab. The light (1)
illuminates when the P.T.O. is operating.

8
NOTE: When the engine is stopped or stalls, the P.T.O.
will automatically disengage. However, the selector
knob must be returned manually to the ‘off’ position
(fully down) otherwise the P.T.O. will not engage when
the engine is restarted.
WARNING
To avoid inadvertent movement of the implement, dis-
engage the P.T.O. after each use.

31- 5
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
Drive from the engine crankshaft pulley to the input
shaft (1) is transmitted to the output shaft (4) using a
multiplate hydraulic clutch.
The clutch is engaged using the solenoid valve (7) and
is applied using 16--18bar low pressure oil through port
(6).
Beneath the cover plate (3) are two gear pumps which
provide lubrication and return excess oil to reservoir
through port (5).

9
Pump (1) referred to as the scavenger pump,
maintains a predetermined reservoir of oil in the P.T.O.
housing for pump (2) which provides lubrication to the
bearings and seals in the assembly

10
P.T.O. Engaged
When the P.T.O. is engaged, Figure 11 the solenoid is
energised and 16--18bar low pressure circuit oil is
applied to the clutch piston through orifice (3). Because
the check valve in orifice (13) is held in the closed
position the pressure applied to the clutch is gradual
and prevents sudden shock engagement of the P.T.O.
Figure 11
Front P.T.O. Engaged
1. Solenoid Valve 8. Input Shaft
2. Lubrication Circuit Pump 9. Lubrication Circuit Reservoir
3. Orifice 10. Lubrication Pump Suction Tube
4. P.T.O. Brake 11. Scavenger Pump Suction Tube
5. Clutch Piston 12. Output Shaft
6. Clutch Plates 13. One Way Check Valve Orifice
7. Lubrication Circuit Relief Valve 14. Scavenger Pump

31- 6
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

11
Front P.T.O. Engaged
Low Pressure Circuit Oil @ 16--18 bar Lubrication Pump Suction Oil

Lubrication Circuit Oil at 1.5--3.5 bar Sump/Return to Reservoir Oil

31- 7
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
P.T.O. Disengaged
When the PTO is disengaged, Figure 13, power to the
solenoid is switched of and the 16--18bar oil pressure
is directed to the P.T.O. brake.
Oil pressure previously applied to the rear of the clutch
piston is now open to reservoir and the large Bellville
washer between the piston and the clutch plates
moves the piston rearwards ejecting the oil to reservoir
through orifice (3) and one way check valve orifice (13).
Because the oil can escape through both orifices the
P.T.O. drive is rapidly disengaged.
When the 16bar pressure is applied to the P.T.O. brake
a small controlled flow of oil also flows through the
orifice (1) Figure 12 in the brake piston and into the
main housing of the P.T.O. assembly.
This controlled leakage maintains a reservoir of oil in
the bottom of the housing for lubricating the P.T.O.
bearings and seals using the lubrication pump.
The pressure of oil within the lubrication circuit is
maintained at 3.5 bar by the lubrication relief valve (7)
located in the input shaft.

12
Because oil continually flows through the orifice in the
P.T.O. brake it is necessary to control the level of oil in
the housing. When the level of oil in the bottom of the
housing is higher than the bottom of the suction tube
(11), the excess oil is returned to reservoir by the
’scavenger’ pump.
Figure 13
Front P.T.O. Disengaged
1. Solenoid Valve 8. Input Shaft
2. Lubrication Circuit Pump 9. Lubrication Circuit Reservoir
3. Orifice 10. Lubrication Pump Suction Tube
4. P.T.O. Brake 11. Scavenger Pump Suction Tube
5. Clutch Piston 12. Output Shaft
6. Clutch Plates 13. One Way Check Valve Orifice
7. Lubrication Circuit Relief Valve 14. Scavenger Pump

31- 8
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

13
Front P.T.O. Disengaged
Low Pressure Circuit Oil @ 16--18 bar Lubrication Pump Suction Oil

Lubrication Circuit Oil at 1.5--3.5 bar Sump/Return to Reservoir Oil

31- 9
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
FAULT FINDING
Problem Possible Causes Correction
P.T.O. permanently engaged P.T.O. Solenoid valve not energised Check electric circuit
Solenoid valve sticking Replace Solenoid Valve
P.T.O. module faulty Replace module
Low power from P.T.O. output shaft Low pressure circuit leak Check if rear PTO exhibits similar
characteristic and perform Low
Pressure Circuit Test and identify
concern in low pressure circuit
P.T.O. piston seals leaking Overhaul P.T.O.
P.T.O. Clutch plates worn Overhaul P.T.O.
P.T.O. output shaft seal leak Worn seal Replace seal and check level of oil
in housing.
Excessive oil level in P.T.O. housing Examine scavenger pump suction
tube for blockage.
Overhaul scavenger pump
P.T.O. bearings overheated/worn Low oil reservoir in P.T.O. housing Check orifice in P.T.O. brake
Lubrication circuit relief valve faulty Check relief valve for signs of
contamination
Lubrication Pump worn Overhaul pump
Lack of oil in P.T.O. Housing Check Oil level. If low examine
orifice in P.T.O. brake
Front lift not raising Diverter valve not open Open valve
Height limit control incorrectly set Adjust control to required setting
Lift arm position sensing Replace potentiometer
potentiometer damaged
Front lift will not raise heavy loads Lift Cylinder seals leaking Overhaul lift cylinders

31- 10
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
OVERHAUL

Hydraulic Front Lift--Removal and installation

(Op. 35 162
1. lower lift arms.
2. Remove the top link (1) and folding lower links (2)
and (3).

14
3. Remove lower guard.

15
4. Disconnect lift arm position potentiometer (1).

16
5. If necessary the potentiometer can be
disassembled as shown.
1. Lever
2. Spring
3. Seal
4. Screw
5. Potentiometer
6. Seal
7. Circlip
8. Bracket

31- 11
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

18
Front Hydraulic Lift Assembly
1. Bolt 7. Pin and Retainer
2. Block 8. Folding Link
3. Bolt 9. Potentiometer Assembly
4. Pin 10. Folding Link
5. Tabbed Washer 11. Shaft
6. Arm Assembly

6. Disassemble with reference to Figure 18.

31- 12
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
7. Disconnect hydraulic connections to lift cylinders
and remove connectors.

19
8. Support each cylinder while removing R clip (1)
and Pin (2) and lower cylinder to the ground.
9. Refer to Figures 23 and 24 for hydraulic pipework
from remote control valves.

20
Installation
1. Re--assemble lift arms and cylinders with
reference to Figure 18.
2. Lower lift arms and install potentiometer. Position
potentiometer worm drive clip so that
potentiometer arm is touching edge of stop pin
when the lift arms are in the lowered position.

21
3. Applying New Holland sealant 82995776 to edge
of guard and install. Ensure potentiometer is not
touching the guard.

31- 13
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

23
Hydraulic Lift Pipework Installation -- All Tractors
A. Front Lift Solenoid Control Valve C. Accumulator
(Top of Transmission) (Left Hand Side of Tractor)
B. Remote Control Valve D. Front Hydraulic Lift Cylinders
--Closed Centre Remotes Shown (Rear of tractor)

31- 14
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

24
Hydraulic Lift Pipework Installation -- Open Centre Remote Valves
A. Remote Control Valves--Open Centre Hydraulics (Rear of Tractor)
B. Front Lift Solenoid Control Valve (Top of Transmission)
1. Decal 5. Dowty Seal
2. Cover 6. Tube
3. Diverter Valve 7. Dowty Seal
4. Banjo Bolt 8. Tube From Solenoid Valve

31- 15
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
OVERHAUL

Front P.T.O.--Removal and installation

(Op. 31 146)
1. Remove the top link (1) and folding lower links (2)
and (3).
2. lower lift arms.
3. Remove front lift arms with reference to Page
31--12.

25
4. Disconnect battery and swing battery tray away
from the radiator.

26
5. Remove P.T.O. breather hose (2) and covers (1).
2

27
6. Disconnect electrical connection to P.T.O. solenoid
(1).

31- 16
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
7. Disconnect hydraulic connections (1) and (2).

29
8. Remove P.T.O. drive chain.
1. Chain
2. Split Pin
3. Pin

30
9. Using pallet forks support lift/P.T.O. assembly (1).
10. Remove securing bolts and carefully lower
assembly to the ground.

31
11. Remove P.T.O. drive shaft assembly.
1. Bolt
2. Bolt
3. Flange
4. Coupling
5. Shaft
6. Retaining Ring
7. Gear

31- 17
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
Installation
1. Installation follows removal procedure in reverse.
2. Ensure driveshaft and P.T.O. housing mounting
bolts are tightened to the specified torque.
3. Check that guards, hoses and cables are not
touching the P.T.O. driveshaft.
4. Check rear axle oil level.

33
5. Prior to operating front P.T.O. after an overhaul run
engine for 3 minutes with P.T.O. disengaged. This
will allow oil to flow through the P.T.O. brake orifice
and replenish the oil in the housing to the correct
level for lubrication of the P.T.O. components.

34
Front P.T.O.
Disassembly and Re--assembly (Op. 31 146)
1. Remove P.T.O. as described on Page 31--11.
2. Position P.T.O. assembly onto suitable support,
remove drain plug (3) and drain oil.
3. Remove solenoid valve (1) and P.T.O. brake (2)

35
4. Remove hydraulic pumps
1. End Plate and ‘O’ Ring
2. Plate
3. Pump Body
4. Thrust Washer
5. ‘O’ Ring
6. Pump Element
7. Pump Element

31- 18
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
5. Loosen bolts and using suitable drift gently
separate then remove P.T.O. housing.

38
1. Circlip 5. Needle Bearing
2. Washer 6. Clutch Housing
3. Needle Bearing 7. Gear
4. Spacer 8. Housing

6. Remove clutch assembly from input shaft.

7. Remove circlips and separate input shaft from
housing. Inspect bearings for wear or damage and
replace if necessary.
1. Disc
2. Circlip
3. Circlip
4. Input Shaft
5. Housing
6. Circlip

31- 19
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

40
8. Remove oil seal (1) circlip (2) P.T.O. shaft (3) and
driven gear (4).
9. Remove pump suction tubes (1) and (2).

41
10. Remove clutch pack locking wire.

31- 20
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

43
1. Clutch Housing 4. Hub
2. Clutch Plates and Separators (6 off each) 5. Locking Wire
3. End Plate 6. Retainer

11. Disassemble clutch pack.

12. Using press remove circlip which retains the piston
return spring. Refer to Figure 47.
WARNING
After removal of circlip release press in a slow and
controlled manner to prevent the piston return
spring causing personal injury.

44
13. Using compressed air remove piston from clutch
housing.

Inspection
1. inspect all bearings and sealing rings and replace
as necessary.
2. Inspect and replace worn clutch plates and
seperators. Clutch friction plates when new are 2.4
mm thick and metal separator plates 1.5mm thick.

31- 21
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
Re--assembly
1. Install pump suction tubes and P.T.O. output shaft,
Figure 40 and 41.
2. Using a suitable piston ring compressor (1) clamp
the piston seal (2) and then place piston into a
refrigerator or freezer for approximately 30
minutes.
This procedure will compress the seal to assist in
re--assembly.
3. Remove piston ring compressor and using suitable
press immediately install piston into clutch
housing.

47
1. Clutch Housing 5. Cup
2. Piston 6. Circlip
3. Bellville (Spring) Washer 7. Spring
4. Cup

4. Install bellville washer and clutch release spring.

Ensure bellville washer is installed with inner
diameter of washer touching the piston.

31- 22
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
5. Re--assemble clutch assembly, Refer to Figure 47
and 43.
6. Apply New Holland sealant 82995770 to mounting
face of P.T.O. housing and Install input gear and
clutch assembly onto clutch housing.

48
7. Tighten retaining bolts to specified torque.

49
8. Apply New Holland sealant 82995770 to hydraulic
pump mounting face.

50
9. Install hydraulic pumps
1. Bolt
2. Bolt
3. Flange
4. Coupling
5. Shaft
6. Retaining Ring
7. Gear

31- 23
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
10. Tighten bolts to specified torque.

52
11. Install P.T.O. assembly onto tractor.

Hydraulic and Electrical Connections

The hydraulic pipework and electrical connections for
the front lift and P.T.O. are shown in the following
illustrations.
The electrical wiring diagrams are shown in Section 55
Chapter 9B pages 18 and 19 of this manual.

31- 24
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

53
P.T.O. Pipework
A. Top Of Transmission C. Right Hand Side of Transmission
B. Front P.T.O. Assembly

1. ‘Tee’ Connector 5. 45_ Elbow

2. Return Hose from Steering Motor 6. Tube--Return to Reservoir
3. Adaptor 7. Tube--16bar supply
4. Tube/Hose Assembly 8. Elbow

31- 25
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

54
Front P.T.O. and Hydraulic Lift Electrical Connections
A. Front Hydraulic Lift Solenoid Valve C. Front P.T.O. Solenoid Valve
B. Harness Connections Under Cab Floor D. Front Lift Potentiometer

31- 26
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

55
Control Panel Wiring Connections
1. Front P.T.O. Warning Light 3. Front P.T.O. Selector Switch
2. Front P.T.O. Height Limit Control

1. Fuse Box -- Front Lift Control Module.

1. Steering console Left hand side -- Front PTO Control

Module

31- 27
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2
ENGINE SIDE RAILS

58
Engine Side Rail Installation
1. Side Rail 4. Bolt
2. Support Bolt 5. Washer
3. Side Rail
For tractors installed with front lift assembly additional 2. Tighten side rail support bolts to a torque of 385Nm
support to the tractor frame is available by fitting (285 [Link]).
engine side rails as shown.
1. The support bolt (1), where fitted, should be
adjusted until it just touches the transmission
casing

31- 28
SECTION 33 -- BRAKES -- CHAPTER 1
SECTION 33 -- BRAKES

Chapter 1 -- Tractor Brakes

CONTENTS

Section Description Pag.

33 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS
Type:
- Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet disc acting on differential
axle shafts
- Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . three wet discs acting on pinion
gear shaft
Controls:
-- Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic, independent pedals (or
latched for joint operation) ,
-- Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front brakes power assisted
mechanical through a hand lever
Brake Oil Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH 610 A
Ambra Brake LHM (mineral oil)
Service Brake Disc Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resin/graphite
Parking Brake Disc Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
Parking Brake Lining Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sintered
or
organic conglomerate
Disc Thickness:
- Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 10 (min 8.6)
Permissible Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 0.7 per face
- Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 6

33- 1
SECTION 33 -- BRAKES -- CHAPTER 1
SPECIFICATIONS
Parking Brake Lining Thickness:
- Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.1 to 3.4
- Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . » 4.2 to 4.5
Hydraulic Actuation System
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 master cylinders independently
operated through the brake
pedals low pressure hydraulics
Booster valve with master
cylinder for front brakes
Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 17.6 bar
Control Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 19
Brake Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 22

TIGHTENING TORQUES
Tightening Torque
DESCRIPTION Thread Size
Nm kgm
Final drive to rear axle housing attaching nuts (C1 page 3) . . . . . . . . . . . . M 14 x 1.5 176 18
Parking brake pad guide screws (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 24 2.5
Brake assembly to rear axle housing attaching screws (C3) . . . . . . . . . . . M 10 x 1.25 49 5

1
REAR SERVICE BRAKE MASTER CYLINDER SECTIONAL VIEW
1. Spring 4. Rear seal
2. Pump body 5. Centre seal
3. Control piston 6. Front seals

33- 2
SECTION 33 -- BRAKES -- CHAPTER 1

a b

2
PARKING AND SERVICE BRAKE SECTIONAL VIEWS
a. Models TM115, 125, 135 & 150 1. Seal
b. Model TM165 2. Brake control piston
C1. Final drive to rear axle housing attaching nuts 3. Final drive case spacer
4. Service brake disc
C2. Parking brake pad guide screws
5. Parking brake discs
C3. Parking brake assembly to rear axle housing
6. Friction pad assembly
attaching screws
7. Parking brake control lever
8. Pads

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on pages 11 and 17.

33- 3
SECTION 33 -- BRAKES -- CHAPTER 1

3
FRONT SERVICE BRAKE SECTIONAL VIEW
1. Outer Plate Retaining Ring 5. Brake Piston
2. Outer Brake Plate 6. Piston Seal
3. Inner Brake Plate 7. Friction Disc
4. Brake Bleed Screw

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on pages 11 and 17.

33- 4
SECTION 33 -- BRAKES -- CHAPTER 1
SPECIAL TOOLS
CAUTION
Operations described in this section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated
with the self--made ones for which you will find the
necessary construction drawings and specifications
directly on this Manual.

List of special tools necessary to perform service

operations covered by this section of the Manual:

X 295016 Parking brake alignment tool.

292400 Universal lifting hook for rear wheels

Tool to be fabricated to disassemble and
4
reassemble the final drives (Mark tool with no.
50078. Dimensions in mm.)
NOTE: Fabricate tool using 38 NCD 4 material.
1. Fabricate from a male eyebolt M12 DIN 580
2. Apply New Holland adhesive 82995772

5
Tool to be fabricated to disassemble and reassemble the final drives (Mark tool with no. 50091. Dimensions in mm.)
Note: Fabricate tool using Aq 42 D material.
1. Make 2 tie--rods in C 40 H&T material

33- 5
SECTION 33 -- BRAKES -- CHAPTER 1
DESCRIPTION AND OPERATION

SERVICE BRAKES increased pressure down to the front brake units. The
Service brakes are wet disc, hydraulically controlled front brake system has a separate brake oil reservoir
type. Where front axle brakes are fitted these are mounted on the right hand side of the hood support.
hydraulically assisted from the low pressure hydraulic Brake discs (one for each rear wheel) are located
system via a booster valve. between the rear axle housing and final drive cases
The two master cylinders, one for each pedal, are and are splined to the differential output axle shafts.
located at the cab front and connected to the respective The front brakes have a similar one disc arrangement
pedals by means of tie--rods. located within the front hubs
The cylinders can be operated individually or together NOTE: The brake oil used is a mineral type, New
when the pedals are latched together by the pin. Holland Specification NH 610 A, and under no
circumstances should a universal oil, ie, DOT 4 type,
The cylinders are connected by a bridge pipe. This be used.
provides balanced braking even if the brake discs are
worn to a different extent.
PARKING BRAKE
The master cylinders are fed from a single reservoir
located under the hood and mounted on the engine by The parking brake is controlled mechanically. It acts on
means of a bracket. the rear pinion gear shaft and is controlled through a
hand lever located at the left of the driver’s seat.
The front axle brake booster valve is supplied brake oil
either from the trailer brake logic head or from a When the parking brake control lever is raised, the
separate logic valve. Either option requires two pedal tensioning cable acts on the actuator forcing the pads
operation to provide oil output. The input oil to the against the three brake discs splined to the tractor rear
booster valve then operates a spool allowing low pinion gear.
pressure hydraulic oil to act on a piston and send oil at

TROUBLESHOOTING
Problem Possible Causes Correction
Pedals are hard to operate 1. Seizure of the hydraulic master Replace the master cylinder.
cylinder.
2. Blocked or flattened brake con- Clean or replace pressure lines.
trol lines.
Brakes remain applied when pedals 1. Stuck master cylinder pistons. Free piston and replace cylinder if
are released. necessary.
2. Seized master cylinder operat- Clean and lubricate linkage, ensure
ing linkage. water and dirt ingress is not
possible.
Brake noise. 1. Worn brake disc lining. Replace brake discs.
Excessive pedal travel 1. Air inside the brake hydraulic cir- Bleed air from brake hydraulic
cuit. circuit.
2. Worn brake master cylinders. Replace cylinders
3. Oil leakage from pressure lines. Repair leakage.

33- 6
SECTION 33 -- BRAKES -- CHAPTER 1
TROUBLESHOOTING
(cont’d.)
Unbalanced braking 1. Wrong tyre pressure. Inflate tyres to correct pressure
2. Worn brake master cylinders. Replace brake master cylinders
3. Blocked or flattened master Repair or replace bridge pipe
cylinder bridge pipe.
4. Blocked or flattened brake Repair or replace pressure lines
control lines.
5. Worn or broken master cylinder Replace cylinders
piston seals.
6. Worn lining on one brake disc (4, Replace disc
page 3).
Poor braking action 1. Worn brake disc linings (4, page Replace brake discs
3).
2. Worn brake master cylinders. Replace brake master cylinders
3. Air in the brake hydraulic circuit. Bleed air from brake hydraulic
system
4. Oil leakage from brake control Repair leakage
lines.
5. Worn or broken hydraulic pump Replace master cylinder
drive piston seals.
6. No/low front brake assistance:
a. Booster valve faulty. Check repair/replace as required
b. Logic head faulty. Check that ball valve is free.
c. Air in front brake circuit. Bleed front brakes
d. Fault in low pressure circuit. Check hydraulic system as
described in section 35.
Inefficient parking brake 1. Brake control misadjustment. Adjust correctly
2. Worn braking pads (8, page 3). Replace pads
Tractor remains braked upon 1. Hindered control lever return Repair as necessary
releasing
g the parking
g brake control travel.
l
lever
2. Seized pads on brake discs Repair and replace damaged parts

33- 7
SECTION 33 -- BRAKES -- CHAPTER 1
REAR BRAKE, RIGHT OR LEFT

Removal -- Installation (Op. 33 202 65)

Separate and remove final drive case as follows:

1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

1
3. Unscrew the plug (3) and drain oil from
transmission and rear axle housings. Collect oil
into a suitable container.

2
4. Jack up the tractor and place a stationary stand
under the rear axle housing and a stationary
support under the left--hand steps to the cab.
5. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the left wheel.

33- 8
SECTION 33 -- BRAKES -- CHAPTER 1
6. Loosen the two screws on the cab roof and fix tool
no. 295027 (4) using two appropriate bolts.
Connect tool to a hoist using metal cables and keep
cables tensioned.

4
7. Unscrew and remove the rear screws attaching the
cab to the supporting brackets (repeat for both rear
mounts).

5
8. Remove the telescopic stabiliser, loosen the
attaching screws and remove the bracket (2)
supporting the cab and the bracket (3) supporting
the telescopic stabiliser.
9. Reinstall the screw and nut on the rear RH mount.

6
10. Loosen the attaching screws and remove the draft
control sensor cable guard.

33- 9
SECTION 33 -- BRAKES -- CHAPTER 1
11. Locate the tool no. 50091 (1), connect it to a hoist
using a cable and unscrew the nuts attaching the
final drive case to the rear axle housing.

8
12. Detach the final drive assembly (2) from the rear
axle housing together with the axle shaft (3).

9
13. Detach the assist ram from the spacer (5), recover
the outer ring gear (4), spacer and friction plate (6).

10
14. Remove piston (7) from the service brake. Press
the control pedal to withdraw the piston from its
seat, if necessary.

33- 10
SECTION 33 -- BRAKES -- CHAPTER 1
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

15. Reinstall the final drive case to the rear axle

housing taking the following into consideration:
-- Reassembly follows the disassembly
procedure in reverse, from step 14 back to step
1.
-- Refer to figures on page 3 to orient the different
parts.
-- Before reinstalling the final drive case to the
rear axle housing, thoroughly clean and
degrease mating surfaces and apply a bead of
liquid gasket of approx. 2 mm of diameter
following patterns shown in the figure below.
-- Check seals for wear or damages and replace
if damaged.
-- Tighten to correct torques as detailed on page
2.

20273

12
Pattern for application of liquid gasket between the final drive case and rear axle housing.

33- 11
SECTION 33 -- BRAKES -- CHAPTER 1
FRONT BRAKE, RIGHT OR LEFT

Removal -- Installation (Op. 33.204)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the [Link]
suitable protection clothing, including goggles, gloves
and footwear.

1. Drain oil from planetary hub.

2. Remove the planetary carrier attaching bolts by
screwing in two alignment pins tool no. 292888

1
3. Insert a slide puller into the drain plug hole and
detach the planetary carrier.

33- 12
SECTION 33 -- BRAKES -- CHAPTER 1
4. Remove the planetary carrier and gears.

3
5. Remove the sun gear retaining ring.

4
6. Remove sun gear.

5
7. Remove the rear sun gear retaining ring.

33- 13
SECTION 33 -- BRAKES -- CHAPTER 1
8. Remove the snap ring retaining the outer brake
disc.

7
9. Remove the brake disc from the ring gear.

8
10. Remove the friction disc.

9
11. Slide the friction disc to driveshaft plate off of the
driveshaft spline.

33- 14
SECTION 33 -- BRAKES -- CHAPTER 1
12. Remove the inner brake disc from the ring gear.

11
13. Remove the piston from the backplate. Apply the
footbrakes if necessary to aid removal.
NOTE: There are 3, 6mm threaded bolt holes in the
piston. Bolts may be inserted and levered on to aid
piston removal.

12
Inspection
1. Inspect the friction plate for wear and damage,
replace as necessary.
2. Inspect the inner and outer brake discs, if badly
scored, worn or cracked replace.
3. If the piston has been removed always install news
seals before reassembly.

Seal Replacement
NOTE: It is advisable to replace the transfer tube
O--rings located at the rear of the piston carrier plate,
while the unit is at this stage of disassembly.
1. Support the hub using a suitable hoist and strap.
Remove the six bolts securing the hub to the swivel
housing and withdraw the ring gear.

33- 15
SECTION 33 -- BRAKES -- CHAPTER 1
2. Lift and remove the piston carrier plate from the
rear of the ring gear by compressing the snap ring
into the carrier with suitable screwdrivers.

14
3. Remove the inner and outer piston seals from the
carrier. Ensure the carrier is free from any debris
and carefully install the new seals, allow the seals
to relax for a few minutes prior to installing the
piston.

15
4. Remove the transfer tube from the rear of the
carrier and replace the O--rings.

16
5. Lubricate the piston with the specified brake oil and
install the piston into the carrier.

33- 16
SECTION 33 -- BRAKES -- CHAPTER 1
6. Reassemble the piston carrier to the ring gear.

18
Installation
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

1. Install the ring gear and piston carrier plate

assembly, inner brake disc, friction disc to
driveshaft plate, friction disc, outer brake disc and
retaining ring.
2. Install the sun gear inner retaining ring, sun gear
and outer retaining ring.
3. Before installing the planetary carrier, thoroughly 24595
clean and degrease the mating surfaces and apply
19
a 2mm bead of sealant as shown in Fig.11. Install
the planetary carrier and tighten the retaining bolts
to the correct torque.
4. Refill the planetary hubs with oil of the correct
specification and quantity.

33- 17
SECTION 33 -- BRAKES -- CHAPTER 1
HYDRAULIC BRAKE MASTER CYLINDER

Removal--Installation (Op. 33 202 46)

WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the hydraulic brake master cylinder as

follows:
1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

1
3. Loosen retaining screws and remove the side
panel (1).

2
4. Remove retaining screws (1) and remove
protection from right side.

33- 18
SECTION 33 -- BRAKES -- CHAPTER 1
5. Loosen fittings (1) and detach brake control lines.
6. Disconnect the line (2) connecting the brake
master cylinders to the reservoir.

4
7. Remove cotter pins and slide out the pins (1)
connecting the clevis on the master cylinder push
rod to the pedal.
8. Loosen the screws (2) retaining the brake master
cylinders to the cab and withdraw unit from tractor
on the engine side.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

9. Reinstall the hydraulic brake master cylinders

taking the following into consideration:
-- Reassembly follows the disassembly
5
procedure in reverse, from step 9 back to step
1.
-- Carry out adjustment detailed below and bleed
air from the brake hydraulic circuit following the
instructions given on page 22.

Service Brake Pedal Height Adjustment

1. With the brake pedals connected to the master
cylinder clevises and the latching pin
disconnected, check the distance (H) from pedal
centre to the floor mat. It should be approximately
185 mm.

33- 19
SECTION 33 -- BRAKES -- CHAPTER 1
2. If this is not the case, release the locknuts (2) and
screw in or out the adjust screw (1) to obtain the
specified distance. Tighten the locknuts.

Brake Pedal Switches Adjustment

After installing new master cylinders or adjusting the
pedal height check that the brake switches are
correctly adjusted:--
1. Locate a 2.5mm (0.10 inch) thick gauge bar
between the switch and brake pedal. Loosen the
switch retaining screws.
2. Push the switch towards the brake pedal to the limit
of the plunger travel whilst ensuring that the pedal
remains stationary. Tighten the retaining screws 7
and remove the gauge. Repeat for the other switch.
After adjustment ensure that both switches can be
heard operating and operating simultaneously.

FRONT BRAKE BOOSTER UNIT

1
Removal -- Installation
WARNING
Handle all components with the greatest care.
Do no insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Remove the front brake booster unit as follows:

1. Raise the engine hood. Disconnect the negative
cable of the battery. Remove the right and left hand
rear panels and place polythene under both of the 1
reservoir caps to prevent excessive brake oil loss.
2. Remove the following tubes from the unit:
Reservoir feed (1)
Low pressure hydraulic feed (4)
Low pressure hydraulic return (3)
brake input feed from logic head valve (5)
Output tube to front axle hubs (2)
NOTE: Label the tubes to ensure correct installation.
3. Remove the two securing bolts (6) and remove the
unit from the vehicle.
NOTE: Illustration shown with cab removed for clarity.

33- 20
SECTION 33 -- BRAKES -- CHAPTER 1
Installation
Ensure the pipework and area where the unit is to be
installed is clean.
1. Install the unit and tighten the two securing nuts to
28Nm ([Link]).

2. Install the following tubes to the unit:

Reservoir feed (1)
Low pressure hydraulic feed (4)
Low pressure hydraulic return (3)
brake input feed from logic head valve (5)
Output tube to front axle hubs (2)

3
3. Remove the polythene from under the reservoir
caps if fitted.
4. Bleed the brakes as described in brake bleeding
and ensure the brake oil reservoir is at the MAX
line.
5. Refit the side panels and reconnect the battery.

33- 21
SECTION 33 -- BRAKES -- CHAPTER 1
HYDRAULIC BRAKE SYSTEM
1
Air Bleeding (Op. 33 202 04).
Air bleeding should be carried out any time the brake
hydraulic system has been serviced or repaired.
Proceed as follows:
1. Thoroughly clean the exterior of the assembly
around the bleed screw (1, Fig. 2) and hydraulic oil
reservoir cap (1, Fig. 1).
2. Ensure that the reservoir (1) is kept above the
minimum before and during bleeding.
3. Initially open all the bleed screws and with the
brake pedals coupled, pump the brakes several 1
times to prime the system with fluid.
4. Uncouple the brake pedals and press the LH brake
pedal slowly and along all its travel to pressurise
oil.
5. Hold the brake pedal down and unscrew the
bleeding screw (1) by half a turn. Let the oil drain
with any air bubbles.
6. Tighten the bleed screw (1) and repeat the above
steps until oil free of air is expelled.
7. Press again the LH brake pedal to pressurise the
circuit. Continue until the pedal operation is felt
normal again.
8. Repeat the above steps for the RH brake pedal.
2
9. Upon completion of bleeding, top up oil in the
reservoir to correct level (1, Fig. 1).
10. If the tractor is fitted with either a hydraulic trailer
brake valve, or with a separate brake logic valve
(used in systems with no trailer brakes or air brake
only systems), perform air bleeding as described
above, then bleed at screws (1) and (3). Couple the
brake pedals and bleed at screw (2).
11. Upon completion of bleeding, top up oil in the
reservoir to correct level (1).

33- 22
SECTION 33 -- BRAKES -- CHAPTER 1
12. If the tractor is fitted with front axle brakes, perform
bleeding as for the standard tractor. Couple the
brake pedals then bleed air from bleed screw (1) at
the booster unit, top up the oil reservoir after
completion of bleeding.
NOTE: To bleed the front brake units it is necessary to
start the engine and allow to idle during the bleeding
process and observe the separate front brake oil
reservoir.

4
13. Rotate the hubs to position the plug (1) in the
vertical position. Remove the plug and ensure the
bleed screw is aligned with the hole.
NOTE: With some wheel options it may be necessary
to bleed the brakes with the wheels removed.

5
14. loosen the screw and attach a suitable bleeding
tube with a one--way valve action. Pump the
latched brake pedals until the fluid expelled is free
from bubbles. Hold the brake pedals down and
remove the tube and tighten the bleed screw.
Repeat for the other wheel.
15. On completion of the procedure refit the axle plug
and ensure the oil level in the reservoir is at the
correct level.
NOTE: If the brake oil has escaped into the hub the
hub should be drained and refilled with the correctly
specified front axle oil, New Holland specification,
Ambra Multi--G.
6
16. If pneumatic trailer brakes are fitted, bleed as for
the standard tractor then with the pedals coupled
bleed at the screw (1) located on the control valve.

33- 23
SECTION 33 -- BRAKES -- CHAPTER 1

8
Brake Bleeding Order

33- 24
SECTION 33 -- BRAKES -- CHAPTER 1
FRONT BRAKE BOOSTER VALVE AND
MASTER CYLINDER

Disassembly -- Reassembly
Prior to disassembly inspect the unit for signs of
obvious leakage between the booster valve and
master cylinder or at any of the tube fittings, this may
give an indication of where a possible fault lies.
1. Remove the front brake master cylinder from the
booster unit.
NOTE: Ensure the shims between the units are
retained for reassembly.
WARNING
The booster valve is not a serviceable item. If it is
showing signs of leakage, damage or suspected of
malfunctioning the complete unit must be replaced.
DO NOT attempt to disassemble and reassemble as
seal damage wll occur, rendering the unit inoperative
with a resultant loss of brake performance.

1
Master Cylinder:

Disassembly
1. Remove the circlip retaining the spool assembly.
2. Gently tap the cylinder, spool end downwards, onto
a firm surface to remove the spool assembly.
3. Withdraw the fluid inlet adaptors and hook out the
end seals.
4. From the spool and spring assembly, bend back
the locking tab and withdraw the spring assembly.
Unhook the rod and disassemble.

Inspection 2
5. Inspect the cylinder bore, if the bore is not in perfect
condition, replace the complete assembly.
6. Regardless of apparent condition, always install
new seals when reassembling a master cylinder.

Reassembly
7. Reassembly is the reversal of disassembly. Coat
all seals with the correctly specified brake oil prior
to fitment.

33- 25
SECTION 33 -- BRAKES -- CHAPTER 1
PARKING BRAKE ASSEMBLY

Removal -- Installation (Op. 33 110 40)

Remove the parking brake assembly as follows:

1. Open and raise the hood.
2. Detach the negative cable (4) from the battery and
insulate.

1
3. Jack up the tractor rear end and place two suitable
stationary stands under the final drive cases. Rear
wheels should be off the ground. Detach vertical
links from the lower lift arms if necessary.

2
4. Sling the wheel using a nylon cable (3), unscrew
the attaching nuts and remove the wheel. Repeat
for the LH wheel.

23556

33- 26
SECTION 33 -- BRAKES -- CHAPTER 1
5. Loosen the screw retaining the steps (6) to the
support bracket.

4
6. Loosen the screw retaining the steps (1) to the cab
floor.

5
7. Empty fuel tanks and remove the clamp (1) on the
line connecting the main tank to the auxiliary tank.

6
8. Remove the clamp and detach bleed line (3)
between the main tank to the auxiliary tank.

33- 27
SECTION 33 -- BRAKES -- CHAPTER 1
9. Loosen the clamp and detach the injection pump
supply line (5), detach connectors (4), loosen and
remove the fuel level sensing unit.

8
10. Loosen the nut of the main tank metal lock--plate
(6), remove plate and remove the tank. Tilt tank to
ease it out from between the cab and mounting
bracket.

9
11. Detach the cable from the parking brake control
lever.
12. Loosen the retaining screws and remove the
parking brake control assembly.

10
13. Straighten the locking tabs (1).

24552

33- 28
SECTION 33 -- BRAKES -- CHAPTER 1
14. Loosen the guide screws (C3) and collect the pads.
1

24553

12
15. Remove the circlip (2).
NOTE: Arrows indicate the reference marks to be
matched during reassembly.

24554

13
16. Slide out the control lever and collect inner lever
(3).
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

17. Reinstall the parking brake assembly taking the

following into consideration:
-- Reassembly follows the disassembly
procedure in reverse, from step 16 back to step
1.
-- Refer to figures on page 3 to orient the different
parts.
14
-- Take into account steps 17, 18, and 19.
-- Before reinstalling the parking brake support
unit to the rear axle housing, thoroughly clean
and degrease mating surfaces and apply a
bead of liquid gasket of approx. 2 mm of
diameter following pattern shown on page 31.
-- Tighten to correct torques as detailed on page
2.

33- 29
SECTION 33 -- BRAKES -- CHAPTER 1
18. To aid reassembly of the parking brake control
assembly, use the tool no. 295016 (2) to install the
discs (1) on the pinion gear.

15
19. Insert tool no. 295016 (2) between the parking
braking pads (3).

16
20. Position the parking brake assembly complete with
tool no. 205016 (2) on the discs, getting as near as
possible to the rear axle housing. Withdraw tool no.
205016 (2), bring the unit to contact the rear axle
housing and lock it in place by tightening the
retaining screws to the specified torque (see page
2).

33- 30
SECTION 33 -- BRAKES -- CHAPTER 1
Pattern for application of liquid gasket between
the parking brake case and rear axle housing.

20275

18
HANDBRAKE CONTROL
1
Travel Adjustment (Op. 33 110 08)
Adjustment of the parking brake control lever travel
should be performed each time the parking brake is
serviced or repaired and when the idle travel of the
lever is excessive.
Proceed as follows:
1. Block front wheels using suitable means.
2. Jack up the tractor rear end using a suitable means
until the wheels are slightly off the ground. 2
3. Raise the parking brake control lever to the third
notch on the quadrant. 1
4. Release the locknut (2) and screw in the adjust
screw (1) until the wheels lock.
5. Lower the parking brake control lever and ensure
that the wheels can rotate freely.
6. Apply the parking brake several times to check that
the assembly does not get blocked or operate
abnormally.
7. Tighten the locknut (2) and lower the tractor.

33- 31
SECTION 33 -- BRAKES -- CHAPTER 1
NOTES

33- 32
SECTION 33 -- BRAKES -- CHAPTER 2
SECTION 33 -- BRAKES

Chapter 2 -- Air Trailer Brakes

CONTENTS

Section Description Page

33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33 000 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
33 000 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

33 000 SPECIFICATIONS
Air Compressor:
Location Right hand side of engine, above fuel injection pump
Drive Belt driven via crankshaft/water pump
Type Single cylinder air cooled
Speed 3,000 rev/min. Maximum
Lubrication Pressure fed from engine
Bore / Stroke 75mm x 36mm
Displacement 159 cm3
Operating Pressure 18 bar (261 lbf.in2) Maximum

System Operating Pressure 8 bar (116 lbf.in2) “Universal” and “German”

7 bar (101 lbf.in2) “Italian”

Unload (relief) Valve Setting 11 bar (160 lbf.in2) “Universal” and “German”
10 bar (145 lbf.in2) “Italian”

Low Pressure Warning Switch Operates at, 4.5 bar (65 lbf.in2) “Universal” and “German”
3.5 bar (50 lbf.in2) “Italian”

Pressure Sender
Pressure (bars) 0 2 6 10

Ohms 10 52 124 184

Maintenance
Drain Reservoir Tanks Daily
Compressor Drive Belt Tension Every 300 hours

33- 1
SECTION 33 -- BRAKES -- CHAPTER 2
33 000 TIGHTENING TORQUES

42--62 Nm
31--46 lbf. ft

13--17
10--13
73--90
54--66

42--62 20--25
31--46 15--18
90--110
66--81

20--25
42--62
15--18
31--46
60--70
44--52

20--25
20--25 15--18
15--18

22--29
16--21
40--51
9--10 29--38
7--7.5

30--35
22--26

33- 2
SECTION 33 -- BRAKES -- CHAPTER 2
There are three versions of the air trailer brake
available.
These can be easily identified by the coupler
configuration at the rear of the cab.

1. Universal
A generally accepted air brake providing a dual line
system.

2
2. “German”
An air brake system designed in accordance with
German TUV specifications providing both single
and dual line operation.

3
3. “Italian”
An air brake system designed to meet Italian
legislation and providing dual line operation.

33- 3
SECTION 33 -- BRAKES -- CHAPTER 2

5
Air Brake Schematic Diagram
“Universal”
1. Compressor 9. Coupler -- Control Line Yellow
2. Unload Valve (8 bar) 10. Coupler -- Supply Line Red
3. Silencer 11. Pressure Gauge
4. 10 litre Reservoir 12. Low Pressure Warning Lamp
5. Drain Valve 13. Pressure Sender
6. Dual Line Control Valve 14. Brake Master Cylinder
7. Solenoid Valve 15. Brake Logic Head
8. Pressure Regulator

Universal Air Brake Option Brakes Engaged

Operating the brake pedal closes the Brake Switches
Brakes Disengaged (15) which sends a signal to the Solenoid Valve (7).
Air from the Compressor (1) is supplied to the Unload When energised this supplies air via the Pressure
Valve (2) which regulates system pressure stored in Regulator (8) to the Control Valve (6) as pilot pressure
the Reservoir (4). to initiate operation of the trailer’s brakes via the Yellow
Control Line Coupler (9).
This pressure is supplied to the trailer via the Red
Supply Line (10) Coupler to disengage the brakes. As the tractor’s brakes are applied, Hydraulic Pressure
from the Master Cylinders (12) is transferred via the
The air in the system also acts on the Pressure Sender
Brake Logic Valve (13) to the Control Valve (6) to
Unit (13) which supplies a variable electrical signal to
progressively increase pressure in the Yellow Control
the Pressure Gauge (11) to indicate the pressure in the
Line (9) to the trailer’s brake control valve to engage
system.
the brakes in line with the tractor brakes.
If the pressure drops below specified limits, the sender
incorporates a switch to illuminate the Warning Lamp
(12).

33- 4
SECTION 33 -- BRAKES -- CHAPTER 2

6
Air Brake Schematic Diagram
“German”
1. Compressor 10. Coupler Single Line Black
2. Unload Valve (8 bar) 11. Coupler Dual Line (Control) Yellow
3. Silencer 12. Coupler Dual Line (Supply) Red
4. Reservoir (2 x 10 litres) 13. Pressure Gauge
5. Drain Valve 14. Low Pressure Warning Lamp
6. Single Line Control Valve 15. Pressure Sender Unit
7. Dual Line Control Valve 16. Brake Master Cylinder
8. Solenoid Valve 17. Brake Logic Valve
9. Pressure Regulator

“German” Air Brake Operation Brakes Disengaged

The German Air Trailer Brake System combines a dual Air from the Reservoir (4) is supplied via the Single Line
line and single line brake system and has the addition Control Valve (6) to the Black Line (10) to disengage
of a second reservoir tank. the trailer’s brakes.

Dual Line Braking System Brakes Engaged

Refer to Universal Braking System. As pressure in the Yellow Line (11) increases, it is
sensed at the Single Line Control Valve (6) to
Single Line Braking System progressively vent the air pressure supplied to the
trailer via the Black Line (10) to apply the trailer’s
The system functions in a similar fashion to dual line
brakes in line with the tractor’s brakes.
braking except for the following.

33- 5
SECTION 33 -- BRAKES -- CHAPTER 2

7
Air Brake Schematic System
“Italian”
1. Compressor 8. Pressure Regulator
2. Unload Valve (7 bar) 9. Pressure Gauge
3. Silencer 10. Low Pressure Warning Lamp
4. Reservoir (10 litres) 11. Pressure Sender Unit
5. Drain Valve 12. Brake Master Cylinder
6. Dual Line Control Valve 13. Brake Logic Valve
7. Solenoid Valve 14. Dual Coupler

“Italian” Air Brake Operation Brakes Engaged

Operating the brake pedal closes the brake switches
Brakes Disengaged (12) which sends a signal to the Solenoid Valve (7).
Air from the compressor (1) is supplied to the Unload When energised this supplies air via the Pressure
Valve (2) which regulates system pressure stored in Regulator (8) to the Control Valve (6) as pilot pressure
the Reservoir (4). to initiate operation of the trailer’s brakes via the Dual
Coupler (18) control line.
This pressure is supplied to the trailer via the Dual
Coupler (18) supply line to disengage the brakes. As the tractor’s brakes are applied hydraulic pressure
from the Master Cylinders (12) is transferred via the
The air in the system also acts on the Pressure Sender
Brake Logic Valve (13) to the Control Valve (6) to
Unit (11) which supplies a variable electrical signal to
progressively increase pressure in the Dual Coupler
the Pressure Gauge (9) to indicate the pressure in the
(14) control line to the trailer’s brake control valve to
system.
engage the brakes in line with the tractor brakes.
If the pressure drops below specified limits the sender
incorporates a switch to illuminate the Warning Lamp
(10).

33- 6
SECTION 33 -- BRAKES -- CHAPTER 2
33 000 DESCRIPTION AND OPERATION

33- 7
SECTION 33 -- BRAKES -- CHAPTER 2
Description Diagram Function
Ref.

Compressor B Belt driven via the crankshaft. Takes filtered air and compresses it to
supply the reservoir tank(s) with pressurised air. The compressor is
lubricated from the engine lube system.

Unload (relief) Valve A Controls the operating pressure within the system to prevent system
damage from excess pressure. Also removes any contamination from
the system during unloading.

Reservoir Tanks D&F Provides storage for the compressed air generated by the compressor.

Brake Pedal Switch H When both brake pedal switches are operated, (both brake pedals
depressed), relay ‘A’ becomes de--energised, this cuts the voltage to the
dual line control valve solenoid.

Dual Line Control Valve G Operated via the brake pedal switch, supplies air pressure to the dual
Solenoid line control valve to establish the trailer brake pressure before the tractor
brakes become effective, thereby preventing any delay in operation.

Dual Line Control Valve G Provides control of the two line braking system in conjunction with the
hydraulic pressure supplied from the brake master cylinder. A
mechanical connection to the handbrake provides full trailer braking
when the handbrake is applied.

Single Line Control C Controls the single line trailer brake system in conjunction with the dual
Valve line control valve and brake master cylinder pressure.

33- 8
SECTION 33 -- BRAKES -- CHAPTER 2
Description Diagram Function
Ref.

Pressure G Connected directly in line with the reservoir, provides an electrical signal
Switch/sender to the cab pressure gauge. When the pressure drops to 4.5/3.5 bar
Assembly (65/50 lbf.in2) or lower the switch closes and completes the circuit to
illuminate the warning lamp on the instrument cluster.

Pressure Gauge I Electrically operated gauge by a signal received from the pressure
switch/sender assembly.

Couplers E Red and yellow couplers for dual line systems. Red is the supply coupler
with full pressure available all the time.
The yellow coupler is the control line. Air pressure at the coupler is
increased as the brake pedal is depressed.
The black coupler is for single line systems. Pressure is available at the
coupler with the brake pedal released, pressure decreases as the pedal
is depressed.
The “Italian” trailer brake uses a dual coupler which has both the supply
and control lines in one coupler.

Brake Logic Valve J Ensures that trailer braking only occurs when both brake pedals are
depressed simultaneously. Hydraulic pressure from both brake master
cylinders act on a ball and plunger arrangement which then allows
pressure oil out to act on the control valve.

Regulating Valve K Provides a means for the operator to “Fine Tune” the pressure supplied
from the solenoid to the control valve dependant upon the
characteristics of the trailers brakes.

33- 9
SECTION 33 -- BRAKES -- CHAPTER 2
33 000 FAULT FINDING
Description Causes Remedy

Instrument cluster light illuminates 1. System pressure below 1. Compressor drive belt broken
when system is running.
running 4 5/3 5 bar.
4.5/3.5 bar
2. Check system for leaks

3. Unload valve failed, stuck open

4. Compressor fault

5. Reservoir drain tap faulty

2. Faulty switch or switch wiring 1. Disconnect wiring to switch. If

light extinguishes replace
switch. If light remains
illuminated check wiring for short
to earth.

Trailer brakes not functioning 1. Air in braking system 1. Bleed brakes

(system air pressure okay)
2. Faulty pilot valve 1. Disconnect supply line to
control valve from pilot valve
assembly. Operate the brakes, if
oil is expelled, pilot valve is okay.
If no oil expelled remove and
inspect pilot valve.

3. Control valve faulty 1. Repair/replace as required

Delay in trailer brake operation 1. Dual line solenoid failed closed 1. Disconnect wiring to solenoid. If
or permanently energised. brakes operate normally inspect
wiring for short to +12v. If still a
delay in operation after wire
disconnection replace solenoid
assembly.

2. Faulty brake switch

System pressure too high (exceeds 1. Faulty unload valve 1. Remove valve clean/replace.
11 bar)

33- 10
SECTION 33 -- BRAKES -- CHAPTER 2

8
Air Brake Electrical System
1. Ignition Switch 7. Relay G
2. Ignition Relay (Normally Open) 8. Pressure/Sender Switch
3. Relay ’A’ (Normally Closed) 9. Pressure Gauge
4. Battery 10. Instrument Lamp Warning Lamp
5. Electronic Management Unit 11. Right Hand Brake Pedal Switch
6. Feed to Stoplamps 12. Left Hand Brake Pedal Switch

33- 11
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT REMOVAL AND
INSTALLATION

Group 33.000
WARNING
Before removing any air system component ensure
that there is no air pressure in the system. This can be
achieved by depressing and releasing the brake pedal
several times with the engine off. Also ensure that the
wheels of the tractor/trailer are chocked.

Compressor -- Figure 9
1. Remove the drive belt (2). 6 1
2. Disconnect air inlet hose (5).
3. Disconnect air outlet tube (1).
5
4. Remove the oil drain tube (4).
5. Remove the four compressor mounting bolts and
lift compressor away from tractor (3). 4 2
6. Reassembly is the reversal of removal, noting the
following point:

3
60--33--012 TI
9
a. Adjust the drive belt to provide 4 mm deflection
with a force of 40N at the centre of the belt run
between tensioner and water pump. The belt is
tensioned by moving the pulley (1) within the slot
of the pulley bracket. Figure 10.

60--33--011 TI
10
Unload Valve -- Figure 11
1. Disconnect pressure feed tube from compressor
(1).
2. Disconnect outlet hose to the reservoir (2).
3. Remove the two retaining bolts (3) and withdraw
valve from tractor.
4. Reassembly is the reversal of removal.

Reservoir Tanks -- Figure 12

33- 12
SECTION 33 -- BRAKES -- CHAPTER 2
NOTE: Removal of the wheel will aid removal of the
reservoir tank(s), but is not essential.
1. Remove all the tubes and hoses connected to the
tank, noting their location.
2. Loosen the strap retaining nuts and lift out the tank.
3. Reassembly is the reversal of removal.

60--33--014 TI
12
Dual Line Solenoid -- Figure 13.
1. Disconnect the electrical connector.
2. Disconnect the two air lines.
3. Remove the two retaining bolts and lift away from
the tractor.
4. Reassembly is the reversal of removal.

13
Dual Line Control Valve -- Figure 14.
1. Disconnect the handbrake cable connection.
2. Disconnect hydraulic brake connection from Pilot
valve assembly, cap the end of the tube to prevent
contamination and excessive loss of brake oil.
3. Disconnect large diameter air lines, noting
locations for reassembly.
Disconnect dual line control valve solenoid.
Remove the two retaining bolts and lift the control valve
assembly complete with bracket and solenoid valve
from the tractor.

33- 13
SECTION 33 -- BRAKES -- CHAPTER 2
4. Reassembly is the reversal of removal, noting the
following points:--
a. When the tube is reconnected it will be
necessary to bleed the braking system. Bleed
each side of the pilot head assembly, first, then
at the bleed screw located in the control valve.
b. Ensure the handbrake cable is adjusted
correctly after assembly:
Assemble the cable and adjust the cable until
the operating arm just begins to move, then
back off adjuster 1/2 turn to provide some
cable slack. Operate handbrake and ensure
full travel of the arm is achieved.

Pilot Head Valve Assembly -- Figure 15

1. Disconnect the two tubes from the braking system
and the outlet tube to the dual line control valve.
Cap the ends of the tubes to prevent dirt ingress.
2. Remove the single retaining bolt (1), Figure 15
and lift away from the tractor.
3. Reassembly is the reversal of removal, noting the
following point:
a. Bleed the braking system of air as described
previously.

15
Pressure Switch/Sender Assembly -- Figure 16.
1. Disconnect wiring to switch.
2. Remove the switch/sender assembly from the tee
connector into the single line control valve.
3. Reassembly is the reversal of removal.

33- 14
SECTION 33 -- BRAKES -- CHAPTER 2
Single Line Control Valve -- Figure 17
1. Disconnect the three air lines to the single line
control valve assembly.
2. Remove the valve to support bracket retaining
bolts and lift away from tractor.
3. Reassembly is the reversal of removal.

17
Coupler -- Figure 18
1. Remove the tube from the rear of the coupler
2. Unscrew the coupler assembly from the bracket.
3. Reassembly is the reversal of removal.

60--33--019 TI
18

33- 15
SECTION 33 -- BRAKES -- CHAPTER 2
Air Line Removal and Installation -- Figure 19
1. To remove an air pipe it is necessary to undo and
remove the complete fitting (1) from the
component. When removed the retaining clip can
then be removed to allow the pipe to be
disassembled from the fitting.

19
2. To install the push-in type air lines the following
should be observed:
• Ensure the seal (1) is correctly seated in the
bottom of the connector fitting.
• Ensure the plastic retaining clip (2) is also
correctly installed in the component connector
fitting.
• Install and tighten the connector fitting (4).
3. Firmly push the pipe connector (3) into the
component connector fitting (4).
WARNING
An air pipe should never be installed as a single item
with the component fitting. The retaining clip may not 20
seat properly and this will lead to pipe disconnection
and air leakage. Always install the fitting, seal and
retaining ring to the component and then install the
pipe into the fitting.

33- 16
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- COUPLERS

A B

21
COUPLERS

Key to Components -- Figure 21

E. Single Line Coupler F. Supply and Control Line Couplers
1. Cover 1. Screw
2. Circlip 2. Guide Piece
3. Bush 3. Spring
4. ‘O’ Ring 4. Tube
5. Valve Ring 5. Cover
6. Valve Body 6. Housing
7. ‘O’ Ring 7. Spring
8. Spring 8. Cap
9. Housing 9. Valve
10. Washer 10. ‘O’ Ring
11. Guide Piece 11. Cap
12. Washer 12. ‘O’ Ring
13. Screw 13. Thrust Piece
14. Guide
15. Screw

33- 17
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- COMPRESSOR

33- 18
SECTION 33 -- BRAKES -- CHAPTER 2
COMPRESSOR

Key to Components -- Figure 22

1. Bolt 21. Seal
2. Sealing Ring 22. Washer
3. Bolt 23. Nut
4. Pressure Valve Support 24. Screw
5. Pressure Valve Plate 25. Bearing and Cover Assembly
6. Suction Valve Plate 26. ‘O’ Ring
7. Washer 27. Crankshaft
8. Bolt 28. Crankcase
9. Bush 29. Connecting Rod Bearing
10. Alternate End Housing 30. Connecting Rod
11. Screw 31. Piston Assembly
12. Cover 32. Gasket
13. ‘O’ Ring 33. Valve Assembly (complete)
14. Sealing Washer 34. Washer
15. Locking Screw 35. Bush
16. Plug 36. Gasket
17. Sealing Ring 37. Plug
18. Cap 38. Washer
19. Bolt 39. Cylinder Head
20. Washer

33- 19
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- UNLOADER VALVE

33- 20
SECTION 33 -- BRAKES -- CHAPTER 2
UNLOADER VALVE

Key to Components -- Figure 23

1. Relief Valve 20. Seal
2. Sealing Ring 21. Spring Seat
3. Adjuster Screw 22. Spring
4. Screw 23. Shims
5. Housing 24. Valve
6. ‘O’ Ring 25. Seal
7. Adjuster Block 26. ‘O’ Ring
8. Seat 27. Tapered Spring
9. Spring 28. Valve
10. Seat 29. Housing
11. ‘C’ Clip 30. Sealing Ring
12. Washer 31. Bolt
13. Plate 32. Bush
14. Spring Seat 33. Valve
15. Spring 34. Spring
16. Washer 35. Filter
17. Bolt 36. Seal
18. Circlip 37. Adaptor
19. Cover 38. Protective Cap

NOTE: After reassembly of the unloader valve it will be necessary to adjust the pressure at which the valve unloads.
Start at a low setting , i.e, the adjuster screw (3), unscrewed several turns. Observe the pressure gauge
within the cab and gradually increase the pressure, by rotating the adjuster clockwise, until 7 bar is
indicated.

33- 21
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- SINGLE LINE CONTROL VALVE

33- 22
SECTION 33 -- BRAKES -- CHAPTER 2
SINGLE LINE CONTROL VALVE

Key to Components -- Figure 24

1. Cap 15. Valve
2. Lockring 16. ‘O’ Ring
3. Diaphragm Disk 17. Lockring
4. Bolt 18. Piston
5. ‘O’ Ring 19. ‘O’ Ring
6. ‘O’ Ring 20. Bolt
7. Valve Tappet 21. ‘O’ Ring
8. Housing 22. Support
9. ‘O’ Ring 23. Spring Washer
10. Compression Spring 24. Diaphragm
11. Spring Plate 25. Bolt
12. Adjuster Screw 26. Cup Seal
13. Locknut 27. Cover
14. End Cap 28. Spring

33- 23
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- DUAL LINE CONTROL VALVE

33- 24
SECTION 33 -- BRAKES -- CHAPTER 2
DUAL LINE CONTROL VALVE

Key to Components -- Figure 25

1. Vent Screw 18. Vent Screw
2. Protective Cap 19. Bolt
3. Bolt 20. Housing
4. Housing 21. Valve with Lockring
5. Lip Seal 22. Sealing Ring
6. ‘O’ Ring 23. Bolt
7. Tappet 24. ‘O’ Ring
8. ‘O’ Ring 25. Valve
9. ‘O’ Ring 26. ‘O’ Ring
10. Tappet 27. Spring
11. Washer 28. Guide
12. Spring 29. ‘O’ Ring
13. Piston 30. Circlip
14. ‘O’ Ring 31. Ball
15. Guide Ring 32. Cap
16. ‘O’ Ring 33. Bolt
17. Rod

33- 25
SECTION 33 -- BRAKES -- CHAPTER 2
COMPONENT OVERHAUL -- SOLENOID VALVE

26
SOLENOID VALVE
Key to Components -- Figure 26
1. Knurled Nut 6. Lock Washer
2. ‘O’ Ring 7. Flange
3. Housing 8. Spool
4. ‘O’ Ring 9. ‘O’ Ring
5. Cylinder Screw 10. Armature

33- 26
SECTION 33 -- BRAKES -- CHAPTER 2
PRESSURE TESTING

Tractor Preparation
1. Position the tractor on a flat, level surface and in a
suitable location to allow the engine to run during
the testing.
2. Chock the wheels and ensure the parking brake is
in the OFF position.
3. To perform the test it will be necessary to obtain the
correct trailer side couplers for the system, to
couple up to the tractor connectors.

27
Use suitable fittings to connect to each trailer side
coupler a 0--10 bar, undamped (100mm), pressure
gauge. Connect the appropriately coloured
couplers to the corresponding tractor coupler.
1. “Italian” trailer brake
2. “German”/”Universal” trailer brake

28
Pre-Test Procedure
NOTE: For all pressure testing illustrations the gauges
represent the following coupler colours:
A = Dual line control (Yellow)
B = Single line supply (Black
C = Dual line supply (Red)
D = Cab Gauge
1. Switch tractor ignition on.
2. All test gauges, including vehicle gauge located on
the left hand ’B’ pillar, must read zero pressure
(drain tanks if required).
NOTE: Tractor ’B’ pillar gauge reads line pressure
which is the same as that shown on the red line coupler
29
gauge.
3. Low pressure warning indicator for the air brake
system must be illuminated on the instrument
cluster. Warning light located in top right hand
corner of the instrument cluster.
NOTE: All figures in ( ) refer to the Italian trailer brake
pressures, where they differ.

33- 27
SECTION 33 -- BRAKES -- CHAPTER 2

1. Start the tractor B

2. System should be fully pressurised within 40 to 60
seconds depending on engine rev setting (a
maximum period of 3 minutes is permitted for the
system to reach operating pressure). When the
system is fully pressurised the gauges must read
as follows:
Gauges Pressure
(Bar)
Dual Line Control (Yellow) (A) 0 C
Single Line Supply (Black) (B) 5.0 -- 6.0
Dual Line Supply (Red) (C) 7.5 -- 8.5 30
(6.5 -- 7.5)
Cab (D) 8.0 (7.0)

NOTE: Cab gauge reads 8.0 (7.0) bar in the green

segment.

3. As the system is being pressurised, the air brake

low pressure warning light on the instrument
cluster should extinguish between 4.5 and 5.5 bar.
NOTE: Indication of malfunctioning must be
investigated and the defect rectified before continuing
with the test.

31
4. Apply tractor parking brake
The gauges must now read the following values:
Gauges Pressure
(Bar)
Dual Line Control (Yellow) (A) 7.5 -- 8.5
(6.5 -- 7.5)
Single Line Supply (Black) (B) 0
Dual Line Supply (Red) (C) 7.5 -- 8.5
(6.5 -- 7.5)
Cab (D) 8.0 (7.0)

In cases where the gauges do not exhibit the above

values, adjust the handbrake cable to the dual line 32
control valve as described on the following page.

33- 28
SECTION 33 -- BRAKES -- CHAPTER 2
Handbrake Control Cable Adjustment
1. Handbrake off, system (red), (C), at full pressure
8 (7) bar (ignition on -- engine off). Check yellow
gauge (A) is on zero.
2. Handbrake up four clicks -- slacken dual valve
operating cable top nut.

33
3. Adjust cable (by tightening the bottom nut first on
the cable assembly) until needle on yellow gauge
(A) just starts to move, lock up top nut.
4. Check operation of handbrake.
Handbrake On = 8 (7) bar yellow
Handbrake Off = 0 bar yellow

34
Leak Test
1. Engine off -- tractor parking brake applied.
2. No deterioration of the red line pressure (8 (7) bar)
must occur over a 10 minute period. Indication of
any leakage must be investigated, the defect
rectified and the test repeated.

33- 29
SECTION 33 -- BRAKES -- CHAPTER 2
Brake Pedal Test Procedure
1. Start the tractor. Engine revs not to exceed 1000
rev/min.
2. Do NOT apply tractor parking brake.

36
3. Release brake pedal link pin so that pedals will
work individually.
4. Apply left hand and right hand brake pedals
individually. No change in pressure readings on
test gauges must occur.

37
5. Reconnect brake pedal link pin, apply brake pedals
fully several operations until red system pressure
below 7 (6) bar -- vehicle compressor will come
back on load -- allow system to reach full pressure
8 (7) bar (loud ’pop’ will be heard as unload valve
opens). Gently apply pressure to linked pedals
until both brake light switches have just clicked on,
brake lights on and 4WD indicator on dash is
illuminated. The gauges will now record the
following values:

Dual Line Systems 38

Gauges Pressure
(Bar)
Dual Line Control (Yellow) (A) 0.5 -- 1.0
Single Line Supply (Black) (B) 4.5 -- 5.0*
Dual Line Supply (Red) (C) 7.5 -- 8.5
(6.5 -- 7.5)
Cab (D) 8.0 (7.0)

* slight drop in pressure must occur

33- 30
SECTION 33 -- BRAKES -- CHAPTER 2
NOTE: If the brake lights operate late into the braking
process, i.e. pedals are depressed more than 20mm
before the brake switches are switched on, no advance
braking on the air brake system will occur. The brake
switches must be reset and the brake test performed
again.

Single Line System

6. Fully apply brake pedal effort with graduated effort.
Yellow line (A), pressure must increase evenly to
a maximum of 7--8 bar. Black line (B), pressure
must decrease evenly to zero bar.

40
Pressure Regulator ON/OFF Test Procedure
1. Set engine at idle revs.
2. Do NOT apply tractor parking brake.
3. With the system fully pressurised 8 (7) bar,
depress the brake pedals several times until the
pressure drops below 7 (6) bar on Red system
gauge (C) and gauge in cab.

41
4. The unload valve, located on the RHS of the engine
must recharge the system to 8 (7) bar.
5. In cases where an unload valve is found to be
faulty, a new unload valve must be fitted and the
test repeated.

33- 31
SECTION 33 -- BRAKES -- CHAPTER 2

33- 32
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 1 -- Hydraulic Circuits

CONTENT

Section Description Page

35 000 Introduction and Circuit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Closed Centre Load Sensing High Pressure Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . 7
Open Centre High Pressure Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Pressure Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tractors with Power Command Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tractors with Range Command Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tractors with Dual Command Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tractors with Shuttle Command Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

35- 1
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1

35- 2
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
INTRODUCTION AND CIRCUIT
IDENTIFICATION
The hydraulic system on TM series tractors are Range Command Transmission Clutch and Range
separated into the following circuits:-- Synchroniser Engagement
Power Command Transmission Clutch
High Pressure Circuit Engagement
Hydraulic Lift Assembly
Remote Control Valves Lubrication Circuit
Trailer Brake (Where Fitted) PTO Clutch Plates
Suspended Front Axle Transmission Clutch Plates
Front P.T.O where fitted Transmission Shaft Pressure Lube
Pump Drive Gear Bearing
Steering Circuit Hydraulic Lift Cross Shaft
Steering Motor and Cylinders The high pressure circuit can be either ‘Open’ or
‘Closed Centre Load Sensing’ design and is dependent
Low Pressure Circuit on tractor model options
Independent Power Take Off (PTO) The steering, low pressure and lubrication circuits are
of the ‘Open Centre’ design however when Supersteer
Differential Lock
axles are fitted the steering circuit has dynamic load
Front Wheel Drive engagement sensing.
Dual Command Transmission Synchroniser and
Clutch Engagement

TRACTOR HYDRAULIC BUILD OPTIONS

High Pressure
Transmission Hydraulic Hydraulic Lift Remote Control
Hydraulic
Pump Valves
System

Shuttle Command Open Centre Gear Pump Mechanical Lower Link Open Centre
Dual Command Closed Centre Variable Flow CCLS Electronic Draft Control Closed Centre
Range Command Closed Centre Variable Flow CCLS Electronic Draft Control Closed Centre
Power Command Closed Centre Variable Flow CCLS Electronic Draft Control Closed Centre

35- 3
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Before commencing work on a tractor it is important to
identify if the tractor has open or closed centre
hydraulics and the type of transmission.
Closed centre load sensing high pressure hydraulic
systems can be identified from the following:--
Closed centre load sensing variable displacement
piston pump.

TIA35017

1
Closed centre remote valves (1) and Electronic
draft control (2). Electronic draft control is not
available on open centre high pressure hydraulic
systems.

2
Tractors installed with the electronic draft control
hydraulic lift assembly use a unique operator control
panel.

3
The lift arm position control (1), in cab fast raise lower
switch (2) and draft loading controls (3) are also unique
to tractors with electronic draft control.

35- 4
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Open centre high pressure hydraulic systems can be
identified from the following:--
Open centre gear pump.

5
Open centre remote control valves

6
The type of transmission installed can be identified by
inspecting the transmission control lever.

Tractors with Power Command transmission have a

single control lever with two (2) shift buttons.

7
Tractors installed with Range Command transmission
have a single control lever with three (3) shift buttons.

35- 5
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Tractors installed with Dual Command transmission
uses two control levers.

9
Tractors installed with Shuttle Command transmission
uses three (3) control levers.

35- 6
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
CLOSED CENTRE LOAD SENSING HIGH
PRESSURE HYDRAULIC CIRCUIT

11
High Pressure Circuit Components and Pipework
Tractors with Variable Flow Piston Pump
1. Remote and EDC Control Valves 4. To Hydraulic Lift and Assist Ram (Where Fitted)
2. To Remotes and Hydraulic Lift Control Valve 5. Variable Flow Hydraulic Pump
3. Return to Reservoir 6. Trailer Brake Valve
(via Transmission Brake Housing) 7. Load Sense Lines

The principal of operation of the closed centre load variable flow piston pump offers significant benefits in
sensing high pressure hydraulic circuit with variable reducing the engine power loss that occurs in open
flow piston pump is to supply oil flow on demand. It also centre systems where a high volume of oil, often far in
enables simultaneous operation of the trailer brakes excess of demand, is continuously pumped round the
hydraulic lift, remote control valve assemblies and hydraulic circuit even when they are not being
front axle suspension where fitted. The load sensing operated.

35- 7
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
The high pressure circuit identifies The following
components.
Hydraulic pump assembly (1) and load sensing
valve (2) are located on the right hand side of the
transmission. The load sensing valve contains a
pressure and flow compensating valve which controls
pump output in accordance with circuit demand.

TI
12
Trailer brake valve which is located beneath the cab
just in front of the hydraulic lift cover. The valve diverts
oil pressure to the trailer brakes whenever both tractor
brake pedals are depressed.

13
The hydraulic lift Electronic Draft Control Valve (2)
is a stack type design mounted together with the
Remote Control Valves (1) at the rear below the cab,
and incorporates the lift cylinder safety valve

The lift cylinder safety valve protects the lift cylinder

from shock loadings and limits the pressure in the
cylinder to 210--215 bar (3050--3100 lbf/in2)
The hydraulic lift control valve is a proportional
solenoid operated valve, controlled by a
microprocessor, to raise and lower the hydraulic lift.

14
The closed centre load sensing remote control
valves (2) are available as two or four valves per
tractor.
For further details on the operation of the trailer brake
valve, remote control valves and electronic draft
control system refer to the appropriate Chapters in this
section of the Repair Manual.

35- 8
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1

15
Electronic Draft Control and Closed Centre Remote Control Valve Stack
--

Electronic Draft Control and Closed Centre Remote Control Valve Stack
1. Remote Control Valve No I 7. Manifold Block
2. Remote Control Valve No II 8. Return to Reservoir
3. Electronic Draft Control Valve 9. To Hydraulic Lift
4. Remote Control Valve No III 10. Load Sensing Line Connection
5. Remote Control Valve No IIII 11. End Cover
6. Inlet Port

35- 9
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
With Reference to Figure 16. If pump output pressure is less than the combined
Operation of the closed centre high pressure hydraulic pressure of the load sense line and spring force of the
circuit is as follows:-- flow control valve, then pump output continues to
increase. When circuit demand is satisfied pump
The components in the high pressure hydraulic circuit
pressure overcomes the combined pressure of the
are connected by their load sensing lines to the
load sense line and flow compensating valve spring.
hydraulic load sensing valve which controls the output
This moves the spool in the flow compensating valve
of the hydraulic pump.
to the right, allowing control pressure oil to be directed
When the trailer brakes, remote control valves, to the variable flow swash plate servo piston, which
hydraulic lift or front axle suspension (where fitted) are de--strokes the pump to adjust output to circuit
operating, the load sensing valve on variable flow demand.
piston pump, compares the pressure in the component
For a detailed explanation on the load sensing
load sense line with the output pressure of the
operating principle of the variable flow piston pump
hydraulic pump.
refer to Chapter 2 in this section of the Repair Manual.

Figure16
Closed Centre Load Sensing High Pressure Hydraulic Circuit
1. Remote Control Valve 6. Front Suspension Control Cylinder
2. Load Sense/Supply Line for Additional Remote Valves 7. Front Suspension Control Valve
3. Load Sense Shuttle Valve 8. Trailer Brake Valve
4. Variable Displacement Hydraulic Pump 9. Electronic Draft Control Valve
5. Mid Mounted Remote Control Valve

35- 10
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
OPEN CENTRE HIGH PRESSURE HYDRAULIC CIRCUIT

3 4

2
8 7 6 5
TIA35175

17
Open Centre High Pressure Circuit Components and Pipework
Tractors with Mechanical Hydraulic Lift and Open Centre Gear Type Hydraulic Pump
1. Open Centre Remote Control Valves 6. Steering, Low Pressure and Lubrication Circuit Gear
2. Lift Cover Control Valve Pump
3. From Remotes to Lift Cover Control Valve 7. High Pressure Circuit Gear Pump
4. To Steering Motor (Steering Circuit) 8. To Hydraulic Lift and Assist Ram (Where Fitted)
5. Steering Motor Return to Low Pressure Circuit

On open centre high pressure hydraulic systems all The priority of operation is given to the order of
components are connected in series and pump flow is components in the circuits, that is trailer brakes,
continually circulating through the hydraulic system remote valves and hydraulic lift. This means for
even when the circuits are not being operated. example when fully operating a remote valve the
hydraulic lift will not operate at the same time unless a
flow divider valve is installed in the remote valve stack.

35- 13
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
The open centre high pressure hydraulic circuits for
tractors installed with mechanically controlled
hydraulic lift are shown in Figures 24 and include the
components shown on the following pages.

Open centre hydraulic pump assembly comprising of

the high pressure gear pump (1) and steering and low
pressure gear pump (2).

18
High pressure circuit relief valve located at the base of
the pump diverts pump flow to sump if the system
pressure reaches 190 bar (2760 lbf/in2).

TIA35201
19
The trailer brake valve is located beneath the cab on
the left hand side of the tractor. The valve diverts oil
pressure to the trailer brakes whenever the right hand
tractor brake pedals is depressed. This is unlike the
valve installed on the closed centre system where both
pedals have to be depressed in order for the valve to
operate.
The trailer brake has absolute priority over other
services in the circuit.

20
The open centre remote valves are available as two
three or four valves per tractor.
The valves can be double--acting with float and kick
out.
Double acting convertible to single--acting with float.
Double acting convertible to single--acting.
When four remote valves are installed the optional flow
divider valve (1) is available enabling simultaneous
operation of remote valve No 1 with another remote
valve or hydraulic lift.

35- 14
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
On Synchro Command tractors which are fitted with
mechanical hydraulic lift, the lift cylinder control valve
assembly is located at the rear of the hydraulic lift
assembly. The lift cylinder safety valve is mounted on
the rear face of the control valve which must be
removed to obtain access.

TIA35172
22
The low pressure regulating valve is located in the
transmission side cover and regulates the pressure in
the low pressure circuit to 16--18 bar (232--261 lbf/in2).

TIA35177
23

35- 15
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
High Pressure Circuit for Tractors with Open
Centre Hydraulics and Mechanical Hydraulic Lift
With Reference to Figure 24. assembly, which controls the raising and lowering of
Both the high and low pressure pumps are driven by a the lift.
‘live’ drive gear train directly connected to the PTO All excess oil flow produced by the hydraulic pump is
clutch input drive shaft and driven by the engine returned direct to the rear axle through the control
flywheel. valve spool located in the hydraulic lift control valve
Oil is drawn through the common intake port and filter assembly.
to both the high and steering/low pressure pump Also located within the assembly is the lift cylinder
assemblies. safety valve, which protect the lift cylinder and seals
The high pressure pump supplies constant oil flow from excessive peaks of pressure during operation.
according to engine speed, through the trailer brake For further details on operation of the mechanical
and open centre remotes. hydraulic lift assembly, trailer brake valve and open
Oil, after passing through the remotes, enters the centre remotes refer to the appropriate Chapters in this
hydraulic lift control valve located at the rear of the lift Section of the Repair Manual.

35- 16
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1

Open Centre High Pressure Hydraulic Circuit Operation 24

Tractors With Mechanical Hydraulic Lift
Hydraulic Lift Operating

Steering System Oil System Pressure Oil Trapped Oil

Low Pressure Circuit Oil

16--18 bar (230--261 lbf/in 2) Return to Reservoir Oil Lubrication Oil

Suction Oil

1. Intake Filter 7. Lift Cylinder Safety Valve

2. High Pressure Circuit Gear Pump 8. Mechanical Hydraulic Lift Assembly
3. Pressure Relief Valve
9. Steering and Low Pressure Circuit Gear Pump
4. Trailer Brake Valve
5. Open Centre Remote Control Valves 10. Steering Motor
6. Lift Control Valve 11. Low Pressure Circuit Pressure Regulating Valve

35- 17
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
LOW PRESSURE HYDRAULIC CIRCUITS

Tractors with Power Command Transmission

The low pressure hydraulic circuit for tractors with
Power Command transmissions is shown on Figure33
The function of the principal components in the circuit
are described as follows
Oil is drawn through the steering and low pressure
circuit pump (1) to the steering flow control valve (2)
which diverts oil to both the low pressure and steering
circuits, with priority flow to steering on demand.
Return flow from the steering circuit combines with the
flow from the pump to the low pressure and lubrication
circuit.
Operation of the priority valve is dependant on type of
front axle installed i.e standard or supersteer axles.
Refer to Steering Section 41 for further details.
1
2
TIA35149
25
The brake booster valve located immediately in front
of the cab fire wall is supplied with oil from the low
pressure circuit.
When both brake pedals are depressed oil from the low
pressure circuit acts on a piston in the brake booster
valve and pressurises the oil in the brake booster
circuit to apply the front brakes.

26
The low pressure regulating valve in the transmission
top cover limits the pressure in this circuit to 16--18 bar
(230--261 lbf/in2) and the excess flow passes into to
the lubrication circuit.

35- 18
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
The transmission top cover contains range solenoids
for engagement of the transmission range clutches,
operation of the differential lock, PTO clutch and brake
and disengagement of the four wheel drive.

NOTE: The four wheel drive is spring applied and the

solenoid is energised whenever disengagement of the
drive is required.

Solenoid Function
C040 Reverse Clutch
C039 High Range Clutch
C042 PTO Engagement 28
C041 Differential Lock
C032 Low Range Clutch
C031 Medium Range Clutch
C034 Four Wheel Drive
C033 PTO Brake

29
PWM Solenoid Valve Function
The pulse width modulated solenoids in the
transmission top cover are used to progressively
engage/disengage the transmission clutches A, B, C,
D and E.
C024 A Clutch
C025 B Clutch
C026 C Clutch
C027 D Clutch
C028 E Clutch

35- 19
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Low pressure circuit oil is directed through the oil
cooler at the front of the tractor and is limited to a
maximum pressure of 7 bar (100 lbf/in2) by the
lubrication valve located in the front of the
transmission. Components lubricated by this oil are
transmission shafts and clutches, hydraulic pump
drive gear, hydraulic lift cross shaft and PTO clutch
lubrication.

TIA35158
31
When the oil is cold and pressure differential across the
oil cooler is higher than 3.5 bar (50 lbf/in2) the cooler
by--pass valve located in the side cover will operate to
ensure that adequate flow to the lubrication circuit is
maintained. This feature of diverting oil from the cooler
assists in aiding a rapid warm up of oil in cold weather
conditions.

Figure 33
Low Pressure Hydraulic Circuit -- Tractors with Power Command Transmission
1. Brake Booster Valve 3. Steering Priority Valve
2. Pulse Width Modulating Valve Manifold 4. Transmission Top Cover

35- 20
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Low Pressure Circuit Operation
Tractors with Range Command Transmission
With Reference to Figure 58.
Oil is drawn through the steering and low pressure
circuit pump (1) to the steering flow control valve (2)
which diverts oil to both the low pressure and steering
circuits, with priority flow to steering on demand.
Return flow from the steering circuit combines with the
flow from the pump to the low pressure and lubrication
circuit.
Operation of the priority valve is dependant on type of 1
front axle installed i.e standard or supersteer axles. 2
TIA35149
Refer to Steering Section 41 for further details.
34
The low pressure regulating valve in the transmission
side cover limits the pressure in this circuit to
16--18 bar (230--261 lbf/in2) and the excess flow
passes into the lubrication circuit.

TIA35047
35
The transmission side cover contains solenoids for
engagement of the transmission range synchronisers, 1 2
operation of the differential lock, PTO clutch and brake
and disengagement of the four wheel drive.

NOTE: The four wheel drive is spring applied and the

solenoid is energised whenever disengagement of the
drive is required.

4
3
TIA35159
36
Solenoid Function
1. Reverse Synchroniser
5 6
2. High Range Synchroniser
3. PTO Engagement
4. Differential Lock
5. Low Range Synchroniser
6. Medium Range Synchroniser 7
7. Four Wheel Drive
8. PTO Brake

8
TIA355160
37

35- 23
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
The pulse width modulated (PWM) solenoid valves in
the clutch oil distribution cover bolted onto the side of
the transmission are used to progressively
engage/disengage the transmission clutches.

PWM Solenoid Valve Function

1. A Clutch
2. B Clutch
3. C Clutch
4. D Clutch 1
5. E Clutch
2

5
TIA35161
38
Low pressure circuit oil is directed through the oil
cooler at the front of the tractor and is limited to a
maximum pressure of 7 bar (100 lbf/in2) by the
lubrication valve located in the front of the
transmission. Components lubricated by this oil are
transmission shafts and clutches, hydraulic pump
drive gear, hydraulic lift cross shaft and PTO clutch
lubrication.

TIA35158
39
When the oil is cold and pressure differential across the
oil cooler is higher than 3.5 bar (50 lbf/in2) the cooler
by--pass valve located in the side cover will operate to
ensure that adequate flow to the lubrication circuit is
maintained. This feature of diverting oil from the cooler
assists in aiding a rapid warm up of oil in cold weather
conditions.

35- 24
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Low Pressure Circuit Operation
Tractors with Dual Command Transmission
With Reference to Figure 59.
Oil is drawn through the steering and low pressure
circuit pump (1) to the steering flow control valve (2)
which diverts oil to both the low pressure and steering
circuits, with priority flow to steering on demand.
Return flow from the steering circuit combines with the
flow from the pump to the low pressure and lubrication
circuit.
Refer to Steering Section 41 for further details. 1
2
TIA35149
41
The low pressure regulating valve in the transmission
side cover limits the pressure in this circuit to
16--18 bar (230--261 lbf/in2) and the excess flow
passes into the lubrication circuit.

TIA35155
42
The solenoids in the side cover with, the exception of
the dump solenoid, are energised to divert flow and
engage the differential lock, PTO clutch and brake and
disengage four wheel drive.
NOTE: The four wheel drive is spring applied and the
solenoid is energised whenever disengagement of the 1
drive is required.

3
TIA35153
43
Solenoid Function
1. Differential Lock
2. PTO Clutch
4
3. PTO Brake
4. Four Wheel Drive
5. Transmission Clutch Dump Solenoid

5
TIA35154

35- 27
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
The pulse width modulated solenoids in the
transmission top cover are used to progressively 1
engage/disengage the transmission forward/ reverse
synchroniser and A and B clutches.
2
Solenoid Function
1. Reverse Synchroniser
2. Forward Synchroniser
3. ‘A’ Clutch
4. ‘B’ Clutch

4
3
TIA35156
45
The dump solenoid in the transmission side cover is a
safety solenoid controlled by the pressure switches in
the A and B clutch circuits. In the unlikely event that
both these clutches are pressurised at the same time
the dump solenoid is energised allowing pressure in
the circuit to be diverted to sump preventing ‘lock up’
of the transmission.

TIA35150

46
Low pressure circuit oil is directed through the oil
cooler at the front of the tractor and limited to a
maximum pressure of 7 bar (100 lbf/in2) by the
lubrication valve (1) located in the front of the
transmission. Components lubricated by this oil are
transmission clutches and shafts, hydraulic pump
drive gear, hydraulic lift cross shaft and PTO clutch
lubrication.

47
When the oil is cold and pressure differential across the
oil cooler is higher than 3.5 bar (50 lbf/in2) the cooler
by--pass valve located in the pipework running along
the side of the transmission will operate to ensure that
an adequate oil flow to the lubrication circuit is
maintained. This feature of diverting oil from the cooler
assists in aiding a rapid warm up of oil in cold weather
conditions.

TIA35045
48

35- 28
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Low Pressure Circuit Operation
Tractors with Shuttle Command Transmission
1
With Reference to Figure 61.
Oil returning from the steering motor joins with the
pump flow through the non priority side of the flow
control valve and is supplied to the transmission low
pressure and lubrication circuit. 2

TIA35176
50
The low pressure regulating valve in the transmission
side cover limits the pressure in this circuit to
16--18 bar (230--261 lbf/in2) and the excess flow
passes into the lubrication circuit.

TIA35177
51
The solenoids in the side cover are energised to divert
flow and engage the differential lock, PTO clutch and
brake and disengage four wheel drive.
1
NOTE: The four wheel drive is spring applied and the
solenoid is energised whenever disengagement of the
drive is required.
2

3
TIA35178
52
Solenoid Function
1. Differential Lock
4
2. PTO Clutch
3. PTO Brake
4. Four Wheel Drive

TIA35179
53

35- 31
SECTION 35 HYDRAULIC SYSTEMS -- CHAPTER 1
Low pressure circuit oil is directed through the oil
cooler at the front of the tractor and limited to a
maximum pressure of 7 bar (100 lbf/in2) by the
lubrication valve (1) located in the mating face of the
transmission side cover. Components lubricated by
this oil are transmission lower shaft, hydraulic pump
drive gear, hydraulic lift cross shaft and PTO clutch
lubrication.

The check valve (2) also located next to the lubrication

valve is called the steering make up valve and is
located below the oil level in the transmission. In the
event of hydraulic circuit failure the check valve allows
the steering motor to draw oil from the transmission
and up to the steering motor to ensure safe operation of 54
the steering system is maintained.

When the oil is cold and pressure differential across the

oil cooler is higher than 3.5 bar (50 lbf/in2) the cooler
by--pass valve located in the pipework running along
the side of the transmission will operate to ensure that
an adequate oil flow to the lubrication circuit is
maintained. This feature of diverting oil from the cooler
assists in aiding a rapid warm up of oil in cold weather
conditions.

TIA35045
55

35- 32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 2 -- Variable Flow Hydraulic Pump Assembly

CONTENTS

Section Description Page

35 000 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Pressure Circuit High Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
High Pressure Circuit Low Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Controlling Maximum System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Initial Fault Finding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission Low Pressure Warning Light ‘ON’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Charge Pressure Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Intake Filter Restriction Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remote Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Load Sensing Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Charge Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Variable Flow Piston Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering Pump/Low Pressure Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic Pump Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Continued Overleaf

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
CONTENT

Section Description Page

35 106 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Charge Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Charge Pressure Filter Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Steering Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pressure and Flow Compensating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Steering Pump Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Charge Pump Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Variable Flow Piston Pump Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump Drive Gear and Bearing Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
SPECIAL TOOLS
NEW HOLLAND PRIOR TOOL
PART No NUMBER
Pump Removal Bracket 295046 NH 35100
Pump Drive Shaft Retainer 295033 NH 35101
By--Pass and Dump Valve Extractor 295025 4FT. 857
2
Pressure Gauge 0--6.6 bar (0--100 lbf\in ) 297320 FT. 4096
Pressure Gauge 0--414 bar (0--6000 lbf\in )2 297156 FT. 8503A
Adaptor Charge Pressure Test 295024 NH 35102
Hydraulic Pressure Test Kit 292870
Adaptor Pump Drive Gear Shaft Pin Removal 50140*
Adaptor Pump Drive Gear Shaft Removal 290793
1 1 7
Tee Adaptor /4 ORSF (F) x /4 ORFS (F) x /16 UNF (F) 297603
Tee Adaptor 3/8 ORSF (F) 3/8 ORFS (M) x 7/16 UNF (F) 297600
Adaptor m10x1 (M) x 7/16 UNF (F) 297404
Adaptor m10x1 (M) x 7/16 JIC (M) 297417
1
Cap /4 ORFS 297604
Quick Release coupler 291924
Quick Release Adaptor x 7/16 UNF (M) 297240
Alignment Dowel Local Manufacture
Plug (Modify adaptor New Holland Part No 83928452)
Flowmeter 0--200 ltrs/min Procure Locally

SEALANT
Flexible Gasket Sealant 82995771

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
35 000 SPECIFICATIONS
Charge Pump

Type Gear Type Pump

Charge Pressure Filter Dump Valve Crack open @ 6.9 bar (100 lbf/in2)
Fully Open @ 12.4 bar (180 lbf/in2)
Charge Pressure Minimum 1.6--3.4 bar (23--50 lbf/in2)
@ 2100 rev/min and variable flow
piston pump ‘On Load’

Charge Pressure Switch Close @ 0.55--0.82 bar (8--12 lbf/in2)

Making charge pressure warning light flash

Variable Flow Closed Centre Load Sensing Piston Pump

Type Variable Flow Piston Pump
(Swash Plate Controlled)

Minimum Output @ 2200 erpm 111 Ltr/min

24 Imp Galls/min
29 US Galls/min

Standby Pressure (Low Pressure Standby) 21--24 bar (310--350 lbf/in2)

Maximum System Pressure (High Pressure Standby) 200--207bar (2900 -- 3000 lbf/in 2)

Steering/Low Pressure Circuit Pump

Type Gear Type Pump

Minimum Output @ 2200 erpm 61.5 Ltr/min

13 Imp Galls/min
16 US Galls/min

Flow to Steering Motor 22--28ltr/min

4.8--6.2 Imp Galls/min
5.8--7.4 US Galls/min

Steering Pressure 190bar (2750 lbf/in2) max

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
TORQUES

50--62
3x
37--46
Nm
lbs. ft

50--62
4x 76--90
37--46 5x 50--62 23--29
56--66 6x 2x
37--46 17--21

25--30 38--42
18--22 28--31

35--40
25--30
62--68
40--50 4x
46--50
30--37

215
24
160
18

TIA35118

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
35 000 DESCRIPTION AND OPERATION
1

3 2
TIA35030
1
Hydraulic Pump Assembly With Variable Displacement Closed Centre Load Sensing
1. Steering, Low Pressure and Lubrication Circuit Gear 2. Gear Type Charge Pump
Type Pump 3. Variable Flow Piston Pump

The variable flow closed centre load sensing hydraulic • A fixed displacement gear type pump, referred to
pump assembly is mounted on the right hand side of as the Steering and Low Pressure Circuit pump,
the rear axle centre housing and contains within its supplying oil for operation of:
body three hydraulic pumps. Steering System
• A charge pump of the gear type to supply oil at a Independent Power Take Off
charge pressure of 1.6--3.4 bar (23--50 lbf/in2) to a Differential Lock
variable flow closed centre load sensing hydraulic Front Wheel Drive Axle
piston pump. Transmission Clutches
Lubrication Circuit
• A variable flow closed centre load sensing piston
Steering and Low Pressure Pump Output @ 2200
type hydraulic pump supplying oil to the high pres-
erpm
sure circuits for operation of:--
61.5 Ltr/min
Trailer Brake
13 Imp Galls/min
Hydraulic Lift Assembly
16 US Galls/min
Remote Control Valves
• Front Axle Suspension
Variable Flow Piston Pump Output on Full Stroke
@ 2200 erpm
111 Ltr/min
21 Imp Galls/min
25 US Galls/min

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

7
6 5 4 3 2 1
TIA33022

2
Variable Flow Piston Pump Pump Components
1. Spring 5. Thrust plate
2. Spring 6. Nine Element Pumping Head
3. Seat 7. End Plate and Servo Piston Assembly
4. Swash Plate 8. Load Sensing Valve

Principal of Operation provide oil flow and absorb engine power even when
All three pumping elements are driven by a ‘live’ drive the hydraulic circuits do not require the total pump
gear train directly connected to the PTO clutch input output.
drive shaft and driven by the engine flywheel.
The operating principal of the fixed displacement gear Variable Displacement Piston Pump
pumps is to provide a constant oil flow directly related The major components of the variable flow piston
to the rotation speed of the pump. pump with closed centre load sensing are:--
The operating principal of a variable flow piston pump 1. A nine element pumping head.
is to provide oil flow on demand and minimises the 2. A plate mechanism (swash plate) to adjust piston
engine power absorbed in driving the hydraulic pump stroke and corresponding pump output.
when the hydraulic circuits do not require maximum
3. A load sensing valve which monitors the
pump flow.
requirements of the hydraulic circuits and signals
The variable flow piston pump in hydraulic systems the pump to increase or decrease hydraulic oil flow
therefore has distinct power loss advantages over accordingly.
fixed displacement gear type pumps, which continually

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2 3 4

8 7 6 5
TIA35042

3
Variable Displacement Piston Pump--Sectional Drawing
1. Pump End Plate 7. Slipper (9 off)
2. Swash Plate Servo Piston 8. Piston and Barrel
3. Swash Plate 9. Inlet Port
4. Swash Plate Return Spring 10. Pumping Head Pre--load Spring
5. Driveshaft Gear 11. Outlet Port
6. Driveshaft

The nine element pumping head is cylindrical in shape works in conjunction with the pressure and flow
and has nine barrels, into each of which, is installed a compensating valves in the load sensing line.
piston. On the end of each piston is pressed a slipper As the pumping head rotates each barrel passes over
which always remains in contact with the face of the the inlet and then the outlet ports of the pump. During
swash plate located at the front of the pumping head. the inlet cycle for each piston and barrel, oil is pumped
The drive shaft, which is driven by the pump drive gear, into the barrel pushing the piston forward so that it
rotates the pumping head. As the pumping head always remains in contact with the swash plate. The
rotates, the pistons move in and out of their barrels, stroke of each piston and volume of oil charged into its
following the contour of the swash plate. For every barrel is therefore dependent on the angle of the swash
revolution of the drive shaft each piston completes one plate.
pumping cycle. After a piston and barrel has completed the inlet stroke,
The swash plate, which does not rotate but pivots further rotation of the head aligns the barrel with the
about the front of the pumping head, is the control outlet port. Oil within the barrel is then forcibly ejected
mechanism that limits the stroke of each piston and by the piston through the exhaust port to the hydraulic
circuits.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

4
CCLS Hydraulic Pump Installation
1. Intake Filter 8. Charge Pressure Filter Dump Valve
2. Oil Low Temperature Switch 9. Charge Pump
3. Intake Filter Restriction Switch 10. Charge Pressure Filter
4. Low Charge Pressure Switch 11. Variable Flow Piston Pump
5. Charge Pressure By--Pass Valve 12. Load Sensing Valve
6. Steering Flow Control Valve (Flow and Pressure Compensating Valves)
7. Steering and Low Pressure Circuit Pump

The location of the principal components in the When the filter is blocked the oil filter restriction
hydraulic pump assembly are identified above. These vacuum switch is activated and illuminates the oil filter
items are shown on the hydraulic circuit diagrams restriction warning light on the instrument panel.
which describe the operating modes of the pump. The Because oil is more viscous (thicker) when cold and
principal function of the valves and switches is as can falsely indicate that the filter requires servicing a
follows:-- low temperature oil switch is also used in the filter
restriction circuit. This switch ensures that the warning
Intake Filter and Restriction Switch light will not operate if the oil temperature is less than
Oil for both the charge and steering pump is drawn 40°C.
from the rear axle centre housing via the intake filter.
The filter incorporates a by--pass valve, which is an Low Charge Pressure Switch
integral part of the replaceable filter and it is therefore The low charge pressure switch will cause a light to
essential that the correct filter is installed at every filter ‘Flash’ on the instrument cluster whenever the charge
change. pressure is less than 0.75 bar (11 lbf/in2)

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Charge Pressure Filter Dump Valve
The charge pressure filter dump valve is a safety relief
valve for relieving excess pressure on the charge
pump should the filter be restricted. This valve will start
to operate if the charge pressure exceeds
6.9--10.3 bar (100--150 lbf/in2).
It should be noted that the charge pressure filter does
not incorporate a by--pass valve thus preventing dirty
oil entering the variable flow pump circuits.

3 2 1
TIA35004
5
Charge Pressure Valve
The charge pressure valve diverts excess oil supplied
by the charge pump and not required by the variable
flow piston pump to the inlet port of the steering and low
pressure circuit pump.
This valve starts to operate at a pressure of 1.6 bar
(23 lbf/in2) and when fully open limits the charge
pressure circuit oil to 3.4 bar (50 lbf/in2) .

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6
Steering Flow Control Valve
(All Models except Supersteer)
The steering flow control valve ensures that 25 ltr/min
(5.5 Imp Galls, 6.6 U.S. Galls/min) of oil is constantly
supplied to the steering motor from the steering and
low pressure circuit pump. All additional flow from the
pump passes directly into the low pressure circuit.

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7
Steering Flow Control Valve
(Models with Supersteer)
On tractors installed with supersteer front axles the
steering flow control valve (2) is dynamically load
sensed.
When the steering wheel is turned slowly The dynamic
load sensing line (3) supplies oil via the steering motor
to the steering rams. When the steering wheel is turned
quickly oil is also supplied to the steering circuit
through the main supply feed (1) to the steering motor.
All excess flow passes into the low pressure circuit (4).
Refer to Steering Systems Section 41 for further
details.
8

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2 3 4 5 6 7

16
8

15
14 13 12 11 10 9
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9
Flow and Pressure Compensating Valves
1. Plug and ‘O’ Ring 9. Tamperproof Cap
2. Housing 10. Locknut
3. Flow Compensating Spool 11. Adjuster and ‘O’ Ring Seal
4. Seat 12. Spring
5. Spring 13. Seat
6. Adjuster and ‘O’ Ring Seal 14. Pressure Compensator Spool
7. Locknut 15. ‘O’ Ring Seals
8. Tamperproof Cap 16. Plug and ‘O’ Ring

Flow and Pressure Compensating Valves

(CCLS Pump Load Sensing Valve)
Output from the variable flow piston pump is If pump output and circuit pressure rises to 200 bar
determined by adjusting the angle of the swash plate (2900 lbf/in2) the pressure compensating valve
in the pump. The flow compensating valves senses the overrides the flow compensating valve and adjusts the
circuit operating pressure and adjusts the swash plate swash plate angle to limit maximum system pressure.
angle to control pump output.

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
HYDRAULIC CIRCUIT OPERATION

With Reference to Figure 10

The charge pressure pump draws oil through the flow to the inlet side of the steering pump to be returned
charge pump inlet filter. to the inlet side port of the charge pump.
Oil drawn by the charge pump flows through the charge The variable flow closed centre load sensing hydraulic
pressure filter to the variable flow piston pump and also pump operates progressively in 4 modes:--
through the charge pressure valve to the inlet port of Low Pressure Standby
the steering pump.
High Pressure Circuit Maximum Demand
Because output from the charge pump can exceed the
High Pressure Circuit Low Demand
combined demand of the steering and variable
displacement pumps an open gallery between the inlet Maximum System Pressure
side of the charge and steering pumps allows excess (High Pressure Standby)

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Hydraulic Pump Oil Flow

System Pressure Return to Reservoir

Control Pressure Steering Circuit

Charge Pressure @ 1.6--3.4bar Low Pressure/Lubrication Circuit

Suction

1. To High Pressure Circuit 10. To Low Pressure Circuit

2. From Compensating Valves 11. Steering and Low Pressure Circuit Pump
3. Intake Filter Restriction Switch 12. Charge Pump
4. Intake Filter 13. Charge Pressure Filter Dump Valve
5. Oil Low Temperature Switch 14. Pump Intake
6. Low Charge Pressure Switch 15. Charge Pressure Filter
7. Charge Pressure By--pass Valve 16. Swash Plate
8. To Steering Circuit 17. Variable Flow Piston Pump
9. Steering Flow Control Valve 18. Servo Piston Return Spring

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Low Pressure Standby

With Reference to Figure 11

Low pressure standby is the system pressure The controlled pressure rise in gallery D operates the
310--350 lbf/in2 (21--24 bar) maintained by the swash plate servo piston, changing the angle of the
hydraulic pump when high pressure hydraulic circuits swash plate in relation to the pumping head. The
are not being operated. change in angle reduces the operating stroke of the
During engine start up, standby pressure has not been pistons and output of the pump.
generated and both the flow and pressure As pump output decreases and the pressure in gallery
compensating valves are held to the left by spring D reduces to less than 350 lbf/in2 (24 bar), the flow
pressure. compensating valve gradually moves under spring
While the spools are held to the left oil pressure pressure to the left bleeding gallery D to sump through
generated by the pump cannot be applied to the swash gallery C. This reduces the control pressure applied to
plate servo piston. The swash plate consequently the servo piston, allowing the servo piston to retract at
remains in the maximum flow position until the pump a controlled rate under pressure from the swash plate
has developed sufficient flow to produce pressure at return spring and re--adjust the angle of the swash
low pressure standby . plate to increase pump output.
As pump output pressure increases to 21--24 bar, this This control process continues maintaining pump
pressure is sensed in gallery E , Figure 11 and applied output pressure at 21--24 bar (low pressure standby)
to the flow compensating spool. The spool gradually until a high pressure circuit is operated and pump
moves against the spring allowing oil flow from gallery system pressure needs to be increased to operate the
E to gallery D. service.

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Low Pressure Standby 11

Standby Pressure @ 21--24bar Return to Reservoir

Control Pressure Steering Circuit

Charge Pressure @ 1.6--3.4bar Low Pressure/Lubrication Circuit

Suction
1. High Pressure Circuit (In Neutral) 3. Flow Compensating Valve
2. Pressure Compensating Valve 4. Swash Plate

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
High Pressure Circuit High Demand

High Pressure Circuit High Demand 12

Standby Pressure @ 190bar Return to Reservoir

Control Pressure Steering Circuit

Charge Pressure @ 1.6--3.4bar Low Pressure/Lubrication Circuit

Suction
1. High Pressure Circuit 3. Flow Compensating Valve
2. Pressure Compensating Valve 4. Swash Plate

When the electronic draft control hydraulic lift, remote compensating spool to move against the standby
control valves or trailer braking system are operated pressure in gallery E, preventing the flow of oil to the
the pressure rise in the hydraulic circuit is sensed by swash plate servo piston through gallery C.
the load sensing line B. The pressure in the sensing The movement of the spool opens gallery D to the
line is now applied to the spring loaded end of the flow return to sump gallery C, allowing the servo piston to
compensating valve. retract under pressure from the swash plate return
The combined pressure from the pilot line and flow spring and adjust the angle of the swash plate to
compensating valve return spring causes the flow increase pump output.

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
High Pressure Circuit Low Demand

High Pressure Circuit Low Demand 13

Standby Pressure @ 190bar Return to Reservoir

Control Pressure Steering Circuit

Charge Pressure @ 1.6--3.4bar Low Pressure/Lubrication Circuit

Suction
1. High Pressure Circuit 3. Flow Compensating Valve
2. Pressure Compensating Valve 4. Swash Plate

When output from the pump is meeting the demand of gallery E to gallery D. The controlled pressure rise in
the hydraulic circuit the output pressure of the gallery D operates the swash plate servo piston and
hydraulic pump in gallery E will continue to rise unless changes the swash plate angle to reduce pump output
the flow from the pump is controlled. according to demand.
As pump pressure increases the differential between It can now be seen that whenever the differential
system pressure E and load sensed pressure B will pressure between system and load sensed pressures
similarly increase. When this differential rises towards approaches 21--24 bar (300--350 lbf/in2) the flow
21 bar (300 lbf/in2) the pressure in gallery E causes the compensator valve will operate to control the angle of
flow compensator spool to move back against the the swash plate and consequently pump flow (output).
spring and load sense pressure in Gallery B to open

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Controling Maximum System Pressure

Controlling Maximum System Pressure 14

Standby Pressure @ 190bar Return to Reservoir

Control Pressure Steering Circuit

Charge Pressure @ 1.6--3.4bar Low Pressure/Lubrication Circuit

Suction
1. High Pressure Circuit 3. Flow Compensating Valve
2. Pressure Compensating Valve 4. Swash Plate

To limit the maximum output pressure of the piston As the pressure in gallery E increases to 2800 lbf/in2
pump and prevent consequential damage that may (193 bar) the pressure compensator valve spool (2)
occur due to excessive pressures, a pressure moves against the valve return spring and opens
compensating valve, located adjacent to the flow gallery E to gallery D. The pressure in gallery D is now
compensator valve, is incorporated in the swash plate applied to the servo piston which changes the swash
control circuit. This valve limits the pressure to 190 bar plate angle to reduce pump output to minimum flow.
(2750 lbf/in2) and operates as follows:-- This operating mode is referred to as high pressure
standby.

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
35 000 FAULT FINDING
Before commencing fault finding refer to the initial Initial Fault Finding Check
check fault finding chart which may identify an obvious Transmission Low Pressure Warning Light ‘On’
cause for the concern and prevent unnecessary
Charge Pressure Light Flashing
component disassembly.
Intake Filter Restriction Warning Light ‘On’
IMPORTANT: If the steering is inoperative, there will
be no lubrication to the transmission or PTO clutch and Power Steering not Working or Working Incorrectly
the tractor must not be run for more than 5 minutes at Trailer Brakes not Working
a maximum engine speed of 1000 rev/min. Hydraulic Lift not Working Correctly
Fault finding charts listed in this Chapter are:-- Remote Control Valves not Working
Initial Fault Finding Checks
To be Performed Before Proceeding to General Diagnostic Procedure

Check if any error

codes have been
identified by the YES Refer to Error code
microprocessor. Refer fault finding charts
to Section 55 for
retrieval of error codes.
NO

Is rear axle oil at correct NO Add oil to rear axle

level on dipstick?
YES

Is oil contaminated with dirt, YES Investigate cause of contamination.

water or anti--freeze? Drain and replace oil
NO

Have oil filters been replaced NO Replace all filters on pump

at correct service interval?
YES

Is Transmission low Set engine speed to 1000 rev/min and

YES check that steering operates.
pressure warning light ON
NO If steering does not operate turn of
engine immediately to avoid damage
Identify functions not operating due to possible lack of oil flow to low
correctly and refer to appropriate pressure and lubrication circuits.
fault finding Chart Refer to Transmission Low Pressure
Warning Light ‘On’ fault finding chart

35- 19
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

16
CCLS Hydraulic Pump Installation
1. Intake Filter 8. Charge Pressure Filter Dump Valve
2. Oil Low Temperature Switch 9. Charge Pump
3. Intake Filter Restriction Switch 10. Charge Pressure Filter
4. Low Charge Pressure Switch 11. Variable Flow Piston Pump
5. Charge Pressure By--Pass Valve 12. Load Sensing Valve
6. Steering Flow Control Valve (Flow and Pressure Compensating Valves)
7. Steering and Low Pressure Circuit Pump

TIA35004 TIA35005
17 18
Charge Pressure Filter Dump Valve Steering Flow Control Valve

35- 20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Transmission Low Pressure Warning Light ‘ON’-- Power Command Transmission

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19 20
Steering Pump Charge Pressure Valve Transmission Low Oil Pressure Switch
Set engine speed to 1000 Is hydraulic oil Carefully operate tractor until
Rev/min YES temperature YES oil temperature increases
Is steering working below 40°C Fault cleared?
correctly? NO NO
NO

Does PTO stop and start Disconnect wiring to low

when engagement switch transmission oil pressure switch
is operated? Is warning light ‘On’?
YES NO
NO
On tractors with power Perform low
Stop engine immediately. pressure circuit
Remove the steering pump command transmission
check for short to chassis check
charge pressure valve, Is pressure 250--280
rotate engine by hand and in Y/O colour wires from
instrument console lbf/in 2 (17--20 bar)?
check that steering pump NO
gears are rotating connector C080 Pin10 to
Do not put fingers inside pressure switch C036
Check orifice in low
steering pump transmission oil pressure
Gears Rotating YES Recheck switch is not blocked
NO Steering and Orifice clear?
Remove pump and PTO operation
NO
check that pump
drive gear rotates Remove and examine
when engine is turned Disassemble pump orifice in pressure
over by hand. YES and inspect for regulating valve
Gear Rotates broken pump drive Fault cleared?
NO shaft NO

Check for broken Remove and examine

drive between engine pressure regulating
flywheel/damper and valve for sticking
pump drive gear Fault cleared?
NO

Replace low
transmission oil
pressure switch
Fault cleared?
NO

Check for large leak in PTO

differential lock, 4 wheel drive and
transmission pressure circuits.

35- 21
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Transmission Low Pressure Warning Light ‘ON’ -- Range/Dual Command Transmissions

TIA35002 TIA35047
21 22
Steering Pump Charge Pressure Valve Transmission Low Oil Pressure Switch
Set engine speed to 1000 Is hydraulic oil Carefully operate tractor until
Rev/min YES temperature YES oil temperature increases
Is steering working below 40°C Fault cleared?
correctly? NO NO
NO

Does PTO stop and start Disconnect wiring to low

Check for broken Remove and examine

drive between engine pressure regulating
flywheel/damper and valve for sticking
pump drive gear Fault cleared?
NO

Replace low
transmission oil
pressure switch
Fault cleared?
NO

Check for large leak in PTO

differential lock, 4 wheel drive and
transmission pressure circuits.

35- 22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Charge Pressure Light Flashing

Is rear axle oil at correct level NO Add oil to rear axle

on dipstick?
YES

Perform charge pressure test Disconnect wiring to low charge

Charge Pressure YES pressure switch
1.6--3.4 bar? Light is extinguished?
NO NO YES

Replace inlet and Locate and repair short Replace

charge pressure filter circuit to chassis in charge pump
Fault cleared? B/N colour wire from and inlet filters
NO instrument console Fault
connector C080 Pin 7 cleared?
Inspect charge pressure filter and charge pressure NO
dump valve and charge switch
pressure valve Recheck charge
Valve sticking open? NO pressure
NO YES Charge Pressure
1.6--3.4 bar?
Disassemble Replace Valve(s) YES
pump and check (DO Not re--adjust
for worn charge these valves) Replace low
pump charge
pressure
switch

Intake Filter Restriction Warning Light On

Is rear axle oil at correct level NO Add oil to rear axle

on dipstick?
YES

Replace inlet and Disconnect wiring to filter restriction

charge pressure filter NO warning light switch
Fault cleared? Light is extinguished?
NO YES

Locate and repair short Replace

circuit to chassis in intake filter
R/N/B colour wire from restriction
instrument console switch
connector C080 Pin 16
and intake filter
restriction switch

35- 23
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Power Steering Not Working or Working Incorrectly

Is transmission low Refer to Transmission

pressure warning YES low pressure warning
light on? light On fault finding
chart
NO

Perform steering test

Fault Confirmed?
YES

Set engine speed to 1000 rev/min Check pump bolt torques

and turn steering to full lock YES and examine for internal
Does transmission warning light leaks/worn pump seals
come on?
NO

Examine steering flow

control valve for sticking
Fault Cleared?
NO

Refer to Section 41
Steering System

Trailer Brakes Not Working

Has all air been bled NO Bleed trailer

from trailer brakes brakes
YES
Is hydraulic lift working
Pressure test trailer satisfactorily? Test
brakes. YES maximum system pressure Adjust flow/pressure
Fault confirmed? at remote valve coupler.
NO compensating valve
Pressure 2700--2800 lbf/in 2 Fault cleared?
(186--193 bar)? NO
YES
Examine
flow/pressure
Operate and hold remote valve to compensating
generate maximum system valve for sticking
Overhaul trailer pressure and at the same time Fault cleared?
NO operate tractor brakes
brake valve NO
Trailer brake valve functions
correctly?
Disassemble variable
YES flow pump and check
swash plate piston for
Examine shuttle valve in load sticking
Clean/replace sensing line between trailer
shuttle valve to YES brake and pressure/flow
trailer brake valve compensating valve
Valve sticking?

35- 24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Hydraulic Lift Not Working Correctly
Is steering system and NO Refer to Transmission Low Pressure
PTO working Warning Light ON fault finding chart
YES

Is charge pressure YES Refer to charge pressure light

light flashing? flashing fault finding chart
NO

Has an Electronic draft control error

code been identified NO Refer to Section 35 Chapter 4,
Fault Cleared? Electronic Draft Control fault finding.
NO

Is hydraulic lift Perform pump leak test to determine if

YES fault relates to either internal leak or
working erratically?
hydraulic circuit leak
NO

Is in cab fast raise/ work NO Move switch to work

switch in work position position
YES

Is hitch enabled YES Capture hitch

symbol illuminated
NO

Check position of controls

on control panel
Fault cleared?
NO

Are lift arms locked in either fully Check EDC valve raise or lower
raised or lowered position YES solenoids for sticking plunger
NO

Perform standby pressure test Adjust/examine flow

Is pressure 300--350 lbf/in 2 NO compensating valve
(21--24 bar)? Fault cleared?
YES NO

Perform High Pressure Standby test (maximum Disassemble variable

system pressure) at remote valve displacement pump and check
Is pressure 2700--2800 lbf/in 2 swash plate piston for sticking
(186--193 bar)?
YES NO

While operating remotes at high Adjust pressure Examine flow/pressure

pressure standby operate compensating valve NO
compensating valve for
hydraulic lift Fault cleared? sticking
Lift operates correctly? Fault cleared?
YES NO

Investigate fault in Examine EDC valve for

load sensing line sticking spools and Place heavy weight on lift arms
from EDC valve leaking lift cylinder safety NO and check if arms leak down
valve under the pressure of load
Fault cleared? YES

Overhaul lift cylinder

35- 25
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Remote Control Valves Not Working
Is hydraulic lift NO Refer to fault finding chart
working? for hydraulic lift not working
YES
Operate all remote valve
Test maximum system pressure levers simultaneously
at each remote valve coupler. Is the pressure at the Overhaul remote
Are pressures at each valve NO defective remote valve NO control valve(s) which
coupler below 2700--2800 lbf/in 2 now 2700--2800 lbf/in 2 fail pressure test
(186--193 bar)? (186--193 bar)?
YES
YES
Examine flow/pressure
compensating valve for sticking Examine load sensing valve
Fault cleared? between remote valve
sections.

35- 26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
PUMP PRESSURE AND FLOW TESTING
IMPORTANT: Before performing any pressure or flow
testing operate the tractor until the oil in the rear axle
is at normal operating temperature. 75°C (170°F).
The following tests check operation of the hydraulic
pump and associated high pressure circuits.

Low Pressure Standby

1. Disconnect load sense line (1) to remote valves
and install plug (2) Tool Number 297604.

23
2. Install 0--42 bar (0--600 lbf/in2) pressure gauge
into lift port of remote valve number 1.
3. Set engine speed to 1500 rev/min.

24
4. Pull and hold remote valve control lever No 1 in the
‘extend’ position.
5. The pressure reading should be 21--24 bar
(310--350 lbf/in2) and is the ‘Low Pressure
Standby.
IMPORTANT: Do Not operate tractor brakes while
remote valve No 1 lever is in operating position,
otherwise the system pressure will increase to
maximum pressure of 200 bar (2900 lbf/in 2)
resulting in damage to the pressure gauge.

TIA35078
25
If pressure reading is marginally away from
Specification adjust flow compensating valve.
If reading is high examine flow compensating valve
(1) spool for sticking.
6. Reconnect load sense line.

35- 27
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
High Pressure Standby
1. Install 0--420 bar (0--6000 lbf/in2) pressure
gauge into lift port of remote valve number 1.
2. Set engine speed to 1500 rev/min.

27
3. Pull and hold remote valve control lever No 1 in the
‘extend’ position.
4. The pressure reading should rise to be 200 bar
(2900 lbf/in2). and is the ‘High Pressure Standby.

TIA35078
28
5. If reading is not to specification adjust pressure
compensating valve (2).

35- 28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Load Sensing Circuit Test
This test checks that the load sense lines which signal
the hydraulic pump to go on and off load are
functioning.
1. Install Tee adaptor (3) 297603 and quick release
adaptor (2) 297240 into load sense line between
compensating valves and trailer brake valve.
2. Connect 0--420 bar (0--6000 lbf/in2) pressure
gauge using quick release coupler 291924.
3. Set engine speed to 1500 rev/min.

30
4. Operate in turn each of the high pressure hydraulic
services (Remote Valves, Trailer Brakes,
Hydraulic lift). As each service is operated the
pressure should rise from 21--24 bar
(310--350 lbf/in2) to a maximum of 190 bar
(2750 lbf/in2). Changes in pressure indicate that
the load sensing line to each service is operating.

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31
Charge Pressure Test
1. Remove charge pressure switch. 1 2
2. Install 0--10 bar (0--100 lbf/in2) pressure gauge (1)
using adaptors (2) as listed below.
adaptor 297404
Quick release adaptor 297240
quick release coupler 291924
or
M10x1.0 7/16 JIC adaptor 297417
NOTE: The thread size of the charge pressure switch
port is M10 x 1 DIN specification.
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32
3. Install flow meter between remote valves I and II.
Ensure inlet hose of flowmeter is installed into
extend port of valve No I.
4. Fully open load valve on flow meter.
5. Set remote valve flow control knobs to maximum
flow.

33
6. Set remote valve No 2 in ‘Float’ position. 7. Set remote valve No 1 in ‘Extend’ position.

35- 29
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
8. Start tractor and set engine speed to 1500 rev/min.

TIA35086
34
9. Move control lever for remote valve No 1 between
extend and neutral position. The charge pressure
readings should not vary outside 1.6--3.4 bar
(23--50 lbf/in2).
If pressure readings below 1.6 bar (23 lbf/in2) are
recorded replace hydraulic filters and re test.
If after retest charge pressure is still below
specification examine both the charge pressure filter
dump valve and charge pressure valve before
disassembling pump to inspect for wear.

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35
Variable Flow Piston Pump Flow Test
To flow test the variable flow piston pump it is
recommended that the output is checked at the remote
valves.
1. Install flow meter between inlet ports of remote
valves I and II.
2. Set flow control knobs to maximum flow.

36
3. Ensure load valve on flow meter is fully ‘Open’.
4. Set tractor engine speed to 1100 rev/min.
5. Set remote valve No 2 in ‘Float’ position and
remote valve No 1 in ‘Extend’ position.

TIA35086
37

35- 30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
6. Adjust load on flow meter to a of pressure of
100bar.
7. If a flow of 45 ltr/min is recorded the pump flow is
to specification.
NOTE: This test is performed at half maximum rated
speed and assumes that pump flow at rated speed is
twice that measured in the test.

TIA35086
38
Steering Pump/Low Pressure Pump Test
There is no relief valve in the steering/low pressure
circuit pump. The following practical test will determine
if steering pump output is sufficient to allow satisfactory
operation of the steering system.

Steering Test
1
1. Set engine speed to 1100 rev/min.
2. Turn steering quickly from lock to lock.
If steering is operating correctly the reaction should
be immediate with no time delay between turning
the steering wheel and movement of the wheels.
3. At full lock the relief valve in the steering motor
should be heard to blow and the engine speed drop
to approximately 970 rev/min.

If transmission low pressure warning light comes

on when the steering is held on full lock this is an
indication that the pump has developed an internal 39
leak. Check torque of pump mounting bolts and if
tight examine pump for leaking seals or wear.

Steering Circuit Pressure Test

1. Install Tee adaptor (2) 297600 and quick release
adaptor (3) 297240 into hose to steering cylinder.
2. Connect 0--420 bar (0--6000
3. Connect 0--420 bar (0--6000 lbf/in2) pressure
gauge (1) using quick release coupler 291924.
4. Set engine speed to 1500 rev/min.
5. Turn steering wheel to full lock and hold in position.
6. Pressure reading of 190 bar should be recorded .

35- 31
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Hydraulic Pump Leak Test
The hydraulic pump leak test should be performed
whenever operation of the hydraulic system is erratic
or the pump is extremely noisy.
The purpose of the test is to, ascertain if the
malfunction of the system is due to an internal pump
leak or alternatively the ingress of air due to a leak
through a component in the system.
1. Disconnect the breather tube (1) from the top of the
hydraulic lift cover (2).

41
2. Attach approximately 11/2 metres of clear plastic
tubing (1) to the breather connection (2) on top of
the transmission and position the tubing so that it
forms a ‘U’ (Similar to a manometer).
3. Fill the tube with sufficient oil to prevent the ingress
of air through the tube.
4. Set tractor engine speed to 1000 rev/min and pull
and hold remote valve lever
If the hydraulic pump has an internal leak oil or bubbles
will sucked from the plastic tube into the transmission.
If the hydraulic circuit has an external leak the oil in the
‘U’ of the plastic tube will be pushed towards the open
end of the tube by the air being drawn into the
transmission casing through the pump. 42
WARNING
If the leak is excessively large it is possible for the oil
to be projected out of the tube. Take care to position the
tube so not to cause injury or project oil into the work
area.

If an external leak is diagnosed use an ‘oil can’ to

selectively apply a film of oil around the joints of the
circuit. For example remote valve tubing joints. When
oil is applied to the leaking joint the noise in the pump
will cease.

43
If an internal leak is identified inspect mounting face at
pump intake port or intake tube in transmission for
missing or damaged ‘O’ ring, Figure 43.

35- 32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
OVERHAUL

44
CCLS Hydraulic Pump Installation
1. Intake Filter 8. Charge Pressure Filter Dump Valve
2. Oil Low Temperature Switch 9. Charge Pump
3. Intake Filter Restriction Switch 10. Charge Pressure Filter
4. Low Charge Pressure Switch 11. Variable Flow Piston Pump
5. Charge Pressure By--Pass Valve 12. Load Sensing Valve
6. Steering Flow Control Valve (Flow and Pressure Compensating Valves)
7. Steering and Low Pressure Circuit Pump

This procedure describes the overhaul of the complete • Low Charge Pressure Switch
pump assembly when removed from the tractor. The • Steering Flow Control Valve
following items however can be serviced with the pump
• Pressure and Flow Compensating Valves
installed on the tractor.
• Steering Pump Assembly
• Charge Pressure Valve
• Charge Pressure Filter Dump Valve

35- 33
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Charge Pressure Valve
1. Remove charge pressure valve manifold from
steering pump.

TIA35002
45
2. Remove circlip (2) and using New Holland Tool No
295025 unscrew valve (3) from manifold (1). 1 2

NOTE: If during pressure testing the charge pressure

reading is away from specified value of 1.6--3.4 bar
(23--50 lbf/in 2) both the charge pressure valve and
charge pressure filter dump valve must be examined
for faulty operation. Do Not attempt to adjust the
valves which is supplied as a pre--set assemblies and
should not be adjusted.

3
TIA35003
46
Charge Pressure Filter Dump Valve
1. Remove Plug (1) and O ring (2).

2. Using New Holland Tool No 295025 unscrew valve

(3) from pump body.

3 2 1
TIA35004
47

35- 34
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Steering Flow Control Valve
(All Models except Supersteer) 1 2 3 4
1. Unscrew plugs (1) and (4) and remove spring (3)
and spool (2).

TIA35005
48
Steering Flow Control Valve
(All Models with Supersteer)
1. Unscrew connector (1) and plug (4). Remove
spring (3) and spool (2).

49
2. Inspect spool for wear or damage. If damaged it is
necessary to replace both spool and steering
pump end plate.

3. Lubricate spool with clean hydraulic oil prior to

re--assembly.

35- 35
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Pressure and Flow Compensator Valve
1. Disconnect load sense line connection and remove
pressure and flow compensating valve assembly.
2. Remove the tamper proof caps, carefully unscrew
each adjuster and remove the component parts.
3. To ensure correct re--assembly keep the
component parts for each valve separate.
NOTE: The stem on the flow compensating spool is
longer than that on the pressure compensating spool.
IMPORTANT: Due to extreme spring pressure within
valves DO NOT remove rear plugs until the adjusters
have been removed. TIA35006
50

1 2 3 4 5 6 7

16
8

15
14 13 12 11 10 9
TIA35165
51
Flow and Pressure Compensating Valves
1. Plug and ‘O’ Ring 9. Tamperproof Cap
2. Housing 10. Locknut
3. Flow Compensating Spool 11. Adjuster and ‘O’ Ring Seal
4. Seat 12. Spring
5. Spring 13. Seat
6. Adjuster and ‘O’ Ring Seal 14. Pressure Compensator Spool
7. Locknut 15. ‘O’ Ring Seals
8. Tamperproof Cap 16. Plug and ‘O’ Ring

35- 36
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Re--assembly of the valves follows the removal
procedure in reverse. On re--assembly observe the
following:--
• Wash all components in a suitable solvent.
• Examine all components for wear or damage. If
the spools are damaged it is necessary to replace
the complete valve assembly.
• Lubricate all parts with clean hydraulic oil.
• To aid re--assembly of pressure and flow compen-
sating valves, the spools should be inserted into
the rear of the housing.

TIA35166
52
• Tighten all plugs and locknuts to the correct torque
as detailed in Specifications.
• When installing valve on pump ensure all ‘O’ ring
seals are correctly installed.
• Pressure test the pump and adjust the pressure
and flow compensating valves to the correct spec-
ification as detailed in Pressure Testing Section of
this Chapter.

TIA35007
53

35- 37
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
PUMP REMOVAL
1. Securely support the tractor on suitable axle
stands and remove the right hand rear wheel.
2. Remove oil filters.

TIA35053
54
NOTE: To prevent excessive loss of oil loosen intake
filter by approximately one turn and leave for one 1
minute to allow oil in filter to drain into sump.
3. Disconnect all electrical and hydraulic connections
to pump.
4. Ensure lubrication pipe banjo connector (1) and
brake line retaining bracket (2) are disconnected
from pump body.

2
A35054 TI
55
5. Where fitted, remove ground speed PTO interlock
safety switch and bracket from pump mounting
boss.

TIA35055
56
6. Manufacture from M12 x 1.25 bolts two alignment
dowels to assist in removing/ installing pump on
tractor. Cut a screwdriver slot across the end face
of each dowel.

TIA35056
57

35- 38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
7. Remove upper pump retaining bolts and install the
two locally manufactured alignment dowels.

TIA35057
58
8. Remove three lower retaining bolts.

TIA35058
59
9. Locate suport tool 297415 onto pump and using
tractor splitting kit MS 2700C remove pump from
tractor.
Alternatively use the New Holland support tool
295046 (1) and use suitable trolley jack to remove
pump, Figure 61.

60
WARNING
The hydraulic pump is a heavy component and weighs
40 kgf. It is important that it is securely supported when
being removed from the tractor.

NOTE: Use a drip tray to collect the small volume of

oil that may be lost from the transmission during
removal of the pump.

TIA35059
61

35- 39
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
INSTALLATION
1. Ensure ‘O’ ring (1) is correctly positioned around 1
drive gear retaining pin and pump alignment
dowels are not damaged.
Two different types of dowel installation are used,
either solid dowels as shown or ring dowels located
around top and bottom pump mounting bolts. If
dowels are damaged always replace with the same
type as originally installed on the tractor.

2
TIA35173
62
2. Clean mating face of pump and transmission and
apply New Holland sealer 82995771 to
transmission face.

TIA35174
63
3. Ensure alignment dowels are installed. The use of
the alignment dowels is an important requirement
when positioning the pump onto the transmission
housing.

TIA35060
64
4. Install pump using the removal procedure in
reverse.
5. After installation ensure pump retaining bolts are
tightened to a torque of 76--90Nm (56--66 lbf ft).

TIA35058

35- 40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Steering Pump Overhaul
The steering pump (i) if required can be serviced with 1
the Variable Flow CCLS hydraulic pump assembly
installed on the tractor. Access to remove the pump is
however restricted and it is recommended that
wherever possible the steering pump is serviced when
the complete pump assembly is removed.

TIA35008
66
For overhaul of the steering flow control valve (2) refer
to Page 35--35.
1. Remove end plate. Observe installation of end
plate and bearing block to ensure correct
re--assembly.
2. Pull steering pump from housing and observe
position of seals in bearing block.
NOTE: During removal of end plate and pump housing
take care not to loose alignment dowels.

TIA35009
67
3. Disassemble pump as shown in Figure 69.
4. Wash all components in a degreasant and dry
thoroughly.
5. Examine each bearing block for wear. Light score
marking should be removed by placing a sheet of
‘0’ grade emery paper, lubricated with paraffin, on
a truly flat surface, then polish the bearing face
using a light rotary motion. Bushes within the
bearing blocks may show a bronze colour but are
worn beyond acceptable limits if the bronze colour
can be seen over the full length of the bush.
6. Inspect pump bodies for wear and damage. It is
normal for gears to cut a light track on the inlet side TIA35010
of the body bore and providing the depth of the 68
track does not exceed 0.004 in (0.10 mm), the body
is re--usable.
NOTE: If pump gears or bearing blocks are worn and
require replacement the complete pumping element
must be replaced as an assembly.

35- 41
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2 3 4 5

11
10 9 8 7 6
TIA35011
69
Steering Pump Assembly Exploded View
1. Drive Gear 7. Plastic Back--up Seal
2. Bearing Block 8. Seal
3. Seal 9. Driven Gear
4. Seal 10. Seal
5. End Plate 11. Plastic back--up Seal
6. Pump Housing 12. Bearing Block

IMPORTANT: When servicing the pump gears,

particular attention must be paid to the following points: 1
• The width of each gear set must be within 0.0002
in. (0.005 mm) of each other to ensure satisfactory
pump efficiency.
• Journals must be within 0.0005 in. (0.013 mm) of
each other.
• Gear faces must be flat. This feature may be
checked by blueing a bearing face and rotating
against the gear. This check will also reveal any
sharp edges on the teeth.
2
7. Install new seals and ‘O’ rings. When installing
TIA35012
seals in the bearing block ensure that the plastic
back--up seal (1) is correctly positioned in the 70
rubber seal (2).

35- 42
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Charge Pump Overhaul
1. Remove hydraulic pump assembly from tractor as
described on Page 35--38
2. Remove 6 bolts securing charge pump housing.

TIA35013
71
3. Carefully separate housing.

72
4. Remove pump gears and bearing block.

73
5. Inspect pump gears and bearing block for wear or
damage.

35- 43
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
6. Inspect drive link oil seal (1) and replace if worn or
damaged 1

TIA35016
75
7. Lubricate all components with hydraulic oil.
8. Re--assemble pump into housing and ensure
bearing block is installed with open side of seals (1)
facing input side of pump as shown.

76
9. Tighten housing retaining bolts to a torque of
50--62Nm.

TIA35013
77

35- 44
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Variable Flow Piston Pump Overhaul
1. Remove hydraulic pump assembly from tractor as
described on Page 35--38.

TIA35017
78
2. Remove pressure and flow compensating valves.

TIA35006
79
3. Remove end plate.

TIA35018
80
4. Examine servo piston (1) and port plate (2) for wear
or damage. Do Not remove port plate unless 1
replacement is required.

2
TIA35019
81

35- 45
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
5. Remove pumping head assembly.

TIA35020
82
6. Using a suitable marker identify each piston and
9
slipper to their corresponding barrel in the pumping 8
1

head.
2
7

3
6
4
5

6
4
5

TIA35167
83
7. Separate pumping head and slipper assembly and
inspect for damage. Where damage is identified 1
the pumping element must be replaced.

5
Pumping Head and Slipper Assembly
1. Pistons and Slippers
2
2. Cone
3. Washer
4. Pumping Head
5. Pins (3 off) 4
3
TIA35168
84
8. If necessary disassemble pumping head spring
assembly by compressing the collar against the 1 2 3
spring.
IMPORTANT: Due to high spring pressure take care
when removing retaining ring. 4
Pumping Head Spring Assembly
1. Pumping Head
2. Washer
3. Spring
4. Collar
5. Retaining Ring
5
TIA35169
85

35- 46
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
9. Remove swash plate assembly by turning pump
housing upside down and striking pump driveshaft
against a solid block of wood.
10. Inspect components for wear and replace if
damaged.

1
TIA35021
86

7
6 5 4 3 2 1
TIA33022

87
Variable Flow Piston Pump and Swash Plate Assembly
1. Spring 5. Thrust Plate
2. Spring 6. Pumping Head Assembly
3. Spring Seat 7. End Plate and Servo Piston Assembly
4. Swash Plate 8. Pressure and Flow Compensating Valves

35- 47
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
11. Separate housing and examine driveshaft, drive
gear and bearing for wear.

TIA35023
88
12. If driveshaft overhaul is required use tool No.
295033 (1) to hold drive shaft splines while
removing drive gear nut. Do Not clamp drive gear
in a vice.

TIA35024
89
13. Remove drive gear

TIA35025
90
14. Remove drive shaft and bearing.
15. Inspect and replace components as necessary.
Refer to specifications for tightening torques.

TIA35026
91

35- 48
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
Pump Drive Gear and Bearing Overhaul
1. To overhaul the pump drive gear (2) and bearings 1 2
it is necessary to separate the tractor between
transmission and rear axle as described in Section
27 and remove the hydraulic pump.
2. Remove retaining bolt (1).
3. Remove shaft retaining pin.

TIA35069
92
NOTE: Groove on pin is positioned horizontally
facing the gears to allow lubrication of bearings. It is im-
portant during re--assembly that the pin is correctly in-
stalled.

93
4. Remove pin using slide hammer and adaptor (1)
1

TIA35071
94
5. Using slide hammer and adaptor (1) remove shaft.
Take care to collect bearings and spacer when 1
removing shaft.

TIA35072
95

35- 49
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2 3 4 5

12 11 10 8 7
TIA35073

96
Pump Drive Gear Assembly
1. Spacer 7. Locking Tab
2. Bearing 8. Plate
3. Drive Gear 9. Sleeve
4. Spacer 10. ’O’ Ring
5. Bearing 11. Pin
6. Bolt 12. Shaft

6. When installing new bearings it will be necessary

to calculate the thickness of spacer (4) to obtain the
correct bearing preload. The spacer is available in
various thickness of 11.80--12.60 mm in steps of
0.025 mm.
7. Measure thickness of each bearing and record as
B1 and B2.

35- 50
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
8. Place bearings in drive gear and measure
dimension ’A’.
9. Calculate thickness of spacer as follows.
Shim Thickness = A--(B1+B2)--0.15 mm
Example
B1 = 15.95 mm
B2 = 15.95 mm
A = 44.45 mm

TIA35075

98
Spacer Thickness
= 44.45--(15.95+15.95)--0.15 1 2
= 44.45--31.9--0.15
= 12.45 mm
10. Install gear (1), bearings (2) and selected
spacer (3).

3
TIA35076
99
11. Insert shaft retaining pin with lubrication groove
positioned horizontally.

100
12. Install locking bolt and tighten to a torque of 50 Nm
(33 lbf ft). Turn idler gear to settle bearings, then 1 2
loosen bolt and re torque to 30 Nm (22 lbf ft) and
bend over locking tab.

TIA35069
101

35- 51
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2
13. Wrap a piece of cord around the idler gear and
using a spring balance check if the pull required to
turn the idler gear is 0.150--0.400 Kg. If pull is away
from specification recalculate thickness of spacer
required.

102

35- 52
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 3 -- Fixed Displacement Gear Pumps

CONTENTS
Section Description Page
35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional Views -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Chapter 5
35 104 Removal -- Installation -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

35 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION

SPECIFICATIONS -- REAR LIFT HYDRAULIC PUMP

Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow, replaceable paper
cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pump intake, on the R.H. side
of axle housing
PUMP
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type, drawing oil from
housing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on the R.H. side of the axle
housing
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C42
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by PTO input shaft
Rotation (from drive end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Engine/pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.264
Max. speed (with engine running at max. power rated speed) . . . rev/min 2780
Corresponding nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 53
Test bench flow rate at 1450 rpm and 153 bar (156 kg/cm):
-- New or reconditioned pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 25.8
-- Used pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 18
-- Test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C° 55 -- 65
-- Test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
Drive/driven gear shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418
Bearing seat I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.475
Gear shaft/seat running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.032 -- 0.075
-- Permissible wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Gear radial clearance in pump body . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.064
Max. permissible wear on pump body, suction side, gear location mm 0.1
Gear width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 30.800 -- 30.815
Bearing width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 -- 24.510
Gear and bearing housing width in pump body . . . . . . . . . . . . . . . . mm 79. 935 -- 79.960
Gear/bearing end float in pump body
(New and reconditioned pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.180

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
SPECIFICATIONS -- HYDROSTATIC STEERING HYDRAULIC PUMP A 31XRP 2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear type, with integral flow
regulator, drawing oil from
rear axle housing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on the R.H. side of axle
housing
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 31 XRP 2
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by PTO input shaft
Rotation (from drive end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anticlockwise
Engine/pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.264
Max. speed
(with engine running at max. power rated speed) . . . . . . . . . . . . . rev/min 2780
Corresponding nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 41
Nominal flow rate at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 14.8
Controlled flow rate starting speed . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 1216
Controlled delivery flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . revI/min 18 -- 22
Drive/driven gear shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418
Bearing seat I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.470
Gear shaft/seat running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.032 -- 0.070
-- Permissible wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Gear radial clearance in pump body . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.064
Max. permissible wear on pump body, suction side, gear location mm 0.1
Gear width (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.000 -- 24.015
Bearing width (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 -- 24.510
Gear and bearing housing (3) width in pump body . . . . . . . . . . . . . . . . . . . . 73. 135 -- 73.160
Gear/bearing end float in pump body
(New and reconditioned pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.180

SPECIFICATIONS -- HYDROSTATIC STEERING HYDRAULIC PUMP A 42 XRP 2

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type, with integral flow
regulator, drawing oil from
rear axle housing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on the R.H. of rear axle
housing
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 42 XRP 2
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by PTO input shaft
Rotation (from drive end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anticlockwise
Engine/pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.264
Max. speed (with engine running at max. power rated speed . . . . rev/min 2780
Corresponding nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 53
Nominal flow rate at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 19.1
Controlled flow rate starting speed . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 1216
Controlled delivery flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/min 23 -- 27

(continued)

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
SPECIFICATIONS -- HYDROSTATIC STEERING HYDRAULIC PUMP A 42 XRP 2
Drive/driven gear shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418
Bearing seat I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.475
Gear shaft/seat running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.032 -- 0.075
-- Permissible wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Gear radial clearance in pump body . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.64
Max. permissible wear on pump body, suction side, gear location mm 0.1
Gear width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 30.800 -- 30.815
Bearing width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 -- 24.510
Gear and bearing housing width in pump body . . . . . . . . . . . . . . . . mm 79. 935 -- 79.960
Gear/bearing end float in pump body
(New and reconditioned pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.180

TIGHTENING TORQUES

1 2

Torque
DESCRIPTION Thread Size
Nm kgm
Nut, pump drive coupling hub (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 UNC--2B 29 3
Screws, filter and pump support (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 x 1.5 83 8.5
Screws, filter cover (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 15 1.5

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
SPECIAL TOOLS -- HYDRAULIC LIFT
CAUTION
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated
with the Dealer made tools for which you will find the
necessary construction drawings and specifications
directly on this Manual.

Support to remove hydraulic pumps assembly

(stamp nr. 50130 on the tool -- Dimensions in
mm).
Manufacture the tool with Fe 42C material.
(*) Dimension to be defined according to hole sizes on
the hydraulic jack.

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4 5
Filter and hydraulic pumps support sections
1. Support body 6. Accessories and hydrostatic steering pump
2. Pump supply tube (8). 7. Filter element
3. Drive gear on PTO shaft 8. Hydraulic lift pump
4. Idler gear 9. Filter supply tube
5. Pump control gear 10. Filter cover

NOTE: During assembly apply New Holland sealant Part No 82995771 on surfaces indicated with X.

DESCRIPTION AND OPERATION

Hydraulic pumps are spur gear and fixed displacement The front hydraulic pump controls hydrostatic steering
according to erpm. and other units such as front and rear differential locks,
They are mounted on the filter support which, in turn, PTO and PTO brake, FWD engagement, POWER
is fixed to the rear axle housing. SHUTTLE or SEMI-- POWERSHIFT transmissions.
The front hydraulic pump is fitted with a flow regulator
They are driven by a gear splined directly to the PTO
to reduce the quantity of oil delivered at high speeds.
drive [Link] is drawn from the rear axle housing by
The rear hydraulic pump supplies oil for the hydraulic
the pumps via common filter.
lift, trailer brake valve and auxiliary valves.

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
HYDRAULIC LIFT SYSTEM OIL PUMP

Removal--Installation (Op. 35 104 10)

Proceed as follows
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

1. Open and raise engine hood..

2. Disconnect negative cable (1) from battery and
insulate.

1
3. Jack up rear of tractor, place a stationary stand
under the right--hand final drive and remove
right--hand rear wheel.

2
4. Unscrew the plug (1) to release oil pressure inside
the filter.

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
5. Loosen retaining screws and remove the supply
tube (1) between pump and filter.

4
6. Remove pump retaining screws (2), loosen the
connector (1) on the hydraulic lift system pressure
regulating valve and remove the pump.
7. Reinstall the hydraulic lift system oil pump
following the removal procedure in reverse.

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
HYDROSTATIC STEERING AND
HYDRAULIC LIFT PUMP CONTROL
ASSEMBLY

Removal--Installation (Op. 27 170 30)

Proceed as follows:
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protective clothing, including goggles, gloves
and footwear.

1. Open and raise engine hood. 1

2. Disconnect the negative cable (1) from battery and
insulate.
3. Jack up rear of tractor, place a stationary stand
under the right--hand final drive and remove
right--hand rear wheel.

2
4. Unscrew the plug (1) to release oil pressure inside
the filter.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
5. Disconnect oil supply line (1) to hydraulic lift and
detach electrical connection (2).

4
6. Remove accessory control valve assembly supply
line (3). Disconnect the differential unlock control
line (4), power steering supply line (2), and lift
lubrication line (1).

5
7. Disconnect PTO lubrication line (1) and oil cooler
return line (2).

6
8. Unscrew hydraulic pump assembly retaining bolts.

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
9. Remove pump assembly using a hydraulic jack
and tool no. 50130 (1) (see page 4).

8
10. With the assembly on a bench, remove tube (1)
between pump and filter.

9
11. Remove retaining screws from support and
remove pumps (1) and (2).
12. During installation of the hydrostatic steering and
hydraulic lift pump control assemblies observe the
following:
-- Installation follows the removal procedure in
reverse, from step 11 back to step 1.
-- Refer to figures on page 5 for correct
re--assembly of the different parts.

10
-- Before installing the hydraulic pump assembly
thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of New
Holland flexible gasket sealant Part No
82995771 following the pattern shown in the
figure.
-- Tighten to correct tightening torques as
detailed on page 3.
Pattern for application of sealant during
installation of the hydraulic pump control
assembly to rear axle housing.

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

12
Hydraulic lift control pump components.

1. Front cover 11. Drive shaft seal

2. Cover seals 12. Circlip
3. Pump body 13. Lockwasher
4. Gear support 14. Nut
5. Drive and driven gear shafts 15. Screw
6. Gear support 16. Washer
7. Bush 17. Tab
8. Drive end cover 18. Bush
9. Drive shaft seal 19. Lockwasher
10. Spacer 20. Nut

HYDRAULIC LIFT CONTROL OIL PUMP

Disassembly-- Assembly with the pump removed 5. Remove supports (4 and 6) and gears (5) from rear
(Op. 35 104 30) cover (8) and pump body (3).
Proceed as follows: 6. Retrieve seals (2) and back--up rings.
1. Remove cover fastening nuts (20), screws (15) and Proceed as follows with disassembled components:
lockwashers. 7. Check flatness and squareness of the gear thrust
2. Remove nut (14) to pump drive shaft along with surfaces relative to bearings by placing a thin layer
lockwasher. of engineers blue between them. Light scoring may
3. Remove rear cover (8), retaining ring (12) and be eliminated with very fine grain abrasive paper
seals (9 and 11). properly lubricated.
4. Mark components (3, 4, 5 and 6) to ensure correct
re--assembly if reused.

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
8. Measure gear to pump body end float. Dimension
(2) must be smaller than dimension (1) by 0.100 to
0.180 mm.
If necessary remove minimum quantities of material
from flat faces of bearing assemblies to obtain
specified end float.
9. Thoroughly clean components. 2
10. Remove seals (2, 9 and 11).
11. Lubricate components with the same oil as used in
the system. Reassemble the pump referring to
Figure 1, and observing the following:
12. Assembly follows the disassembly procedure in
25227
reverse, from step 6 back to step 1.
13
-- Always work in very clean conditions, to
prevent contamination from foreign matter
which could damage the pump.
-- Match the components (3, 4, 5 and 6, Figure1)
previously marked, see op.4, page 5, to
reassemble them in their original position.
-- Assemble the gear supports (4 and 6 Figure 1)
into the pump body. Ensure the supports are
installed the correct way round and the
lubrication grooves are facing the gears.
-- Install plastic back--up rings over the seals (2,
Figure 1).
-- Assemble seals (9 and 11, Figure 1) and
spacers (10) on drive end cover (8). Note that
the gap between the sealing lips should be
opposite the spacer. Fill the gap with AMBRA
GR 75 MD grease.

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

1
Accessory control pump components

1. Plug 14. Washer

2. Pump body 15. Bush
3. Gear support 16. End cover seals
4. Drive and driven gear shafts 17. Seal
5. Gear support 18. Plug
6. Drive end cover 19. Flow regulator unit
7. Drive shaft seals 20. Lockring
8. Spacer 21. Spring
9. Drive shaft seals 22. Spool
10. Circlip 23. Seals
11. Lockwasher 24. Spool seat
12. Nut 25. Seal
13. Screw

ACCESSORIES AND HYDROSTATIC STEERING OIL PUMP

Disassembly--Assembly with the pump detached 5. Remove bearings (3 and 5), gears (4) from drive
(Op. 41 206 20) end cover (6) and pump body (2).
Proceed as follows: 6. Retrieve seals (16) and back--up rings.
1. Remove screws (13) and lockwashers (14). 7. Remove plugs (1 and 18) along with seals,
2. Remove nut (12) to pump drive shaft along with disassemble the flow regulator components, i.e.:
lockwasher (11). spool seat (24), spool (22), spring (21), from the
body (19).
3. Remove drive end cover (6), circlip (10) and seals
(7 and 9). Proceed as follows, with disassembled components:
4. Mark details (2, 3, 4 and 5) to reassemble them in 8. Check flatness and squareness of the gears thrust
the same position, if fit for reuse. surfaces relative to bearings by placing a thin layer

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3
of engineers blue between them. Light scoring may
be eliminated with very fine grain abrasive paper
properly lubricated.
9. Measure gear to pump body end float. Dimension
(2) must be smaller than dimension (1) by 0.100 to
0.180 mm.
If necessary remove minimum quantities of material 2
from flat faces of bearing assemblies to obtain
specified end float.
10. Thoroughly clean all components.
11. Remove seals (2, 9 and 11, Figure 1).
12. Lubricate components with the same oil as used in
25227
the system. Reassemble pump referring to figure
1 and observing the following: 2
-- Assembly follows the disassembly procedures
in reverse, from step 7 back to step 1.
-- Always work in very clean conditions, to
prevent contamination from foreign matter
which could damage the pump.
-- Match the components (2, 3, 4 and 5, Figure1)
previously marked, to reassemble them in their
original position.
-- Re--assemble the gear supports (3 and 5,
Figure 1) into the pump body. Ensure the
supports are installed the correct way round
and the lubrication grooves are facing the
gears.
-- Install plastic back--up rings over the seals.
-- Assemble seals (9 and 11, Figure 1) and
spacers (8) on drive end cover (6). Note that
the gap between the sealing lips should be
opposite the spacer. Fill the gap with AMBRA
GR 75 MD grease.

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 4 -- Electronic Draft Control

CONTENTS
Section Description Page

35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Principal of Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation of Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Operation of Lift Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trouble Shooting and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Draft Control Error Codes -- Power Command Tractors . . . . . . . . . . . . . . . . . . 27
Electronic Draft Control Error Codes -- Range/Dual Command Tractors . . . . . . . . . . . . . . 81
Overhaul
35 138 Electronic Draft Control Valve -- Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 134
35 138 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
35 130 Load Sensing Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
35 134 Hydraulic Lift Cover -- Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
35 134 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CAUTION: Observe the following precautions when arc welding on tractors installed
with electronic draft control
• Where possible, disconnect the part or implement • If welding is to be carried out in close proximity of
to be arc welded from the tractor. the tractor microprocessors then they should be
• Disconnect both battery cables from the battery. removed from the tractor.
Isolate the cable ends to avoid contact with each • Never allow welding cables to lay on, near or
other and the tractor. across any electrical wiring or electronic compo-
• Position the welder earth (ground) clamp as close nent while welding is in progress.
to the welding area as possible.

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
35 000 SPECIFICATIONS

MAXIMUM LIFT CAPACITY -- ALL MODELS

Test results to OECD criteria--links horizontal, maximum hydraulic pressure:
Without Assist Ram
610 mm (24 in.) to rear of ball ends 4425 Kgf
9755 lbf
With 1 Assist Ram
610 mm (24 in.) to rear of ball ends 5530 kgf
11314 lbf
With 2 Assist Rams
610 mm (24 in.) to rear of ball ends 6475 kgf
14275 lbf
VALVE SETTINGS
Lift Cylinder Relief Valve 2850--3050 lbf/in2 (197--210 bar)
(located in EDC Valve)

HYDRAULIC LIFT COVER

Hydraulic Lift Cylinder Bore Diameter 115.036 -- 115.071 mm 4.528 -- 4.530 in

Hydraulic Lift Cylinder Piston Diameter 114.978 --115.000 mm 4.526 -- 4.527 in

Hydraulic Lift Cylinder to Piston Clearance 0.036 -- 0.093 mm 0.0014 -- 0.0037 in

Hydraulic Lift Cross Shaft End Float 0.2 -- 1.4 mm 0.0079 -- 0.0551 in
(with lift arms installed)
GASKET SEALER
Flexible Gasket Sealant New Holland Part No 82995771
SPECIAL TOOLS
NEW HOLLAND
PART No

Hydraulic Lift Bracket 293983

Hydraulic Lift Lifting Hook 291359/2

Lift Piston Installation Ring (optional) 293813

Lift Cross Shaft Seal Installer 293985

Flowmeter Suitable for measuring 0--120 ltrs/min --

Flowmeter Hoses Procure locally to suit Flowmeter used --

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
TORQUES

Nm
lbs. ft

59--65
2x
TIA35198 43--48

279
206

142
105

142
105
TIA35199
1

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
DESCRIPTION AND OPERATION

2
Position/Draft Control Schematic
1. Performance Monitor Radar 6. Load Sensing Pins
2. Control Panel 7. Lift Arm Position Sensing Potentiometer
3. Instrument Panel 8. Implement Depth/Draft Controls
4. Electronic Draft Control Valve 9. Microprocessor
5. Hydraulic Lift
Principal of Draft Control
One method of providing a more constant depth lower links and using a microprocessor translate these
control is to take advantage of the fact that draft loading variations into electrical signals for controlling the draft
increases with implement depth. If a fixed implement loading and working depth of an implement.
draft is maintained a fixed implement depth will result, The smoothness and accuracy provided during
providing the tractor speed and type of soil being operation gives this system a clear advantage over
worked remain constant. conventional mechanical systems.
The hydraulic lift electronic draft control system In addition to providing draft control, it is also
provides a means of accurately controlling implement necessary to provide a system where the hydraulic
draft and soil penetration depth on fully or semi links can be maintained at a position relative to the
mounted implements. tractor regardless of draft forces on the implement.
The principle of electronic draft control, is to sense This method of maintaining the implement position is
draft variations through two load sensing pins in the called position control.

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

3
Electronic Draft Control Component Layout
1. Rear Fender External Lift/Lower Switch 4. Implement Depth/Draft Controls
2. Draft Sensitivity and Drop Rate Controls 5. EDC Microprocessor
3. Instrument Cluster

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

4
Electronic Draft Control Component Layout -- Continued
1. Electronic Draft Control Valve 4. CCLS Variable Flow Hydraulic Pump
2. Lift Arm Position Sensing Potentiometer 5. Load Sensing Pin
3. Performance Monitor Radar

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
COMPONENTS

Hydraulic Lift Assembly and Control Valve

The hydraulic lift Electronic Draft Control valve (EDC
valve) is a stack type proportional solenoid operated
valve (2) mounted with the remote control valves (1) at
the rear of the tractor.
The valve responds to pulse width modulated signals
from the microprocessor to direct pump pressure oil to
and from the hydraulic lift cylinder in direct proportion
to the degree of lift required.

5
The hydraulic lift cover has an integral cylinder and can
be fitted with optional external assist rams for
additional lift capacity.

TIA35114

6
Hydraulic Pump
Oil flow to the electronic draft control system is
provided by the ‘Closed Centre Load Sensing’ variable
flow piston pump which adjusts output according to
hydraulic circuit demand.

TIA35053
7
Electronic Draft Control (EDC) Processor
The processor is the management system for the
electronic draft control hydraulic lift assembly.
The processor is housed in a protective casing and
connected to the electrical harness via multi--pin
connectors. The processor contains no serviceable
parts and requires direct replacement when faulty.
On tractors with Dual Command or Range Command
transmissions the processor is located beneath the
control panel to the right of the operator.

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
On tractors installed with Power Command
transmission the processor (1) is located behind the
panel to the right of the operators seat
The processor converts electronic signals from the
operator controls, lift arm position sensing
potentiometer and lower link load sensing pins to
operate the pulse width modulating valve and
raise/lower the hydraulic lift.
The processor also has a self diagnostic capability
which detects when the system is not functioning
correctly. When this occurs an error code is generated
and held in the processor memory so they may be
retrieved when diagnosing faults on the tractor.
9
Load Sensing Pins
The load sensing pins sense draft variations applied by
an implement on the lower links.
The pins react to draft shear forces in the horizontal
plane but not forces due to the weight of the implement.

TIA35062
10
Each load sensing pin consists of a hollow metal tube
(1) containing a circuit board (4) and load sensing core 5 1
(2). Within the core material are three wire coils (3)
supported by metal rods. The coils are energised by
the 8.5 volt supply and create a stable pattern of
magnetic flux within the core.
The outer casing of the pin is made from a metal with
unique electromagnetic properties. When the metal is
subjected to a shear force, which is centred on the
wasted section (5) of the pin, the natural magnetism of
the pin casing changes, which distorts the magnetic 4
flux pattern of the core and is transformed into an 3 2
electrical output signal. This signal which is TIA35195
proportional to the draft load acting on the implement
11
is then received by the processor.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
In Cab Operator Controls
The lift arm position control lever (1) is used to raise
and lower the hydraulic lift arms. The lever is used to
set the lower limit working depth of an implement.
The draft loading control (3) has a scale of zero to 10
and is used to select the implement draft forces which
directly effects the working depth of the implement
when lowered into the ground using the lift arm position
lever.
Draft control is in operation when the scale of 0 to 9 is
selected. Zero is the minimum draft setting and 9 the
maximum.
When Position 10 is selected the hydraulic lift is in
‘Position Control’ and draft forces applied to the
implement have no effect on the working depth. in this 12
condition the implement depth and position of the lift
arms is controlled only by the lift arm position control
lever.
The raise lower switch (2) is a three position switch that
enables the implement to be raised and lowered
without moving the lift control lever.
Pressing and releasing the bottom of the switch
causes the implement to lower to the preset working
depth. The switch will spring into the mid position when
released.
Pressing and holding the bottom of the switch causes
the implement to fully lower and overrides the lowering
limit set by the lift arm position control lever. The lift
arms will raise back to the preset depth when the
button is released.
The drop rate control (1), adjusts the speed at which
the lift arms drop during a lowering cycle.
The height limit control (2) restricts the maximum
height the lift arms can be raised and is used to prevent
large implements from striking the rear of the cab or
platform. This control restricts the lift height when
either the lift control lever or external lift/lower switches
are used.
When transporting equipment on the 3 point linkage
turning the drop rate control fully anti--clockwise to the
transport lock (padlock symbol) will prevent the
implement from accidentally lowering and damaging
the road surface.
13

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
When transporting equipment implement bounce can
lead to lack of steering control at speeds. By turning the
drop rate control fully anti--clockwise and using the
raise lower switch to raise the implement, ‘Dynamic
Ride Control is selected and functions whenever the
tractor is operating at speeds above 8 kph (5 MPH).
Dynamic Ride Control is an automatic system to
counter implement bounce.
Whenever the front wheels hit a bump causing the front
of the tractor to rise, the hydraulic system will
immediately react to counter the movement and
minimise implement bounce to provide a smoother
ride.
The slip limit control (3), available only with the optional 14
radar sensor unit, enables the operator to select a
wheel slip threshold. When the wheel start to slip
beyond the set limit the working depth of the implement
is automatically reduced until wheel slip returns to the
set level.
The slip limit ‘on’ indicator (4), will illuminate when slip
control is activated and the implement is raised to
restore the selected slip rate.
The warning light (5) has two functions:--
A ‘Flashing Light’ warns that there is a malfunction in
the Electronic Draft control system. A warning of this
malfunction in the system is repeated on the
instrument panel as a ‘Read your Manual’ symbol (1),
Figure 15 and 16 .

15
A ‘Steady Light’ is a hitch disabled warning and
indicates that the hydraulic lift is disabled and cannot
be operated using the in cab controls. This condition is
also repeated on the instrument panel as a hitch
disabled symbol (2) The ‘hitch disabled warning will
display if:
• The position control lever has been moved while
the engine is stopped.
• One of the external power lift switches has been
operated to raise or lower the lift arms.
To put the controls back into phase with the linkage
move the raise/lower switch to the central position,
start the engine and move the lift arm control lever
slowly forward or rearward until the warning light goes 16
out.

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Because soil conditions in a field can vary it is
necessary to select the sensitivity rate (draft loading
operating band) at which the system responds to
changes in draft loading.
This is achieved using the draft sensitivity control (1)
which has a scale of 0 to 10.
Position 10 on the control is the most sensitive where
minor variations in soil density will cause the hydraulic
system to respond with repeated movements of the
linkage in ordure to maintain the draft loading within
required operating band.
Turning the control towards position 1 (fully clockwise)
will progressively decrease the rate of sensitivity. This
allows the draft loading on the pins to vary within a 17
larger operating band before the system responds and
makes automatic corrections to implement depth.
The movement indicator lights (2) and (3) will illuminate
every time the system reacts to adjust the draft
loading.
When operating in ‘Position Control’ the digital display
on the instrument panel will indicate the position of the
lift arms over a scale of ‘0’ to‘99’ (1). A display of ‘0’
indicates that the links are fully lowered and ‘99’ that
they are fully raised.

18
When operating in ‘Draft Control’ the display will
change to ‘dr’.

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Rear Fender Lift Lower Switches
These externally operated switches (1) allow the
hydraulic linkage to be raised and lowered by the
operator while standing beside the tractor, so aiding
attachment and detachment of implements.
CAUTION
Before leaving the tractor to operate the external
switches:
• Move the gearshift levers to neutral.
• Disengage the P.T.O.
• Apply the parking brake.
With the engine running, move the hand throttle lever 20
to the low idle position (fully rearwards).

The operator must only activate the external switches

(1) while standing to the side of the tractor (outboard 1
of the rear tyres). To avoid damage to implement or
tractor, operation of the in cab and external hydraulic
controls should not be carried out simultaneously.

21
WARNING
Before using the external hydraulic power lift switches,
ensure that no person or object is in the area of the im-
plement or 3-point linkage.
Never operate the external switches while standing:
• Directly behind the tractor or tyres.
• Between the lower links.
• On or near the implement.
• Never extend arms, legs, any part of the body or
any object into the area near the 3-point linkage or
implement while operating the external switch.
• Never have an assistant working the opposite set
of controls.
• When moving to the opposite set of controls, move
around the tractor or implement.
• Do not cross between the implement and tractor.

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
OPERATION OF DRAFT CONTROL
In draft control the working position of the lift arms is
affected by the lift arm position control lever, draft
loading control, draft sensitivity and slip limit control. All
these controls interact with each other to achieve the
desired operation of the hydraulic lift.
D Draft Load on Implement
W Working Depth
(Set by Draft Loading Control)
L Lower Limit
(Set By Lift Arm Position Control Lever)
C Correction Band
(Set by Sensitivity Control) 22

23
The lower limit working depth of an implement in the
soil is controlled by the lift arm position control lever.
Irrespective of any draft loading applied to the
implement the maximum depth of the implement will
never exceed this setting.
The depth of the implement is sensed using the lift arm
position control potentiometer which sends a signal to
the microprocessor to turn off power to the lower
solenoid of the hydraulic control valve when maximum
depth has been reached.

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

25
Draft Control --Low Sensitivity Setting If the draft loading applied to the implement exceeds
When draft control has been selected the working the sensitivity setting the control valve raising solenoid
depth of the implement is controlled by the draft loading is energised and the implement is raised sufficiently
(red band) and draft sensitivity (blue band) applied to until draft loading are restored to the nominal value set
the load sensing pins. by the draft loading control.
If draft loading fluctuate within the sensitivity band the When draft loading decreases due to lighter soil being
lift control valve will remain in the neutral condition and encountered the lowering solenoid would be energised
implement depth will remain constant. to lower the implement further into the ground and
restore the draft force. The working depth of the
When a low draft sensitivity (sensitivity knob turned
implement will however never be lower than that set by
counter clockwise) is selected large variations in draft
the lift arm position control lever.
control are allowed before changes are made to
implement depth. This provides a more constant
implement working depth.

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

26
Draft Control -- High Sensitivity Setting The wide band less sensitive draft control setting,
When high sensitivity is selected (sensitivity knob Figure 25, is used where a more constant implement
turned clockwise) the draft forces will often reach the depth is required and acceptable traction can be
minimum and maximum draft control settings. In this achieved.
situation the hydraulic control valve will make more NOTE: If Position control has been selected the draft
corrections to implement depth in order to achieve the forces applied to the load sensing pins will have no
required draft loading. effect and implement depth is controlled only by the lift
This more sensitive selection of implement draft arm control lever.
control is used when working on undulating ground and
weight Transfer for adequate traction is essential.

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
HYDRAULIC OPERATION OF LIFT Load Check Valve
CONTROL VALVE The load check valve prevents oil trapped in the lift
The components within the Electronic draft control are cylinder escaping to reservoir. The valve will only open
as shown and function as follows:-- when the pressure flowing across the raise spool is
greater than the pressure of the trapped oil in the lift
cylinder.
Flow Control Spool
The flow control spool regulates flow from the parallel
Lift Cylinder Relief Valve
gallery, running through the centre of the remote valve
and electronic draft control valve sections to the The lift cylinder relief valve protects the lift cylinder
hydraulic lift. The valve compares the pressure in the from excessive shock loads and operates at 200bar.
parallel gallery with the operating pressure of the
hydraulic lift and regulates flow to the hydraulic lift Lower Solenoid
circuit according to lift circuit demand. The lower solenoid is identical in design to the pulse
width modulated raise solenoid. The solenoid is
Raise Spool activated by the processor and controls operation of
The raise spool directs flow to the lift circuit and is the lowering metering valve in order to maintain the
directly controlled by the pulse width modulating raise desired rate of implement drop.
solenoid.
Lowering Metering Valve
Raise Solenoid The lowering metering valve controls the rate of flow
The raise solenoid is a pulse width modulated solenoid from the lift cylinder to reservoir when lowering the
controlled by the electronic draft control processor. hydraulic lift. The valve is operated by the pulse width
Activation of the solenoid is controlled by the electronic modulated lowering solenoid.
draft control processor and is proportional to the speed
of lift required.

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

27
Electronic Draft Control Valve Components
1. Flow Compensating Valve 5. Lift Cylinder Relief Valve
2. Raise Spool 6. Lowering Solenoid
3. Raise Solenoid 7. Lowering Metering Valve
4. Load Check Valve
--

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Neutral The trapped pressurised oil in the lift circuit is applied
NOTE: The hydraulic lift cylinder is a single acting to the right hand end of the metering valve through the
cylinder requiring only a single port for raising and small drilling ‘X’. The applied pressure holds the
lowering the lift arms. metering valve in the closed position preventing oil flow
from gallery ‘E’ to the return to reservoir gallery (F).
When the hydraulic lift is in ‘Neutral’ the control valve
solenoids are not energised. When the valve is in neutral, gallery ‘C’ and load
sensing galleries‘D’ are open to reservoir, through the
Oil flow from the parallel gallery ‘A’ flows past the flow
centre of the raising spool and gallery ‘F’.
compensator spool into gallery ‘B’ where it is blocked
by the lands of the raising spool. Gallery ‘G’ is a common return to reservoir gallery
running through the centre of the valve stack.
Oil under pressure in the hydraulic lift circuit is
prevented from entering gallery ‘C’ by the load check
valve (5).

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Electronic Draft Control--Neutral

Pump Pressure Oil Trapped Oil

Return To Reservoir

1. Lowering Metering Valve 5. Load Check Valve

2. Flow Compensator Spool 6. Lift Cylinder Safety Valve
3. Raising Spool 7. Lowering Solenoid
4. Raising Solenoid

35- 19
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Raising
When the hydraulic lift is raised using the operator The differential pressures applied to each end of the
controls or the electronic draft control system makes flow control spool causes the spool to move to a state
adjustments to reduce implement depth the pulse of equilibrium and automatically adjusts the flow from
width modulated raise solenoid is energised by the the parallel gallery ’A’ across the metering lands ‘Y’ and
microprocessor. through galleries ‘B’ and ’E’ to the lift cylinder.
Controlled energising of the solenoid by the The flow control spool is essential to ensure that flow
microprocessor enables the solenoid to move the from the parallel gallery ‘A’ to the hydraulic lift is
spool to the left in proportion to the rate of lift required accurately controlled irrespective of the operating
by the system. pressure of any remote control valve circuits which are
When system pressure is sufficient to lift the check operating simultaneously with the hydraulic lift.
valve (5) of it’s seat, oil from gallery ‘B’ flows into gallery When the lift arms reach the required height the
‘E’ and operates the lift cylinder microprocessor switches off the signal to the solenoid
Pressure oil in the lift circuit is applied through the small and the raise spool is moved to the right by the spring
drilling ‘X’ to the right hand end of the metering valve to re--establish the neutral condition.
‘H’ and holds the valve in a closed position preventing If the lift arms are subjected to shock loading and
oil in gallery ‘E’ returning to reservoir through gallery pressure in the hydraulic lift circuit exceeds 200bar the
(F). pressure is vented to reservoir through the lift cylinder
The operating pressure of the hydraulic lift cylinder is safety valve.
sensed in gallery ‘C’ and load sensing gallery ‘D’ which Figure 29 illustrates flow through the flow control spool
controls hydraulic pump output. Refer to Chapter 6 when the hydraulic lift is the highest pressure operating
Closed Centre Remote Valves for further details on circuit in the system.
operation of the load sensing circuit. Figure 30 illustrates operation of the flow control spool
The pressure in gallery ‘C’ is applied to the left hand when the hydraulic lift is operating at a lower pressure
spring loaded end of the flow control spool while at the but simultaneously with a remote control valve which
same time system pressure in gallery ‘B’ is applied to is operating at a higher pressure. In this situation the
the right hand end of the flow control spool. system pressure in parallel gallery ‘A’ is higher than the
operating pressure of the hydraulic lift.

35- 20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

29
Electronic Draft Control--Raising (High Pressure Lift)

Electronic Draft Control--Raising 30

(Low Pressure Lift while Remote Valves Operating at High Pressure)
Hydraulic Lift Pressure
Pump Pressure Oil (Lower than Pump Pressure)

Return To Reservoir
1. Metering Valve 5. Load Check Valve
2. Flow Compensator Spool 6. Lift Cylinder Safety Valve
3. Raising Spool 7. Lowering Solenoid
4. Raising Solenoid

35- 21
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Lowering
Lowering of the hydraulic lift arms is achieved by
venting the oil trapped in the hydraulic lift cylinder back
to reservoir through the lowering metering valve in a
controlled manner.
Lowering Metering Valve
1. Sleeve
2. Metering Spool
3. Pilot Spool
4. Plug
5. Circlip

The lowering cycle should be considered as a 2 stage

operation.
Stage 1: The pulse width modulating solenoid is
energised and the plunger (1) moves the pilot spool (6)
to the right. The oil trapped on the right hand end of the
lowering valve ‘H’ is now control vented over the lands
of the pilot spool (2) to reservoir through gallery ‘F’.
The pressure of oil trapped oil in the lift cylinder Gallery
‘E’ is applied to the chamfer face (4) of the metering
spool (3), causing the spool to move to the right.

32
Oil from the lift cylinder flows across the valve metering
lands (5) and returns to reservoir allowing the lift arms
to lower under the weight of the implement.
The rate of lowering is electronically controlled by the
processor and pulse width modulated lowering
solenoid which adjusts the clearance over the metering
lands (5).

35- 22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Electronic Draft Control--Lowering 35

Pressure Oil Trapped Oil

Return To Reservoir

1. Lowering Metering Valve 5. Load Check Valve

2. Flow Control Spool 6. Lift Cylinder Safety Valve
3. Raising Spool 7. Lowering Solenoid
4. Raising Solenoid

35- 23
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
35000 -- TROUBLE SHOOTING AND
CALIBRATION
The EDC electronic management system has an
inbuilt self diagnostic facility which is able to store error
codes and the time since the last occurrence. This
facility utilises the digital display of either the EIC or
AEIC instrument panels to indicate, in coded format,
any malfunction in the electrical and electronic circuitry
or the processor.
A full listing of error codes and fault finding charts
applicable to the Electronic draft control system are
shown on the following pages.

36
These error codes are not displayed automatically on
the instrument panel and must be retrieved using the
H menu diagnostics.
The ’H’ menu mode, described in Section 55, provides
several modes to aid diagnosing faults. One particular
mode which should be used, before any connections
are split, is the H5, switch diagnostics mode. This will
provide testing of many switch circuits, including the
switch itself. If this mode highlights a fault within a
circuit then more detailed fault finding can be directed
towards a particular circuit.

37
The following ’H’ menu mode routines are provided to
allow access to Error codes:
Hb -- Retrieve error codes for viewing.
Hc -- Clear processor memory of stored error codes
Hd -- View error codes live. This allows normal
operation of the tractor with error codes able to display
as they occur.
A full description of the ’H’ menu routines can be found
in Section 55.

38
Electronic Draft Control error codes when retrieved will
flash on the instrument panel.

35- 24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
The self diagnostic capability is generally limited to
diagnosis of the electrical and electronic circuitry and
related components, however, there are some codes,
which can be generated if pressure switch circuits are
not closed because of an actual lack of hydraulic
pressure.
Any malfunction of the mechanical and hydraulic
components must be diagnosed using conventional
techniques, performance characteristics and tooling,
such as pressure testing equipment.
Trouble--shooting and fault finding should always be
carried out in a logical and planned sequence. Many
apparent faults associated with electronic components
are often hastily diagnosed and result in the
replacement of expensive components. An extra few
minutes confirming the apparent fault will result in a
more positive and cost effective repair.

Prior to detailed fault finding, items like the Earth

connections and battery should be cleaned and tested
to ensure that they are functioning correctly.
Processors are often blamed for any malfunction but
the real truth is that this item is usually sound and that
the fault is due to poor contacts in the associated
connectors.
Each connector illustrated and identified in the wiring
diagrams in Section 55 and referred to in the following
fault finding procedure, has the same identification
reference. For example, the main processor
connectors are referred to as Connectors C127 and
C128 in the illustration and also referred to as C127
and C128 in the fault finding procedure. Often in the
fault finding flow chart the connector and pin are
abbreviated and will read, for example, C127--10. The
C127 refers to the connector and the 10 to the pin
number.
Section 55 contains complete wiring diagrams,
connector identifications and a list of circuit numbers
as used within the circuit diagrams.
40
Where the fault finding procedure requires checks for
continuity a visual inspection of the wiring should be
made prior to conducting tests to ensure that obvious
‘mechanical’ damage has not occurred to the harness
or the connectors.
Where possible the inbuilt tractor diagnostics should
be utilised to determine the area of the fault.

35- 25
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
A good quality multi--meter is an essential item to
perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high range
and work downwards to avoid damaging the
instrument.
IMPORTANT: Care should be used when using the
multi--meter, only use the instrument as instructed to
avoid damage to the internal elements of the
micro--processor. When checking the continuity of
wiring, sensors or switches it is necessary to isolate the
TA60--21--01
electronic processor and ensure the keystart is turned 4
off to prevent possible further damage. The keystart
41
should only be switched on and the processor
connected where specifically instructed in the fault
finding procedure.
If it is found necessary to clean the connectors an
approved contact spray should be used. DO NOT USE
ANY OTHER METHOD FOR CLEANING
TERMINALS. Do not use a cleaner that contains
Trichloro--ethylene, this solvent will damage the plastic
body of the connector.
Where possible it is recommended that connectors are
probed from the rear, certain connectors like C079,
C080 and C081, instrument panel connectors, should
always be probed from the rear.
Test probe kit Tool No 297448 has been specially
developed for probing and continuity testing
connectors in conjunction with a standard multimeter.
The use of the correct test probes in the kit will enable
testing of connectors without damage.

42
Connector terminals should only be removed using the
special tools supplied in electrical repair kit, Tool
No.294070 and the wires should not require excessive
pulling efforts to remove.

35- 26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
ELECTRONIC DRAFT CONTROL ERROR CODES
POWER COMMAND TRACTORS
The following listing details the Electronic Draft Control Each connector and pin is identified using alpha
error codes that can be displayed on the instrument numeric codes.
panel whenever a fault is detected in the system.
For example the wiring from the microprocessor to the
Should an error occur, reference should be made to the slip control potentiometer is identified as C239--4 to
appropriate page of the fault finding procedure. C0121--1 colour TQ/R. This indicates the wiring runs
from the microprocessor connector C239 pin number 4
When using the fault finding charts ensure the correct to the slip control potentiometer connector C121 pin
chart for Power Command or Range/Dual Command number 1 and is a turquoise wire with a red tracer.
transmissions is selected.
Error Code Error Description Page
Code 2 Tractor Performance Monitor Radar Disconnected . . . . . . . . . . . . 28
Codes 3, 4 and 5 Speed Sensor Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Codes 6 and 7 Slip Control Potentiometer or Circuit Failed . . . . . . . . . . . . . . . . . . 32
Code 8 Raise/Work Switch Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Code 9 Both External Lift/Lower Fender Switches are being
Operated Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Codes 10 and 11 Height Limit Control Potentiometer Failed . . . . . . . . . . . . . . . . . . . 42
Codes 12 and 13 Drop Rate Potentiometer Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Codes 14 and 15 Right Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . 46
Codes 16 and 17 Left Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . . 48
Code 18 Both Load Sensing Pins Disconnected . . . . . . . . . . . . . . . . . . . . . . 50
Codes 19 and 20 Incorrect Load Sensing Pin Reference Voltage . . . . . . . . . . . . . . . 52
Codes 21 and 22 Draft Control Frequency Potentiometer or Circuit Failed . . . . . . . 54
Code 23 Control Panel Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Code 24 Perform Hydraulic Lift Autocalibration . . . . . . . . . . . . . . . . . . . . . . . 57
Code HL Height Limit Incorrectly Set to Perform Autocalibration . . . . . . . . 57
Codes 25 and 26 Lift Control Lever Potentiometer Disconnected or
Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Codes 27 and 28 Lift Arm Position Sensing Potentiometer Disconnected
or Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Code 29 Hydraulic Control Valve Disconnected . . . . . . . . . . . . . . . . . . . . . . 66
Code 30 Ground Signal to Microprocessor Open Circuit . . . . . . . . . . . . . . . 66
Code 31 Chassis Harness Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Code 32 Draft Load Potentiometer shorted to 12 volts . . . . . . . . . . . . . . . . 68
Code 33 Draft Load Potentiometer Open Circuit or Shorted to Ground . . 68
Code 49 Wheel Speed Sensor Open/Short Circuit . . . . . . . . . . . . . . . . . . . . 70
Code 53 Microprocessor 5 volt Reference Shorted to 12 volts . . . . . . . . . . 72
Code 54 Microprocessor 5 volt Reference Shorted to Ground . . . . . . . . . . 72
Code 57 EDC Microprocessor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Code 59 Microprocessor 5 volt Reference Voltage Open Circuit . . . . . . . . 74
Code 63 and 65 EDC Hydraulic Valve Lower Solenoid Open/Short Circuit . . . . . . 76
Code 64 and 66 EDC Hydraulic Valve Raise Solenoid Open/Short Circuit . . . . . . 78
Code 67 EDC Hydraulic Valve Supply Voltage to Low . . . . . . . . . . . . . . . . . 78

35- 27
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 2 Poor or No Signal From Tractor Performance Monitor Radar

Is tractor Reconnect
performance NO Performance
monitor radar Monitor Radar
connected?
YES Disconnect radar assembly
connector C068. Turn Check fuse No 9. If fuse
key--start switch ‘ON’ and keeps blowing check for
Drive tractor at greater
than 16kmh (10 mph) measure voltage between a short circuit in the
NO
female pins C068-- 3 (R)
NO wiring harness between
Instrument panel shows
tractor speed? and C068--1 (B) female pin C068--3 (R)
Is voltage approximately and tractor chassis
YES Error cleared?
12 volts?
YES NO
NO
Disconnect microprocessor connector C239 and Check for open circuit
instrument panel connectors between female pin
On tractors with Analogue Electronic Instrument panel C068--3 (R) and fuse No 9,
disconnect ground speed connector C237 next to diagnostic Check for ‘open’ circuit
plug. Check for ‘open’ circuit between pin C239--20 (G) and between female pin
female pin C068-- 2 (G) C068--1 B) and tractor
Open circuit? chassis
YES NO Open circuit?
YES
Locate and Check for ‘short’ circuit Locate and
repair open between female pin Locate and repair
YES repair short open circuit
circuit C068--2 (G) and tractor circuit
chassis.
Short circuit?

35- 28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 2 Poor or No Signal From Tractor Performance Monitor Radar

44 48

46 49

35- 29
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 3 Radar (Ground speed) greater than wheel speed
Error Code 4 Wheel speed greater than maximum speed of tractor
Error Code 5 Wheel speed zero when radar is indicating ground speed

If error code 3 or 5 is
displayed perform test
procedure for Error Code 2
Error Cleared?
NO

Error Code 3
Check position of TPM radar Point radar at ground
Is radar pointing at tractor YES and tighten fixing
wheel or excessively
vibrating?
NO

Error Code 4 and 5

Remove output speed sensor and
examine for damage YES Re--tighten/replace
Was speed sensor loose in speed sensor
transmission housing or
damaged?
NO

Error Code 4
Tractors with ground speed PTO
Remove speed sensor and check for Disassemble
damaged (distorted or bent) speed YES transmission
pickup disc inside transmission and replace disc
Speed pickup disc damaged?
NO

Error Code 5
Turn Keystart switch Off and On YES Refer to error
Is error code 49 displayed? code 49
NO

Replace output speed

sensor

35- 30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 3 Radar (Ground speed) greater than wheel speed
Error Code 4 Wheel speed greater than maximum speed of tractor
Error Code 5 Wheel speed zero when radar is indicating ground speed

TIA35061
50

35- 31
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 6 Slip control voltage low (short or open circuit)
Error Code 7 Slip control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 32 and turn slip While in H9 Channel 32 wiggle wiring
control knob fully clockwise and then fully counter YES connectors to check for intermittent
clockwise circuit. Channel 32 values will change if
Do the values range from 84 to14 intermittent circuit detected.
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance Replace
across male pins NO
control panel
C121--1 (TQ/R) and C120--1 (LN)
C121--1 (TQ/R) and C120--4 (B)
Does resistance vary between 80--340 Ω?
YES

Turn key start switch ‘ON’ and measure voltage

across female pins C120--1 (LN) and C120--4 (B) NO
of harness Disconnect microprocessor
Is voltage approximately 5 volts? connector C101. Check for open
circuit between female pins C120--1
YES
(LN) and C101--12 (LN), then
C120--4 (B) and C101--1 (B)
Disconnect microprocessor connector C239. Open circuit?
Check for open circuit between female pins NO YES
C121--1 (TQ/R) and C239--4 (TQ/R)
Open circuit? Check for short circuit Locate and
YES NO
between female pins repair open
C120--1 (LN) and circuit
Locate and Check for short circuit between C120--4 (B) or a short
repair open female pins C121--1 (TQ/R) and
circuit to chassis Locate
circuit C120--4 (B). Repeat check between between each of
C121--1 (TQ/R) and C120--1 (LN) and
these pins YES repair
Short circuit? Short circuit? short
YES NO circuit
NO
Locate and Check for short Replace
repair short circuit between NO
YES microprocessor
circuit C121--1 (TQ/R)
and chassis
Short circuit?

35- 32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 6 Slip control voltage low (short or open circuit)
Error Code 7 Slip control voltage high (damaged potentiometer or short to +12 volts)

52 54

53 55

35- 33
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure

Enter switch diagnostics mode

Do Not start the engine.
The display will show d0
YES

Move the fast raise/work switch NO Go to continuation of Error

between raise and work positions, Code 8 On Next Page
several times
Does the display change between:
0, d3 and d4 YES System O.K.
d3 and d0 YES Disconnect EMU
d4 and d0 Does display change YES Replace
from 0. d3 and d4 EMU
YES
NO

Disconnect raise/work switch connector

C240. With the switch in the raise
Disconnect raise/work switch position, check for open circuit between YES Replace
connector C240. With the switch switch contacts E and F switch
in the work position, check for Open circuit?
open circuit between switch NO
contacts G and F YES Replace switch
Open circuit? Disconnect
NO microprocessor connector
C239. Check for open
Disconnect microprocessor Locate and circuit in harness between
connector C239. Check for open YES repair open YES switch connector
circuit between C240--G (TQ/P) circuit C240--E (TQ/W) and
and C239--31 (TQ/P) microprocessor connector
Open circuit? C239--19 (TQ/W)
NO Check harness for NO Open circuit?
short circuit between
Check for short circuit switch connector Locate and
between C240--F (R/LG/B) C240--E (TQ/W) and YES repair short
and C240--G (TQ/P) C240--F (R/LG/B) circuit
or tractor chassis or tractor chassis
Short circuit? Short circuit?
YES NO NO

Locate and Replace

repair short microprocessor
circuit

35- 34
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure

58 60

59 61

35- 35
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure (Continued)

Error Code 8
Continued
From Previous
Page

Disconnect fast raise/work switch

connector C240. With the keyswitch Locate open circuit in R/LG/B
turned ‘OFF’, check for open circuit YES coloured wire between
between C240--F (R/LG/B) and fuse 1 C240--F and fuse 1
Open circuit?

With the raise/work switch in the raise

position, check for open circuit between
switch contacts C240--F and C240--E.
With the raise/work switch in the lower YES Replace switch
position, check for open circuit between
switch contacts C240--F and C240--G
Open circuit?
NO

Disconnect microprocessor connector

C239. Check for short circuit between Locate and repair short circuit in
terminals C239--19 (TQ/W) YES
wires from C239--19 and 31 to fast
and C239--31 (TQ/P) raise/work switch C240--E (TQ/W)
Short circuit? and C240--G (TQ/P)
NO

Check for open circuit between

C240--E (TQ/W) and C239--19 (TQ/W) YES Locate and repair open
Open circuit? circuit
NO

Check for open circuit between

C240--G (TQ/P) and C239--31 (TQ/P) YES Locate and repair open
Open circuit? circuit
NO

Replace
microprocessor

35- 36
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure (Continued)

60--55--012 TI
62 65

63 66

64 67

35- 37
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated
Simultaneously

Visibly verify fender switches are not sticking

in the raise or lower position YES Clean, fix or replace
Switch sticking? fender switch
NO

Has fuse No 9 YES Replace fuse

blown?
NO

Enter switch diagnostics mode menu H5.

The display will show d0
YES

In turn, depress and hold each fender Go to continuation

switch in the raise position YES of Error Code 9 On
Does the display change from d0 to d2? Next Page
NO

Disconnect fender switch connector

C134/C135 which does not change the With switch in raise position
display. With the keyswitch in the ‘ON’ YES
check for open circuit between
position, check voltage between C134 or switch contacts 3 and 7
C135 (5150--G) wire and tractor chassis Open circuit?
Is voltage 12 volts? NO YES
NO
Disconnect microprocessor Replace
connector C239. Check for open switch
Locate and circuit between terminals C239--5
repair open and C134 or C135 (5150--K/W)
circuit in green Locate and
coloured wire at fender switch YES repair open
wire between Open circuit?
fender switch circuit
and fuse No 9 NO

Check for short circuit between G

and K/W wires at fender switch
Short circuit?
NO YES

Replace Locate and

microprocessor repair short
circuit

35- 38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated

60--55--012 TI
69 72

70 73

71 74

35- 39
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated
Simultaneously

Error Code 9
Continued
From Previous
Page

In turn, depress and hold each fender

switch in the lower position YES System O.K.
Does the display change from d0 to d1?
NO

Disconnect fender switch which does not

change the display. With switch in lower
position check for open circuit between YES Replace
switch contacts 3 and 1 switch
Open circuit?
NO

Disconnect microprocessor
connector C239. Check for open
Locate and
circuit between terminals YES repair open
C239--6 (K/G) and C134 or C135
circuit
(5095--K/G) coloured wire at fender
switch
Open circuit?
NO

Check for short circuit between Locate and

C134 or C135 (5150--G) and YES repair short
(5095--K/G) wires at fender switch. circuit
Short circuit?
NO

Replace
microprocessor

35- 40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated (Continued)

76 78

77 79

35- 41
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 10 Height limit control voltage low (short or open circuit)
Error Code 11 Height limit control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 30 and turn While in H9 Channel 30 wiggle wiring
height limit control knob fully clockwise and then YES connectors to check for intermittent
fully counter clockwise circuit. Channel 30 values will change if
Do the values range from 84 to14 intermittent circuit detected.
YES

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance
across male pins
C120--7 (K/O) and C120--1 (LN) NO Replace
C120--7 (K/O) and C120--4 (B) control panel
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage Disconnect microprocessor
across female pins C120--1 (LN) and connector C101. Check for open
NO
C120--4 (B) of harness circuit between female pins C120--1
Is voltage approximately 5 volts? (LN) and C101--12 (LN). Repeat
YES check between C120--4 (B) and
C101--1 (B)
Disconnect microprocessor connector C239 Check Open circuit?
for open circuit between female pins C120--7 (K/O) NO YES
and C239--13 (K/O)
Open circuit? Check for short Locate and
YES NO circuit between repair open
female pins circuit
Locate and Check for short circuit between C120--1 (LN) and
repair open C120--7 (K/O) and C120--4 (B). C120--4 (B) or a Locate
circuit Repeat check between C120--7 short circuit to and
chassis between YES
(K/O) and C120--1 (LN). repair
Short circuit? each of these pins short
YES NO Short circuit? circuit
NO
Locate and YES Check for short
repair short circuit between NO Replace
C120--7 (K/O) and microprocessor
chassis
Short circuit?

35- 42
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 10 Height limit control voltage low (short or open circuit)
Error Code 11 Height limit control voltage high (damaged potentiometer or short to +12 volts)

80 82

81 83

35- 43
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 12 Drop rate control voltage low (short or open circuit)
Error Code 13 Drop rate control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 29 and turn While in H9 Channel 29 wiggle wiring
height limit control knob fully clockwise and then YES connectors to check for intermittent
fully counter clockwise circuit. Channel 29 values will change if
Do the values range from 84 to14 intermittent circuit detected.
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance NO Replace
across male pins control panel
C120--2 (LN/Y) and C120--1 (LN)
C120--2 (LN/Y) and C120--4 (B)
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage

across female pins C120--1 (LN) and Disconnect microprocessor
NO connector C101. Check for open
C120--4 (B)
Is voltage approximately 5 volts? circuit between female pins C120--1
YES (LN) and C101--12 (LN). Repeat
check between C120--4 (B)
Disconnect microprocessor connector C239. and C101--1 (B)
Check for open circuit between female pins Open circuit?
C120--2 (LN/Y) and C239--35 (LN/Y) NO YES
Open circuit?
Check for short Locate and
YES NO circuit between repair open
female pins circuit
Locate and repair Check for short circuit C120--1 (LN) and
open circuit between C120--2 (LN/Y) and C120--4 (B) or a
C120--4 (B). Repeat check Locate
short circuit to and
between C120--1 (LN) chassis between
and C120--2 (LN/Y) YES repair
each of these pins short
Short circuit? Short circuit?
YES NO circuit
NO

Locate and repair YES Check for short Replace

short circuit circuit between NO
microprocessor
C120--2 (LN/Y) and
chassis
Short circuit?

35- 44
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 12 Drop rate control voltage low (short or open circuit)
Error Code 13 Drop rate control voltage high (damaged potentiometer or short to +12 volts)

85 87

86 88

35- 45
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 14 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 15 Pin short circuit to +12 volts, failed or corroded pin

Is right hand load NO Reconnect pin

sensing pin connected?
YES
Where possible remove implement to
ensure load sensing pins are not
Turn keystart
being subjected to any draft loading YES switch off and On NO Replace
Enter diagnostic mode H9 microprocessor
Error cleared?
Channel 33
Is the value approximately 48?. YES
NO
Check for intermittent
Turn key--start switch ‘OFF’ Install circuit in wiring to pin
new pin and turn--key start switch
‘ON’ (if new pin not available YES Install new pin
interchange left and right hand pins)
Error cleared?
NO

Disconnect microprocessor connectors C101

and C239 and ‘both’ load sensing pins,
connectors C048 and C047
Check for open circuit between male pins YES Locate and repair
C048--1 (B) and C101-- 1(B) open circuit
C048--2 (LN/P) and C239--17 (LN/P)
C048--3 (K) and C239--2 (K)
Open circuit?
NO

Check for short circuit between

C048--1, C048--2 and C048--3 or a
Locate and repair
short circuit to chassis between each YES
short circuit
of these pins
Short circuit?
NO

With microprocessor connectors

disconnected, turn key--start switch ‘ON’
and measure the voltage between tractor
chassis and C048--2 (LN/P) YES Replace
microprocessor
Repeat check between C048--3 (K) and
tractor chassis
Is voltage approximately 0 Volts?

35- 46
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 14 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 15 Pin short circuit to +12 volts, failed or corroded pin

90 92

91 93

35- 47
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 16 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 17 Pin short circuit to +12 volts, failed or corroded pin

Is left hand load sensing NO Reconnect pin

pin connected?
YES

Where possible remove implement to

ensure load sensing pins are not Turn keystart
being subjected to any draft loading YES switch off and On NO Replace
Enter diagnostic mode H9 Channel 34 Error cleared? microprocessor
Is the value approximately 48?. YES
NO
Check for intermittent
Turn key--start switch ‘OFF’ Install circuit in wiring to pin
new pin and turn--key start switch ‘ON’
(if new pin not available interchange YES Install new pin
left and right hand pins)
Error cleared?
NO

Disconnect microprocessor connectors C101 and

C239 and ‘both’ load sensing pins, connectors
C048 and C047
Check for open circuit between male pins YES Locate and repair
C047--1 (B) and C101--1 (B) open circuit
C047--2 (LN/P) and C239--14 (LN/P)
C047--3 (K) and C239--2 (K)
Open circuit?
NO

Check for short circuit between male pins

C047--1, C047--2 and C047--3 or a short YES Locate and repair
circuit to chassis between each of these pins short circuit
Short circuit?
NO

With microprocessor connectors

disconnected, turn key--start switch ‘ON’ and
measure the voltage between tractor chassis
and C047--2 (LN/P) Repeat check between YES Replace
C047--3 (K) and tractor chassis microprocessor
Is voltage approximately 0 Volts?

35- 48
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 16 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 17 Pin short circuit to +12 volts, failed or corroded pin

95 97

96 98

35- 49
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 18 Both Load Sensing Pins Disconnected

Are both load sensing NO Reconnect pins

pins connected?
YES

Visibly inspect harnesses to both pins Repair or

for damage YES replace harness
Harness damaged? as appropriate
NO

Disconnect microprocessor connectors C101 and C239

and ‘both’ load sensing pin, connectors C048 and C047.
Check for open circuit between male pins
C048--1 (B) and C101--1 (B)
C048--2 (LN/P) and C239--17 (LN/P) Locate and
C048--3 (K) and C239--2 (K) YES repair open
C047--1 (B) and C101--1 (B) circuit
C047--2 (LN/P) and C239--14 (LN/P)
C047--3 (K) and C239--2 (K)
Open circuit?
NO

Replace
microprocessor

35- 50
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 18 Both Load Sensing Pins Disconnected

TIA35062
100

103
101

104
102

105

35- 51
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 19 Pin reference voltage less than 8 volts (short or open circuit)
Error Code 20 Pin reference voltage greater than 8 volts (short to +12 volts)

Enter diagnostic mode H9

Channel 15 YES Turn keystart switch Off and On
Is the value approximately 79? Error Cleared?
NO YES
YES
Check for
Disconnect both load sensing pin intermittent circuit
connectors C047 and C048. Turn on wiring to pins
keystart switch On and measure YES Replace
voltage between Microprocessor
C048--3 and C048--1
C047--3 and C047--1
Is voltage approximately 8 volts?
NO

Disconnect microprocessor connectors.

Check for open circuit between
C047--2 and C239--14
C048--2 and C239--17
Open circuit?
NO

Turn key start switch ‘OFF’. Install new load

sensing pin(s) from another tractor if available.
Turn key--start switch ‘ON’ YES Install new pin(s)
Error cleared?
NO

Disconnect microprocessor connectors and ‘both’

load sensing pin connectors C048 and C047. Check
for short circuit between tractor chassis YES Locate and repair
C048--3 (K) and C047--3 (K) short circuit
Short circuit?
NO

With microprocessor connectors disconnected, turn

key--start switch ‘ON’ and measure the voltage between Examine harness for
tractor chassis C048--3 (K). Repeat check between male NO damage resulting in voltage
pin C047--3 (K) and tractor chassis supply direct from battery
Is voltage approximately 0 Volts?
YES

Replace
microprocessor

35- 52
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 19 Pin reference voltage less than 8 volts (short or open circuit)
Error Code 20 Pin reference voltage greater than 8 volts (short to +12 volts)

106 108

107 109

35- 53
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 21 Position/draft control voltage low (short or open circuit)
Error Code 22 Position/draft control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 31. Refer to wiring diagram and

Turn position/draft sensitivity control knob fully YES check for intermittent circuit
clockwise and then fully counter clockwise on wiring to control panel
Do the values range from 84 to14
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance NO Replace
across male pins control panel
C120--3 (LN/W) and C120--1 (LN)
C120--3 (LN/W) and C120--4 (B)
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage Disconnect microprocessor
NO connector C101. Check for open
across C120--1 (LN) and C120--4 (B)
Is voltage approximately 5 volts? circuit between female pins C120--1
YES (LN) and C101--12 (LN). Repeat
check between C120--4 (B)
Disconnect microprocessor connector C239. and C101--1 (B)
Check for open circuit between female pins Open circuit?
C120--3 (LN/W) and C239--3310 (LN/W) NO YES
Open circuit? Check for short
YES NO Locate and
circuit between repair open
female pins circuit
Locate and repair Check for short circuit C120--1 (LN) and
open circuit between C120--3 (LN/W) and C120--4 (B) or a
C120--4 (B). Repeat check Locate
short circuit to and
between C120--1 (LN) chassis between
and C120--3 (LN/W) YES repair
each of these pins short
Short circuit? Short circuit?
YES NO circuit
NO

Locate and repair YES Check for short Replace

short circuit circuit between NO microprocessor
C120--3 (LN/W)
and chassis
Short circuit?

35- 54
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 21 Position/draft control voltage low (short or open circuit)
Error Code 22 Position/draft control voltage high (damaged potentiometer or short to +12 volts)

110 112

111 113

114

35- 55
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 23 Control Panel Disconnected

Are control panel connectors NO

C120 and C121 connected? Reconnect control panel
YES

Examine harness from control Ensure all harnesses are

panel for severe damage NO correctly connected.
Damaged harness? Error cleared
YES NO

Repair or replace harness Replace EDC control

as necessary panel and retest tractor

35- 56
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 24
Perform Hydraulic Lift Calibration

Calibration of Lift Arm Potentiometers and Lift

Control Pod

This procedure is required whenever:--

The lift arm position sensing potentiometer, lift control
pod or EDC valve have been replaced.
or
The microprocessor has been replaced or its memory
has been reset using Diagnostic Menu H8. TIA35183
115
13. Lower lift arms and disconnect vertical rods from
hanger on automatic pick--up hitch (where fitted).
This will allow the lift arms to raise to their
maximum position.
14. Position raise/work switch to work position.

116
15. Turn all the EDC operator controls fully clockwise.
NOTE: If the height limit control has not been turned
fully clockwise to the maximum height position, the
Error Code HL will be displayed.

117
16. Start engine and set speed to 1100 rpm.
17. Move lift control lever forward and fully lower the
lift.

118

35- 57
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
18. Fully raise the hydraulic lift and ensure pick--up
hitch rods do not catch or jam on lift linkage.
When the lift arms reach the fully raised position
the pump will momentarily reach high pressure
standby.

119
19. Check that the lift arm position display increases to
99.

120
20. Reconnect and adjust the rod on the automatic
pick--up hitch as follows:--
Move the lift control lever forward sufficiently to to
allow the lift arms to lower slightly.
Reconnect the pick--up hitch lift rods.
Adjust the length of the lift rods so that when the hy-
draulic lift is fully raised using the external fender
switches, the lift rods are slightly loose.
21. Check that the automatic pick--up hitch operates
correctly.

121

35- 58
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
CALIBRATION OF THE EDC VALVE
This calibration is required if either the EDC valve or
the microprocessor has been replaced or its memory
has been reset using Diagnostic Menu H8.
Perform the calibration with warm hydraulic oil and a
suitable implement or weight mounted on the hydraulic
lift. The weight of the implement should be sufficient to
overcome any friction in the hydraulic lift assembly and
enable the lift arms to lower without binding.
1. Enter H1 mode, using the diagnostic tool.
Refer to Section 55
or
122
2. Press and hold fast raise lower switch in lowering
position against the spring and at the same time
start the engine.

123
3. The display will change to CA or CAL depending on
instrument

124
Transmission oil temperature will be displayed in
‘Display of Gears’

125

35- 59
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
4. Capture the hitch then fully lower and fully raise the
hydraulic lift.
5. Leave the hitch in the fully raised position while it
does a series of three very small raise/lower
corrections.

TIA35205
126
Each time the hitch makes a correction the display
will progressively change from 0 to 1 to 2 and then
En or End depending on type of instrument cluster
installed.

127
6. Key off the tractor to store the calibrations.

128
NOTE: Calibration can be performed several times to
provide a better average of the valve thresholds. The
thresholds (the current required to start the EDC valve
raise and lower solenoids to operate) may be viewed
in mode H3 and are displayed in amps x 100, i.e, 0.530
amps will be displayed as 53. The raise threshold is
displayed first followed by the lower.

TIA35205
129

35- 60
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Valve Calibration Review
(H3 Diagnostic Routine)
(Analogue Electronic Instrument Cluster Shown)
1. Enter the diagnostic routine and depress the
button on the diagnostic switch ‘three times’ until
the display on the instrument panel changes to
‘H3’.

130
2. After approximately 4 seconds the display will
change to show the EDC valve solenoid raise and
lower thresholds.
The threshold values will differ for each tractor with
a nominal value of approximately 50.

131

35- 61
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 25 Lift lever potentiometer control voltage low (short or open circuit)
Error Code 26 Lift lever potentiometer control voltage high (damaged potentiometer
or short to +12 volts)

Is lift control lever YES Replace lift Control Pod

potentiometer damaged
NO

Enter diagnostic mode H9 Channel 28

Fully lower and then raise the lift arm YES Refer to wiring diagrams and
position control lever check for intermittent circuit
Do the values range from 9 to 83 on wiring to lift control pod
NO

Disconnect potentiometer connector C240 and

measure resistance between black and white
wires from potentiometer. Repeat test between
red and white wires NO Replace lift control pod
Does resistance vary between 100--600Ω as
lever is moved in both directions?
YES
Disconnect microprocessor
Turn key start switch ‘ON’ and measure voltage connector C239 and check for open
across male pins C240--D (B) and C240--C (LN) YES circuit between male pins C240--A
Is voltage approximately 5 volts? (LN/B) and C239--36 (LN/B)
NO Open circuit?
NO YES
Disconnect microprocessor connectors C101 and C239
Check for open circuit between male pins C240--D (B) Check for short Locate and
and C101--1 (B). Repeat check between C240--C (LN) circuit between repair open
and C101--12 (LN) male pins C240--A circuit
Open circuit? (LN/B) and C240--D
NO YES (K/B). Repeat check
between C240--A
Check for short circuit Locate and (LN/B) and C240--C
between male pins C240--C repair open (LN/G)
(LN) and C240--D (B) or a circuit Short circuit? YES Locate
short circuit to chassis NO and
between each of these pins repair
Short circuit? Check for short short
NO YES circuit between YES circuit
C240--A (LN/B) and
Replace Locate and tractor chassis
microprocessor repair short Short circuit?
circuit NO

Replace
microprocessor

35- 62
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 25
Lift lever potentiometer control voltage low
(short or open circuit)
Error Code 26
Lift lever potentiometer control voltage high
(damaged potentiometer or short to
+12 volts)

134

132 135

133 136

137

35- 63
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 27 Lift arm position sensing control voltage low (short or open circuit)
Error Code 28 Lift arm position sensing control voltage high (damaged potentiometer
or short to +12 volts)

Is lift arm position sensing potentiometer or YES Repair/replace potentiometer

linkage damaged?
NO

Enter diagnostic mode H9 Channel 27. Refer to wiring diagram and

Fully lower and then raise the hydraulic lift arms. check for intermittent circuit
(Ensure auto pickup hitch lift rods do not restrict YES
on wiring to lift control lever
maximum movement of arms when fully raising lift) potentiometer
Do the values range from 15 to 79
NO

Disconnect potentiometer linkage and connector

C052 and measure resistance between green
and orange wires from potentiometer. Repeat NO
test between green and black wires. Replace potentiometer
Does resistance vary between 100--4000Ω as
lever is moved in both directions?
YES

Turn key--start switch ‘ON’ and measure voltage Disconnect microprocessor

across female pins C052--2 (B) and connector C101 and check for
YES open circuit between female pins
C052--1 (LN)
Is voltage approximately 5 volts? C052--1 (LN) and C101--12 (LN)
NO Open circuit?
NO YES
Disconnect microprocessor connectors C101
and C239. Check for open circuit between Check for short circuit Locate and
female pins C052--1 (LN) and C101--12 (LN). between female pins repair open
Repeat check between C052--2 (B) and C052--2 (B) and circuit
C239--30 (B) C052--3 (B). Repeat
Open circuit? check between C052--1
NO YES (LN) and C052--3 (B)
Short circuit?
Check for short circuit between Locate and YES Locate
female pins C052--2 (B) and repair open NO
and
C052--3 (B) or a short circuit to circuit repair
chassis between each of these Check for short circuit short
YES circuit
pins between C052--1 (K/N)
Short circuit? and tractor chassis
NO YES Short circuit?
NO

Replace Locate and repair

microprocessor short circuit Replace
microprocessor

35- 64
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 27 Lift arm position sensing control voltage low (short or open circuit)
Error Code 28 Lift arm position sensing control voltage high (damaged potentiometer
or short to +12 volts)

138 140

139 141

142

35- 65
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 29 Hydraulic Control Valve Disconnected

Are hydraulic control valve NO Reconnect valve

solenoid connectors C217 and
C218 connected?
YES

Examine harness from connector

C217 and C218 for severe damage NO Replace
Harness damaged? microprocessor
YES

Repair harness or
replace control
valve if necessary

Error Code 30 Signal Ground Open Circuit

Disconnect EDC control panel connectors C120

and C121 and microprocessor connector C101.
Check for ‘open’ circuit between female pins YES Locate and repair
C120--4 (B) and C101--1 (B) open circuit
Open circuit?
NO

Check for ‘open’ circuit between

C120--1 and C120--4 of control YES Locate and repair
panel open circuit
Open circuit?
NO

Measure resistance between

male pins C120--1 and C120--4 of Examine microprocessor
control panel YES connector C101 for
Is resistance approximately damage to terminal pin
300--500Ω? C101--1
NO

Replace EDC control

panel

Error Code 31 Chassis Harness Disconnected

Is chassis harness NO
connected? Reconnect connector
YES
Perform checks for Error Code 18 but
Examine tractor harness for damage do not replace microprocessor at this
NO stage of examination
Harness damaged?
YES Error cleared?
NO
Repair or replace harness
Perform checks for Error
Codes 27 and 28

35- 66
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 29, 30 and 31 Hydraulic Control Valve Disconnected

143 147

144 148

145 149

146

35- 67
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 32 Draft Load Potentiometer shorted to +12v

Disconnect EDC control module connector

C240.
Turn Key start switch ON. NO Replace
Measure voltage across C240--D and C240--C microprocessor
Is voltage greater than 5v ?
YES

Examine harness for short circuit

to a 12 volt power supply from the
fuse panel or direct from the
battery.
Fault found?
NO

Replace microprocessor

Error Code 33 Draft Load Potentiometer Open Circuit or Short to Ground

Disconnect EDC control module connector C240

and microprocessor connectors C239 and C101.
Check for open circuit between
C240--A and C239--36 NO Locate and repair
open circuit
C240--C and C101--12
C240--D and C101--1
Open Circuit?
NO

Check for short circuit between

C240--C and C240--D
Similarly check for short circuit YES Locate and repair
between C240--A and tractor short circuit
chassis?
NO

Replace EDC control module

Error Cleared?
NO

Replace microprocessor

35- 68
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 32 Draft Load Potentiometer
shorted to +12v
Error Code 33 Draft Load Potentiometer
Open Circuit or Short to Ground

152

150 153

151 154

155

35- 69
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 49 Output Speed Sensor Open or Short Circuit

Enter diagnostic mode H9 Channel 9 YES Inspect for intermittent

Is the value approximately 64 open/short circuit
NO

Disconnect output speed sensor connector

C038 and microprocessor connector C101.
Check for open circuit between YES Locate and repair
C038--2 and C101--3 open circuit
C038--3 and C101--1
Open circuit?
NO

Check for short circuit between C038--2

and C038--3. Similarly check for short YES Locate and repair
circuit between C038--2 and tractor short circuit
chassis
NO

Replace output speed sensor

Error cleared?
NO

Replace microprocessor

35- 70
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 49 Output Speed Sensor Open or Short Circuit

156

157 159

158 160

35- 71
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 53 Microprocessor 5 volt reference Shorted to 12 volts

Inspect for intermittent short

Enter diagnostic mode H9 Channel 14 circuit to 12 volt supply from
Is the value greater than 49 NO
battery or fuse panel
and error code 53 displayed Error cleared?
YES NO
Disconnect connectors C120 and C121.
Turn keystart switch On and measure voltage NO Replace microprocessor
across C120--1 and C120--4
Is voltage greater than 5 volts?

YES

Examine harness for a short circuit to

a 12 volt power supply from the fuse
panel or direct from the battery
Error cleared?
NO

Replace microprocessor

Error Code 54 Microprocessor 5 volt reference Shorted to Ground

Enter diagnostic mode H9 Channel 14 Inspect for intermittent short circuit

Is the value less than 49 NO to to tractor chassis
and error code 54 displayed Error cleared?
YES NO

Remove EDC control panel and disconnect Replace

connectors C120 and C121. NO microprocessor
Turn keystart switch On and measure voltage
across female pins C120--1 and C120--4
Is voltage less than 5 volts?
YES

Disconnect micro processor connector Check for short circuit in wire from
C101. Check for short circuit between NO C101--12 to C120--1 and tractor chassis
C101--12 and C101--1. Error cleared?
Short circuit? NO
YES
Replace
Locate and repair microprocessor
short circuit

35- 72
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 53 Microprocessor 5 volt reference Shorted to 12 volts
Error Code 54 Microprocessor 5 volt reference Shorted to Ground

161 163

162 164

35- 73
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 57 EDC Microprocessor Failure

Disconnect microprocessor
Remove and examine fuse 12 NO
connector C101 and check for open
Fuse blown? circuit between
YES C101--17
C101--18
Check for short circuit between C239--25
C239--25 and fuse 12
C101--17 Open circuit?
C101--18 YES NO
and tractor chassis.
Short Circuit? Locate and repair Replace
YES NO open circuit Microprocessor

Locate and Replace fuse turn keystart

repair short switch off and On
circuit Error cleared?
YES NO

Check for Replace

intermittent Microprocessor
short circuit?

Error Code 59 Micro--processor Reference Voltage Open Circuit

Inspect for intermittent open circuit

in wiring from microprocessor
Enter diagnostic mode H9 Channel 14 YES connector C101--12 (LN)
Is the value approximately 49 and C120--1 (LN)
NO Error cleared?
NO
Remove EDC control panel and disconnect
connectors C120 and C121. Replace
Turn keystart switch On and measure voltage YES
microprocessor
across female pins C120--1 and C120--4
Is voltage approximately 5 volts?
NO

Disconnect microprocessor connector C101.

Check for open circuit between
C101--12 (LN) and C120--1 (LN)
C120--4 (B) and C101--1 (B)
Open circuit?.
NO

Replace
microprocessor

35- 74
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 57 EDC Microprocessor Failure
Error Code 59 Micro--processor Reference Voltage Open Circuit

165 167

166 168

169

35- 75
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 63 EDC Hydraulic Valve Lower Solenoid Open Circuit
Error Code 65 EDC Hydraulic Valve Lower Solenoid Short Circuit

Disconnect EDC valve connector C218.

Measure resistance across the coil Replace lower
NO
Is resistance approximately 8Ω? solenoid

YES
Turn key--start switch ‘ON’. Measure
voltage across female pin C218--5090 (K/R)
and tractor chassis.
Is voltage approximately 12 volts? NO Disconnect microprocessor connector
YES
C100 and C239.
Check for open circuit between C239--1
(K/R) and C218 K/R)
Disconnect microprocessor connectors NO C100--26(K/U/B) and C218 (K/G/B)
C100 and C239. Check for short circuit Open circuit?
between female pin C100--26 (K/G/B) and
YES
C239--1 (K/R).
Similarly check for short circuit to chassis
between each of these pins Locate and
Short circuit? repair open
NO
circuit
YES

Locate and Replace

repair short microprocessor
circuit

Error Code 64 EDC Hydraulic Valve Raise Solenoid Failed Open Circuit
Error Code 66 EDC Hydraulic Valve Raise Solenoid Failed Short Circuit

Disconnect EDC valve connector C217.

Measure resistance across the coil Replace lower
NO
Is resistance approximately 8Ω? solenoid

YES
Turn key--start switch ‘ON’. Measure
voltage across female pin C217--5085 (K/U)
and tractor chassis.
Is voltage approximately 12 volts? NO Disconnect microprocessor connector
YES
C100 and C239.
Check for open circuit between C239--24
(K/U) and C217 K/U)
Disconnect microprocessor connectors NO C100--27(K/U/B) and C217 (K/U/B)
C100 and C239. Check for short circuit Open circuit?
between female pin C100--27 (K/U/B) and
YES
C239--24 (K/U).
Similarly check for short circuit to chassis
between each of these pins Locate and
Short circuit? repair open
NO
circuit
YES

Locate and Replace

repair short microprocessor
circuit

35- 76
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 63, 64, 65 and 66 EDC Hydraulic Valve Solenoid Failures

170 173

171 174

172 175

176

35- 77
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 67 EDC Hydraulic Valve Supply Voltage to Low

Enter diagnostic mode H9 Channel 13 YES Perform checks for

Is the value approximately 3 Error Codes 63 to 66
NO

Check for 12 volts at fuse 12 and

check for open circuit between
Fuse 12 and C239--25 (N/R/B)
Open circuit
YES NO

Locate and Replace

repair open microprocessor
circuit

35- 78
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 67 EDC Hydraulic Valve Supply Voltage to Low

60--55--012 TI
177

178 179

35- 79
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

35- 80
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
ELECTRONIC DRAFT CONTROL ERROR CODES
RANGE/DUAL COMMAND TRACTORS
The following listing details the Electronic Draft Control Each connector and pin is identified using alpha
error codes that can be displayed on the instrument numeric codes.
panel whenever a fault is detected in the system.
For example the wiring from the microprocessor to the
Should an error occur, reference should be made to the slip control potentiometer is identified as C128--16 to
appropriate page of the fault finding procedure. C0121--1 colour TQ/R. This indicates the wiring runs
from the microprocessor connector C128 pin number
When using the fault finding charts ensure the correct 16 to the slip control potentiometer connector C121 pin
chart for Power Command or Range/Dual Command number 1 and is a turquoise wire with a red tracer.
transmissions is selected.
Error Code Error Description Page
Code 2 Tractor Performance Monitor Radar Disconnected . . . . . . . . . . . . 82
Codes 3, 4 and 5 Speed Sensor Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Codes 6 and 7 Slip Control Potentiometer or Circuit Failed . . . . . . . . . . . . . . . . . . 86
Code 8 Raise/Work Switch Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Code 9 Both External Lift/Lower Fender Switches are being
Operated Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Codes 10 and 11 Height Limit Control Potentiometer Failed . . . . . . . . . . . . . . . . . . . 96
Codes 12 and 13 Drop Rate Potentiometer Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Codes 14 and 15 Right Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . 100
Codes 16 and 17 Left Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . . 102
Code 18 Both Load Sensing Pins Disconnected . . . . . . . . . . . . . . . . . . . . . . 104
Codes 19 and 20 Incorrect Load Sensing Pin Reference Voltage . . . . . . . . . . . . . . . 106
Codes 21 and 22 Draft Control Frequency Potentiometer or Circuit Failed . . . . . . . 108
Code 23 Control Panel Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Code 24 Perform Hydraulic Lift Autocalibration . . . . . . . . . . . . . . . . . . . . . . . 111
Code HL Height Limit Incorrectly Set to Perform Autocalibration . . . . . . . . 111
Codes 25 and 26 Lift Control Lever Potentiometer Disconnected or
Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Codes 27 and 28 Lift Arm Position Sensing Potentiometer Disconnected
or Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Code 29 Hydraulic Control Valve Disconnected . . . . . . . . . . . . . . . . . . . . . . 120
Code 30 Ground Signal to Microprocessor Open Circuit . . . . . . . . . . . . . . . 120
Code 31 Chassis Harness Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Code 32 Draft Load Potentiometer shorted to 12 volts . . . . . . . . . . . . . . . . 122
Code 33 Draft Load Potentiometer Open Circuit or Shorted to Ground . . 122
Code 49 . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor Open/Short Circuit . . . . . . . . . . . . . . . . . . . . 124
Code 53 . . . . . . . . . . . . . . . . . . . . Microprocessor 5 volt Reference Shorted to 12 volts . . . . . . . . . . 126
Code 54 . . . . . . . . . . . . . . . . . . . . Microprocessor 5 volt Reference Shorted to Ground . . . . . . . . . . 126
Code 57 EDC Microprocessor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Code 59 Microprocessor 5 volt Reference Voltage Open Circuit . . . . . . . . 128
Code 63 and 65 EDC Hydraulic Valve Lower Solenoid Open/Short Circuit . . . . . . 130
Code 64 and 66 EDC Hydraulic Valve Raise Solenoid Open/Short Circuit . . . . . . 130
Code 67 . . . . . . . . . . . . . . . . . . . . EDC Hydraulic Valve Supply Voltage to Low . . . . . . . . . . . . . . . . . 132

35- 81
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 2 Poor or No Signal From Tractor Performance Monitor Radar

Is tractor Reconnect
performance NO Performance
monitor radar Monitor Radar
connected?
YES Disconnect radar assembly
connector C068. Turn Check fuse No 9. If fuse
key--start switch ‘ON’ and keeps blowing check for
Drive tractor at greater
than 16kmh (10 mph) measure voltage between a short circuit in the
NO
female pins C068-- 3 (R)
NO wiring harness between
Instrument panel shows
tractor speed? and C068--1 (B) female pin C068--3 (R)
Is voltage approximately and tractor chassis
YES Error cleared?
12 volts?
YES NO
NO
Disconnect microprocessor connector C128 and Check for open circuit
instrument panel connectors between female pin
On tractors with Analogue Electronic Instrument panel C068--3 (R) and fuse No 9,
disconnect ground speed connector C237 next to diagnostic Check for ‘open’ circuit
plug. Check for ‘open’ circuit between pin C128--15 (G) and between female pin
female pin C068-- 2 (G) C068--1 B) and tractor
Open circuit? chassis
YES NO Open circuit?
YES
Locate and Check for ‘short’ circuit Locate and
repair open between female pin Locate and repair
YES repair short open circuit
circuit C068--2 (G) and tractor circuit
chassis.
Short circuit?

35- 82
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 2 Poor or No Signal From Tractor Performance Monitor Radar

180 184

181

182 185

183

35- 83
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 3 Radar (Ground speed) greater than wheel speed
Error Code 4 Wheel speed greater than maximum speed of tractor
Error Code 5 Wheel speed zero when radar is indicating ground speed

If error code 3 or 5 is
displayed perform test
procedure for Error Code 2
Error Cleared?
NO

Error Code 3
Check position of TPM radar Point radar at ground
Is radar pointing at tractor YES and tighten fixing
wheel or excessively
vibrating?
NO

Error Code 4 and 5

Remove output speed sensor and
examine for damage YES Re--tighten/replace
Was speed sensor loose in speed sensor
transmission housing or
damaged?
NO

Error Code 5
Turn Keystart switch Off and On YES Refer to error
Is error code 49 displayed? code 49
NO

Replace output speed

sensor

35- 84
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 3 Radar (Ground speed) greater than wheel speed
Error Code 4 Wheel speed greater than maximum speed of tractor
Error Code 5 Wheel speed zero when radar is indicating ground speed

TIA35061
186

187

35- 85
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 6 Slip control voltage low (short or open circuit)
Error Code 7 Slip control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 33 and turn slip While in H9 Channel 33 wiggle wiring
control knob fully clockwise and then fully counter YES connectors to check for intermittent
clockwise circuit. Channel 33 values will change if
Do the values range from 84 to14 intermittent circuit detected.
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance NO Replace
across male pins control panel
C121--1 (TQ/R) and C120--1 (LN)
C121--1 (TQ/R) and C120--4 (B)
Does resistance vary between 80--340 Ω?
YES

Turn key start switch ‘ON’ and measure voltage

across female pins C120--1 (LN) and C120--4 (B) NO
of harness Disconnect microprocessor
Is voltage approximately 5 volts? connector C127. Check for open
circuit between female pins C120--1
YES (LN) and C127--5 (LN), then
C120--4 (B) and C127--1 (B)
Disconnect microprocessor connector C127. Open circuit?
Check for open circuit between female pins NO YES
C120--1 (LN) and C127--5 (LN)
Open circuit? Check for short circuit Locate and
YES NO
between female pins repair open
C120--1 (LN) and circuit
Locate and Check for short circuit between C120--4 (B) or a short
repair open female pins C121--1 (TQ/R) and
circuit to chassis Locate
circuit C120--4 (B). Repeat check between between each of
C121--1 (TQ/R) and C120--1 (LN) and
these pins YES repair
Short circuit? Short circuit? short
YES NO circuit
NO
Locate and Check for short Replace
repair short circuit between NO
YES microprocessor
circuit C121--1 (TQ/R)
and chassis
Short circuit?

35- 86
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 6 Slip control voltage low (short or open circuit)
Error Code 7 Slip control voltage high (damaged potentiometer or short to +12 volts)

188 190

189 191

35- 87
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure

Enter switch diagnostics mode

Do Not start the engine.
The display will show d0
YES

Move the fast raise/work switch NO Go to continuation of Error

Disconnect raise/work switch connector

C240. With the switch in the raise
Disconnect raise/work switch position, check for open circuit between YES Replace
connector C240. With the switch switch contacts E and F switch
in the work position, check for Open circuit?
open circuit between switch NO
contacts G and F YES Replace switch
Open circuit? Disconnect
NO microprocessor connector
C128. Check for open
Disconnect microprocessor Locate and circuit in harness between
connector C128. Check for open YES repair open YES switch connector
circuit between C240--G (TQ/P) circuit C240--E (TQ/W) and
and C128--29 (TQ/P) microprocessor connector
Open circuit? C128--26 (TQ/W)
NO Check harness for NO Open circuit?
short circuit between
Check for short circuit switch connector Locate and
between C240--F (R/LG/B) C240--E (TQ/W) and YES repair short
and C240--G (TQ/P) C240--F (R/LG/B) circuit
or tractor chassis or tractor chassis
Short circuit? Short circuit?
YES NO NO

Locate and Replace

repair short microprocessor
circuit

35- 88
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure

192

193 195

194 196

35- 89
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure (Continued)

Error Code 8
Continued
From Previous
Page

Disconnect fast raise/work switch

With the raise/work switch in the raise

Disconnect microprocessor connector

C128. Check for short circuit between Locate and repair short circuit in
terminals C128--26 (TQ/W) YES
wires from C128--26 and 29 to fast
and C128--29 (TQ/P) raise/work switch C240--E (TQ/W)
Short circuit? and C240--G (TQ/P)
NO

Check for open circuit between

C240--E (TQ/W) and C128--26 (TQ/W) YES Locate and repair open
Open circuit? circuit
NO

Check for open circuit between

C240--G (TQ/P) and C128--29 (TQ/P) YES Locate and repair open
Open circuit? circuit
NO

Replace
microprocessor

35- 90
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 8 Raise/Work Switch Failure (Continued)

60--55--012 TI
197 200

198 201

199 202

35- 91
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated
Simultaneously

Visibly verify fender switches are not sticking

in the raise or lower position YES Clean, fix or replace
Switch sticking? fender switch
NO

Has fuse No 9 YES Replace fuse

blown?
NO

Enter switch diagnostics mode menu H5.

The display will show d0
YES

In turn, depress and hold each fender Go to continuation

switch in the raise position YES of Error Code 9 On
Does the display change from d0 to d2? Next Page
NO

Disconnect fender switch connector

C134/C135 which does not change the With switch in raise position
display. With the keyswitch in the ‘ON’ YES
check for open circuit between
position, check voltage between C134 or switch contacts 3 and 7
C135 (5150--G) wire and tractor chassis Open circuit?
Is voltage 12 volts? NO YES
NO
Disconnect microprocessor Replace
connector C128. Check for open switch
Locate and circuit between terminals C128--21
repair open and C134 or C135 (5150--K/W)
circuit in green Locate and
coloured wire at fender switch YES repair open
wire between Open circuit?
fender switch circuit
and fuse No 9 NO

Check for short circuit between G

and K/W wires at fender switch
Short circuit?
NO YES

Replace Locate and

microprocessor repair short
circuit

35- 92
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated

203

60--55--012 TI
204 207

205 208

206 209

35- 93
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated
Simultaneously

Error Code 9
Continued
From Previous
Page

In turn, depress and hold each fender

switch in the lower position YES System O.K.
Does the display change from d0 to d1?
NO

Disconnect fender switch which does not

change the display. With switch in lower
position check for open circuit between YES Replace
switch contacts 3 and 1 switch
Open circuit?
NO

Disconnect microprocessor
connector C128. Check for open
Locate and
circuit between terminals YES repair open
C128--28 (K/G) and C134 or C135
circuit
(5095--K/G) coloured wire at fender
switch
Open circuit?
NO

Check for short circuit between Locate and

C134 or C135 (5150--G) and YES repair short
(5095--K/G) wires at fender switch. circuit
Short circuit?
NO

Replace
microprocessor

35- 94
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 9 Both External Lift/Lower Fender Switches Are Being Operated (Continued)

210

211 213

212 214

35- 95
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 10 Height limit control voltage low (short or open circuit)
Error Code 11 Height limit control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 31 and turn While in H9 Channel 31 wiggle wiring
height limit control knob fully clockwise and then YES connectors to check for intermittent
fully counter clockwise circuit. Channel 31 values will change if
Do the values range from 84 to14 intermittent circuit detected.
YES

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance
across male pins Replace
C120--7 (K/O) and C120--1 (LN) NO
control panel
C120--7 (K/O) and C120--4 (B)
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage Disconnect microprocessor
across female pins C120--1 (LN) and NO connector C127. Check for open
C120--4 (B) of harness circuit between female pins C120--1
Is voltage approximately 5 volts? (LN) and C127--5 (LN). Repeat
YES check between C120--4 (B) and
C127--1 (B)
Disconnect microprocessor connector C128 Check Open circuit?
for open circuit between female pins C120--1 (K/O) NO YES
and C128--31 (K/O)
Open circuit? Check for short Locate and
YES NO circuit between repair open
female pins circuit
Locate and Check for short circuit between C120--1 (LN) and
repair open C120--7 (K/O) and C120--4 (B). C120--4 (B) or a Locate
circuit Repeat check between C120--7 short circuit to and
chassis between YES
(K/O) and C120--1 (LN). repair
Short circuit? each of these pins short
YES NO Short circuit? circuit
NO
Locate and YES Check for short
repair short circuit between NO Replace
C120--7 (K/O) and microprocessor
chassis
Short circuit?

35- 96
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 10 Height limit control voltage low (short or open circuit)
Error Code 11 Height limit control voltage high (damaged potentiometer or short to +12 volts)

215 217

216 218

219

35- 97
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 12 Drop rate control voltage low (short or open circuit)
Error Code 13 Drop rate control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 30 (Refer to While in H9 Channel 30 wiggle wiring

Section 55) and turn height limit control knob YES
connectors to check for intermittent
fully clockwise and then fully counter clockwise circuit. Channel 30 values will change if
Do the values range from 84 to14 intermittent circuit detected.
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance
across male pins
C120--2 (LN/Y) and C120--1 (LN) NO Replace
C120--2 (LN/Y) and C120--4 (B) control panel
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage

across female pins C120--1 (LN) and Disconnect microprocessor
NO connector C127. Check for open
C120--4 (B)
Is voltage approximately 5 volts? circuit between female pins C120--1
YES (LN) and C127--5 (LN). Repeat
check between C120--4 (B)
Disconnect microprocessor connector C128. and C127--1 (B)
Check for open circuit between female pins Open circuit?
C120--2 (LN/Y) and C128--10 (LN/Y) NO YES
Open circuit?
Check for short Locate and
YES NO circuit between repair open
female pins circuit
Locate and repair Check for short circuit C120--1 (LN) and
open circuit between C120--2 (LN/Y) and C120--4 (B) or a
C120--4 (B). Repeat check Locate
short circuit to and
between C120--1 (LN) chassis between
and C120--2 (LN/Y) YES repair
each of these pins short
Short circuit? Short circuit?
YES NO circuit
NO

Locate and repair YES Check for short Replace

short circuit circuit between NO
microprocessor
C120--2 (LN/Y) and
chassis
Short circuit?

35- 98
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 12 Drop rate control voltage low (short or open circuit)
Error Code 13 Drop rate control voltage high (damaged potentiometer or short to +12 volts)

220 222

221 223

224

35- 99
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 14 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 15 Pin short circuit to +12 volts, failed or corroded pin

Is right hand load NO Reconnect pin

sensing pin connected?
YES
Where possible remove implement to
ensure load sensing pins are not
Turn keystart
being subjected to any draft loading YES switch off and On NO Replace
Enter diagnostic mode H9 microprocessor
Error cleared?
Channel 34
Is the value approximately 48?. YES
NO
Check for intermittent
Turn key--start switch ‘OFF’ Install circuit in wiring to pin
new pin and turn--key start switch
‘ON’ (if new pin not available YES Install new pin
interchange left and right hand pins)
Error cleared?
NO

Disconnect microprocessor connectors C127

and C128 and ‘both’ load sensing pins,
connectors C048 and C047
Check for open circuit between male pins YES Locate and repair
C048--1 (B) and C127--1(B) open circuit
C048--2 (LN/P) and C128--11 (LN/P)
C048--3 (K) and C127--25 (K)
Open circuit?
NO

Check for short circuit between

C048--1, C048--2 and C048--3 or a
Locate and repair
short circuit to chassis between each YES
short circuit
of these pins
Short circuit?
NO

With microprocessor connectors

35- 100
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 14 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 15 Pin short circuit to +12 volts, failed or corroded pin

225 227

226 228

229

35- 101
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 16 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 17 Pin short circuit to +12 volts, failed or corroded pin

Is left hand load sensing NO Reconnect pin

pin connected?
YES

Where possible remove implement to

ensure load sensing pins are not Turn keystart
being subjected to any draft loading YES switch off and On NO Replace
Enter diagnostic mode H9 Channel 35 Error cleared? microprocessor
Is the value approximately 48?. YES
NO
Check for intermittent
Turn key--start switch ‘OFF’ Install circuit in wiring to pin
new pin and turn--key start switch ‘ON’
(if new pin not available interchange YES Install new pin
left and right hand pins)
Error cleared?
NO

Disconnect microprocessor connectors C127 and

C128 and ‘both’ load sensing pins, connectors
C048 and C047
Check for open circuit between male pins YES Locate and repair
C047--1 (B) and C127--1 (B) open circuit
C047--2 (LN/P) and C128--33 (LN/P)
C047--3 (K) and C127--25 (K)
Open circuit?
NO

Check for short circuit between male pins

C047--1, C047--2 and C047--3 or a short YES Locate and repair
circuit to chassis between each of these pins short circuit
Short circuit?
NO

With microprocessor connectors

35- 102
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 16 Open circuit connection to pin, short circuit to ground or failed pin
Error Code 17 Pin short circuit to +12 volts, failed or corroded pin

230 232

231 233

234

35- 103
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 18 Both Load Sensing Pins Disconnected

Are both load sensing NO Reconnect pins

pins connected?
YES

Visibly inspect harnesses to both pins Repair or

for damage YES replace harness
Harness damaged? as appropriate
NO

Disconnect microprocessor connectors C127 and C128

and ‘both’ load sensing pin, connectors C048 and C047.
Check for open circuit between male pins
C048--1 (B) and C127--1 (B)
C048--2 (LN/P) and C128--11 (LN/P) Locate and
C048--3 (K) and C127--25 (K) YES repair open
C047--1 (B) and C127--1 (B) circuit
C047--2 (LN/P) and C128--33 (LN/P)
C047--3 (K) and C127--25 (K)
Open circuit?
NO

Replace
microprocessor

35- 104
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 18 Both Load Sensing Pins Disconnected

TIA35062
235

238
236

239
237

240

35- 105
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 19 Pin reference voltage less than 8 volts (short or open circuit)
Error Code 20 Pin reference voltage greater than 8 volts (short to +12 volts)

Enter diagnostic mode H9

Channel 9 (Dual Command) YES Turn keystart switch Off and On
Channel 13 (Range Command) Error Cleared?
Is the value approximately 79? NO YES
YES
Check for
Disconnect both load sensing pin intermittent circuit
connectors C047 and C048. Turn on wiring to pins
keystart switch On and measure YES Replace
voltage between Microprocessor
C048--3 and C048--1
C047--3 and C047--1
Is voltage approximately 8 volts?
NO

Disconnect microprocessor connectors.

Check for open circuit between
C047--2 and C128--33
C048--2 and C128--11
Open circuit?
NO

Turn key start switch ‘OFF’. Install new load

sensing pin(s) from another tractor if available.
Turn key--start switch ‘ON’ YES Install new pin(s)
Error cleared?
NO

Disconnect microprocessor connectors and ‘both’

load sensing pin connectors C048 and C047. Check
for short circuit between tractor chassis YES Locate and repair
C048--3 (K) and C047--3 (K) short circuit
Short circuit?
NO

With microprocessor connectors disconnected, turn

35- 106
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 19 Pin reference voltage less than 8 volts (short or open circuit)
Error Code 20 Pin reference voltage greater than 8 volts (short to +12 volts)

241 243

242 244

35- 107
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 21 Position/draft control voltage low (short or open circuit)
Error Code 22 Position/draft control voltage high (damaged potentiometer or short to +12 volts)

Enter diagnostic mode H9 Channel 32. Refer to wiring diagram and

Turn position/draft sensitivity control knob fully YES check for intermittent circuit
clockwise and then fully counter clockwise on wiring to control panel
Do the values range from 84 to14
NO

Remove EDC control panel and disconnect

connectors C120 and C121.
While turning slip limit control, measure resistance
across male pins
C120--3 (LN/W) and C120--1 (LN) NO Replace
C120--3 (LN/W) and C120--4 (B) control panel
Does resistance vary between
90--360 Ω? (with slip control)
170--520 Ω? (Less slip control)
YES

Turn key start switch ‘On’ and measure voltage Disconnect microprocessor
NO connector C101. Check for open
across C120--1 (LN) and C120--4 (B)
Is voltage approximately 5 volts? circuit between female pins C120--1
YES (LN) and C127--5 (LN). Repeat
check between C120--4 (B)
Disconnect microprocessor connector C128. and C127--1 (B)
Check for open circuit between female pins Open circuit?
C120--3 (LN/W) and C128--9 (LN/W) NO YES
Open circuit? Check for short
YES NO Locate and
circuit between repair open
female pins circuit
Locate and repair Check for short circuit C120--1 (LN) and
open circuit between C120--3 (LN/W) and C120--4 (B) or a
C120--4 (B). Repeat check Locate
short circuit to and
between C120--1 (LN) chassis between
and C120--3 (LN/W) YES repair
each of these pins short
Short circuit? Short circuit?
YES NO circuit
NO

Locate and repair YES Check for short Replace

short circuit circuit between NO microprocessor
C120--3 (LN/W)
and chassis
Short circuit?

35- 108
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 21 Position/draft control voltage low (short or open circuit)
Error Code 22 Position/draft control voltage high (damaged potentiometer or short to +12 volts)

245 247

246 248

249

35- 109
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 23 Control Panel Disconnected

Are control panel connectors NO

C120 and C121 connected? Reconnect control panel
YES

Examine harness from control Ensure all harnesses are

panel for severe damage NO correctly connected.
Damaged harness? Error cleared
YES NO

Repair or replace harness Replace EDC control

as necessary panel and retest tractor

35- 110
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 24
Perform Hydraulic Lift Calibration

Calibration of Lift Arm Potentiometers and Lift

Control Pod

This procedure is required whenever:--

The lift arm position sensing potentiometer, lift control
pod or EDC valve have been replaced.
or
The microprocessor has been replaced or its memory
has been reset using Diagnostic Menu H8. TIA35183
250
3. Lower lift arms and disconnect vertical rods from
hanger on automatic pick--up hitch (where fitted).
This will allow the lift arms to raise to their
maximum position.
4. Position raise/work switch to work position.

251
5. Turn all the EDC operator controls fully clockwise.
NOTE: If the height limit control has not been turned
fully clockwise to the maximum height position, the
Error Code HL will be displayed.

252
6. Start engine and set speed to 1100 rpm.
7. Move lift control lever forward and fully lower the
lift.

253

35- 111
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
8. Fully raise the hydraulic lift and ensure pick--up
hitch rods do not catch or jam on lift linkage.
When the lift arms reach the fully raised position
the pump will momentarily reach high pressure
standby.

254
9. Check that the lift arm position display increases to
99.

255
10. Reconnect and adjust the rod on the automatic
pick--up hitch as follows:--
Move the lift control lever forward sufficiently to to
allow the lift arms to lower slightly.
Reconnect the pick--up hitch lift rods.
Adjust the length of the lift rods so that when the hy-
draulic lift is fully raised using the external fender
switches, the lift rods are slightly loose.
11. Check that the automatic pick--up hitch operates
correctly.

256

35- 112
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
CALIBRATION OF THE EDC VALVE
This calibration is required if either the EDC valve or
the microprocessor has been replaced or its memory
has been reset using Diagnostic Menu H8.
Perform the calibration with warm hydraulic oil and a
suitable implement or weight mounted on the hydraulic
lift. The weight of the implement should be sufficient to
overcome any friction in the hydraulic lift assembly and
enable the lift arms to lower without binding.
1. Enter H1 mode, using the diagnostic tool.
Refer to Section 55
or
257
2. Press and hold fast raise lower switch in lowering
position against the spring and at the same time
start the engine.

258
3. The display will change to CA or CAL depending on
instrument

259
Transmission oil temperature will be displayed in
‘Display of Gears’

260

35- 113
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
4. Capture the hitch then fully lower and fully raise the
hydraulic lift.
5. Leave the hitch in the fully raised position while it
does a series of three very small raise/lower
corrections.

TIA35205
261
Each time the hitch makes a correction the display
will progressively change from 0 to 1 to 2 and then
En or End depending on type of instrument cluster
installed.

262
6. Key off the tractor to store the calibrations.

263
NOTE: Calibration can be performed several times to
provide a better average of the valve thresholds. The
thresholds (the current required to start the EDC valve
raise and lower solenoids to operate) may be viewed
in mode H3 and are displayed in amps x 100, i.e, 0.530
amps will be displayed as 53. The raise threshold is
displayed first followed by the lower.

TIA35205
264

35- 114
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Valve Calibration Review
(H3 Diagnostic Routine)
(Analogue Electronic Instrument Cluster Shown)
1. Enter the diagnostic routine and depress the
button on the diagnostic switch ‘three times’ until
the display on the instrument panel changes to
‘H3’.

265
2. After approximately 4 seconds the display will
change to show the EDC valve solenoid raise and
lower thresholds.
The threshold values will differ for each tractor with
a nominal value of approximately 50.

266

35- 115
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 25 Lift lever potentiometer control voltage low (short or open circuit)
Error Code 26 Lift lever potentiometer control voltage high (damaged potentiometer
or short to +12 volts)

Is lift control lever YES Replace lift Control Pod

potentiometer damaged
NO

Enter diagnostic mode H9 Channel 29 Refer to wiring diagrams and

Fully lower and then raise the lift arm YES check for intermittent circuit
position control lever on wiring to lift control pod
Do the values range from 9 to 83
NO

Disconnect potentiometer connector C240 and

measure resistance between black and white
wires from potentiometer. Repeat test between
red and white wires NO Replace lift control pod
Does resistance vary between 100--600Ω as
lever is moved in both directions?
YES
Disconnect microprocessor
Turn key start switch ‘ON’ and measure voltage connector C128 and check for open
across male pins C240--D (B) and C240--C (LN) YES circuit between male pins C240--A
Is voltage approximately 5 volts? (LN/B) and C128--30 (LN/B)
NO Open circuit?
NO YES
Disconnect microprocessor connectors C127 and C128
Check for open circuit between male pins C240--D (B) Check for short Locate and
and C127--1 (B). Repeat check between C240--C (LN) circuit between repair open
and C127--5 (LN) male pins C240--A circuit
Open circuit? (LN/B) and C240--D
NO YES (K/B). Repeat check
between C240--A
Check for short circuit Locate and (LN/B) and C240--C
between male pins C240--C repair open (LN/G)
(LN) and C240--D (B) or a circuit Short circuit? YES Locate
short circuit to chassis NO and
between each of these pins repair
Short circuit? Check for short short
NO YES circuit between YES circuit
C240--A (LN/B) and
Replace Locate and tractor chassis
microprocessor repair short Short circuit?
circuit NO

Replace
microprocessor

35- 116
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 25
Lift lever potentiometer control voltage low
(short or open circuit)
Error Code 26
Lift lever potentiometer control voltage high
(damaged potentiometer or short to
+12 volts)

269

267 270

268 271

272

35- 117
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 27 Lift arm position sensing control voltage low (short or open circuit)
Error Code 28 Lift arm position sensing control voltage high (damaged potentiometer
or short to +12 volts)

Is lift arm position sensing potentiometer or YES Repair/replace potentiometer

linkage damaged?
NO

Enter diagnostic mode H9 Channel 28. Refer to wiring diagram and

Disconnect potentiometer linkage and connector

Turn key--start switch ‘ON’ and measure voltage Disconnect microprocessor

across female pins C052--2 (B) and connector C101 and check for
YES open circuit between female pins
C052--1 (LN)
Is voltage approximately 5 volts? C052--1 (LN) and C127--5 (LN)
NO Open circuit?
NO YES
Disconnect microprocessor connectors C127
and C128. Check for open circuit between Check for short circuit Locate and
female pins C052--1 (LN) and C127--5 (LN). between female pins repair open
Repeat check between C052--2 (B) and C128--8 C052--2 (B) and circuit
(B) C052--3 (B). Repeat
Open circuit? check between C052--1
NO YES (LN) and C052--3 (B)
Short circuit?
Check for short circuit between Locate and YES Locate
female pins C052--2 (B) and repair open NO
and
C052--3 (B) or a short circuit to circuit repair
chassis between each of these Check for short circuit short
YES circuit
pins between C052--1 (K/N)
Short circuit? and tractor chassis
NO YES Short circuit?
NO

Replace Locate and repair

microprocessor short circuit Replace
microprocessor

35- 118
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 27 Lift arm position sensing control voltage low (short or open circuit)
Error Code 28 Lift arm position sensing control voltage high (damaged potentiometer
or short to +12 volts)

273 275

274 276

277

35- 119
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 29 Hydraulic Control Valve Disconnected

Are hydraulic control valve NO Reconnect valve

solenoid connectors C217 and
C218 connected?
YES

Examine harness from connector

C217 and C218 for severe damage NO Replace
Harness damaged? microprocessor
YES

Repair harness or
replace control
valve if necessary

Error Code 30 Signal Ground Open Circuit

Disconnect EDC control panel connectors C127

and C121 and microprocessor connector C101.
Check for ‘open’ circuit between female pins YES Locate and repair
C120--4 (B) and C127--1 (B) open circuit
Open circuit?
NO

Check for ‘open’ circuit between

C120--1 and C120--4 of control YES Locate and repair
panel open circuit
Open circuit?
NO

Measure resistance between

male pins C120--1 and C120--4 of Examine microprocessor
control panel YES connector C127 for
Is resistance approximately damage to terminal pin
360Ω? C127--1
NO

Replace EDC control

panel

Error Code 31 Chassis Harness Disconnected

35- 120
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 29, 30 and 31 Hydraulic Control Valve Disconnected

278 282

279 283

280 284

281

35- 121
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 32 Draft Load Potentiometer shorted to +12v

Disconnect EDC control module connector

C240.
Turn Key start switch ON. NO Replace
Measure voltage across C240--D and C240--C microprocessor
Is voltage greater than 5v ?
YES

Examine harness for short circuit

to a 12 volt power supply from the
fuse panel or direct from the
battery.
Fault found?
NO

Replace microprocessor

Error Code 33 Draft Load Potentiometer Open Circuit or Short to Ground

Disconnect EDC control module connector C240

and microprocessor connectors C239 and C101.
Check for open circuit between
C240--A and C128--30 NO Locate and repair
open circuit
C240--B and C128--32
C240--C and C127--5
C240--D and C127--1
Open Circuit?
NO

Check for short circuit between

C240--C and C240--D
Locate and repair
Similarly check for short circuit YES
short circuit
between C240--A and tractor
chassis?
NO

Replace EDC control module

Error Cleared?
NO

Replace microprocessor

35- 122
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 32 Draft Load Potentiometer
shorted to +12v
Error Code 33 Draft Load Potentiometer
Open Circuit or Short to Ground

287

285 288

286 289

290

35- 123
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 49 Output Speed Sensor Open or Short Circuit

Enter diagnostic mode H9 YES Inspect for intermittent

Channel 20 (Dual Command) open/short circuit
Channel 19 Range Command
Is the value approximately 64 (Dual Command)
Is the value approximately 49 (Range Command)
NO

Disconnect wheel speed sensor connector C046

and microprocessor connector C127.
Check for open circuit between YES Locate and repair
C046--1 and C127--6 open circuit
C046--2 and C127--1
Open circuit?
NO

Check for short circuit between C046--1

and C046--2. Similarly check for short YES Locate and repair
circuit between R2--1 and tractor chassis short circuit
NO

Replace wheel speed sensor

Error cleared?
NO

Replace microprocessor

35- 124
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 49 Output Speed Sensor Open or Short Circuit

291

292 293

35- 125
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 53 Microprocessor 5 volt reference Shorted to 12 volts

Enter diagnostic mode H9

Channel 5 (Dual Command) Inspect for intermittent short
Channel 12 (Range Command) circuit to 12 volt supply from
Is the value greater than 49 NO
battery or fuse panel
and error code 53 displayed Error cleared?
YES NO
Disconnect connectors C120 and C121.
Turn keystart switch On and measure voltage NO Replace microprocessor
across C120--1 and C120--4
Is voltage greater than 5 volts?

YES

Examine harness for a short circuit to

a 12 volt power supply from the fuse
panel or direct from the battery
Error cleared?
NO

Replace microprocessor

Error Code 54 Microprocessor 5 volt reference Shorted to Ground

Enter diagnostic mode H9

Channel 5 (Dual Command
Channel 12 (Range Command) Inspect for intermittent short circuit
Is the value less than 49 NO to to tractor chassis
and error code 54 displayed Error cleared?
YES NO

Remove EDC control panel and disconnect Replace

connectors C120 and C121. NO microprocessor
Turn keystart switch On and measure voltage
across female pins C120--1 and C120--4
Is voltage less than 5 volts?
YES

Disconnect micro processor connector Check for short circuit in wire from
C127. Check for short circuit between NO C127--1 to C120--1 and tractor chassis
C127--5 and C127--1. Error cleared?
Short circuit? NO
YES
Replace
Locate and repair microprocessor
short circuit

35- 126
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 53 Microprocessor 5 volt reference Shorted to 12 volts
Error Code 54 Microprocessor 5 volt reference Shorted to Ground

294 296

295 297

35- 127
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 57 EDC Microprocessor Failure

Disconnect microprocessor
Remove and examine fuse 12 NO
connector C127 and check for open
Fuse blown? circuit between
YES C127--29
and fuse 12
Check for short circuit between Open circuit?
C127--29 YES NO
and tractor chassis.
Short Circuit? Locate and repair Replace
YES NO open circuit Microprocessor

Locate and Replace fuse turn keystart

repair short switch off and On
circuit Error cleared?
YES NO

Check for Replace

intermittent Microprocessor
short circuit?

Error Code 59 Micro--processor Reference Voltage Open Circuit

Enter diagnostic mode H9 Inspect for intermittent open circuit

Channel 5 (Dual Command) in wiring from microprocessor
Channel 12 (Range Command) YES connector C101--12 (LN)
Is the value approximately 49 and C120--1 (LN)
NO Error cleared?
NO
Remove EDC control panel and disconnect
connectors C120 and C121. Replace
YES
Turn keystart switch On and measure voltage microprocessor
across female pins C120--1 and C120--4
Is voltage approximately 5 volts?
NO

Disconnect microprocessor connector C101.

Check for open circuit between
C127--5 (LN) and C120--1 (LN)
C120--4 (B) and C127--1 (B)
Open circuit?.
NO

Replace
microprocessor

35- 128
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 57 EDC Microprocessor Failure
Error Code 59 Micro--processor Reference Voltage Open Circuit

298 300

299 301

35- 129
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 63 EDC Hydraulic Valve Lower Solenoid Open Circuit
Error Code 65 EDC Hydraulic Valve Lower Solenoid Short Circuit

Disconnect EDC valve connector C218.

Measure resistance across the coil Replace lower
NO
Is resistance approximately 8Ω? solenoid

YES
Turn key--start switch ‘ON’. Measure
voltage across female pin C218--5090 (K/R)
and tractor chassis.
Is voltage approximately 12 volts? NO Disconnect microprocessor connector
YES
C127.
Check for open circuit between
C127--27 (K/G/B) and C218 K/G/B)
Disconnect microprocessor connectors NO C127--19(K/R) and C218 (K/R)
C127. Check for short circuit between Open circuit?
female pin C127--19 (K/R) and
YES
C127--27 (K/G/B).
Similarly check for short circuit to chassis
between each of these pins Locate and
Short circuit? repair open
YES NO
circuit

Locate and Replace

repair short microprocessor
circuit

Error Code 64 EDC Hydraulic Valve Raise Solenoid Failed Open Circuit
Error Code 66 EDC Hydraulic Valve Raise Solenoid Failed Short Circuit

Disconnect EDC valve connector C217.

Measure resistance across the coil Replace lower
NO
Is resistance approximately 8Ω? solenoid

YES
Turn key--start switch ‘ON’. Measure
voltage across female pin C217--5085 (K/U)
and tractor chassis.
Is voltage approximately 12 volts? NO Disconnect microprocessor connector
YES
C127.
Check for open circuit between
C127--26 (K/U) and C217 K/U)
Disconnect microprocessor connectors NO C127--28(K/U/B) and C217 (K/U/B)
C127. Check for short circuit between Open circuit?
female pin C127--28 (K/U/B) and
YES
C127--20 (K/U).
Similarly check for short circuit to chassis
between each of these pins Locate and
Short circuit? repair open
NO
circuit
YES

Locate and Replace

repair short microprocessor
circuit

35- 130
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 63, 64, 65 and 66 EDC Hydraulic Valve Solenoid Failures

302 305

303 306

304 307

35- 131
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 67 EDC Hydraulic Valve Supply Voltage to Low

Enter diagnostic mode H9 YES Perform checks for

Channel 8 (Dual Command) Error Codes 63 to 66
Channel 10 Range Command
Is the value approximately 3
YES

Check for 12 volts at fuse 12 and

check for open circuit between
Fuse 12 and C127--29 (N/R/B)
Open circuit
YES NO

Locate and Replace

repair open microprocessor
circuit

35- 132
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Error Code 67 EDC Hydraulic Valve Supply Voltage to Low

60--55--012 TI
308

309 310

35- 133
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
ELECTRONIC DRAFT CONTROL
VALVE--OVERHAUL

Removal
(Op:35 138 20)
3. Manufacture three guide pins from 8mm mild steel
rod. Taper end of rod and cut screwdriver slot as
shown.

311
4. Lower hydraulic links and thoroughly clean remote
valve stack.
5. Remove trailer brake socket (1) and disconnect
electrical connections to each electronic draft
control solenoids (2).

312
6. Disconnect control cables from remote valves 1
and 2.

313
7. Remove a clamping bolt and install guide pin made
in step 1.
NOTE: The valve stack is very heavy DO NOT attempt
to remove valves without the use of guide pins.
8. Repeat procedure for remaining two clamp bolts.

314

35- 134
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
9. Remove end plate and valve assemblies.

315
10. Remove electronic draft control valve.

316
Installation
1. Install using removal procedure in reverse.
2. Tighten clamp bolts to torque of 30 Nm in sequence
1,2,3.

317

35- 135
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

318
Electronic Draft Control Valve Components
1. Flow Compensating Valve 5. Lift Cylinder Relief Valve
2. Raise Spool 6. Lowering Solenoid
3. Raise Solenoid 7. Lowering Metering Element
4. Load Check Valve
--

Disassembly
(Op. 35 138 24)
1. Remove ‘O’ ring (1) and load sense check valve
(2).

319

35- 136
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
2. Remove load hold valve
1. Valve
2. Washer
3. Guide
4. Circlip
5. Plug
6. Washer
7. Spring
8. Rubber Seal

320
3. Unscrew knob (1) and remove ‘O’ ring (2) and coil
(3) from each solenoid (4).

321
4. Remove retainer (1), solenoid core (2) and ‘O’ ring
(3).
5. Repeat procedure for opposite solenoid.

322
6. Remove Lift Cylinder Safety Valve.
1. Seat
2. Valve
3. Spring
4. Copper Washer
5. Shims
6. End Cap

323

35- 137
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
7. Manufacture box spanner (1) from 18mm internal
diameter steel tube and remove lift cylinder safety
valve seat (2).

324
8. Remove flow compensating spool (1).
WARNING
A large spring (3) is positioned beneath the plug (4),
take extreme care when removing plugs.

325
9. Remove solenoid assembly (4), ‘O’ ring (3), raise
spool (2) and spring (1).

326
10. To remove the lowering metering valve it is
necessary to disassemble the valve in stages as
follows:--
11. Remove retaining screws.

327

35- 138
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
12. Use piece of 14mm hexagonal bar with an 11mm
hole drilled through centre to screw the nozzle (1)
further into valve housing. This will reduce the
pressure of the metering valve spring on circlip (2).
13. Remove circlip (2), seat (3) and spring (4).
14. Remove Nozzle.

328
15. Remove locking ring (1) use a 17mm piece of
hexagonal bar (1) with 11mm hole drilled down
centre.

329
16. Pull metering element (1) from housing.

330
17. Disassemble metering element components.
1. Sleeve
2. Metering Element
3. Pilot Spool
4. Plug
5. Circlip

331

35- 139
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

332
Metering Valve Components
1. Locking Screw 7. Metering Valve
2. Sleeve 8. Locking Ring
3. Plug 9. Nozzle
4. Locking Screw 10. Seat
5. Orifice 11. Circlip
6. Shim

Re--Assembly
1. Re--assembly follows disassembly procedure in
reverse.
2. When installing nozzle (5) and locking ring (6)
ensure serrated edge of orifice and nozzle align
with locking screws (1) and (4).

35- 140
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
LOAD SENSING PIN REPLACEMENT

Removal
(Op:35 130 50)
1. Lower hydraulic lift arms.
2. Disconnect load sensing pin connectors. The
connectors are located on top of the hydraulic lift
cover and can be accessed from the rear of the
tractor.

TIA35093
333
3. Remove wiring protection guard at pin.
A B

TIA35185
334
4. Remove spacers (2) and clamp (1).
1

2
TIA35095
335
5. Withdraw Pin.

Installation
1. Install pin using procedure in reverse and torque
clamp bolts to the specified torque.

TIA35096
336

35- 141
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
HYDRAULIC LIFT COVER--OVERHAUL

Removal
(Op No 35 134 30)
1. Lower lift arms

337
2. Disconnect lift rods and assist ram (where fitted).

TIA35184
338
3. Disconnect and remove lift arm position sensing
potentiometer.

TIA35067
339
4. Raise rear of cab for additional clearance.
On cabs with rear suspension mounts raise the
rear of the cab and support each side on suitable
blocks (1).

340
5. On cabs with rubber rear suspension mounts. Support cab and remove rear mounting bolts.

35- 142
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
Re--install mounting bolts into cab and lower cab
until bolts rest on top of cab mounts on rear axle.

TIA35181
341
6. Remove trailer socket (1) and disconnect electrical
connections to each electronic draft control
solenoid (2).

342
7. Disconnect remote valve control linkage and
connecting pipework. refer to Figure 345.

343
8. Using suitable lifting equipment remove valve
stack.
9. Remove ‘O’ ring (1).

344

35- 143
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

345
Hydraulic Pipework and Components
1. Remote and EDC Control Valves 4. To Hydraulic Lift and Assist Ram (Where Fitted)
2. To Remotes and Hydraulic Lift Control Valve 5. Variable Flow Hydraulic Pump
3. Return to Reservoir 6. Trailer Brake Valve
(via Transmission Brake Housing) 7. Load Sense Lines
10. Disconnect connections to hydraulic lift cover lift
cover.

35- 144
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
11. Remove lift cover mounting bolts and fit lifting
bracket (1) New Holland Tool No 293983 to top of
lift cover.
12. Connect lifting hook (2) New Holland Tool
No 291359/2 to bracket.

346
13. Using hoist carefully raise cover sufficiently to
enable removal from tractor.

347
Disassembly
(Op:35 134 42)
14. Disassemble Lift cover with reference to
Figure 349

348

35- 145
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

349
Hydraulic Lift Cover
1. Bush 13. Rod
2. Bush 14. Piston
3. Cross Shaft 15. Back up Ring
4. Arm 16. Seal
5. Bush 17. Dowel (2 off)
6. Bush 18. Cylinder
7. Seal 19. ‘O’ Ring
8. Spacer 20. Seal
9. Arm 21. Connecting Tube
10. Bolt 22. Seal
11. Washer 23. ‘O’ Ring
12. Spacer 24. Pin

35- 146
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
15. To remove piston from cylinder insert an airline into
the inlet port or alternatively tap the open end of the
cylinder onto a piece of wood.

350
Re-- Assembly and Installation
1. Wash all parts in suitable cleaning fluid.
2. Re--assembly and installation follows the
disassembly procedure in reverse while observing
the following requirements.
3. When installing the piston apply petroleum jelly to
outer surface of seal and carefully insert into
cylinder.

351
4. The use of New Holland Special Tool No 293813
(1) will aid assembly without risk of damaging
piston seals
5. When installing lift cylinder tighten retaining bolts
to a torque of 142 Nm (105 lbf ft)

352

35- 147
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4
6. Use New Holland seal installer 293985 to install
new cross shaft seals

353
7. Ensure the positioning mark on the ends of the
cross shaft align with the corresponding marks on
the lift arms.
8. Tighten lift arm retaining bolts to a torque of
142 Nm 105 lbf ft).

354
9. When installing lift cover onto tractor apply a
continuous bead of New Holland sealant
82995771 to mating face of cover while ensuring
a ring of sealant is also applied around each
mounting bolt hole.
10. Install lift cover retaining bolts and tighten to
specified torque.

355

35- 148
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 5 -- Mechanical Rear Hydraulic Lift

CONTENTS

Section Description Page

35 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS -- REAR HYDRAULIC LIFT

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with separate position or draft
control plus mixed position/draft
control feature
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through two independent levers
Variable--speed sensitivity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic, through a hydraulic
unit located inside the lift control
valve
LIFT-O-MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For fast raise/lower through
push--buttons, without using the
draft or position control levers
Drop rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through a bolt and nut located
on the lift control valve
Single--acting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- Bore and stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 115 x 159
-- Displacement cm3 1651
Pressure regulating valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 190 to 195 (194 -- 199 kg/cm2)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 210 to 215 (214 -- 219 kg/cm2)
Piston dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 114.978 --115.000
Cylinder bore dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 115.036 -- 115.071
Piston to bore clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.036 -- 0.093

(to be continued)

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
SPECIFICATIONS -- REAR HYDRAULIC LIFT
(continued)
Cross shaft (3, Fig. 3) dia. at the bushings:
-- RH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 64.970 -- 65.000
-- LH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 69.970 -- 70.000
Lift casing press--fit bush inner dia:
-- RH side (3, Fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 65.100 -- 65.184 (1)
-- LH side (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 70.100 -- 70.184 (1)
Cross shaft to bushes clearance . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.214
Bushes to bush seats interference . . . . . . . . . . . . . . . . . . . . . . . . . . » 0.065 -- 0.185
Shaft end play (with lift arms installed) . . . . . . . . . . . . . . . . . . . . . . . » 0.2 -- 1.4
Draft control shaft (4, Fig. 4) outer dia. . . . . . . . . . . . . . . . . . . . . . . mm 21.967 -- 22.000
Support seat inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 22.020 -- 22.072
Shaft to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.105
Position control shaft (5, Fig. 4) dia. . . . . . . . . . . . . . . . . . . . . . . . . . mm 13.973 -- 14.000
Position control shaft inner dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 14.016 -- 14.059
Draft control shaft to position control shaft clearance . . . . . . . . . . mm 0.016 -- 0.086
Control spool (8, fig. 5) to seat clearance . . . . . . . . . . . . . . . . . . mm 0.008 -- 0.012 (2)
Pilot valve (10) to control valve housing seat clearance . . . . . . . . mm 0.008 -- 0.014 (2)
Check valve return spring (12, Fig. 5):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 25.5
-- Compressed length under a load of 52 to 56 N (5.28 to 5.72 kg)mm 17.5
Control spool return spring (5, Fig. 5)
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.5
-- Compressed length under a load of 31.7 to 35 N (3.23 to 3.57 kg)mm 34
Pilot valve return spring (9, Fig. 5):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44
-- Compressed length under a load of 103 to 114.7 N (10.5 to 11.7 kg) .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 29
Drop rate control valve spring (14, Fig. 5):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 34
-- Compressed length under a load of 67 to 73 N (6.86 to 7.46 kg) mm 27
Sensitivity valve spring (4, Fig. 5):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 48
-- Compressed length under a load of 65 to 71 N (6.6 to 7.2 kg) . mm 32
Sensitivity valve spring (1, Fig. 5):
-- Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 21
-- Compressed length under a load of 0.9 to 1 N (0.09 to 0.11 kg)mm 13

(1) Final dimension to be obtained without reaming

(2) Upon assembly, control spools and pilot valves are selected to obtain the required end play

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
SPECIFICATIONS -- IMPLEMENT LINKAGE
(continued)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--point hitch
Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd
Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Through lower links and sensing
bar
Max. lifting capacity with gravity centre at 610 mm from lower link ball ends,
starting with links in horizontal position (top link connected to top bracket
hole):
-- Without assist ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 4810
-- With assist ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 6730
Max. lower link displacement, with vertical lift
rods fully extended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 740
Sensing bar diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 34.861 -- 34.900
Sensing bar end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.9 -- 4.5

TIGHTENING TORQUES
DESCRIPTION Tightening Torques
Thread Torque
size
Hydraulic lift
Bolts, lift to rear axle housing (C1, page 4) . . . . . . . . . . . . . . . . . . . . . . . . M 14x1.5 142 14.5
Bolts, control valve to lift (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 32 3.3
Bolts, lift arm plates (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14x1.5 142 14.5
Plug, pilot valve (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 20x1.5 54 5.5
Cylinder safety valve (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 20x1.5 83 8.5
Plug, check valve (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 24x1.5 83 8.5
Nut, position control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.25 14.7 1.5
Nuts, lever quadrant bracket retaining studs . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 23 2.4
Bolts, lift cylinder . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5 279 28.5
Implement linkage
Bolts, sensing bar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18x1.5 304 31
Bolts, top link support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18x1.5 304 31
Nut, draft control rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.25 36 3.7
Nut, arm back--up ring screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12x1.25 98 10
Remote control valves
Bolts, remote control valves . . . . M 10x1.25 127 13

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
SPECIAL TOOLS -- HYDRAULIC LIFT X 291862 Cylinder safety valve setting ring
spanner
CAUTION
Caution -- Operations described in this Section of the
X 291863 Lift pressure regulating valve setting
Manual must be performed using the following
ring spanner
ESSENTIAL tools marked with the identification code
(X).
X 293865 Guard, seal assembly on drop rate
To work safely and achieve the best technical results adjust pin
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated 292870 Pressure test kit
with the Dealer made tools for which you will find the
necessary construction drawings and specifications 290284 Valve setting hand pump
directly on this Manual.
X 290828 Cylinder safety valve setting connector

291359 Hydraulic lift lifting hook X 290824 Lift pressure regulating valve setting
connector
X 293813 Piston assembly ring (with lift seals)
X 293982 Control spool leak test connector
X 293985 Cross shaft seal punch
X 293978 Arm raise adjustment spanner
291215 Lift linkage spring
disassembly/assembly hook X 293984 Pilot valve seal guard

X 293839 Punch, roller bearings on control valve X 293980 Draft control adjustment tool
lever bush
X 293979 Draft and position control adjustment tool
X 293838 Punch, roller bearings on draft control
lower lever
293987 Arm shaft bush rod

X 293838 Punch, roller bearings on draft control

293988 Nut (use with tool no. 293987)
upper lever
293989 Bush (use with tool no. 293987)
X 293838 Punch, roller bearings on draft actuator
arm
293983 Adapter (use with tool no. 291359)
X 293981 Draft control adjustment alignment pin

Tool to be fabricated for disassembly/assembly of lift

case bushes.
Use with rod tool no. 293987. (Mark tool with no. 50150
-- Dimensions in mm).
Fabricate tool using UNI C40 material.

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

2
Lift Arm Control Shaft Sectional View

1. Lift arm, right--hand side 5. Shaft (4) support bushes, left--hand side
2. Seal 6. Seal.
3. Shaft (4) support bushes, right--hand side 7. Lift arm, left--hand side.
4. Lift arm control shaft

3
Lift Longitudinal View (Position Control).
1. Lift casing. 3. Lift arm control shaft.
2. Position actuator arm. 4. Control spool.

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on page 19.

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

4
Lift Longitudinal and Sectional Views
A. Draft actuator linkage cross section. 5. Position control shaft.
1. Lift casing. 6. Control valve spool (3) lever pivot pin.
2. Draft actuator linkage. 7. Lift--O--Matic external control lever.
3. Control spool. 8. Idler linkage pivot pin.
4. Draft control shaft.

NOTE: During installation apply liquid gasket on surfaces marked with an X as detailed on page 19.

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

5
Lift Hydraulic Control Valve Sectional Views
1. Sensitivity valve spring. 9. Pilot valve return spring.
2. Seal and ring. 10. Pilot valve.
3. Seal and ring. 11. Check valve ball.
4. Sensitivity valve spring. 12. Check valve return spring.
5. Control spool return spring. 13. Cylinder safety valve.
6. Seal and ring. 14. Drop rate control valve spring.
7. Control spool seat. 15. Seal and ring.
8. Control spool.

NOTE: Upon assembly of seals 2, 3, 6 and 15, heat back--up rings in oil at a temperature of approximately 50°C.
Upon assembly of seal (15) and back--up ring, use guard tool no. 293865.
Upon assembly of seal (6) and back--up rings, use guard tool no. 293984. Seals (2 and 3) and back--up rings
can be assembled without using guards but care must be taken not to damage them.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
DESCRIPTION AND OPERATION
The mechanical lift can be operated in either Position Draft control is performed through the sensing bar
or Draft control, or in mixed position/draft control. located in a special case attached under the rear axle
The lift is controlled through two dedicated levers housing.
located at the operator’s right side. It is fitted with the The lift lower links and linkage rods are connected to
Lift--O--Matic device for fast implement raise and lower the sensing bar.
without using the position and draft control levers.

Trapped oil
Suction oil
Delivery oil

6
Hydraulic Lift Circuit

A. Position actuator linkage operation. 3. Hydraulic control valve.

B. Draft actuator linkage operation. 4. Pressure regulating valve.
1. Hydraulic pump. 5. Filter.
2. Remote control valve.

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Exhaust oil

Pressure oil
Trapped oil

Suction oil
Delivery oil
7
Oil Flow in Raising

A. Draft control operation (detail). 4. Check valve.

1. Control spool. 5. Drop rate control valve.
2. Pilot valve. 6. Cylinder safety valve.
3. Sensitivity valve.

When lift arms are raised using the position control oil opens the check valve (4) and acts on the arm
lever located at the operator’s right side, internal links raising piston.
transfer motion to the control spool (1), as shown by the During draft control operation (detail a), raising is
arrows. The control spool (1) moves and cuts off the oil achieved through the sensing bar, which transfers
flow to both the pilot valve (2), which moves under the motion to the control spool (1) through the linkage rod
action of the spring, and sensitivity valve (3).Pressure (7), as shown by the arrows.

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Exhaust oil

Pressure oil
Trapped oil

Suction oil
Delivery oil

8
Oil Flow in Neutral

1. Control spool. 4. Check valve.

2. Pilot valve. 5. Drop rate control valve.
3. Sensitivity valve. 6. Cylinder safety valve.

When the lift arms have reached the preset height, the pressure oil overcomes the spring force, moves the
inner linkage stops. With the control spool (1) in this valve and opens a discharge port directing oil into the
position, oil flows through the sensitivity valve (3) on to axle housing instead of the lift cylinder.
the pilot valve (2) piston, which under the action of

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Exhaust oil

Pressure oil
Trapped oil

Suction oil
Delivery oil

9
Oil Flow in Lowering
A. Draft control operation (detail ). 4. Check valve.
1. Control spool. 5. Drop rate control valve.
2. Pilot valve. 6. Cylinder safety valve.
3. Sensitivity valve.
When the position control lever, located at the motion to the control spool (1) through the linkage rod
operator’s right side, is lowered, the lift arms lower. (7), as shown by the arrows.
Internal links transfer motion to the control spool (1), as NOTE: Drop rate of the implement connected to the lift
shown by the arrows, which moves downwards under arms depends on the position of the drop rate control
the action of the spring. Oil in the cylinder is pushed out valve (5). If the valve (5) adjust screw is unscrewed, the
by the piston towards the discharge through the drop discharge hole between the drop rate valve and control
rate control valve and the hole left open by the control valve housing is reduced and the implement takes a
spool. Delivery oil, through the valve (5), acts on the longer time to be lowered. If it is fully screwed in, the
pilot valve (2) piston, moves the valves against the discharge hole is larger and the implement is lowered
force of the spring and opens a discharge port directing more quickly.
oil into the axle housing instead of the lift cylinder.
During draft control operation (detail a), lowering is
achieved through the sensing bar which transfers

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
TROUBLESHOOTING -- HYDRAULIC LIFT
Problem Possible Causes Correction
Hydraulic lift not raising. 1. Clogged oil filter. Replace filter.
2. Pilot valve stuck in discharge. Repair pilot valve.
3. Faulty hydraulic pump. Overhaul or replace pump.
Lift bounces when raising. 1. Clogged oil filter. Replace filter.
2. Air leaks on pump suction side Check fittings and seals for air
leaks.
Lift raising too slowly. 1. Clogged oil filter. Replace filter.
2. Oil leaks through seals with con- Replace faulty sealing items.
sequent pressure drop: piston
seals or cylinder inlet fitting.
3. Faulty hydraulic pump. Overhaul or replace pump.
Lift lowering too slowly. 1. Drop rate incorrectly adjusted. Adjust correctly.
Lift lowering too quickly. 1. Drop rate incorrectly adjusted. Adjust correctly.
Lift operation too fast. 1. Foreign particles between ball Disassemble valve, remove foreign
and ball seat on the flow control particles and inspect oil filter.
valve
2. Defective flow control valve ball Replace delivery control valve.
sealing
3. Delivery control valve piston Disassemble valve, remove causes
binding for piston binding.
Lift operation too slow . 1. Blocked delivery control valve Disassemble valve, remove
holes. obstructions and inspect oil filter.
2. Delivery control valve piston Disassemble valve, remove causes
binding. for piston binding.

(to be continued)

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
(cont’d)
Problem Possible Causes Correction
Lift fails to keep load raised (with 1. Faulty check valve sealing. Disassemble, inspect, clean and
engine running, there is a replace interested parts, if
continuous rhythmic height necessary.
oscillation; with engine shut off, the
load is lowered).
2. Oil leaks through the control Replace seals.
spool seat seals.
3. Poor control spool sealing. Disassemble and check sealing.
Replace control spool and seat, if
faulty.
4. Oil leaks through raise piston Replace seals.
seals or cylinder inlet fitting
seals.
5. Poor cylinder safety valve Replace valve.
sealing or valve setting too low.
Pressure regulating valve operating 1. Lift arm travel incorrectly Adjust correctly.
with lift arms fully raised. adjusted.
Poor lifting capacity. 1. Pressure regulating valve Replace valve.
incorrectly adjusted.
1. Cylinder safety valve incorrectly Replace valve.
adjusted.
2. Poor pump yield Overhaul or replace pump.
(generally, accompanied by a
considerable increase in lifting
time).

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
REAR HYDRAULIC LIFT DANGER
Lift and handle all heavy components using lifting
Removal--Installation (Op. 35 110 30) equipment of appropriate capacity. Ensure that units or
parts are supported by suitable slings or hooks. Ensure
that no-one is in the vicinity of the load to be lifted.

Remove the hydraulic lift from the rear axle housing as

follows:
1. Open and raise engine hood.
2. Detach negative cable (1) from battery and
insulate.
3. Remove the top link.

1
4. Loosen the retaining screw and remove the flow
control adjuster knob (1).

2
5. Loosen the retaining screws and remove the
remote valve protection cover (1).

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
6. Disconnect remote valve supply and exhaust lines
(2 and 1).

4
7. Remove cotter pins (1) and disconnect control
cables from remote valves.

5
8. Loosen the retaining bolts and remove the remote
valve assembly.

6
9. Slide out cotter pins (1), remove hinge pins (2) and
detach lift rods (3) from lift arms.

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
10. Disconnect and remove the hydraulic control valve
lines (1 and 2).

8
11. Disconnect the accessory socket (1) and remove
it from the support bracket (2).

9
12. Detach the PTO speed sensor connector (1).

10
13. Disconnect the hydraulic lift control levers (2 and 4)
and the Lift--O--Matic control cable (1). Detach the
lift lubrication line (3).

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
14. Loosen retaining bolts and lift the control valve (1)
from the lift casing.

12
15. Loosen lift casing to rear axle housing attaching
bolts.

13
16. Fix tool No. 293983 (1) to the lift.
NOTE: When assembling the bracket tool No. 293983,
make sure that the mounting holes on the lift casing are
not plugged. If so, remove cork plugs.

14
17. Assemble hook tool No. 291359 (1) on tool No.
293983 (2) and tighten the safety screw. Remove
the hydraulic lift using a hoist.

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
18. Reinstall the hydraulic lift to the rear axle housing
observing the following:
-- Reinstallation follows the removal procedure in
reverse. Thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant, New Holland Part No 82995771 to the
rear axle housing following the pattern shown
in the side figure.
-- Re--install the control valve to the lift after
applying a bead of sealant as shown in figure
5, page 38.
-- Re--assemble the cork plugs on the upper side
of the lift casing, if removed to install the
bracket tool No. 293983. 16

35- 19
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
REAR LIFT EXTERNAL CONTROLS

Disassembly--Assembly (Op. 35 110 17)

WARNING
Handle all components with the greatest [Link] not
insert hands or fingers between the [Link]
suitable protection clothing, including goggles, gloves
and footwear.

Lift external controls can be disassembled and

reassembled with either the lift on a work bench or still
in the tractor.
Proceed as follows:
1. Unscrew the three nuts attaching the guard (1) to
the lift casing.

1
2. Remove guard and springs (1).

2
3. Unscrew the retaining nut and retrieve the position
and draft external control levers (1 and 2,
respectively) along with friction pads.
4. Reassemble the lift external controls following the
disassemble procedure in reverse.

35- 20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
REAR LIFT INTERNAL CONTROLS

Disassembly--Reassembly (Op. 35 110 40)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles,
gloves and footwear.

Proceed as follows:
1. Fix the lift on a rotary stand. When installing the lift
on the stand ensure the fixing brackets are not
attached to the two lift cover bolt holes adjacent to
the control valve. These holes are used to attach
the control valve adjusting tool No. 293980 as
described on Page 24 Figure 10.
2. Remove the four retaining screws and
disassemble cylinder (1) and piston.

1
3. Remove lubrication line (1).

2
4. Disassemble the position and draft control internal
control levers (2 and 1, respectively) along with the
linkage.

35- 21
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
5. Loosen the retaining pin (1), disassemble the
control valve actuator arm, lever and spring.
Retrieve the thrust washer (2).

4
6. Remove the two retaining screws and disassemble
the control valve lever along with the threaded rod
(1).

5
7. Remove the retaining pin (1) and disassemble the
draft control inner lever. Retrieve the thrust washer
(2) and the pin retaining ring.

6
8. Using punch tool No. 293838 (1), replace the roller
bearings on the draft actuator arm.

35- 22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
9. Using punch tool No. 293838 (1), replace the roller
bearings on the draft control internal lever.
10. Using punch tool No. 293839, replace control valve
lever bearings.
11. Reassemble lift levers following the disassembly
procedure in reverse. Perform adjustments
described in the following pages.
NOTE: Adjustments should be performed in the
sequence they are described.

35- 23
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
Position Control Adjustment
Proceed as follows:
12. Fix tool No. 293980 (1) on a surface plate and
screw in or out the end of the rod (3) until the upper
end of the rod is perfectly flat with the tool. Lock the
nut (2).

9
13. Connect the LIFT--O--MATIC lever to tool
No. 293980 (1) using the special pin.

10
14. Move the position control external lever (1) fully
forward, to touch the quadrant stop.
15. Ensure the inner link is in contact with the lift
casing.

11
16. Using a spanner tool No. 293978 (2), unscrew the
adjusting screw (1) until the screw is no longer
touching the lift control levers.

35- 24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
1. Assemble tool no. 293979 (1) in place of the control
valve and check that the tool end rests on the
control valve lever.

13
2. Using two spanners, undo the locknut (1).

14
3. Adjust the threaded rod until the face of the rod (1)
is exactly aligned with the outer reference face of
the tool (2), as shown in the figure14.

15
4. Tighten the threaded rod (2) and locknut (1).

35- 25
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
5. Move the position control external lever (1) fully
backward to touch the quadrant stop and turn the
cross shaft as to bring the piston to end of forward
stroke.

17
6. Check that the face of the rod (1) is either level or
further recessed with respect to the inner reference
face of the tool (2).

18
Draft Control Adjustment
Proceed as follows:
7. Move the position and draft control external levers
(2 and 1, respectively) fully backward, to touch the
quadrant stop.

19
8. Disassemble the eccentric pin (1, Fig. 6) retaining
the draft control internal lever. Insert tool no.
293981 (1) in the pin hole.
NOTE: Using a lever as shown in the figure, unload the
control valve rod spring to assist eccentric pin removal
and subsequent installation of service pin (1).

35- 26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
9. Tighten the screw (2) of tool no. 293980 (1).

21
10. Disconnect the threaded rod (1) at the draft control
internal lever.

22
11. Turn the threaded rod (1, Fig 22) until the face of
the rod is aligned with the outer reference plane of
tool no. 293979 (2), as shown figure 224.
NOTE: One turn of the threaded rod corresponds to
moving the tool rod (1) by approximately 3 mm.
12. Remove pin tool no. 293981 (1, Fig. 20) and install
the eccentric pin (1, Fig. 24) taking care that the pin
cam is turned towards the front of the tractor.
Tighten the retaining ring nut to the lift casing.

23
13. Turn the eccentric pin until the rod (1) is exactly
aligned with the outer reference face of tool no.
293979 (2, Fig 23).
14. Tighten the eccentric pin locknut.

35- 27
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
Max Lift Height Adjustment
Proceed as follows:
15. Move the position control external lever (1) fully
forward, to touch the quadrant stop.
16. Ensure that the inner link is touching the lift casing.

25
17. Using a spanner tool no. 293978 (2), screw in the
adjust screw (1).
18. Continue to adjust screw until the face of the rod (1)
is exactly aligned with the inner reference face of
tool no. 293979 (2), as shown in the figure.

26
19. Reinstall the lift assembly into the tractor observing
the following:
-- Reinstallation follows the removal procedure in
reverse, from step 18, page 19, back to step 1.
-- Tighten to correct torques as detailed on page
3.
-- Adjust mounting position of the draft control rod
as detailed in the following pages.
Once adjusted, the draft control rod should
protrude from the axle housing upper side by
31.5 ± 0.1 mm.

35- 28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
Draft Control Rod Mounting Position Adjustment
Proceed as follows:
20. Place tool no. 293980 (1) on a surface plate and
using a depth gauge measure the distance (H1)
from the tool base on the surface plate to the depth
gauge base on the tool. Stamp reading (H1) on the
tool

28
21. Attach tool no. 293980 (1) to two holes of the axle
housing. The draft control rod (2) should enter
exactly into the tool hole.
22. Using a depth gauge, read distance (H2) from the
face of draft control rod (2) upper end and the depth
gauge base on the tool.
23. Dimension (H2) is given by:
H2 = H1 - 31,5 mm
where:
H1 =reading on tool no. 293980 when assembled
on the surface plate.
31,5 mm = operating protrusion of the draft control
rod from the axle housing upper side.
29
24. If this is not the case, turn the threaded rod of the
draft control rod in to increase dimension (H2) or
out to decrease dimension.

35- 29
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
LINKAGE ADJUSTMENT (OP. 35 110 08)

Position Control Rod Adjustment

Proceed as follows:
1. Move the position control lever (1) to end of travel
on the quadrant. Check that distance (L) is 15 to
20 mm.
2. Move the position control external lever (2) fully
forward to touch the quadrant stop.

1
3. Connect the control rod (1) and adjust rod length,
if necessary.
4. Lock rod (1) using the locknuts.

2
Draft Control Rod Adjustment
Test conditions:
-- Apply a load of 1630 to 2150 kg to the lower links
ball ends
-- Run the engine at medium speed
-- Oil temperature of 30° to 40° C.
Proceed as follows:
5. Move the position control lever (1) fully forward on
the quadrant and the draft control lever (2) at a
distance (L1) of 15 to 20 mm from beginning of the
slot.

3
6. Move the draft control external lever (1) fully
backward to touch the quadrant stop.
7. Connect the control rod and adjust rod length, if
necessary.

35- 30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
8. Move the draft control lever (2) to a distance (L2)
of 100 to 105 mm (or 2/3 of the quadrant travel)
from beginning of the slot. Check that in this
position the arms start raising.
9. If not, turn the eccentric pin (2, Fig. 4) to reset
correct distance.
10. Lock the eccentric pin using the locknut (3, Fig. 4).

5
LIFT--O--MATIC ADJUSTMENT
Proceed as follows:
11. Move the draft and position control levers (1 and 2,
respectively) fully forward on the quadrant.
12. Raise the arms using the lever (4).

6
13. Screw in the nut (1) until the arms lower.
14. With the lever (4, Fig. 6) still in the same position,
loosen the nut (1) until arms start to raise.
15. Loosen the nut (1) by a further 11/2 turns.
16. Using levers (3 and 4, Fig. 6), lower and raise arms
several times to test correct operation of
LIFT--O--MATIC.

35- 31
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
4. Move levers (1 and 2) fully forward on the quadrant
(arms fully lowered).
5. Using the position control lever (1), raise arms to
the desired height.

10
6. Release the knob (2) and move the mobile sector
(3) clockwise until it contacts the roller (1) on the
LIFT--O--MATIC control lever (4).
NOTE: Arm raise height limit acts only on the
LIFT--O--MATIC device and leaves the other functions
of the lift unchanged. Consequently, it is possible to
perform full arm raising using the control levers (1 and
2, Fig. 3).

35- 33
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
LIFTING CYLINDER AND CROSS SHAFT
DISASSEMBLY--REASSEMBLY (OP. 35 110 42)
Proceed as follows:

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protective clothing, including goggles,
gloves and footwear.

1. Fix the lift on a rotary stand.

2. Remove the four retaining screws and
disassemble cylinder (1) and piston.

1
3. Remove lift arms (1). Before removal ensure that
there are reference marks on both the lift arms and
cross shaft. If not, scribe marks as shown.

2
4. Remove the cross shaft (1) and retrieve inner arm
(2) from inside the lift casing. Before disassembly,
ensure that there are reference marks on both
inner arm and cross shaft. If not, scribe marks as
shown.
5. Check cross shaft seals for wear. Remove if
unserviceable.

35- 34
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
6. Blow compressed air into the inlet hole and remove
piston from the cylinder.

4
7. Detach the piston oil inlet fitting (1) and check ‘O’
rings for wear.

5
8. Insert piston into the cylinder bore using drive tool
no. 293913 (1) to prevent damages to the seal.
9. Reinstall the cross shaft taking care to match the
reference marks on the cross shaft and inner arm.

6
10. To prevent damage to the lips on the seal, roll up
a piece of 0.05 to 0.1 mm thick brass sheet 200x90
mm flexible brass sheet with a thickness of 0.05 to
0.1 mm. Slide the seal onto the rolled up sheet of
brass and then slide the brass roll (1) and seal over
the cross shaft splines. Using your hands push the
seal into its seat and carefully remove the brass
sheet.

35- 35
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
11. Using installer tool no. 293985 (1) assemble the
seals onto the cross shaft.

8
12. Re--assemble the lift arms (1) on to the cross shaft
taking care to align reference marks.

35- 36
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
LIFT CONTROL VALVE

Removal--Installation (Op. 35 114 10)

Proceed as follows:
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

1. Disconnect the two oil delivery and return tubes (2

and 1, respectively) from the control valve.

1
2. Remove the drop rate valve screw locknut (1).

2
3. Remove the socket head screws. Remove the
control valve cover (1).

35- 37
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
4. Remove the four retaining screws and remove the
control valve.
5. Reinstall the control valve to the lift casing following
the removal procedure in reverse. Ensure sealant
is applied to the mating surface of the valve and lift
casing as shown below.

4
6. Thoroughly clean mating surfaces and apply a
2 mm bead of New Holland sealant Part No
82995771 to the lift casing following the pattern
shown in the side figure.

35- 38
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
LIFT CONTROL VALVE (REMOVED)

Disassembly--Reassembly (Op. 35 114 14)

Proceed as follows:
WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts. Wear
suitable protective clothing, including goggles, gloves
and footwear.

1. Remove the cylinder safety valve (1).

1
2. Remove the pilot valve spool (1).

2
3. Remove the check valve (1).

35- 39
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
4. Remove the control spool (1).

4
5. Remove the control spool seat (1).

5
6. Remove the plug (1) and retrieve the flow control
valve spring and pin.

6
7. Remove flow control valve piston (1), spring (3) ball
(2) and pin (4).

35- 40
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
8. Check control spool seat seals for wear. Replace
if damaged using protection tool no. 293984 (1)
and following the advice given on page 8.
9. Check control spool operating conditions as
follows:

8
10. Assemble control spool (2) and seat (1) on tool no.
293982 (3).

9
11. Assemble the control spool spring (2) and plug (3)
of tool no. 293982 (1). Screw in until touching and
check that the control spool slides freely along its
seat.

10
12. Assemble tool no. 293982 (1) on the hand pump
tool no. 290284 (2) filled with oil HYDROSYSTEM
68. Connect a dial indicator to the tool and fix using
the screw.

35- 41
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
13. Prime the hand pump and at the same time screw
in the tool screw (1) until oil stops coming out from
the control spool seat discharge hole.
14. Reset gauge to zero in this condition.
15. Screw the tool screw (1) further in to move the
control spool by 1.8 to 2 mm. Check the distance
on the dial indicator.

12
16. Prime the hand pump to bring system oil to the
initial pressure of 245 bar (250 kg/cm2). Check on
the pressure gauge that pressure drops from 196
bar (200 kg/cm2) to 98 bar (100 kg/cm2) in more
than six seconds. If not, replace the control spool.
The control spool and its seat are available in
service as a matched set.

13
17. Check control valve cover seals for damage and
replace, if necessary.

14
18. Check the drop rate pin seal for damages. If
necessary, replace seal using protection tool no.
293865 and observing the note on page 8.

35- 42
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
19. Check the cylinder safety valve setting as follows:
20. Assemble the cylinder safety valve (1) on the valve
fitting tool no. 290828 (2) and connect fitting to the
hand pump tool no. 290284 (3).
21. Prime the hand pump (3) and check that the
cylinder safety valve opens at a pressure of 210 to
215 bar (214 to 219 kg/cm2). If valve setting is not
to specification, the best thing to do is to replace the
valve. In case of need, however, it is possible to
adjust valve setting through the threaded plug
using the spanner tool no. 291862. Tighten the
fitting to increase the valve setting value, loosen to
decrease.
22. Reassemble control valve observing the following:
-- Re--assembly follows the disassembly
procedure in reverse, from step 21 back to step
1.
-- Refer to figures on page 8 for correct
orientation of the different parts.
-- Tighten to correct torques as detailed on
page 3.

35- 43
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
MAX HEIGHT ADJUSTMENT (WITH THE LIFT
IN THE TRACTOR)
Max height adjustment can be performed with either
the lift on a work bench or still in the tractor.
With the lift on a bench, refer to that detailed on page
28.
With the lift installed in the tractor, proceed as follows:
1. Detach the control valve housing from the lift as
detailed on page 37. Assemble tool no. 293979 at
its place.

2. Move the position control lever (1) fully backward

on the quadrant.
3. Manually fully raise lift arms.

17
4. Check that the face of rod (2) is exactly aligned with
the internal reference face of tool no. 293979 (1).
If not, turn the adjust screw using the spanner tool
no. 293978 (3).

35- 44
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
DROP RATE ADJUSTMENT
Proceed as follows:
1. Apply a load of 1630 to 2150 kg to the lower link ball
ends.
2. Bring system oil to a temperature of 30° to 40°C.
3. Remove the protective cap from the control valve
housing.
4. Release the locknut and using a screwdriver, turn
the adjust pin (1) in to increase the drop rate, or out
to decrease.
5. Once the required drop rate has been obtained,
tighten the lock nut and re--assemble the protective
cap. 1

OIL FILTER

Replacement (Op. 35 100 06)

Proceed as follows:
1. Loosen the screw (1) to allow oil to dump from the
oil filter to the axle housing.
2. Loosen the screws (3) and remove cover (2).
3. Slide out the filter paper cartridge located inside the
filter body.
4. Insert a new cartridge, install cover (2) and tighten
the screws (3 and 1).

35- 45
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5
LIFT PRESSURE REGULATING VALVE

Removal--Installation (Op. 35 114 30)

The lift pressure regulating valve (high pressure circuit
relief valve) is located between the oil supply tube and
hydraulic pump.
If faulty, remove and replace the valve.

LIFT PRESSURE REGULATING VALVE

Setting (Op. 35 114 32)

Proceed as follows: 1
1. Run the engine until oil reaches a temperature of
approximately 50°C.
2. Insert fitting tool no. 293449 (1) into a remote valve
coupler and connect to a 0 to 250 bar pressure
gauge from test kit no. 292870.
3. Move and hold the remote valve lever until the
pressure regulating valve operates.
4. With the engine running at medium speed, the
pressure gauge should read approx. 186 to 191 bar
(190 to 195 kg/cm2). If the valve setting is not to
specification, the best thing to do is to replace the
valve. In case of need, however, it is possible to
adjust valve setting through the threaded plug
using the spanner tool no. 291863. Tighten the 1
threaded plug to increase valve setting, loosen to
decrease.
NOTE: The pressure regulating valve setting can also
be checked as a bench test, as follows:
5. Mount the pressure regulating valve (1) on the test
fitting tool no. 290824 (2) and connect fitting to the
hand pump tool no. 290284 (3).
6. Prime the hand pump (3) and check that the
pressure regulating valve opens at a pressure of
approximately 186 to 191 bar.
NOTE: The pressure regulating valve is set with oil flow
in production. Consequently, the test performed using
the hand pump tool no. 290284 should be considered
as indicative only. Therefore, we advise to test the
pressure regulating valve setting with the valve
installed in the tractor, as previously described.

1
35- 46
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 6 -- Closed Centre Remote Control Valves

CONTENTS

Section Description Page

35 000 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Flow In Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Flow in Raising (Cylinder Extend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Flow in Lowering (Cylinder Retract) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil Flow in Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation of Detent Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation of Two or More Control Valves Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fault Finding and Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Individual Valve Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Complete Valve Stack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remote Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
SPECIAL TOOLS
Flowmeter 0--200 ltrs/min Procure Locally
SPECIFICATIONS
Remote Valve Output 90 ltrs/min. @ 100bar@2200erpm
Detent Regulating Valve Pressure Pre set non adjustable

TORQUES

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
DESCRIPTION AND OPERATION
Closed centre remote control valves (1) are installed
on all tractors with a closed centre load sensing
variable displacement hydraulic pump.

NOTE: On closed centre remote installations the

upper port of the valve is the cylinder retract port and
the lower port is the cylinder extend port. This is
OPPOSITE to the remote valves installed on previous
New Holland tractors.
Up to four remote control valves may be installed and
each operating lever is colour coded for identification:
2
Lever Colour Valve Position/No.
Green Right--hand outer -- I
Blue Right--hand inner -- II
Ginger Left--hand inner -- III
Black Left--hand outer -- IIII

Each remote valve has four operating positions.

Raise (R) -- Pull a lever toward you to extend the

cylinder to which it is connected.

Neutral (N) -- Push the lever forward to select neutral 3

and de-activate the connected cylinder.

Lower (L) -- Push the lever forward, past neutral, to

retract the cylinder.

Float (F) -- Push the lever fully forward, beyond the

‘lower’ position, to select ‘float’. This will permit the
cylinder to extend or retract freely, allowing equipment
such as scraper blades to ‘float’ or follow the ground
contour.
When four remote control valves are specified, an
alternative joystick control may be fitted to operate
remote control valves III and IIII. The joystick,
located at the front of the right-hand console,
operates in a cross pattern. The joystick has the
added advantage of being able to operate two
remote control valves simultaneously by moving the
lever diagonally between valve No. III and No. IIII
positions.

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
The remote valves (1) are a stack type design clamped
together with the hydraulic lift electronic draft control
valve (2).

6
Electronic Draft Control and Closed Centre Remote Control Valve Stack
1. Remote Control Valve No I 7. Manifold Block
2. Remote Control Valve No II 8. Return to Reservoir
3. Electronic Draft Control Valve 9. To Hydraulic Lift
4. Remote Control Valve No III 10. Load Sensing Line Connection
5. Remote Control Valve No IIII 11. End Cover
6. Inlet Port

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

7
Remote Control Valve and EDC Control Valve Interconnecting Galleries

Pump Pressure Return To Reservoir

Load Sensing
1. Parallel Supply Gallery 3. Return to Reservoir
2. Load sensing Gallery

All valve sections have a common parallel inlet and

return to reservoir gallery.

The load sensing gallery passes through the centre of

the valve stack and signals the pump to increase or
decrease output according to demand.

The parallel gallery and load sensing system enables

two or more valves to be operated simultaneously
without loss of efficiency.

‘O’ ring seals (1) and load sense check valves (2)
between each valve section ensure the highest circuit
load sense pressure is transmitted to control output of
8
the hydraulic pump. 8

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
The principal hydraulic components within each backwards and the load to momentarily drop before
remote control valve section are:-- pump system pressure has risen to hold and then raise
the load further. The load hold check valve prevents
this situation from occurring.
Flow Control Adjuster
The flow control adjuster is manually operated and Lock Valve
adjusts oil flow through the remote valve. Turning the
adjuster changes the size of the restriction in the path The lock valve is located in the raise port of the remote
of oil flowing through the flow control spool. valve and is closed whenever the remote valve is in
neutral. The lock valve prevents leakdown of an
implement should there be any leakage across the
Flow Control Spool lands of the spool when in the neutral position. The lock
valve is automatically opened whenever the control
The flow control valve spool senses pressure spool is moved from the neutral position.
differential across the restriction set by the flow control
adjuster and regulates flow through the remote valve.
Because each flow control spool individually senses Control Valve Spool
the pressure differential in the remote valve being
operated, two or more circuits working at different The control valve spool is spring centred to a neutral
pressures can be controlled simultaneously. position and when moved directs oil flow to the raise or
lower ports of the control valve.

Load Hold Check Valve

Spool Centering and Detent Mechanism
The check valve prevents a backflow of pressure from
the remote valve circuit when the control spool is The spool centering mechanism spring loads the
operated and pump system pressure is less than the control valve spool to the neutral position. When the
backpressure in the circuit. spool is moved to the Raise, Lower or Float positions
the mechanism holds the spool in position using ball
This is explained by the following example:-- bearings which engage in grooves within a detent
cage.
When a cylinder is holding a heavy load and the control
valve spool is moved from the neutral to raise position, A factory set detent regulating valve in the mechanism
the pump system pressure may be less than the back automatically releases the balls and returns the spool
pressure in the remote valve circuit. When this occurs to neutral whenever operating pressure exceeds the
the back pressure would cause oil in the circuit to flow preset value.

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

9
Closed Centre Remote Control Valve Components
1. Flow Control Adjuster 4. Control Valve Spool
2. Flow Control Spool 5. Load Holding Check Valve
3. Check Valve 6. Spool Centering Mechanism
--

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OIL FLOW IN NEUTRAL
When the remote valves are in neutral the control valve The galleries to the raise and lower ports are blocked
spool is held in the central position by the centering by the lands on the main control spool.
spring.
The pin on the lock valve is positioned in the waisted
Oil flow from the parallel gallery (A) to the raise and section of the spool allowing the valve to be spring
lower ports is blocked by the lands of the main control loaded into the closed position preventing an extended
spool. cylinder retracting under load should there be a slight
leakage in the main spool.
Gallery ‘C’ and load sensing gallery ‘D’ are vented to
reservoir through galley ‘G’.

Figure 10
Single Remote Control Valve Operation--Neutral
1. Flow Control Adjuster 7. Lock Valve
2. Metering Land 8. Raise (Cylinder Extend) Port
3. Flow Control Spool 9. Lower (Cylinder Retract) Port
4. Load Hold Check Valve 10. Spool Centering and Detent Mechanism
5. Main Control Spool 11. Manually Adjusted Flow Control Restriction
6. Pin

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Single Remote Control Valve Operation--Neutral 10

Pump Pressure Return to Reservoir

Trapped Oil

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OIL FLOW IN RAISING (CYLINDER EXTEND)
When the remote valve lever is moved to the raise If the load hold check valve (4) was not installed the
position the control spool moves to the left and the situation could occur where pump pressure is
spring loaded detent balls engage with the left hand insufficient to support the load in the raise port when
groove in the detent mechanism (10). the remote valve is moved from neutral to raise
condition. Under this situation the load would
Moving the spool to the raise position causes the pin momentarily drop until pump pressure was sufficient to
(6) on the lock valve to ride up the ramp of the spool and support the load.
hold the valve in the open position.
The rate of flow through the remote control valve is
Gallery ‘B’ is now open to gallery ‘C’ and gallery ‘E’ is adjusted by the manual flow control knob (1), which
open to gallery ‘F’. manually changes the size of restriction (11).

The flow from gallery ‘C’ is blocked by the load hold To maintain set flow through the remotes under all
check valve ball (4) until pressure in the gallery is conditions with varying pump inlet pressure in parallel
sufficient to lift the ball of its seat against the back gallery ‘A’ the flow control spool senses the differential
pressure in the lift port gallery ‘E’. pressure across the manually adjusted flow control
restriction (11) between galleries ‘A’ and ‘B’.
Oil can flow from:--
The differential pressure sensed on each end of the
Gallery ‘C’ past the load hold check valve into spool causes the spool to move to a new state of
Gallery ‘E’. equilibrium and continually regulates the flow across
the spool metering lands (2) to maintain a constant flow
Across the flat on the main control spool to Gallery through the manual flow control restriction (11)
‘F’. irrespective of pressure in other hydraulic circuits.
Through the lock valve (7).
Out through the raise port (8) of the remote valve. The pressure in gallery ‘C’ is also transmitted down the
load sensing gallery ‘D’ to the flow compensating valve
Exhaust oil from the extending cylinder returns through of the variable flow piston pump where pump output is
the lowering port and gallery (H), around the land on regulated according to circuit demand.
the main control spool and back to reservoir via the
common gallery ‘G’.

Figure 11
Single Remote Control Valve Operation--Raising (Cylinder Extend)
1. Flow Control Adjuster 7. Lock Valve
2. Metering Land 8. Raise (Cylinder Extend) Port
3. Flow Control Spool 9. Lower (Cylinder Retract) Port
4. Load Hold Check Valve 10. Spool Centering and Detent Mechanism
5. Main Control Spool 11. Manually Adjusted Flow Control Restriction
6. Pin

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Single Remote Control Valve Operation--Raising (Cylinder Extend)

Pump Pressure Return to Reservoir

Remote Valve Operating Pressure

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OIL FLOW IN LOWERING (CYLINDER RETRACT)
When the remote valve lever is moved to the lower back pressure in gallery ‘E’. When the load hold check
position the control spool moves to the right and the valve ball lifts of the seat oil flows into gallery ‘H’, round
spring loaded detent balls engage with the middle the control valve spool to gallery ‘G’ and out through
groove in the detent mechanism. the lowering port of the remote valve coupling.

In a similar manner as for the raise cycle of the remote Exhaust oil from the Retracting cylinder returns to
valve the position of the spool causes the pin on the reservoir gallery ‘G’ though the raising port and lock
lock valve to hold the valve in the open position. valve (7).

Gallery ‘B’ is now open to gallery ‘C’ and gallery ‘E’ is Pump output and system pressure will continually
open to gallery ‘H’. react to the maximum demand of the tractor high
pressure hydraulic circuits as sensed through the load
Oil from the parallel gallery ‘A’ flows past the flow sensing lines.
control valve spool and restrictor (2) into gallery ‘C’ and
the load sensing gallery ‘D’. Flow through the remotes is controlled in exactly the
same manner as described in the ‘Oil Flow In Raising’
The load hold check valve ball (4) remains closed until section by sensing differential pressure across
pump system pressure is sufficient to overcome the manually flow control restriction (11).

Figure 12
Single Remote Control Valve Operation--Lowering (Cylinder Retract)
1. Flow Control Adjuster 7. Lock Valve
2. Metering Land 8. Raise (Cylinder Extend) Port
3. Flow Control Spool 9. Lower (Cylinder Retract) Port
4. Load Hold Check Valve 10. Spool Centering and Detent Mechanism
5. Main Control Spool 11. Manually Adjusted Flow Control Restriction
6. Pin

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Single Remote Control Valve Operation--Lowering (Cylinder Retract) 12

Pump Pressure Return to Reservoir

Remote Valve Operating Pressure

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OIL FLOW IN FLOAT
The float position allows the free flow of oil from both The position of the spool causes the pin (7) on the lock
the raise and lower ports of the remote valve permitting valve to hold the valve in the open position.
the cylinder to extend or retract freely. This feature is
particularly useful to allow equipment such as scraper The raise and lower ports of the remote valve are open
blades to ‘float’ or follow the ground contour. to reservoir gallery ‘G’ allowing a free flow of oil from
one port of the cylinder to the other.
When the remote valve lever is pushed fully forward to
the float position the spool is moved fully to the right Should a void occur in the circuit oil will be drawn by
and the spring loaded detent balls (10) engage with the suction from one side of the cylinder to the other.
right hand groove in the detent mechanism.

Oil flow from the gallery (B) to the raise and lower ports
is blocked by the lands of the spool.

Figure 13
Single Remote Control Valve Operation--Float
1. Flow Control Adjuster 7. Lock Valve
2. Metering Land 8. Raise (Cylinder Extend) Port
3. Flow Control Spool 9. Lower (Cylinder Retract) Port
4. Load Hold Check Valve 10. Spool Centering and Detent Mechanism
5. Main Control Spool 11. Manually Adjusted Flow Control Restriction
6. Pin

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Single Remote Control Valve Operation--Float 13

Pump Pressure Return to Reservoir

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OPERATION OF DETENT PRESSURE REGULATING VALVE
Under normal operating conditions excessive When the control valve spool is moved to the raise or
pressures in the remote circuits are protected by the lower position the detent balls of the spool centering
detent pressure regulating valve which returns the and detent mechanism (1) are held in detents by the
control valve spool to neutral when the operating tapered face of the spring loaded plunger .
pressure of the cylinder exceeds the factory preset
value. In the raise or lower condition the operating pressure of
the remote valve circuit is also sensed in the centre
If the remote valve control lever is physically held by drilling of the spool through the small radial drillings (2).
the operator to prevent the spool returning to neutral As pressure increases a force is applied to the small
the maximum operating pressure is restricted to a ball (4) in the end of the spool (3) which pushes the
maximum of 200 bar by the pressure compensating detent regulating valve piston (5) and spring loaded
valve in the closed centre load sensing (CCLS) plunger (6) to the left. The detent balls in the centering
hydraulic pump. mechanism are no longer held in the detent by the
tapered face of the spring loaded plunger and the
Operation of the detent regulating valve is as follows:-- centering spring moves the spool to neutral.

Figure 14
Operation of Detent Pressure Regulating Valve
1. Spool Centering and Detent Mechanism 5. Detent Piston
2. Radial Drillings 6. Spring Loaded Plunger
3. Main Control Spool 7. Detent Balls
4. Ball

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Operation of Detent Pressure Regulating Valve 14

Remote Valve Pressure @ 200 bar Return to Reservoir

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
FAULT FINDING AND PRESSURE TESTING
Remote Control Valves Not Working
Is hydraulic lift NO Refer to fault finding chart
working? for hydraulic lift not working
YES
Operate all remote valve
Operate and hold control lever to levers simultaneously
Test maximum system pressure at Is the pressure at the Overhaul remote
each remote valve coupler. NO defective remote valve NO control valve(s) which
Are pressures at each valve now 200--207 bar fail pressure test
coupler below 200--207 bar (2900--3000 lbf/in 2)?
(2900--3000 lbf/in 2)?
YES
YES
Examine load sensing valve
Examine flow/pressure between remote valve
compensating valve for sticking sections.
Fault cleared?

Remote Valve Flow Test

1. Install flow meter between inlet ports of remote
valves I and II.
2. Set flow control knobs to maximum flow.

17
3. Ensure load valve on flow meter is fully ‘Open’.
4. Set tractor engine speed to 1100 rev/min.
5. Set remote valve No 2 in ‘Float’ position and
remote valve No 1 in ‘Extend’ position.

TIA35086
18
6. Adjust load on flow meter to a of pressure of
100bar.
7. If a flow of 45 ltr/min is recorded output from the
remote valves is to specification.
NOTE: This test is performed at half maximum rated
speed and assumes that flow at rated speed is twice
that measured in the test. Performing the test at 2200
rev/min will give an output of 90 ltr/min.
8. Use same principal to check flow through other
remote valves.

35- 21
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
OVERHAUL

(Op. 35 204 40)

NOTE: Individual remote valve assemblies can be
removed from the tractor without the need to remove
the complete valve stack

Remote Valve Sections 1 and 2

Removal
9. Manufacture three guide pins as shown from 8mm
mild steel rod. Taper end of rod and cut screwdriver
slot as shown in inset.
19
10. Lower hydraulic links and thoroughly clean remote
valve stack.
11. Disconnect control cables at rear of remote valves.

20
12. To aid re--assembly draw a diagonal line across the
valve stack.

21
13. Remove a clamping bolt and install guide pin made
in step 1.
NOTE: The valve stack is very heavy DO NOT attempt
to remove valves without the use of guide pins.
14. Repeat procedure for remaining two clamp bolts.

22
15. Remove end plate and valve assemblies.

35- 22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
Installation
1. Install using removal procedure in reverse.

23
Remote valves 3 and 4
Removal
1. Install guide pins using same procedure as for
remote valves 1 and 2.
NOTE: Small shims (1) are positioned between the
manifold (2) and remote valve number 3 (3). Take care
when installing guide pins not to damage the shims.
2. Remove end plate and valve assemblies.

24
Installation
1. Apply petroleum jelly to the shims (1) and position
on each guide pin.

Ensure load sense check valve (2), spring (3) and

‘O’ rings (4) are located in manifold block.

25
2. Install remote valves and end cap

35- 23
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
3. To prevent shims from moving out of position use
hand pressure to clamp valve stack together while
removing each guide pin and installing clamp bolt.

27
4. Tighten clamp bolts to 30Nm in sequence 1,2,3.

28
Removal and Installation--
Complete Valve Stack
1. Steam clean remote control valve assembly prior
to removal.
2. Lower hydraulic links.
3. Remove covers on remote valve couplers.

29
4. Remove trailer socket (1) and disconnect electrical
connections to each electronic draft control
solenoid (2).

35- 24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
5. Disconnect remote valve control linkage.

31
6. Remove load sense line (2) and disconnect
hydraulic pipes (1) at rear of remote valve stack.

32
7. Using suitable lifting equipment support remote
valve assembly, remove base securing bolts and
lift valve stack from tractor.
8. Retrieve ‘O’ ring (1)

33
9. Installation follows removal procedure in reverse.
Tighten retaining bolts to torque of 43Nm.

35- 25
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
REMOTE VALVE DISASSEMBLY

35
Closed Centre Remote Control Valve Components
1. Flow Control Adjuster 4. Control Valve Spool
2. Flow Control Spool 5. Load Holding Check Valve
3. Check Valve 6. Spool Centring Mechanism
--

1. Disassemble using following instructions and

illustrations.
2. Remove ‘O’ ring (1) and load sense check valve
(2).
3. Remove flow control adjuster knob and unscrew
flow control adjuster from valve body

35- 26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

37
Remote Valve and Coupler Housing
1. Valve Section 4. Coupler Housing
2. ‘O’ Ring 5. Seat
3. Coupler 6. ‘O’ Ring

4. The couplers are serviced as an assembly and

should not be disassembled.

5. Remove spool.
NOTE: Prior to removing spool ensure flats(1) on end
of spool are in vertical position as shown. If it is
necessary to rotate spool Do not use force otherwise
damage to spool and load check valve pin will occur.

35- 27
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
6. Remove load holding valve from raise port as
follows:--
Using small screwdriver, open the two slots (1) on
keeper (2) and turn keeper through 90 deg.
Remove spring seat (3) from housing
Remove load check valve and plunger

40
Load Check Valve
1. Plunger 5. Washer
2. Load Holding Valve 6. Spring
3. Ball 7. Spring Seat
4. Spring 8. Keeper

35- 28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
7. Carefully remove flow control valve plug.
WARNING
A large spring (1) is positioned beneath the plug, take
extreme care when removing plug.

42
Flow Control Spool and Check Valve
1. Flow Control Spool 7. Retainer
2. Retainer 8. Plug
3. Spring 9. Back--up Ring
4. Spring Guide 10. ‘O’ Ring
5. Plug and ‘O’ Ring 11. Spring
6. Plastic Cap 12. Check Valve Ball

35- 29
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

43
Control Valve Spool
1. End Cap 8. Spacer
2. ‘O’ Ring 9. Back--Up Ring
3. Shims 10. Detent Release Orifice
4. Spool Centring Mechanism 11. Ball
5. Spool 12. Plunger
6. ‘O’ Ring 13. Spring
7. ‘O’ Ring 14. Spring Seat

8. Remove control valve spool by unscrewing the should be restricted to washing in an approved
spool centring mechanism. It is not recommended degreasing agent without removing the orifice from
that the mechanism is disassembled. within the spool.
9. Housed within the centre of the spool is the detent
release orifice. This is factory preset and servicing

35- 30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6
Re--Assembly
1. Re--assembly follows the disassembly procedure
in reverse. Install the load holding valve prior to
installing control valve spool.
2. Prior to inserting control valve spool in housing
ensure flats (1) on end of spool are in vertical
position as shown. Do Not rotate spool once
inserted into bore otherwise damage to spool and
load holding valve plunger will occur.

35- 31
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

35- 32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 7 -- Open Centre Remote Control Valves

CONTENTS

Section Description Page

35 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- SPECIAL TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION

SPECIFICATIONS
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full--flow, paper cartridge (same filter as for
the hydraulic lift circuit)
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear--type (same pump feeding the hydraulic
lift circuit, see Chapter 3)
Remote Control Valves
Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular pack (4 valves max.)
Secured to the top of lift cover
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operated by hand levers
190 --195 (194 --199 kg/cm2)
Double acting convertible to single acting
Pressure regulating valve adjustment . . . . . . . . . bar Double acting to single acting with automatic
release
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting with float and automatic release

TIGHTENING TORQUES
Remote control valves
Screws, remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10 x 1.25 127 13

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
SPECIAL TOOLS
CAUTION
Operations described in this Section of the Manual
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
To work safely and achieve the best technical results
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated
with the Dealer made tools for which you will find the
necessary construction drawings and specifications
directly on this Manual.

List of special tools necessary to carry out the different

operations described in this Section.

292870 Pressure test kit

294039 (X) Flow control adjuster adjustment tool

293195 Kontak one--way valve seal protection

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

a b

24447
c
1
Sectional Views -- Remote Control Valve

A. Remote control valve for double--acting cylinder 15. Cover

B. Remote control valve for single--acting cylinder 16. Spacer
C. Double--acting remote control valve with float 17. Taper pin
and automatic release 18. Seal
1. Single to double acting switching valve 19. Spring
2. Seal 20. Detent balls
3. Valve retaining cap 21. Ball support
4. Seal 22. Seal
5. Seal 23. Inner pin
6. Check valve seat 24. Spring
7. Check valve 25. Cover
8. Control support 26. Release pressure adjusting screw
9. Valve control spool 27. Valve spool return spring
10. Seal 28. Retainer
11. Seal 29. Seal
12. Seal 30. Seal
13. Retainer 31. Ball seat body
14. Valve spool return spring

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

2
Sectional View -- Flow Control Adjuster

1. Control pin knob 8. Seal

2. Control pin 9. Plug
3. Snap ring 10. Control pin support plug
4. Seal 11. Spring pin
5. Seal 12. Tabbed bush
6. Flow control valve 13. Flow control adjuster body
7. Spring

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
Sectional View -- Trailer Brake Release Pressure
Regulating Valve

1. Inlet
2. Valve
3. Valve body
4. Seal
5. Spring
6. Outlet

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
DESCRIPTION AND OPERATION position will select the float position. The cylinder
The remote control valves are used to control external extends or retracts freely, allowing implements
hydraulic implements connected to the tractor. such as loaders to adapt to the ground profile.
Tractors may be equipped with up to 4 remote control If four remote control valves are fitted, it is possible to
valves, which are secured to the upper side of the lift install an alternative joy--stick control replacing control
housing. levers for remote valves I and II. Raise, Neutral, Lower
and, only for valve I, Float.
The remote valves are operated by means of control
levers located at the operator’s right side. Moving the joystick rearward or forward will raise or
lower the implement connected to remote control valve
Each lever and corresponding valve are colour coded, I. If the joystick is pushed still forward, beyond the lower
as follows: position, the valve reaches the floating position.
Lever Colour Valve Location and No. Moving the joystick towards the left or right will raise or
lower the implement connected to remote control valve
Green external, RH -I II. The floating position is not available for remote
Blue internal, RH -II control valve II.
The joystick control has the advantage of activating two
Brown internal, LH -III
remote control valves at the same time by toggling the
Black external, LH -III lever through positions for remote control valves I and
I II.
Tractors fitted with 4 remote control valves are
Each remote valve control lever has three or four equipped with a flow control adjuster which is located
positions, as required by the type of valve controlled. between valve I and valve II.
1. Raise -- Pulling the lever towards the operator will The flow control adjuster varies the oil flow to cylinder
extend the cylinder and raise the implement. I. The control knob should be turned anticlockwise to
2. Neutral -- Pushing the lever from the operator and reduce the flow, clockwise to increase it.
away from the raise position will select the neutral If the oil flow to valve I is increased, the amount of oil
position and deactivate the cylinder connected. available for remaining valves and the hydraulic lift will
3. Lower -- Pushing the lever farther from the be reduced.
operator, beyond the neutral position, will retract Refer to page 7 for detailed operation of the hydraulic
the cylinder and lower the implement. remote valves.
4. Float (valves I and III only) -- Pushing the lever still
farther from the operator and beyond the lower

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
SCHEMATICS -- OPERATING PHASES OF A REMOTE CONTROL VALVE CONTROLLING A
DOUBLE -- OR SINGLE--ACTING CYLINDER (FIGURES 4 & 5 AND 6 &7, RESPECTIVELY)

4. RAISE -- When the cab control lever is pulled, the

valve spool (2) moves and allows the oil to flow from the
supply passage (E) to the cylinder lower chamber
through the check valve (3) and passage (G) and from
the cylinder upper chamber to the exhaust passage (L)
through the passage (H), deviating the oil supply
directed to the hydraulic lift valve. If the lever is kept
pulled, full raise is achieved when the cylinder has
reached the end of its stroke. Once released, the lever
automatically moves back to the neutral position under
the action of the return spring and all the oil flow from
the pump is sent to the lift valve through the passages
(M).

4
5. LOWER -- To lower the implement, it is necessary to
push the cab control lever. The valve spool (2) moves
to the position shown in Figure 5 and allows oil trapped
into the cylinder lower chamber to dump into the
exhaust passage (L) through the passage (G) while
upper chamber opens to the supply passage (E)
through the passage (H) and check valve (3).

5
6. RAISE -- When the cab control lever is pulled, the
valve spool (2) moves and allows oil to flow from the
supply passage (E) to the cylinder through the check
valve (3) and passage (G). Passage (H), which is in use
when controlling double--acting cylinders, is left
unused now and remains permanently connected to
the exhaust passage (L) through the switching valve
(1) opening.

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
7. LOWER -- When the cab control lever is pushed, the
valve spool (2) moves to the position shown in figure 7.
Oil trapped in the cylinder, under the weight of the
implement raised, flows to the exhaust passage (L)
through the passage (G) while all oil flowing from the
pump is sent to the exhaust passage (L) through the
check valve (3) and passage (H).
Pressure oil
Suction, delivery or exhaust oil
Trapped oil
NOTE: Fully tighten screw (1) to control a
double--acting cylinder; unscrew to control a
single--acting cylinder.
7

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
SCHEMATICS -- OPERATING PHASES OF A REMOTE CONTROL VALVE CONTROLLING A
DOUBLE--ACTING CYLINDER WITH AUTOMATIC RELEASE
Pressure oil
Suction, delivery or exhaust oil
Trapped oil

RAISE

When the cab control lever is pulled, the valve spool (2) 178 kg/cm2) and through the drilling (V) overcomes the
moves and the balls (26) enter the left--hand seat action of the tapered pin spring (23). Within the
where they remain trapped by the support (28) and chamber (T), oil pressure against the support (28)
spring (24). Spool (2) movement allows oil to flow from increases until it overcomes the spring force and
the supply passage (E) to the cylinder lower chamber moves the support (28) back . As a consequence, the
through the check valve (3) and passage (G) and from two balls (26) fall on the support (38) releasing the
the cylinder upper chamber to the exhaust passage (L) spool (2), that, under the action of the spring (6),
through the passage (H), deviating the oil supply returns to the neutral position. Consequently, all oil
directed to the hydraulic lift valve. Upon full raise, oil flowing from the pump is sent to the lift valve through
pressure increases reaching 170 to 175 bar (173 to the passages (M).

9
LOWER
To lower the implement, it is necessary to move the cab the passage (G) while the upper chamber opens to the
control lever forward. The valve spool (2) moves and supply passage (E) through the passage (H) and the
the balls (26) enter the central seat where they remain check valve (3). When the implement is fully lowered
trapped by the support (28) and spring (24). This , automatic release will take place, as previously
condition allows oil trapped into the cylinder lower described.
chamber to dump to the exhaust passage (L) through

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
SCHEMATICS -- OPERATING PHASES OF A REMOTE CONTROL VALVE CONTROLLING A
DOUBLE ACTING CYLINDER WITH AUTOMATIC RELEASE AND FLOAT

Suction, delivery or exhaust oil

Trapped oil

FLOAT

To engage float of the valve, the cab control lever lower chambers, respectively, through the passages
should be pushed fully forward. The valve spool (2) (H and G). Under these conditions, the implement
moves and the balls (26) enter the right--hand seat connected rests on the ground with its weight and can
where they remain trapped by the support and spring adapt to the ground profile allowing use of the hydraulic
(24). With the spool (2) in this position, the path is open lift. When floating, the automatic release cannot take
between the two passages (M) which send all oil place as there is no pressure inside the remote control
flowing from the pump to the lift valve and between the valve.
two exhaust passages (L) and the cylinder upper and

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
REMOTE CONTROL VALVE ASSEMBLY

Removal -- Installation (Op. 35 204 40)

WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

Remove the remote control valves from the hydraulic

lift as follows:
1. Open and raise engine hood.
2. Disconnect negative cable (1) from battery and
insulate.
3. Remove the top link rod.

1
4. Loosen the retaining screw and remove the flow
adjuster control knob (1).

2
5. Loosen the retaining screws and remove the
remote valve protection cover (1).

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
6. Disconnect remote valve supply and exhaust lines
(2 and 1).

4
7. Slide out the cotter pins (1) and disconnect control
cables from respective remote valves.

5
8. Loosen the retaining screws and remove the
remote control valve assembly.
9. Reinstallation of the remote control valves follows
the removal procedure in reverse

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
REMOTE CONTROL VALVE ASSEMBLY
(removed)

Disassembly--Assembly (Op. 35 204 46)

WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Convertible single to double acting remote

control valve
Disassemble the different components of the remote
control valve making reference to sectional views on 3 4 5
page 3 and observe the following: 1 2
1. Detach cover (5), retrieve spring (4) and retainer.
2. Slide out the valve spool (3).
3. Detach the control lever support (1) and retrieve
seal (2).
24452 8 7 6
4. Loosen the plug (6) and retrieve the single to
double acting switching valve (7).
5. Withdraw the valve seat (8) and retrieve the check
valve and spring. 1
6. Check seals for damages before re--assembly.

Double--acting remote control valve with float

and automatic release
Disassemble the different components of the remote 1 2 3 4
control valve making reference to sectional views on
page 3 and observe the following:
1. Loosen retaining screws, retrieve cover (4) and
spacer (3).
2. Loosen retaining screws and retrieve the control
lever support (1) and seal (2).

24453

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
3. Slide out valve spool (1).
4. Withdraw the valve seat and retrieve the check
valve and spring. 1
5. Check seals for damages before re--assembly.

24454

Valve Control Spool Sticking Test (Figures 4 and

5)
3
NOTE: Using a test equipment filled with oil
HYDROSYSTEM 66, the following tests should be
performed with a temperature of approximately 60°C
and a flow of 12.5 L/min, which can be obtained by
turning the electrical motor to the highest speed (1450
rpm).
Connect the remote control valve assembly to be
tested to the test equipment as shown (Figures 4 and
5) and observe the following:
-- Double--acting valves (Fig. 4): the two ports for oil
supply to the implement cylinder should be
connected to the ball connector (3) using
respective lines (2) and banjo fittings (1).
4
-- Single--acting valves (Fig. 5): the return passage
(2) should be connected to the port for cylinder oil
supply of the remote valve being tested through the
banjo fitting (1) (the hole is located on the opposite
side to the switching valve).
After connecting the items as shown in the schematics,
test the remote control valve as follows:
-- Start the hydraulic pump and move the valve spool
hand control lever (in both directions for
double--acting valves).
-- Gradually increase pressure by turning the flow
test equipment handwheel. Check that pressure is
172 bar (175 kg/cm2) on the test equipment
pressure gauge. Under these conditions, the 5
control spool of the valve being tested should slide
normally and return freely to the neutral position as
the control lever is released.

Schematic for the installation of testing

equipment and accessories for control spool
sticking test on double--acting (Fig. 4) and
single--acting (5) valves.
-- Repeat the test on all remaining valves after
carrying out connections as required.

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
Schematics for installation of testing equipment
and accessories for valve spool leak test

Remote Control Valve Leak Test

Connect the remote control valve assembly to be
tested to the test equipment as shown in the
schematics (Figure 6). Consider that the T fitting (1)
should be connected to single-- or double--acting
valves using adequate reductions.
After connecting items as shown in the schematics,
perform the test as follows:
-- Start the hydraulic pump and gradually increase
pressure by turning the flow test equipment
handwheel and check on the test equipment 6
pressure gauge that pressure is 147 bar (150
kg/cm2).
-- Collect leak oil coming out from fitting (2) into the
graded bottle for one minute exactly. It should not
exceed 25 cm3/min for a new valve or 60 cm3/min
for a worn valve.
Repeat on all valves, testing alternatively either supply
passage to the respective implement cylinder.

AUTOMATIC RELEASE PRESSURE

ADJUSTMENT
Connect the remote valve to the test equipment.
Start the hydraulic pump and tighten the release
pressure adjusting screw (26, page 3) until obtaining a
pressure of 170 to 175 bar (173 to 178 kg/cm2).
Lock the screw (26) by tightening the locknut.

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
FLOW CONTROL ADJUSTER
Disassembly -- Assembly (Op. 35 204 46)
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

WARNING
Always use suitable tools to align holes. DO NOT USE
1
HANDS OR FINGERS.

Proceed as follows: 2
1. Remove the snap ring, raise the Tabbed bush (2),
3
loosen the control pin (1) and remove the pin (1)
seat (3).

24455

1
2. Loosen the plug (3) and retrieve the spring (2) and
valve (1).
1 2

2
3. Check seals (1, 2 and 3) for damages before
re--assembly.

1 2 3

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
FLOW CONTROL ADJUSTER
Flow--rate Adjustment (on the tractor)
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protective clothing, including goggles, gloves
and footwear.

WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

Adjustment should be carried out with the engine shut

off.

Proceed as follows:
1. Loosen the retaining screw and retrieve the flow
adjuster control knob (1).

4
2. Loosen the retaining screws and remove the
remote valve protection cover (1).

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
3. Drive out the snap ring (1). 24458

24458

6
4. Slide out the tabbed bush (3) and screw in the
control pin. Do not force. Install the bush with the
right hand side of the tab touching the stop pin (2).
if necessary slightly turn the control pin (1) to obtain
contact.
2
1

24462

7
5. Instal tool no. 294039 (2) over the control pin and
position tool so that it touches the opposite side of
1
the stop pin to that which the tab on the bush is
contacting (1) Fig. 4).

24463

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
6. Unscrew the control pin (1) until the tab on the bush
(3, Fig. 4) now touches the edge of tool no. 294039
(2).
7. Without moving the control pin (1), withdraw tool 1
no. 294039 (2) and tabbed bush (3, Fig. 4).
Re--install the tabbed bush, but this time with the
left hand side of the tab touching the pin.
8. Install the snap ring (1, page 24, Fig. 3).
9. Install the protection cover (1, page 24, Fig. 2) and 2
tighten retaining screws.
10. Fit the knob so that when the control pin (1) is fully
unscrewed the pointer is in the “max” zone and
24464
when screwed in is in the “min” zone. (Check that
when turning the knob to the min position the 9
pointer is between the 18° to 27° angle indicated on
page 3). Lock using the setscrew.
NOTE: The flow rate adjustment should be considered Flow from pump to Flow to be obtained at
as indicative only. For perfect adjustment, it is flow control adjuster the flow control adjuster
necessary to perform bench hydraulic setting outlet
considering the following: (l/min)
Test oil AMBRA MULTI G at a temperature of 50°C. l/min)
Connect the flow control adjuster to the pump, screw
in the control pin until it bottoms.. Do not force. 25 7 -- 8
Unscrew the control pin until obtaining a flow 30 7,2 -- 8,2
corresponding to data in the table coming out from the
35 7,3 -- 8,3
right--hand side outlet (looking at the flow control
adjuster from the plug (9, page 3) side). 40 7,4 -- 8,4
45 7,6 -- 8,6
50 7,8 -- 8,8
55 8 -- 9

35- 19
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7
NOTES

35- 20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 8 -- Trailer Brake Auxiliary Valve

CONTENTS

Section Description Page

35 000 Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Trailer Brake Auxiliary Valve Sectional View.
(Open centre circuit) .
1. Check valve
2. Flow regulator
3. Pilot valve and body
4. Pilot valve piston
5. Pressure relief valve
6. Body piston

1
Pilot Valve (Closed Centre Circuit). Details which
Change with Respect to Sectional View Fig. 1.

DESCRIPTION AND OPERATION

Trailer brake valve is located on the rear axle housing the pilot valve. Hydraulic operation is described on
in front of the hydraulic lift and controlled by the lift pages 3, 4 and 5.
control pump. For ITALY only, the trailer brake valve has the capability
Trailer brake valve has priority over auxiliary valves to keep the trailer brakes engaged even when engine
and hydraulic lift. is not running, the pump has failed or low oil flow has
Trailer brake valves assembled on the open centre or occurred. Operation is described on pages 6, 7, 8 and
closed centre circuits are similar, as they only differ for 9.

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
TRAILER BRAKE AUXILIARY VALVE

Trapped oil
Suction, delivery or discharge oil

Tractor braking circuit oil (brakes not applied)

3
Trailer Brake Auxiliary Valve Circuit Schematic
1. Trailer brake valve to tractor braking system line. 6. Lift valve.
2. Trailer brake auxiliary valve. 7. Hydraulic pump.
3. Auxiliary valve. 8. Pressure relief valve.
4. Oil supply line to trailer brake. 9. Filter.
5. Oil supply line to implements.

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
TRAILER BRAKES NOT APPLIED When tractor
brakes are not applied, oil from the hydraulic circuit
linked to the valve through the fitting (Y) is not under
pressure. Therefore the piston (5) of the pilot valve (6)
and the body piston (7) are not applied as shown in
Figure 4.
Oil from hydraulic pump (1, Figure 3) through the fitting
(P1), passes through diaphragm (1) and waisted
section (3), undergoes a pressure drop and
consequently moves the flow regulator (2) to the right.
Most of the flow is directed to auxiliary valves through
the fitting (N). Remaining part of the flow reaches the
hydraulic lift through the passage (4), body piston (7)
and fitting (R). 4
Pressure oil Trailer Brakes Not Applied.
N. To auxiliary valves.
Suction, delivery and discharge oil P1. From lift circuit hydraulic pump.
R. Discharge oil to lift.
Trapped oil Y. From tractor brakes.

Tractor braking circuit oil

(brakes not applied)
Tractor braking circuit oil
(under pressure)
BRAKES BEING APPLIED When tractor brake pedals
are pressed, hydraulic circuit oil in the fitting (Y) is
pressurised and moves the piston (7), pressure relief
valve (6) and body piston (8) leftwards. The body piston
stops the flow between the oil discharge fitting (R) and
both trailer braking fitting (B) and passage (5).
Oil pressure inside the flow regulator (4) is still present
even and the regulator, under the spring force, moves
to the left as shown in Figure 5.
Part of the oil from the hydraulic pump flows through
the fitting (P1) and reaches the auxiliary valves through
the fitting (N). Remaining flow arrives at trailer braking
device through the diaphragm (2), passage (3), check
valve (1) and fitting (B). 5
Increased oil pressure in the trailer brake fitting (B) acts Brakes Being Applied
on the active surface (9) of the body piston (8) against B. To trailer brake.
the pressure applied to the piston (7) by the tractor N. To auxiliary valves.
braking circuit oil.
P1. From lift circuit hydraulic pump.
R. Discharge oil to lift.
Y. From tractor brakes.

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
BRAKING -- If tractor brake pedals are kept pressed,
oil pressure in the trailer brake fitting (B) increases and,
acting on the active surface (10) of the body piston (9),
moves the piston towards the right against the
pressure relief valve (8) and spring (7) force.
When oil pressure in the trailer braking system is equal
to the spring pressure (7), the body piston (9) remains
in the position shown in Figure 6 and allows oil from the
hydraulic pump to discharge into the lift circuit through
the fitting (P1), diaphragm (2), waisted section (5),
passage (6) and fitting (R).
Because of the diaphragm (2) and waisted section (5)
oil pressure in the flow regulator drops (4) causing the
flow regulator to move to the right. Consequently, 6
passage (3) and check valve (1) close. Braking.
Further pressure on tractor brake pedals moves the B. To trailer brake.
piston (7, Figure 5), pressure relief valve (8) and body P1. From lift circuit hydraulic pump.
piston (2) to the left, thus creating an oil pressure
R. Discharge oil to lift.
increase in the trailer braking system and repeating the
phases described in BRAKES BEING APPLIED. Y. From tractor brakes.
If owing to external actions the trailer braking circuit Pressure oil
pressure increases, the body piston (9) quickly opens
and restores communication between the trailer brake Suction, delivery or discharge oil
fitting (B) and oil discharge fitting in the lift circuit (R)
perfectly balancing oil pressure within the braking
Trapped oi
system and pressure relief valve springs (7).
When tractor brake pedals are released, oil pressure
in the fitting (Y) decreases and conditions illustrated in Tractor braking circuit oil
Figure 4 are re--established. (under pressure)

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
Closed Centre Circuit Pilot Valve Operation
1. Piston.
2. Bleed screw.
3. Piston.
4. Ball.
5. Pilot piston.
6. Plunger.
7. Ball.

Brakes Not Applied.

When tractor brakes are not applied, passages (A and
B) are not under pressure.
7
Single--Pedal Braking.
When only one brake pedal is pressed, pressure flows
to the trailer brake valve pilot valve. Brake control oil
pressure through the passage (B) moves the ball (4)
against the piston (3). As no pressure oil comes from
passage (A), the ball (4) moves the plunger (6) and the
ball (7). Oil pressure keeps the ball (4) against the
piston (3) closing the passage. Therefore oil can’t act
on pilot piston (5) and consequently the trailer brake
valve is not actuated.

8
Tractor braking circuit oil
(brakes not applied)
Tractor braking circuit oil
(under pressure)
Two--Pedal Braking.
When both pedals are depressed pressure oil enters
the pilot valve from both passages (A and B).
Oil pressure moves the two pistons (1 and 3) one
against the other while the plunger (6) keeps the two
balls (4 and 7) off the holes located on the two pistons
(1 and 3).
In this situation pressure oil contacts the pilot piston (5)
operating the trailer brake valve.

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Delivery or suction oil

Discharge oil
Tractor braking circuit oil
(brakes not applied)
Trailer brake release
pressure oil
10

TRAILER BRAKE VALVE ELECTRO--HYDRAULIC OPERATION DIAGRAM (ITALY ONLY)

ENGINE RUNNING, BRAKES NOT APPLIED.

1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking
control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6.
Trailer brake disengagement pressure regulating valve -- 7. Trailer braking valve (see pages 3 and 4) -- 8. Trailer brake circuit
safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Hydraulic lift and auxiliary valve supply line -- 13.
Brake pump -- 14. Trailer--tractor coupler -- 15. Trailer brake control line -- 16. Trailer brake engaged indicator switch 17-- 19.
Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake engaged switch -- 22. Trailer brake engaged light
indicator.

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
The unique braking mechanism on Italian trailers
automatically applies the trailer brakes whenever the
tractor engine is stoppped, output from the hydraulic
pump on the tractor is very low or the tractor is
disconnected from the trailer. To release the trailer
braking mechanism a pressure of 11 to 12 bar (11.2 to
12.2 kg/cm2) is required at the trailer brake coupling
whenever the handbrake is released while the engine
is running. This pressure is controlled by the oil
discharge valve in the trailer brake valve located on the
tractor. The following diagrams describe the operating
sequences of the Italian trailer braking system,
Oil from hydraulic pump (9) flows to the trailer braking
valve (7). From this valve the greatest part of the oil is
sent to auxiliary valves and hydraulic lift through the
passage (12). A small part of the oil flows to the oil
discharge valve (6) which adjusts pressure 11 to 12 bar
(11.2 to 12.2 kg/cm2). Pressure oil at 11 to 12 bar
(11.2 to 12.2 kg/cm2) from the trailer brake valve flows
to the trailer brake through the solenoid valve (5a),
line (15) and coupler (14). This pressure is necessary
to overcome the spring force (19) and remove the
retainer, while the spring (17) moves the pin (18)
eliminating the braking action on the trailer.
Notice -- At engine start--up, reduce time necessary to
reach the trailer brake release pressure by pressing
the brake pedals (linked together) with the parking
brake control lever lowered. The light indicator (22) will
go off when the trailer brake is released.

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Delivery or suction oil

Discharge oil
Tractor braking circuit oil
(under pressure)
Braking pressure oil

TRAILER BRAKE VALVE ELECTRO--HYDRAULIC OPERATION DIAGRAM (ITALY ONLY)

ENGINE RUNNING, BRAKES APPLIED.

A. Brake pump (13) to brake trailer valve (7) connecting line -- 1. Parking brake control lever -- 2. Parking brake indicator
circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally
open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake disengagement pressure regulating valve -- 7.
Trailer braking valve (see pages 3 and 4) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Brake
control line -- 12. Hydraulic lift and auxiliary valve supply line -- 13. Brake pump -- 14. Trailer--tractor coupler -- 15. Trailer
brake control line -- 16. Trailer brake engaged indicator switch 17-- 19. Springs -- 18. Trailer brake control pin -- 20. Battery --
21. Parking brake engaged switch -- 22. Trailer brake engaged light indicator.
Pressure oil resulting from application of the brake pedals flows through the passage (A), closes the outlet (R) which
is open to discharge through the valve (6). Consequently oil pressure from the hydraulic pump (9) increases.
Pressure oil (12 to 150 bar -- 12.2 to 153 kg/cm2) goes out from the trailer brake valve (7) through the passage
(B),flows to the solenoid valve (5a) which is open and reaches the trailer brake through the line (15). Here it
overcomes the spring force (17 and 19) and moves the pin (18) which applies the brakes on the trailer.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Delivery or suction oil

Discharge oil
Tractor braking circuit oil
(brakes not applied)
12
TRAILER BRAKE VALVE ELECTRO--HYDRAULIC OPERATION DIAGRAM (ITALY ONLY)
ENGINE STOPPED OR RUNNING BUT WITH LOW HYDRAULIC PUMP FLOW.
1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking
control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6.
Trailer brake disengagement pressure regulating valve -- 7. Trailer braking valve (see pages 3 and 4) -- 8. Trailer brake circuit
safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Hydraulic lift and auxiliary valve supply line -- 13.
Brake pump -- 14. Trailer--tractor coupler -- 15. Trailer brake control line -- 16. Trailer brake engaged indicator switch 17-- 19.
Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake engaged switch -- 22. Trailer brake engaged light
indicator.
With the engine running or stopped, in case of low hydraulic pump flow (9) there is no or very low oil pressure reaching
the trailer brake valve (7). Consequently the switch (8) closes. With the switch (8) closed current energises the relay (3).
The relay closes and current reaches and energises solenoid valves (5a and 5b) closing the former and opening the latter.
In this condition line and trailer brake oil (15), subject to the spring force (19), can reach the discharge through the solenoid
valve (5b), in this condition braking action is performed mechanically following the spring (19) pressure on the pin (18). Oil
discharge creates a pressure drop which closes the switch (16), and current, passing through the switch (16), reaches the
instrument panel light indicator (22), which lights up.

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Delivery or suction oil

Discharge oil
Tractor braking circuit oil
(brakes not applied)
13
TRAILER BRAKE VALVE ELECTRO--HYDRAULIC OPERATION DIAGRAM (ITALY ONLY)
ENGINE RUNNING, PARKING BRAKE ENGAGEMENT.
1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control
solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake
disengagement pressure regulating valve -- 7. Trailer braking valve (see pages 3 and 4) -- 8. Trailer brake circuit safety switch -- 9.
Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Hydraulic lift and auxiliary valve supply line -- 13. Brake pump -- 14.
Trailer--tractor coupler -- 15. Trailer brake control line -- 16. Trailer brake engaged indicator switch 17-- 19. Springs -- 18. Trailer
brake control pin -- 20. Battery -- 21. Parking brake engaged switch -- 22. Trailer brake engaged light indicator.
Parking brake (1) engagement makes the switch (21) close. Therefore current is allowed to reach and excite the relay
(2),and through the closed relay contact (2) it excites the solenoid valves (5a and 5b) closing the former and opening
the latter. In this condition line and trailer brake oil (15), subject to the spring (19) force can reach the discharge
through the solenoid valve (5b). Braking action is performed mechanically following the spring (19) pressure on the
pin (18). Oil discharge creates a pressure drop which closes the switch (16), and current, passing through the switch
(16), reaches the instrument panel light indicator (22), which lights up.
Notice -- After parking brake engagement, wait approx. 10 seconds before stopping the engine to permit complete
oil discharge from trailer brake cylinder and obtain optimal braking action.

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
TRAILER BRAKE VALVE PRESSURE TESTING AND TROUBLESHOOTING

TEST CONDITIONS.
Oil temperature 40° to 50° C. Electrical system powered.
Engine speed 1000 rpm. Parking brake disengaged.

TRAILER BRAKE DISENGAGEMENT PRESSURE TEST

(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 (1) into the trailer brake
coupler and connect it to a 0 to 40 kg/cm2 pressure
gauge from kit no. 292870.
2. With engine and oil as detailed above, pressure
should be 11 to 12 bar (11.2 to 12.2 kg/cm2).
3. Make sure that light indicator (22, Figure 13 ) is off.
4. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).

TROUBLESHOOTING
Problem Possible cause Correction
Trailer brake disengagement 3. Parking brake (1, Figure 13) Disengage parking brake.
pressure = 0 bar (light indicator on engaged.
22, Figure 13).
4. Trailer brake disengagement Replace valve.
pressure valve misadjusted (6)
5. Faulty trailer brake circuit safety Replace switch.
switch (8).
6. Faulty hydraulic pump (9). Overhaul or replace pump.
7. Delivery solenoid valve (5a) Repair or replace solenoid valve.
stuck closed.
8. Discharge solenoid valve (5b) Repair or replace solenoid valve.
stuck open.
Trailer brake disengagement 1. Trailer brake disengagement Replace valve.
pressure = 0 to 11 bar pressure valve misadjusted (6).
(0 to 11.2 kg/cm2).
Correct trailer brake 1. Faulty trailer brake engaged indi- Replace switch.
disengagement pressure but light cator switch (16).
indicator (22) is on.
Trailer brake disengagement 1. Faulty indicator lamp (22). Replace lamp.
pressure not correct but light
indicator (22) is off.
2. Faulty trailer brake engaged indi- Replace switch.
cator switch (16).

NOTE: The switch (8) can be recognized by the red paint point between the two switch blades.

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
TRAILER BRAKING SYSTEM PRESSURE TEST
(ALL MODELS)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 250 kg/cm2 pressure gauge
from kit no. 292870.
2. Couple both brake pedals together and with engine
and oil in the conditions described at the beginning
of this chapter, apply the foot brake. The pressure
gauge reading should increase depending on
pedal effort up to 135 to 145 bar (138 to 148
kg/cm2).
3. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).
25265

TROUBLESHOOTING.
Problem Possible cause Correction
Pressure higher or lower than 1. Faulty trailer braking auxiliary Replace trailer braking auxiliary
specified. valve pressure regulating valve valve.
(3, Figure 13).
2. Faulty hydraulic pump (9). Replace pump.

HYDRAULIC SYSTEM LEAK TEST

(ALL MODELS)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 250 kg/cm2 pressure gauge
from kit no. 292870.
2. Couple both brake pedals together and with engine
and oil in the conditions described at the beginning
of this chapter apply the foot brakes for a minimum
of 10 seconds. The pressure gauge reading should
increase up to 135 to 145 bar (138 to 148 kg/cm2)
and remain constant.
3. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).
25265

TROUBLESHOOTING.
Problem Possible cause Correction
Excess pressure peaks are 1. Oil leaks from hydraulic system. Locate leaks and repair.
observed when applying the brake
pedals for 10 seconds.
2. Solenoid valve leak Replace solenoid valve.
(5b, Figure 13).
3. Trailer brake auxiliary valve (7) Replace trailer brake auxiliary
leaks. valve.

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
PARKING BRAKE ENGAGEMENT TEST
(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 40 kg/cm2 pressure gauge
from kit no. 292870.
2. With engine and oil in the conditions described at
the beginning of this chapter, fully raise parking
brake control lever (1, Figure 13).
3. Check if pressure is 0 bar and light indicator (22,
Figure 13) is on.
4. With parking brake engaged disconnect pressure
gauge and fitting no. 293190 (1).
25265

17
TROUBLESHOOTING.
Problem Possible cause Correction
Trailer brake disengagement 1. Faulty parking brake engaged Replace switch.
pressure does not zero when switch (21, Figure 13).
parking
ki brake
b k isi applied.
li d
2. Faulty parking brake indicator Replace relay.
circuit relay (2).
3. Discharge solenoid valve Repair or replace solenoid valve.
(5b)faulty or stuck closed.

TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST

(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 in trailer brake coupler and
connect it to a 0 to 40 kg/cm2 pressure gauge from
kit no. 292870.
2. With parking brake ‘Off’ and tractor brakes not
applied, operate and hold the remote control valve
lever and allow the system pressure relief valve to
operate. Keep this position for a few seconds and
quickly release the control lever.
3. Check if parking brake disengagement pressure
remains at the specified value: 11 to 12 bar (11.2
to 12.2 kg/cm2).
4. Engage parking brake, disconnect pressure gauge 25265

and fitting no. 293190 (1). 18

TROUBLESHOOTING.
Problem Possible cause Correction
Trailer brake disengagement 1. Trailer brake circuit safety switch Replace switch.
pressure is permanently zeroed (8, Figure 13) adjustment
when operating the levers exceeding rated value (3 ± 0.5
described above. bar).
2. Switches (8 and 16) reversed in Move switches to correct positions
the specified positions or with or reverse power supply cables.
exchanged power supply cables.

NOTE: The switch (8) can be recognized by the red painted dot between the two switch blades.

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8
NOTES

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9
SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 9 -- Assist Ram

CONTENTS

Section Description Page

SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single--acting1
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 75
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 150

1
Assist Ram Sectional View

1. Assist ram cylinder 3. Seal

2. Pin 4. Dust seal

DESCRIPTION AND OPERATION

An assist ram can be installed to increase hydraulic lift The assist ram is single--acting type and controlled by
power. the oil flow from the lift control valve, which operates
The assist ram is connected to the left hand lift arm and the hydraulic lift.
anchored on the rear axle centre housing.

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9
ASSIST RAM

Removal--Installation (Op. 35 116 30)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protective clothing, including goggles,
gloves and footwear.

Remove the assist ram as follows:

1. Open and raise engine hood.
2. Detach negative cable (1) from battery and
insulate. 2
3. Fully lower lift arms .

4. Disconnect the oil supply line (2), slide out pins (3

and 4) and remove the assist ram.
5. Reinstallation of the assist ram follows the removal
procedure in reverse.

ASSIST RAM

Disassembly -- Reassembly (Op. 35 116 33)

WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protective clothing, including goggles,
gloves and footwear.

Disassemble the assist ram as follows:

1. Withdraw the piston (2, Fig. 1) from the assist ram 3
cylinder and check for distortion or roughness.
2. Check seal (3, Fig. 1) and dust seal (4). Replace
if necessary.
3. Lubricate components with specified oil and instal
the piston (2).

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
SECTION 35 -- HYDRAULIC SYSTEM

Chapter 10 -- Hydraulic Pressure Testing

CONTENT

Section Description Page

35 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CCLS Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Open Centre Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Low Pressure Warning Light On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Charge Pressure Light Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intake Filter Restriction Light On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power Steering Not Working Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trailer Brakes Not Working Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Lift Not Working Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remote Control Valves Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lift Ram Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Load Sensing Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Charge Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Variable Flow Piston Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic Pump Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering Pump/Low Pressure Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering Circuit Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Open Centre Lift Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Command Transmission Clutch Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Range Command Transmission Clutch Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dual Command Transmission Clutch Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

35- 1
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Trailer Brake Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Trailer Brake Valve Electro--Hydraulic Operation Diagram (Italy Only) . . . . . . . . . . . . . . . . 32
Trailer Brake Disengagement Pressure Test (Italy Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Trailer Brake System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Trailer Brake System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Trailer Brake Engagement Test (Italy Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Trailer Brake Circuit Safety Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cooler Bypass Valve -- Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Brake Booster Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

35- 2
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
INTRODUCTION

Pressure test kit 297611 has been developed for Low Pressure System
pressure testing the Series TM tractors and contains Lubrication
adaptors specifically designed for access to test ports.
Brake Boost Valve
This chapter describes the procedure for performing
Trailer Brake Valve
the following pressure tests using this kit and other
standard fittings already available through New Before commencing hydraulic pressure testing
Holland Logistics. perform the fault finding checks on Page 35--7
followed by the fault finding procedure for the type of
concern identified. Following these checks may
High Pressure System identify an obvious cause for the concern and prevent
High Pressure Standby unnecessary component disassembly.
Sensing Line Pressure The hydraulic pump is the heart of the hydraulic system
Low Pressure Standby and the chapter describes in detail the tests necessary
to confirm that pump output is to specification. Once
CCLS Pump Charge Pressure
specified pump output has been confirmed attention
Steering can be focused on the appropriate pressure testing of
Lift Ram Pressure individual components in the hydraulic circuit.

35- 3
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
SPECIAL TOOLS

DESCRIPTION NEW HOLLAND

PART NUMBER
Tee adaptor 11/16 ORFS female x 11/16 ORFS male x 7/16 UNF female 297600*
Tee adaptor 7/16 JIC female x 7/16 JIC male x 7/16 UNF female 297601*
7
Adaptor M10 banjo x /16 UNF female 297602*
9 9 7
Tee adaptor /16 ORFS female x /16 ORFS male x /16 UNF female 297603*
Blanking Cap 9/16 ORFS 297604*
7
Blanking Cap /16 ORFS 297605*
Adaptor 7/16 UNF female x 1/2 BSP male 297606*
7
Adaptor /16 UNF female x M12 x 1.5p male 297607*
7
Adaptor /16 UNF female x M14 x 1.5p male 297608*
Adaptor M14 banjo x M14 x 1.5p female 297609*
Tee adaptor 7/16 UNF female x 1/4 BSP hose tail x 1/2 hose 297610*
7/ UNF male Quick release adaptor 297240*
16
Adaptor M10 x 1.0p x 7/16 UNF female 297404*
11
Blanking Cap /16 ORFS 297671
Pressure Gauge 0--10 bar 293241#
Pressure Gauge 0--40 bar (5 off) 293242#
Pressure Gauge 0--250 bar 293244#
Remote valve coupling 5101741 or 293449
Quick release adaptor 291924
Pressure gauge hose 292246#
1/ NPT fitting to attach hose 292246 to gauge 291927#
8
Adaptor M10 x 1.0p x 7/16 JIC male (enables use of gauges with 7/16 JIC hoses if used) 297417
diagnostic switch 295041
Bypass connector 295044
Trailer brake fitting 293190#
Flow Meter 120 ltr/min minimum (procure locally)
* Part of hydraulic adaptor kit 297611
# Part of hydraulic pressure test kit 292870

35- 4
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
SPECIFICATIONS -- CLOSED CENTRE SYSTEMS
MAIN HYDRAULIC PUMP
Type Variable Flow Closed Centre
Load Sensing Piston Pump
Minimum Output @ 2200 erpm 111 Ltr/min
29 US gal/min
Standby Pressure 21--24 bar (310 --350 lbf/in2)
Maximum System Pressure 200--207 bar (2900--3000 lbf/in2)

STEERING/LOW PRESSURE PUMP

Type Gear Type Pump
Minimum Output @ 2200 erpm 61.5 Ltr/min
16 US gal/min
Flow to Steering Motor 22--28 Ltr/min
5.8--7.4 US gal/min
Steering Pressure 186 bar (2700 lbf/in2)

SPECIFICATIONS -- OPEN CENTRE SYSTEMS

MAIN HYDRAULIC PUMP
Type Fixed Displacement Gear Type
Engine/Pump RPM Ratio 1 : 1.264
Minimum Output @ 2200 erpm 53 Ltr/min
14 US gal/min
Maximum System Pressure 190--195 bar (2750--2850 lbf/in2)

STEERING/LOW PRESSURE PUMP -- 2 WHEEL DRIVE

Type Gear Type Pump
Minimum Output @ 2200 erpm 41 Ltr/min
11 US gal/min
Steering Pressure 186 bar (2700 lbf/in2)

STEERING/LOW PRESSURE PUMP -- 4 WHEEL DRIVE

Type Gear Type Pump
Minimum Output @ 2200 erpm 53 Ltr/min
14 US gal/min
Steering Pressure 186 bar (2700 lbf/in2)

35- 5
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10

1
CCLS Hydraulic Pump Installation
1. Intake Filter 8. Charge Pressure Filter Dump Valve
2. Oil Low Temperature Switch 9. Charge Pump
3. Intake Filter Restriction Switch 10. Charge Pressure Filter
4. Low Charge Pressure Switch 11. Variable Flow Piston Pump
5. Charge Pressure By--Pass Valve 12. Load Sensing Valve
6. Steering Flow Control Valve (Flow and Pressure Compensating Valves)
7. Steering and Low Pressure Circuit Pump

TIA35004 TIA35005
2 3
Charge Pressure Filter Dump Valve Steering Flow Control Valve

35- 6
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10

4
Open Centre Hydraulic Pump Location -- Right Hand Side of Transmission

FAULT FINDING

Is rear axle oil at correct NO Add oil to rear axle

level on dipstick?
YES

Is oil contaminated with dirt, water YES Investigate cause of contamination.

or anti--freeze? Drain and replace oil
NO

Have oil filters been replaced NO Replace all filters on pump

at correct service interval?
YES

Is Transmission low Set engine speed to 1000 rev/min and

YES check that steering operates.
pressure warning light ON
NO If steering does not operate turn of
engine immediately to avoid damage due
Identify functions not operating to possible lack of oil flow to low
correctly and refer to appropriate pressure and lubrication circuits.
fault finding Chart Refer to Transmission Low Pressure
Warning Light ‘On’ fault finding chart

35- 7
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Transmission Low Pressure Warning Light ‘ON’-- Power Command Transmission

TIA35002
5 6
Steering Pump Charge Pressure Valve Transmission Low Oil Pressure Switch
Set engine speed to 1000 Is hydraulic oil Carefully operate tractor until
Rev/min YES temperature YES oil temperature increases
Is steering working below 40°C Fault cleared?
correctly? NO NO
NO
Does PTO stop and start Disconnect wiring to low
when engagement switch transmission oil pressure switch
is operated? Is warning light ‘On’?
YES NO
NO
On tractors with power Perform low pressure
Stop engine immediately. circuit check
Remove the steering pump command transmission
check for short to chassis Is pressure 250--280
charge pressure valve, lbf/in2 (17--20 bar)?
rotate engine by hand and in Y/O colour wires from
check that steering pump instrument console
connector C080 Pin10 to NO
gears are rotating
Do not put fingers inside pressure switch C036
Check orifice in low
steering pump transmission oil pressure
Gears Rotating YES Recheck switch is not blocked
NO Steering and Orifice clear?
Remove pump and PTO operation
NO
check that pump drive
gear rotates when Remove and examine
engine is turned over Disassemble pump orifice in pressure
by hand. YES and inspect for regulating valve
Gear Rotates broken pump drive Fault cleared?
NO shaft NO

Check for broken Remove and examine

drive between engine pressure regulating
flywheel/damper and valve for sticking
pump drive gear Fault cleared?
NO

Replace low
transmission oil
pressure switch
Fault cleared?
NO

Check for large leak in PTO

differential lock, 4 wheel drive and
transmission pressure circuits.

35- 8
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Charge Pressure Light Flashing

Is rear axle oil at correct level NO Add oil to rear axle

on dipstick?
YES

Perform charge pressure test Disconnect wiring to low charge

Charge Pressure YES pressure switch
1.6--3.4 bar? Light is extinguished?
NO NO YES

Replace inlet and Locate and repair short Replace

Intake Filter Restriction Warning Light On

Is rear axle oil at correct level NO Add oil to rear axle

on dipstick?
YES

Replace inlet and Disconnect wiring to filter restriction

charge pressure filter NO warning light switch
Fault cleared? Light is extinguished?
NO YES

Locate and repair short Replace

circuit to chassis in intake filter
R/N/B colour wire from restriction
instrument console switch
connector C080 Pin 16
and intake filter
restriction switch

35- 9
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Power Steering Not Working or Working Incorrectly

Is transmission low Refer to Transmission

pressure warning YES low pressure warning
light on? light On fault finding
chart
NO

Perform steering test

Fault Confirmed?
YES

Set engine speed to 1000 rev/min Check pump bolt torques

and turn steering to full lock YES and examine for internal
Does transmission warning light leaks/worn pump seals
come on?
NO

Examine steering flow

control valve for sticking
Fault Cleared?
NO

Refer to Section 41
Steering System

Trailer Brakes Not Working

Has all air been bled NO

Bleed trailer brakes
from trailer brakes
YES
Is hydraulic lift working
Pressure test trailer satisfactorily? Test
brakes. YES maximum system pressure Adjust flow/pressure
Fault confirmed? at remote valve coupler.
NO compensating valve
Pressure 2700--2800 lbf/in2 Fault cleared?
(186--193 bar)? NO
YES
Examine
flow/pressure
Operate and hold remote valve to compensating
generate maximum system valve for sticking
Overhaul trailer pressure and at the same time Fault cleared?
NO operate tractor brakes
brake valve NO
Trailer brake valve functions
correctly? Disassemble variable
YES flow pump and check
swash plate piston for
Examine shuttle valve in load sticking
Clean/replace sensing line between trailer
shuttle valve to YES brake and pressure/flow
trailer brake valve compensating valve
Valve sticking?

35- 10
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Hydraulic Lift Not Working Correctly
Is steering system and Refer to Transmission Low Pressure
NO
PTO working Warning Light ON fault finding chart
YES

Is charge pressure YES Refer to charge pressure light

light flashing? flashing fault finding chart
NO

Has an Electronic draft control error

code been identified NO Refer to Section 35 Chapter 4,
Fault Cleared? Electronic Draft Control fault finding.
NO

Is hydraulic lift Perform pump leak test to determine if

YES fault relates to either internal leak or
working erratically?
hydraulic circuit leak
NO

Is in cab fast raise/ work NO

Move switch to work
switch in work position position
YES

Is hitch enabled YES Capture hitch

symbol illuminated
NO

Check position of controls

on control panel
Fault cleared?
NO

Are lift arms locked in either fully Check EDC valve raise or lower
raised or lowered position YES solenoids for sticking plunger
NO

Perform standby pressure test Adjust/examine flow

Is pressure 300--350 lbf/in2 NO compensating valve
(21--24 bar)? Fault cleared?
YES NO

Perform High Pressure Standby test (maximum Disassemble variable

system pressure) at remote valve displacement pump and check
Is pressure 2700--2800 lbf/in2 swash plate piston for sticking
(186--193 bar)?
YES NO

While operating remotes at high Adjust pressure Examine flow/pressure

pressure standby operate compensating valve NO
compensating valve for
hydraulic lift Fault cleared? sticking
Lift operates correctly? Fault cleared?
YES NO

Investigate fault in Examine EDC valve for

load sensing line sticking spools and Place heavy weight on lift arms
from EDC valve leaking lift cylinder safety NO and check if arms leak down
valve under the pressure of load
Fault cleared? YES

Overhaul lift cylinder

35- 11
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Remote Control Valves Not Working
Is hydraulic lift NO
Refer to fault finding chart
working? for hydraulic lift not working
YES
Operate all remote valve
Test maximum system pressure at levers simultaneously
each remote valve coupler. Is the pressure at the Overhaul remote
Are pressures at each valve NO defective remote valve NO control valve(s) which
coupler below 2700--2800 lbf/in2 now 2700--2800 lbf/in2 fail pressure test
(186--193 bar)? (186--193 bar)?
YES
YES
Examine flow/pressure
compensating valve for sticking Examine load sensing valve
Fault cleared? between remote valve
sections.

35- 12
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
PUMP PRESSURE AND FLOW TESTING
IMPORTANT: Before performing any pressure or flow
testing operate the tractor until the oil in the rear axle
is at normal operating temperature. 75°C (170°F).
The following tests check operation of the hydraulic
pump and associated high pressure circuits.

Low Pressure Standby

1. Disconnect load sense line (1) to remote valves
and install cap (2) Tool Number 297604.

7
2. Attach 0--40bar (0--600lbf/in2) gauge 293242 to
remote valve coupling using remote valve coupling
5101741 or 293449, adaptor 297606, quick
release fitting 297240, quick release coupler
291924 and hose 292246.
3. Set engine speed to 1500 rev/min.

8
4. Pull and hold the respective remote valve control
lever in the ‘extend’ position.
5. The pressure reading should be 21--24 bar
(310--350 lbf/in2) and is the ‘Low Pressure
Standby.
IMPORTANT: Do Not operate tractor brakes while
the remote valve lever is in the operating position,
otherwise the system pressure will increase to
maximum pressure of 200 bar (2900 lbf/in 2)
resulting in damage to the pressure gauge.

TIA35078
9
If pressure reading is marginally away from
Specification adjust flow compensating valve.
If reading is high examine flow compensating valve
(1) spool for sticking.
6. Reconnect load sense line.

35- 13
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
High Pressure Standby
1. Attach 0--250bar (0--3600lbf/in2) gauge 293244 to
remote valve coupling using remote valve coupling
5101741, fitting 297606, quick release fitting
297240, quick release coupling 291924 and hose
292246.
2. Set engine speed to 1500 rev/min.

11
3. Pull and hold the respective remote valve control
lever in the ‘extend’ position.
4. The pressure reading should rise to be 200 bar
(2900 lbf/in2). and is the ‘High Pressure Standby.

TIA35078
12
5. If reading is not to specification adjust pressure
compensating valve (2).

35- 14
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Lift Ram Pressure Test
IMPORTANT: Before performing any pressure or flow
testing, operate the tractor until the oil in the rear axle
is at normal operating temperature. 75°C (170°F).
The following tests checks the operation of the EDC
valve / lift cover control valve and lift rams.
1. Insert Tee--piece, 297600, between the lift cylinder
elbow and flexible hose. Install quick release fitting
297240 to the tee--piece and install 0--250bar
gauge 293244 with quick release coupler, 291924
and hose 292246.
2. With the key ON, disconnect the lift arm
potentiometer. Error code 27 will be displayed or
stored in the memory. 14
3. Key OFF and reconnect the potentiometer.
4. Start the engine, Error code 24 (EDC requires
calibration) will be displayed or stored in the
memory. Set the engine speed to 1500 rev/min.

15
5. Move the position control lever fully down and then
fully up. Maximum pump pressure will be applied
for approximately 2 seconds as the pressure relief
valve operates.
6. The gauge should reach 200--207 bar (2900--3000
lbf.in2).
7. If the pressure is low this may indicate either a
faulty EDC valve / lift cover control valve or a fault
in one of the lift rams.

35- 15
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Load Sensing Circuit Test
This test demonstrates how to check that the load
sense lines which signal the hydraulic pump to go on
and off load are functioning. With the test equipment
installed as shown the load sensing circuit to the
hydraulic remote valves is being tested. To test other
load sense circuits it is necessary to install the test
equipment in the load sense line of the specific circuit
to be tested.
1. Install Tee adaptor (3) 297603 and quick release
fitting 297240 (2) into load sense line.
2. Connect 0--250 bar (0--3600 lbf/in2) pressure
gauge (1), 293244, using quick release coupler
291924. 17
3. Set engine speed to 1500 rev/min.
4. Operate in turn each of the remote valves. As each
valve is operated the pressure should rise from
21--24 bar (310--350 lbf/in2) to a maximum of
190 bar (2750 lbf/in2). Changes in pressure
indicate that the load sensing line to each valve is
operating.

TIA35078
18
Charge Pressure Test
1. Remove charge pressure switch. 1 2
2. Install 0--10 bar pressure gauge, 293241, (1) using
adaptors (2) as listed below.
adaptor 297404
Quick release fitting 297240
quick release coupler 291924
or
M10x1.0 7/16 JIC adaptor 297417
if using JIC fittings on test hose
NOTE: The thread size of the charge pressure switch
port is M10 x 1 DIN specification. TIA35081
19
3. Install 180 ltr/min flow meter between remote
valves I and II. Ensure inlet hose of flowmeter is
installed into extend port of valve No I.
4. Fully open load valve on flow meter.
5. Set remote valve flow control knobs to maximum
flow.

35- 16
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
6. Set remote valve No 2 in ‘Float’ position.
7. Set remote valve No 1 in ‘Extend’ position.
8. Start tractor and set engine speed to 1500 rev/min.

TIA35086
21
9. Move control lever for remote valve No 1 between
extend and neutral position. The charge pressure
readings should not vary outside 1.6--3.4 bar
(23--50 lbf/in2).
If pressure readings below 1.6 bar (23 lbf/in2) are
recorded replace hydraulic filters and re test.
If after retest charge pressure is still below specification
examine both the charge pressure filter dump valve
and charge pressure valve before disassembling
pump to inspect for wear.

TIA35086
22
Variable Flow Piston Pump Flow Test
To flow test the variable flow piston pump it is
recommended that the output is checked at the remote
valves.
1. Install flow meter between inlet ports of remote
valves I and II.
2. Set flow control knobs to maximum flow.

23
3. Ensure load valve on flow meter is fully ‘Open’.
4. Set tractor engine speed to 1100 rev/min.
5. Set remote valve No 2 in ‘Float’ position and
remote valve No 1 in ‘Extend’ position.

TIA35086
24

35- 17
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
6. Adjust load on flow meter to a of pressure of
100bar.
7. If a flow of 45 ltr/min is recorded the pump flow is
to specification.
NOTE: This test is performed at half maximum rated
speed and assumes that pump flow at rated speed is
twice that measured in the test.

TIA35086
25
Hydraulic Pump Leak Test
The hydraulic pump leak test should be performed
whenever operation of the hydraulic system is erratic
or the pump is extremely noisy.
The purpose of the test is to, ascertain if the
malfunction of the system is due to an internal pump
leak or alternatively the ingress of air due to a leak
through a component in the system.
1. Disconnect the breather tube (1) from the top of the
hydraulic lift cover (2).

26
2. Attach approximately 11/2 metres of clear plastic
tubing (1) to the breather connection (2) on top of
the transmission and position the tubing so that it
forms a ‘U’ (Similar to a manometer).
3. Fill the tube with sufficient oil to prevent the ingress
of air through the tube.
4. Set tractor engine speed to 1000 rev/min and pull
and hold remote valve lever
If the hydraulic pump has an internal leak, oil or bubbles
will be sucked from the plastic tube into the
transmission.
If the hydraulic circuit has an external leak the oil in the
‘U’ of the plastic tube will be pushed towards the open
end of the tube by the air being drawn into the 27
transmission casing through the pump.

WARNING
If the leak is excessively large it is possible for the oil
to be projected out of the tube. Take care to position the
tube so not to cause injury or project oil into the work
area.

35- 18
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
If an external leak is diagnosed use an ‘oil can’ to
selectively apply a film of oil around the joints of the
circuit. For example remote valve tubing joints. When
oil is applied to the leaking joint the noise in the pump
will cease.
If an internal leak is identified inspect mounting face at
pump intake port or intake tube in transmission for
missing or damaged ‘O’ ring, Figure 28.

28
Steering Pump/Low Pressure Pump Test
There is no relief valve in the steering/low pressure
circuit pump. The following practical test will determine
if steering pump output is sufficient to allow satisfactory
operation of the steering system.

If transmission low pressure warning light comes

on when the steering is held on full lock this is an
indication that the pump has developed an internal 29
leak. Check torque of pump mounting bolts and if
tight examine pump for leaking seals or wear.

Steering Circuit Pressure Test

1. Install Tee adaptor (2) 297600 and quick release
fitting (3) 297240, into hose to steering cylinder.
2. Connect 0--250 bar (0--3600 lbf/in2) pressure
gauge (1) 293244, with hose 292246, using quick
release coupler 291924.
3. Set engine speed to 1500 rev/min.
4. Turn steering wheel to full lock and hold in position.
5. Pressure reading of 186 bar should be recorded .

35- 19
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Steering Relief Valve Pressure Test
IMPORTANT: There is no relief valve in the
steering/low pressure pump and the following pressure
test must only be performed as specified below. Failure
to observe this precaution may result in severe
damage to the hydraulic pump.

1. Turn steering onto full left hand lock.

2. Disconnect the left hand turn feed hose.
3. Install Tee adaptor (4) 297600 and quick release
fitting (2) 297240, into the solid tube. Cap the
bottom of the Tee--piece with blanking cap, 297671
or a standard No 6 cap (11/16 in ORFS female
thread cap purchased locally (3).
4. Connect 0--250 bar (0--3600 lbf/in2) pressure
gauge, 293244 (1), with hose 292246, using quick
release coupler 291924.
5. Start tractor and set engine speed to 1450 rev/min.
Turn steering wheel to the left with a pull of
approximately 22 N (2.25 kgf, 5 lbf) and observe
the pressure reading. 31
NOTE: The use of a force greater than 5 lbf. at the rim
of the steering wheel may lead to slightly inaccurate
readings due to the pumping action of the hydrostatic
steering motor.
If the steering test was satisfactory but the pressure
readings are away from specification the relief valve in
the steering motor must be adjusted.
The pressure reading should be:--
186 bar (2700 lbf/in2) for all models.
6. If the system pressure is not to specification
proceed to Relief Valve Adjustment.

Low Pressure System Test

The low pressure circuit can be checked on all models
by removing the low pressure warning switch, located
in the transmission side cover for Range, Dual and
Shuttle command transmissions and in the top cover of
the Power Command transmission, and inserting fitting
(1) 297607 with a quick release fitting (2) 297240.
Attach 40 bar (600 lbf.in2) gauge (3) 293242 using
quick release coupler 291924 and hose 292246.
Start and run the engine at 1500 rev/min. The gauge
should read 16--18 bar (235--265 lbf.in2).

35- 20
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Power Command Transmission, low pressure warning
light switch (1)

33
Range Command Transmission low pressure warning
light switch.

TIA35047
34
Dual Command Transmission low pressure warning
light switch.

TIA35155
35
Shuttle Command Transmission low pressure warning
light switch.

TIA35177
36

35- 21
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
OPEN CENTRE (FIXED DISPLACEMENT
PUMP)
LIFT PRESSURE REGULATING VALVE

Removal--Installation (Op. 35 114 30)

The lift pressure regulating valve (high pressure circuit
relief valve) is located between the oil supply tube and
hydraulic pump.
If faulty, remove and replace the valve.

LIFT PRESSURE REGULATING VALVE

37
Setting (Op. 35 114 32)
Proceed as follows:
1. Run the engine until oil reaches a temperature of
approximately 50°C.
2. Insert fitting tool no. 293449 or 5101741(1) into a
remote valve coupler and connect to a 0 to 250 bar
pressure gauge 293244 from test kit no. 292870.
3. Move and hold the remote valve lever until the
pressure regulating valve operates.
4. With the engine running at medium speed, the
pressure gauge should read approx. 186 to 191 bar
(190 to 195 kg/cm2). If the valve setting is not to
specification, the best thing to do is to replace the
valve. In case of need, however, it is possible to
adjust valve setting through the threaded plug
using the spanner tool no. 291863. Tighten the 38
threaded plug to increase valve setting, loosen to
decrease.
NOTE: The pressure regulating valve setting can also
be checked as a bench test, as follows:
5. Mount the pressure regulating valve (1) on the test
fitting tool no. 290824 (2) and connect fitting to the
hand pump tool no. 290284 (3).
6. Prime the hand pump (3) and check that the
pressure regulating valve opens at a pressure of
approximately 186 to 191 bar.
NOTE: The pressure regulating valve is set with oil flow
in production. Consequently, the test performed using
the hand pump tool no. 290284 should be considered
as indicative only. Therefore, we advise to test the
pressure regulating valve setting with the valve
installed in the tractor, as previously described.

35- 22
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
POWER COMMAND TRANSMISSION
PRESSURE TESTING
Transmission Clutches, A,B,C,D,E, F1, F2, F3 and
R
Where F1 = Slow Range
F2 = Medium Range
F3 = Fast Range
1. Prepare the tractor for pressure testing:
(iii) Start and drive the tractor to warm the
transmission oil to a minimum operating
temperature of 60°C (140°F).

40
(i) Ensure handbrake is fully applied.
2. Install diagnostic switch (1), Tool No. 295041 (prior
no 4FT.950) into the white diagnostic plug of the
tractor harness, Figure 40.
3. Install suitable pressure gauges (0--40bar, 0--600
lbf.in2) with the appropriate New Holland quick
release couplers, nine if available, into each of the
clutch pressure test points as follows:--.

41
Pressure gauge, hose and adaptor details:
1. Pressure gauge, 293242
2. Quick release adaptor, 291924 2
3. Hose 292246 1
4. Adaptor, 291927

42
(a) Located in the raised horizontal manifold, under
A B
the right hand foot step are the test ports for E D C
clutches A,B,C,D and E, Figure 43.

TA6021003
43

35- 23
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
(b) Mounted on the left hand side of the
transmission is the Medium Range Test Port (1).
On some tractors it will be necessary to remove the
existing quick release fitting and install the adaptor,
297609 (1) for easier access. Refit quick release
fitting into adaptor. Fit gauge, 293242 0--40bar
(0--600lbf/in2) with hose, 292246 and quick release
coupler 291924 (2).

44
(c) Mounted on Right Hand side of the transmission
is the Reverse Range Test Port (1) and clutches A
to E test ports (2).

45
(d) Mounted on the top of the transmission is the
Slow Range Test Port (1), and the Fast Range Test
Port (2).
For improved access to the slow range test port
remove the existing quick release fitting and install
the adaptor, 297609. Fit gauge 293242 with hose
292246 and quick release coupler 291924.

46
4. Start the engine and enter HJ mode (1). Depress
the clutch pedal and move the shuttle lever into
forward. Release the clutch. The upper character
on the display will show ‘A’, indicating that clutch ‘A’
solenoid will be energised.

35- 24
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
5. To energise the solenoid press and hold the
downshift button and observe the pressure reading
on the gauge which should be 17±1 bar.
NOTE: The clutch pedal (1) should be depressed
before energising the solenoid. Once energised the
pedal should be released slowly to avoid harsh clutch
engagement.

48
6. The pressure can be controlled with the clutch
pedal. When the pedal is depressed the lower two
digits will change to a number 0--16 indicating the
approximate pressure in bars, as long as the clutch
pedal is correctly calibrated. With the pedal fully
released ‘FP’ will be displayed indicating Full
Pressure. Here clutch A is indicating approximately
7 bar (3).
7. To select other clutches, repeatedly press the
upshift button (2) and then depress the downshift
button (1) to energise the solenoid.
8. If all gauges read low, suspect a fault in the low
pressure hydraulic system, refer to section 35.

9. If one or more gauges read correct and the other

gauges are low this indicates that the hydraulic
system is okay and that the fault lies within the
transmission assembly. Remove and inspect the
relevant solenoid valve assembly, if no fault is
found suspect an internal transmission fault. it will
be necessary to remove the transmission and
disassemble the relevant area to locate the fault.

35- 25
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
RANGE COMMAND TRANSMISSION PRESSURE
TESTING

4. Prepare the tractor for pressure testing:

(iii) Start and drive the tractor to warm the
transmission oil to a minimum operating
temperature of 50°C (122°F).
(i) Ensure the handbrake is fully applied and
wheels chocked.
5. Install diagnostic switch (1) Tool No.295041
(4FT.950) into the white diagnostic plug of the
tractor harness.
49
For ease of testing use (0--40bar, 0--600 lbf.in2)
pressure test gauge with quick release coupler as
shown. 2
1. Pressure gauge, 293242 1
2. Quick release adaptor, 291924
3. Hose 292246
4. Adaptor, 291927 4

50
Transmission Clutches, A,B,C,D and E
A B
E D C
6. Install adaptors 297404 and quick release fitting
297240 into test ports and attach gauges.
If pressure gauges with 7/16 in JIC hoses are used
then 10--1.00 mm x 7/16 JIC adaptors 297417
(NH.35--103) can be installed into the test ports as
an alternative fitting.

TA6021003
51
7. Start the engine and enter HJ mode. Depress the
clutch pedal and move the shuttle lever into
forward. Release the clutch. The upper character
on the display will show ‘A’, indicating that clutch ‘A’
solenoid will be energised. To energise the
solenoid press and hold the downshift button and
observe the pressure reading on the gauge which
should be 17±1 bar.

35- 26
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
8. To select other clutches, B, C ,D or E, repeatedly
press the upshift button and then depress the
downshift button to energise the solenoid.

9. The pressure can be controlled with the clutch

53
Low, Medium, High and Reverse Synchroniser
Pressure Testing 2
1
Figure 54 -- 1. Reverse synchroniser test point
2. High synchroniser test point

Figure 55 -- 1. Low synchroniser test point

2. Medium synchroniser test point
TIA35159

54
Due to the operating characteristics of the
transmission it is not possible to pressure test the 2
synchroniser circuits during normal tractor operation.

To check the pressure within the synchroniser circuits it

is recommended that the clutch calibration procedure
using, H1, mode ‘N’ is used.

TIA355160
55
1. Install adaptors 297404 and quick release fitting
297240 into test ports.
Where access is restricted banjo fitting 297602 and
quick release fitting 297240 can be used
2. Attach (0--40bar, 0--600 lbf.in2) pressure test
gauge with quick release coupler 291924 to each
test port.
If pressure gauges with 7/16 in JIC hoses are used
then 10--1.00 mm x 7/16 JIC adaptors 297417
(NH.35--103) can be installed into the test ports as
an alternative fitting.
TA6021013
56

35- 27
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
3. Start engine and use diagnostic switch (1) to enter
mode H1.

57
4. Depress the clutch pedal and position the shuttle
lever in forward.

5. Depress the clutch pedal and position the shuttle

lever in forward.

6. Set engine speed to 1100 rev/min.

58
7. Cycle through H1 to ‘N’, using the upshift button.

8. Depress the downshift button to activate all of the

synchroniser solenoids.

59
9. Each gauge should indicate 17±1 bar when the
solenoids are activated and zero when
deactivated.

10. If all gauges read low, suspect a fault in the low

pressure hydraulic system, refer to section 35.

11. If one or more gauges read correct and the other

35- 28
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
DUAL COMMAND TRANSMISSION PRESSURE
TESTING
Transmission Clutches A and B

1. Prepare the tractor for pressure testing:

(iii) Start and drive the tractor to warm the
transmission oil to a minimum operating
temperature of 50°C (122°F).
(i) Ensure the handbrake is fully applied and
wheels chocked.
(i) Remove the instrument console side covers, lift and TA6021012
remove cab rubber mat and remove the floor pan.
61
(iii) Ensure the handbrake is fully applied and wheels
chocked.

(iv)Disconnect a range switch connector and install

bypass connector, Special Tool 295044 (4FT.951)
into the harness, (1) Figure 61.
For ease of testing use (0--40bar, 0--600 lbf.in2)
pressure test gauge with quick release coupler as
shown. 2
1. Pressure gauge, 293242 1
2. Quick release adaptor, 291924
3. Hose 292246
4. Adaptor, 291927 4

62
2. Install adaptors 297404 and quick release fitting
297240 into test ports A and B and attach gauges.
If pressure gauges with 7/16 in JIC hoses are used
then 10--1.00 mm x 7/16 JIC adaptors 297417
(NH.35--103) can be installed into the test ports as
an alternative fitting.

35- 29
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
3. Start the engine, engage 1st GEAR, and shuttle to
FORWARD, leaving the RANGE IN NEUTRAL.
Increase engine speed to approximately. 1200
rev/min.

4. Using the Hi--Lo buttons on the main shift lever,

switch between Hi and lo drive and observe the
gauges.
TA6021005
64

Each clutch should obtain 16--18 bar

(235--261 lbf/in2) maximum pressure, when fully
engaged and zero pressure when disengaged.

TA6021007
65

During the swapping of clutches there is an overlap

period where both clutches have approximately 5 bar
(75 lbf/in2) at the crossover point.

When the clutch pedal is depressed a gradual reducing

67
35- 30
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Shuttle Synchroniser Operating Piston Pressure
Testing

NOTE: Due to the operating characteristics of the R F

1. Prepare the tractor as described for testing the A

TA6021010
and B clutches.
68
NOTE: If only pressure testing the synchroniser piston
it is not necessary to install the range switch bypass
connector, tool number 295044 (4FT.951).

2. Install the pressure gauges, adaptors and hoses

into the test points located in the top cover, Figure
68.

3. Enter the calibration mode for the synchroniser:--

(i) Press and hold engaged, both the Hi--Lo shift

buttons on the main lever. With the buttons
depressed start the engine.

(ii) ‘CAL’ will be displayed on the instrument panel.

Release the buttons.

(iii) Press and hold in both the Hi--Lo shift buttons again.
After a few seconds ‘SOC’ will be displayed and the
synchroniser calibration will commence.

Pressures
Stage Forward (F) Reverse (R)
1 NO NO
The table (Figure 70) shows the synchroniser
calibration stages and at what stage pressure can be
2 NO YES
expected to be seen.
3 B CLUTCH PRESSURISED

4 NO NO

5 YES NO

35- 31
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
TRAILER BRAKE VALVE PRESSURE TESTING AND TROUBLESHOOTING

Delivery or suction oil

Discharge oil
Tractor braking circuit oil
(brakes not applied)
71
TRAILER BRAKE VALVE ELECTRO--HYDRAULIC OPERATION DIAGRAM (ITALY ONLY)
ENGINE RUNNING, PARKING BRAKE ENGAGEMENT.
1. Parking brake control lever -- 2. Parking brake indicator circuit relay -- 3. Trailer brake circuit relay -- 4. Trailer braking control
solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Discharge solenoid valve (normally closed) -- 6. Trailer brake
disengagement pressure regulating valve -- 7. Trailer braking valve (see pages 3 and 4) -- 8. Trailer brake circuit safety switch -- 9.
Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Hydraulic lift and auxiliary valve supply line -- 13. Brake pump -- 14.
Trailer--tractor coupler -- 15. Trailer brake control line -- 16. Trailer brake engaged indicator switch 17-- 19. Springs -- 18. Trailer
brake control pin -- 20. Battery -- 21. Parking brake engaged switch -- 22. Trailer brake engaged light indicator.
Parking brake (1) engagement makes the switch (21) close. Therefore current is allowed to reach and excite the relay
(2),and through the closed relay contact (2) it excites the solenoid valves (5a and 5b) closing the former and opening
the latter. In this condition line and trailer brake oil (15), subject to the spring (19) force can reach the discharge
through the solenoid valve (5b). Braking action is performed mechanically following the spring (19) pressure on the
pin (18). Oil discharge creates a pressure drop which closes the switch (16), and current, passing through the switch
(16), reaches the instrument panel light indicator (22), which lights up.
Notice -- After parking brake engagement, wait approx. 10 seconds before stopping the engine to permit complete
oil discharge from trailer brake cylinder and obtain optimal braking action.

35- 32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
TEST CONDITIONS.
Oil temperature 40° to 50° C. Electrical system powered.
Engine speed 1000 rpm. Parking brake disengaged.

TRAILER BRAKE DISENGAGEMENT PRESSURE TEST

(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 (1) into the trailer brake
coupler and connect it to a 0 to 40 bar pressure
gauge 293242.
2. With engine and oil as detailed above, pressure
should be 11 to 12 bar (11.2 to 12.2 kg/cm2).
3. Make sure that light indicator (22, Figure 71 ) is off.
4. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).

TROUBLESHOOTING
Problem Possible cause Correction
Trailer brake disengagement 1. Parking brake (1, Figure 71) Disengage parking brake.
pressure = 0 bar (light indicator on engaged.
22, Figure 71).
2. Trailer brake disengagement Replace valve.
pressure valve misadjusted (6)
3. Faulty trailer brake circuit safety Replace switch.
switch (8).
4. Faulty hydraulic pump (9). Overhaul or replace pump.
5. Delivery solenoid valve (5a) Repair or replace solenoid valve.
stuck closed.
6. Discharge solenoid valve (5b) Repair or replace solenoid valve.
stuck open.
Trailer brake disengagement 1. Trailer brake disengagement Replace valve.
pressure = 0 to 11 bar pressure valve misadjusted (6).
(0 to 11.2 kg/cm2).
Correct trailer brake 1. Faulty trailer brake engaged indi- Replace switch.
disengagement pressure but light cator switch (16).
indicator (22) is on.
Trailer brake disengagement 1. Faulty indicator lamp (22). Replace lamp.
pressure not correct but light
indicator (22) is off.
2. Faulty trailer brake engaged indi- Replace switch.
cator switch (16).

NOTE: The switch (8) can be recognized by the red paint point between the two switch blades.

35- 33
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
TRAILER BRAKING SYSTEM PRESSURE TEST
(ALL MODELS)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 250 bar pressure gauge
293244.
2. Couple both brake pedals together and with engine
and oil in the conditions described at the beginning
of this chapter, apply the foot brake. The pressure
gauge reading should increase depending on
pedal effort up to 135 to 145 bar (138 to 148
kg/cm2).
3. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).
25265
73

HYDRAULIC SYSTEM LEAK TEST

(ALL MODELS)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 250 bar pressure gauge
293244.
2. Couple both brake pedals together and with engine
and oil in the conditions described at the beginning
of this chapter apply the foot brakes for a minimum
of 10 seconds. The pressure gauge reading should
increase up to 135 to 145 bar (138 to 148 kg/cm2)
and remain constant.
3. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1).
25265
74

TROUBLESHOOTING.
Problem Possible cause Correction
Excess pressure peaks are 1. Oil leaks from hydraulic system. Locate leaks and repair.
observed when applying the brake
pedals for 10 seconds.
2. Solenoid valve leak Replace solenoid valve.
(5b, Figure 71).
3. Trailer brake auxiliary valve (7) Replace trailer brake auxiliary
leaks. valve.

35- 34
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
PARKING BRAKE ENGAGEMENT TEST
(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 (1) in trailer brake coupler
and connect it to a 0 to 40 bar pressure
gauge293242.
2. With engine and oil in the conditions described at
the beginning of this chapter, fully raise parking
brake control lever (1, Figure 71).
3. Check if pressure is 0 bar and light indicator (22,
Figure 71) is on.
4. With parking brake engaged disconnect pressure
gauge and fitting no. 293190 (1).
25265
75
TROUBLESHOOTING.
Problem Possible cause Correction
Trailer brake disengagement 1. Faulty parking brake engaged Replace switch.
pressure does not zero when switch (21, Figure 71).
parking
ki brake
b k isi applied.
li d
2. Faulty parking brake indicator Replace relay.
circuit relay (2).
3. Discharge solenoid valve Repair or replace solenoid valve.
(5b)faulty or stuck closed.

TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST

(ITALIAN TRAILER BRAKES ONLY)
Proceed as follows:
1. Insert fitting no. 293190 in trailer brake coupler and
connect it to a 0 to 40 bar pressure gauge 293242.
2. With parking brake ‘Off’ and tractor brakes not
applied, operate and hold the remote control valve
lever and allow the system pressure relief valve to
operate. Keep this position for a few seconds and
quickly release the control lever.
3. Check if parking brake disengagement pressure
remains at the specified value: 11 to 12 bar (11.2
to 12.2 kg/cm2).
4. Engage parking brake, disconnect pressure gauge
and fitting no. 293190 (1). 25265
76
TROUBLESHOOTING.
Problem Possible cause Correction
Trailer brake disengagement 1. Trailer brake circuit safety switch Replace switch.
pressure is permanently zeroed (8, Figure 71) adjustment
when operating the levers exceeding rated value (3 ± 0.5
described above. bar).
2. Switches (8 and 16) reversed in Move switches to correct positions
the specified positions or with or reverse power supply cables.
exchanged power supply cables.

NOTE: The switch (8) can be recognized by the red painted dot between the two switch blades.

35- 35
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 10
Cooler Bypass Valve -- Lubrication Pressure
IMPORTANT: Before performing any pressure or flow
testing operate the tractor until the oil in the rear axle
is at normal operating temperature. 75°C (170°F).
The following test checks the operation of the cooler
bypass valve and lubrication valve and should be
performed if insufficient lubrication pressure is
suspected.
1. Insert the Tee--piece, 297610, (1), with quick
release fitting, 297240, (2), into the lubrication
tube, between the transmission top cover and the
oil cooler.
2. Install 27 bar (300 lbf.in2) gauge, 297167, (3) using
hose 292246 and quick release coupler 291924. 77
3. The following pressures should be observed at the
different engine rev/min.

3.0 bar @ 1000 erpm

3.5 bar @ 1500 erpm
7.5 bar @ 2000 erpm
Brake Booster Valve Pressure Test
The system works from the low pressure circuit and
therefore the engine must be running to measure
operation pressures. Both brake pedals must be
pressed simultaneously to operate the booster due to
the logic head in the braking system.
1. Insert a banjo 297602, (1), quick release fitting
297240, (3), in place of the bleed fitting on the
booster.
2. Install a 100 bar (1450 lbf.in2) gauge, 293243, (2).
3. Disconnect the front axle tube where the solid tube
joins the flexible hose.
78
4. Install tee--piece, 297601, (1), with quick release
adaptor, 297240, (4) and blanking cap 297605, (2).
Fit the gauge 293243, (3) with quick release
coupling, 291924 and bleed the front brake line
before commencing the pressure test.
NOTE: Isolating the front brakes eliminates the
possibility of testing with air or leaks at that end of the
system.
5. The following pressures, in bar, should be
observed with the engine OFF and with the engine
at 1000 rev/min with both brake pedals depressed.

0 rev/min 1000 rev/min

79
Booster valve input 45--55bar 45--55bar
Brake Oil pressure 10--15bar 50--55bar

NOTE: Pressures obtained at maximum brake pedal

force.

35- 36
SECTION 41 -- STEERING -- CHAPTER 1
SECTION 41 -- STEERING

Chapter 1 -- Hydrostatic Steering System

CONTENTS

Section Description Page

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
41 204 Steering Motor -- Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering Motor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steering Column -- Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
41 216 Two Wheel Drive Steering Cylinder -- Removal and Installation . . . . . . . . . . . . . . . . . . . . 26
Two Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Four Wheel Drive Steering Cylinder -- Removal and Installation . . . . . . . . . . . . . . . . . . . . 28
Four Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

41- 1
SECTION 41 -- STEERING -- CHAPTER 1
41 000 SPECIFICATIONS
HYDROSTATIC SYSTEM
Pump specifications 2WD 4WD 4WD
with SuperSteer
Minimum Pump Output
Litres/min. 39.1 61.5 61.5
[Link]/min. 8.57 13.48 13.48
U.S. Galls/min. 10.34 16.27 16.27
Steering Motor Displacement 125cc/revolution 160cc/revolution 100/180cc/revolution
Relief Valve Maximum Differential 170 Bar 170 Bar 170 Bar
Pressure Setting 2465 lbf.in2 2465 lbf.in2 2465 lbf.in2
Absolute Gauge Pressure 186 Bar 186 Bar 186 Bar
2700 lbf.in2 2700 lbf.in2 2700 lbf.in2
TWO WHEEL DRIVE AXLE
Standard Tyre (Front) 11.00 x 16
Maximum Steering angle 55°
Steering Wheel Turns Left to Right 3.98
(Lock to Lock) Right to Left 5.03
Cylinder Double Acting
Unbalanced
Turning Radius with Brakes 3.9m
Turning Radius less Brakes 4.3m
Toe--out 0--13 mm
FOUR WHEEL DRIVE AXLE
Standard Tyre (Front)
Class 3 380--70R28
Class 4 16.9R x 28
Maximum Steering angle 55° or 65° with SuperSteer
Steering Wheel Turns
(Lock to Lock)
Class 3 Axle 4.3
Class 4 Axle 4.8
Cylinder 2 off double acting Unbalanced
115 125 135 150 165
Turning Radius with Brakes 4.15m 4.15m 4.0 4.0m 4.0m
(4WD disengaged)
Turning Radius less Brakes 4.6m 4.6m 4.65m 4.65m 4.65m
(4WD disengaged)
Turning Radius
(with SuperSteer)
Toe--In 0--6mm

41- 2
SECTION 41 -- STEERING -- CHAPTER 1
41 000 TIGHTENING TORQUES

Steering General
Nm [Link]

Steering Wheel Retaining Nut 23.0 17.0

Front Wheel Nut 2WD 314.0 230.0
Front Wheel Nut 4WD 211.0 156.0
Motor End Cover 23.0 17.0
Cylinder, Rod End Nut (2WD) 270.0 200.0
Cylinder, Tube End Nut (2WD) 360.0 265.0
Cylinder, Tube End Pin Retaining Bolt (4WD) 24.0 17.0
Column to Frame Bolt 23.0 17.0

41 000 -- SPECIAL TOOLS

DESCRIPTION New Holland Tool Number [Link] Ltd Tool Number
Pressure Gauge (0--6000 lb/in2) 292870 FT8503A
Roto--glyd Seal Installer 294056 --
Adaptor (Gauge to Hose) -- FT8503--8
Test Hose E1NN F493 AA (Finis Code 3936707)
Adaptor (Test hose to tractor tube) 7/16 JIC Male x 9/16 JIC Male

41- 3
SECTION 41 -- STEERING -- CHAPTER 1
41 000 -- DESCRIPTION AND OPERATION

1
Hydrostatic Steering System Component Layout (Range Command shown)
1. Left Hand Turn Hose 6. Steering Pump
2. Steering Cylinder 7. Pump Output Line
3. Right Hand Turn Hose 8. Resonator (System Silencer) (not Supersteer)
4. Steering Return / Lubrication Line 9. Resonator to Steering Motor Line
5. Inlet to Pressure Regulating Valve 10. Steering Motor
All models have fitted as standard, hydrostatic steering On two wheel drive units the steering cylinder is fixed
systems that are powered when the engine is running at one end to the front axle beam and at the other to an
by hydraulic pumps mounted on the rear axle. eye on the spindle steering arm.
There are two basic types of fixed displacement On four wheel drive units two steering cylinders are
steering pump used depending on whether the main used, one for each wheel. The cylinders are fixed at
hydraulic system has a closed centre or open centre one end to the axle casing and the piston end to
system. steering arms from the swivel housings.
Both open and closed centre hydraulic systems The pressure relief valve for the system is contained
incorporate a steering pump as part of the hydraulic within the steering motor itself.
pump assemblies and both types share the main intake
filter of that system. OPERATION -- All models except Supersteer
The pumps, driven by a gear straight from the P.T.O. Oil is drawn from the rear axle and into the pump
shaft, pressurise the steering column operated through a filter, pressurised by the rotation of the gears,
steering motor. The pressurised oil from the steering and expelled through the pump outlet port to the
motor drives the axle mounted double acting steering steering motor. The oil is pumped to the steering motor
cylinder (2WD), or twin cylinders (4WD). via a flow priority valve which restricts oil to the steering
The steering motor is similar across the vehicle range motor when the steering is not in use and diverts oil to
and is bolted to a bracket within the steering console the low pressure hydraulic system. When the steering
and connected to the steering column by a splined is in use, the valve then diverts oil to the steering motor.
shaft. A resonance damper filter is also in line between the
The supersteer model uses a load sensing flow priority valve and steering motor, this reduces the
non-reactive motor. noise from the system and smooths the output from the
The steering column is adjustable for varying angles of pump. The pressurised oil when received at the
tilt on all models. steering motor is directed to the steering actuating
cylinder when the steering wheel is turned.

41- 4
SECTION 41 -- STEERING -- CHAPTER 1

Return Oil
Suction Oil (Restricted by Cooling and Lubrication
Trapped Oil Pump Oil

2
Steering Operation Schematic -- Neutral Position
1. Metering Unit 8. Pressure Relief Valve
2. Check Valve 9. Control Valve Sleeve
3. Non Return Valve 10. Control Valve Spool
4. Resonance Damper Filter (not Supersteer Models) 11. Suction Valves (2WD Only)
5. Pump and Flow Control Valve 12. Bias Valve (2WD Only)
6. Filter 13. Steering Cylinder/s
7. Return via Cooling and Lubrication

The steering motor incorporates a metering unit which Neutral Position

regulates the volume of oil supplied to the cylinder so With the steering wheel held still, the leaf springs in the
that it is proportional to the angular movement of the steering motor return and hold the spool and sleeve in
steering wheel. The metering unit in combination with the neutral position. This ensures no more oil is
the check valve also allows the steering to be operated supplied to the steering cylinder, Figure 2. The
MANUALLY without pressurised oil being supplied trapped oil is, however, allowed to transfer between the
from the pump. left and right turn sides of the cylinder/s, allowing the
Suction valves, item 10 Figure 2, only used on two wheels to react to the ground to provide feedback for
wheel drive models, prevent cavitation in the steering the driver.
cylinder as oil is transferred from a small area to a large
area when the steering motor is in the neutral position.
The system is fully hydrostatic and as such there is no
mechanical connection between the steering column
and the steering wheels.

41- 5
SECTION 41 -- STEERING -- CHAPTER 1

Suction Oil Pressure Supply

Metering Unit Supply Metered Oil to Steering Cylinder

Return Oil
(Restricted by Cooling and Lubrication
3
Oil Flow Schematic
A-- Right Hand Turn B-- Left Hand Turn

Right Hand Turn Left Hand Turn

When the steering wheel is turned the movement of the When turning the wheel to the left oil flows along the
control valve spool in its sleeve forms a series of sleeve and operates in a similar manner as described
passages. During right turns the oil flows through the in right hand turn, Figure 3.
sleeve along a groove in the valve spool and into a
passage in the steering motor housing which leads to Manual Turning (no Power Assistance)
the metering unit, Figure 3.
In the event of a power steering pump failure or loss of
The metering unit is turned by the drive shaft and oil pressure, the power steering system can be
directs oil along another set of passages in the spool operated manually. Turning the steering wheel rotates
and sleeve and into the steering cylinder. Return oil the metering unit rotor and forces oil into the power
from the other side of the cylinder is directed through steering cylinder (2WD) or cylinders (4WD).
the valve spool and sleeve to a return passage in the
On the suction side of the metering unit, return oil flows
housing.
from the cylinder and is drawn through the check valve
to feed the metering unit.

41- 6
SECTION 41 -- STEERING -- CHAPTER 1

Steering Motor Pressure Oil Exhaust Oil

Suction Oil

Steering Operation -- Supersteer Models -- Manual Steering

1. Steering Pump 7. Metering Unit

2. Priority Valve Spool 8. Amplifying Valve
3. Relief Valve 9. Priority Valve Load Sense Orifice
4. Check Valve 10. Priority Valve Orifice
5. Control Valve Sleeve/Spool 11. Check Valve
6. Shock Valves

Operation -- Supersteer Models When there is no steering pump output, i.e. engine off
The steering motor fitted to models with the supersteer or pump failure, the amplifying valve restricts the oil to
front axle is a load sensing non-reactive type. The pass through the metering unit only, thereby supplying
motor is designated as a 100--180, meaning that, with 100 cc/rev of oil to the rams. This has the effect of
the use of a flow amplification valve the system can increasing the amount the steering wheel needs to
produce either 100 cc or 180 cc of oil, depending on rotate but reducing the effort required, necessary for
whether the steering pump is supplying oil to the motor. these emergency conditions.

41- 7
SECTION 41 -- STEERING -- CHAPTER 1

Steering pump pressure Oil Trapped Oil

Dynamic Steering Oil Exhaust Oil

Low Pressure Regulated Oil Suction Oil

5
Steering Operation -- Supersteer Models -- Engine Running, Steering Wheel Stationary

1. Steering Pump 7. Metering Unit

With the engine running and the steering wheel sleeve/spool. If the front wheels hit a large obstruction,
stationary the flow priority valve directs most of the pressure increase in the rams is relieved by the shock
pump oil into the low pressure circuit. The pump oil valves, which open and return oil to the low pressure
supplied to the dynamic load sense line is also circuit.
redirected by the steering motor control valve Smaller shocks to the front wheels are relieved by the
sleeve/spool to the low pressure circuit. Oil is also check valve, item 11.
trapped in the steering rams by the control valve

41- 8
SECTION 41 -- STEERING -- CHAPTER 1

Steering Pump Pressure Oil Low Pressure Regulated Oil

Dynamic Steering Oil Exhaust Oil

Metering Unit Pressure Oil Suction Oil

6
Steering Operation -- Supersteer Models -- Engine Running, Steering Wheel Speed less than 20 rev/min.

1. Steering Pump 7. Metering Unit

With the engine running, turning the steering wheel at for the steering rams is provided by the dynamic
speeds less than 20 rpm will not induce any additional sensing oil, passing through the metering unit.
oil, via the amplification valve, and therefore all the oil

41- 9
SECTION 41 -- STEERING -- CHAPTER 1

Steering Pump Pressure Oil Low Pressure Regulated Oil

Dynamic Steering Oil Exhaust Oil

Metering/Amplifying Valve Oil Suction Oil

7
Steering Operation -- Supersteer Models -- Engine Running, Steering Wheel Speeds greater than 20 rev/min.

1. Steering Pump 7. Metering Unit

As the speed at which the steering wheel is rotated This system provides fast rates of turning when
increases, the amplification valve progressively allows required and more subtle steering movements at
more oil to the motor and hence to the steering rams. slower speeds, i.e. straight line corrections.

41- 10
SECTION 41 -- STEERING -- CHAPTER 1
41 000 -- FAULT FINDING

IMPORTANT: When effecting a repair the cause must be corrected to avoid a repeat failure.

PROBLEM POSSIBLE CAUSE REMEDY

No steering or excessive effort 1. Air in system 1. Check for loose connections or
to steer damaged tubing. Purge system
of air.
2. Steering system relief valve 2. Check system pressure.
sticking/faulty
3. Worn pump 3. Inspect and repair.
4. Leaking steering cylinder 4. Inspect and repair.
5. Broken or damaged steering 5. Inspect and replace as required.
column coupling
6. Damaged or worn metering unit 6. Inspect and replace as required.
Steering wanders 1. Excessive play in steering 1. Inspect and replace as required.
linkage joints
2. Leaking steering cylinder 2. Inspect and repair.
3. Damaged or worn metering unit 3. Inspect and replace as required.
Drift to Left, Two Wheel Drive 1. Bias valve faulty 1. Replace or repair
only
Front wheels surge when 1. Leaking steering cylinder 1. Inspect and repair.
steering
2. Damaged or worn metering unit 2. Inspect and replace as required

41- 11
SECTION 41 -- STEERING -- CHAPTER 1
41 000 -- SYSTEM TESTING
When the hydrostatic steering system is in operation, 3 1
the pressure of oil supplied by the steering pump, item
3, Figure 8, to the steering motor, can rise towards the
maximum setting of the steering motor relief valve,
which is 170 bar (2465 lbf/in2) depending on tractor
model.
The pressure oil leaving the steering motor returns to
the transmission side cover, item 1, Figure 8, and the
regulating valve, item 2, Figure 8. The return oil then
becomes the low pressure oil supply for components
such as, front and rear differential locks, P.T.O. clutch 2
and brake and four wheel drive systems, where fitted. 60--41--023 TI
8

Steering Pump
There is no relief valve in the steering/low pressure
pump. The following practical test will determine if
steering pump output is sufficient to allow satisfactory
operation of the steering system.

Steering Test
1. Set engine speed to 1000 rev/min.
2. Turn steering quickly from lock to lock. If steering
is operating correctly the reaction of the steering
should be immediate with no time delay between
turning the steering wheel and movement of the
wheels. At full lock the relief valve in the steering
motor should be heard to blow and the engine
speed should drop to approximately 970 rev/min.

41- 12
SECTION 41 -- STEERING -- CHAPTER 1
Steering Relief Valve Pressure Test
IMPORTANT: There is no relief valve in the
steering/low pressure pump and the following pressure
test must only be performed as specified below. Failure
to observe this precaution may result in severe
damage to the hydraulic pump.
1. Turn steering onto full left hand lock.
2. Disconnect left hand turn feed hose at steering
cylinder.

3. Install a 0--6000 lbf/in2 pressure gauge FT. 8503A,

item 1, Figure 10, using adaptor FT8503--8, item 1
2, Figure 10 and a locally procured 7/16 JIC male
x 9/16 JIC male adaptor, item 3, Figure 10.
Using kit 292870 install adaptor 293874 and
291318 into the place of the banjo fitting of the
steering hydraulic cylinder.
4. Start tractor and set engine speed to 1450 rev/min.
Turn steering wheel to the left with a pull of
approximately 22 N (2.25 kgf, 5 lbf) and observe
the pressure reading.
NOTE: The use of a force greater than 5 lbf. at the rim 3 2
of the steering wheel may lead to slightly inaccurate 60--41--024 TI
readings due to the pumping action of the hydrostatic 10
steering motor.
If the steering test was satisfactory but the pressure
readings are away from specification the relief valve in
the steering motor must be adjusted.
The pressure reading should be:--
186 bar (2700 lbf/in2) for all models.
5. If the system pressure is not to specification
proceed to Relief Valve Adjustment.

Differential Pressure
Differential pressure is the difference in pressure
between the supply and sump ports on the steering
motor. Measured (gauge) pressure is equal to the relief
valve setting plus system back pressure.
System back pressure should be 16 bar (232 lbf/in2) for
all models.
The flow of oil on leaving the steering motor returns to
the pump body for distribution to the low pressure and
lubrication circuits. The pressure of oil returning from
the steering motor is regulated at a pressure of
16.0 bar (232.0 lbf/in2), by the low pressure regulating
valve at 2100 revs/min. As the pressure is regulated,
excess oil in the low pressure circuit flows through the
regulating valve, into an adjacent lubrication circuit
relief valve which limits the pressure of oil in the
lubrication circuit to 7 bar (100 lbf.in2).

41- 13
SECTION 41 -- STEERING -- CHAPTER 1

1
13
2
12
3

9 B 10
T
11

8 7 A 6

11
Steering Motor Relief Valve Adjustment

1. Plug 8. Size 8 ORS Swivel Running Tee

2. Steering Shaft 9. Size 10 ORS Swivel Running Tee
3. Relief Valve 10. Pressure Gauge [Link] 2
4. Fabricated Steering Motor Output Hose 11. Size 6 ORS Blanking Cap
5. Tractor Tubes to Steering Cylinder 12. Spring
6. Fabricated Hose for Pump Supply to Steering Motor 13. Adjuster
7. Pressure Gauge [Link] 2

41- 14
SECTION 41 -- STEERING -- CHAPTER 1
Relief Valve Adjustment -- All Models 3. With the engine running, turn the steering motor
With reference to Figure 11. shaft to obtain full lock. The pressure gauge
reading at point ‘A’ should read 186 bar (2700
NOTE: To adjust the steering system relief valve it is
[Link] 2). The gauge pressure at point ‘B’ should be
necessary to remove the steering motor from the
in the region of 16 bar (235 [Link] 2).
steering bracket, to gain access to the hexagon
headed adjusting screw. 4. To establish actual (differential) pressure subtract
gauge ‘B’ reading from the gauge ‘A’ reading. The
1. Disconnect the steering motor from the steering
differential pressure should be to the specification
bracket, as detailed previously in this Chapter, and
of:
remove from the tractor.
Gauge ‘A’ 186 bar (2700 [Link] 2) minus Gauge ‘B
2. Fabricate suitable test hoses to connect from the 235 [Link] 2 (16 bar) =
tractor pressure and return tubes. Connect the 2465 [Link] 2 (170 bar) on all models
hoses into locally procured tee pieces and install
5. If the pressure readings are not correct, reset the
pressure gauges. Start the engine and idle
adjuster (item 13), 11, using an 8mm hexagon key.
between 1450 and 1500 rev/min. Run the tractor
Half a turn on the adjuster equates to
until the transmission oil reaches normal working
approximately 200 lbf.in2 (13.8 bar).
temperature of approximately 68°C (155°F).

41- 15
SECTION 41 -- STEERING -- CHAPTER 1
41 204 -- STEERING MOTOR - OVERHAUL

5 15 16
14
17 1
18
19

13
12
11
10

5 2

3
9

5
8
7

6 5 4
60--41--001 TI

12
Steering Motor (2WD + 4WD Less Supersteer)

1. Pin 11. Ball

2. Centering Springs 12. Relief Valve Seat
3. Retaining Bolts 13. Relief Valve (Kit items)
4. Dowel Pin Bolt 14. Spring
5. ‘O’ Ring Seal (Kit) 15. Complete Assembly
6. End Plate 16. Ball
7. Rotor and Stator Assembly 17. Pin
8. Manifold Plate 18. Thrust Bearing and Washers
9. Drive Shaft 19. Spacer
10. Retainer

NOTE: Parts/Motors are common between the two steering pumps, with the exception of items 7,10,12 and 13,
Figure 12.

41- 16
SECTION 41 -- STEERING -- CHAPTER 1
Removal
1. Position the tractor on a hard level surface and
apply the parking brake.
2. To gain access to the steering motor :--
Raise the engine hood
Remove the left hand steering column console
Remove left hand engine side cover
3. Disconnect the four supply/return tubes and ‘O’
ring seals from the steering motor and cap the ends
of the tubes.
4. Remove the roll pin from the drive collar to
separate the steering shaft, Figure 13. 60--41--018 TI
5. Remove the four bolts at the base of the steering 13
column and slide the steering motor from the upper
section of the steering column, Figure 13.
6. Remove the steering motor from the front of the
cab through the engine compartment.

Dlsassembly
1. With the steering motor connectors removed note
position of the non return valve.
2. Hold the steering motor securely in a vice using a
tube connector as shown in, Figure 14.
NOTE: The position of the pin bolt must remain the
same on re--assembly.
3. Remove the end plate bolts, end plate and ‘O’ ring,
Figure 14.

60--41--002 TI
14
4. Remove metering unit, valve plate and ‘O’ ring
seals, note mating surfaces for correct
re--assembly, Figure 15.

60--41--003 TI
15

41- 17
SECTION 41 -- STEERING -- CHAPTER 1
5. Lift out rotor drive-shaft, Figure 16.

60--41--004 TI
16
6. Unscrew the check valve retainer, Figure 17 and
shake out the check and suction valves.

60--41--005 TI
17
7. Remove the relief valve assembly, Figure 18.
IMPORTANT: The relief valve must be set to the
correct pressure setting on re--assembly. Follow the
correct procedure as detailed under the heading
‘Pressure relief valve setting’, of this Chapter.

60--41--006 TI
18
8. Remove the inner and outer valve sleeves,
bearings and thrust washer, Figure 19.
NOTE: When removing spool and sleeve ensure drive
pin is in a horizontal position so that it cannot fall into
an internal gallery and make removal difficult.

60--41--007 TI
19

41- 18
SECTION 41 -- STEERING -- CHAPTER 1
9. Once spool is disassembled from the body ensure
oil seal is removed, Figure 20.

60--41--008 TI
20
IMPORTANT: Upon re--assembly ensure washer, item
1, Figure 21 is installed with chamfer towards the 1
valve sleeve.
10. Remove the control valve spool and sleeve, Figure
21.

60--41--009 TI

21
11. Remove centering springs, Figure 22.
NOTE: Arrangement of the leaves must remain the
same upon re--assembly.
12. Remove drive pin, Figure 22.
13. Push inner sleeve from outer sleeve.
14. Remove ‘O’ ring and back-up ring.

60--41--010 TI
22

41- 19
SECTION 41 -- STEERING -- CHAPTER 1

23
Steering Motor (with Supersteer)

1. Relief Valve 16. Amplification Orifice

2. Spring for Relief Valve 17. Amplification Spool
3. Shock Valve 18. Spring
4. Shock Valve 19. Plug
5. Dust Seal Ring 20. Drive Link
6. LS Check Valve, Ball 21. Spacer
7. LS Check Valve, Screw 22. O--ring
8. Shaft Seal 23. Distributor Plate
9. Bearing 24. Gear Wheel Set
10. Ring 25. O--ring
11. Cross Pin 26. End Cover
12. Set of Springs 27. Washer
13. Housing, Spool and Sleeve 28. Special Screw
14. Thread Bushing 29. Special Screw
15. Ball ø 8.5 mm 30. Name Plate

Inspection abrasive. Ensure all parts are thoroughly cleaned

1. Wash all parts in a suitable solvent to remove any prior to re-assembly.
foreign particles and dry with a clean lint free cloth 3. Check leaf springs for damage. Replace if
or compressed air. necessary.
2. Inspect valve sleeves for, damage or wear. Minor 4. Discard all ‘O’ ring seals and replace with new
burrs or scratches can be removed with a fine seals on re-assembly.

41- 20
SECTION 41 -- STEERING -- CHAPTER 1
Re-Assembly
1. Assemble inner and outer sleeves so that the leaf
spring slots align.
2. Install the drive pin, Figure 24.

60--41--010 TI
24
3. Install the leaf springs and push fully into position,
Figure 25.

60--41--012 TI
25
4. Install leaf spring retainer, and bearing, Figure 26.
NOTE: The inner bearing race must be positioned with
the chamfer side facing the spool, 21.

60--41--009 TI

26
5. Apply a light coating of hydraulic oil onto the sleeve
item 2 and insert into the steering motor body, item
3, Figure 27.
6. Coat the ‘O’ ring and back-up ring, item 4, Figure
27, with hydraulic fluid and position them onto the
seal installer guide.
-- Use New Holland special tool No. 293388 to
install oil seal type kin--ring.
-- Use New Holland special tool No. 294056 to
install oil seal type roto--glyd.

60--41--013 TI
27

41- 21
SECTION 41 -- STEERING -- CHAPTER 1
7. Position the seal guide tool into the sleeve and
push down with a twisting action, Figure 28.
8. Remove tools once the seal has seated.

60--41--014 TI
28
9. With the seal installed in the motor body refit
control valve, Figure 29.
NOTE: Ensure that the Drive is in a horizontal position
to aid re--assembly.

60--41--015 TI
29
10. Once the control valve is seated correctly refit the
check and suction valves, Figure 30.
11. Screw the check valve down to just below the
surface of the housing.

60--41--005 TI
30
12. Refit the ‘O’ Ring and place the end plate in
position.

60--41--016 TI
31

41- 22
SECTION 41 -- STEERING -- CHAPTER 1
Metering Unit Reassembly
1. To aid reassembly install the control valve into the
housing so that the drive pin is perpendicular to the
front face of the housing.
2. Install drive link into the steering motor body,
Figure 32, ensuring that the link engages correctly
over the drive pin.

60--41--004 TI
32
3. Assemble the metering unit rotor and stator and
install new lightly greased ‘O’ rings to either side of
the stator, Figure 33.
4. Assemble the rotor and stator onto the drive link.

60--41--003 TI
33
5. Install the end plate and bolts, ensure the pin
bolt(1) is fitted in position ‘7’. Tighten the bolts in
6 4
two steps, first to 8 [Link] (10.8 Nm) and then to 21
[Link] (28.4 Nm) in sequence as shown, Figure 34.
1 2

3 7

41- 23
SECTION 41 -- STEERING -- CHAPTER 1
6. Install the relief valve assembly, items 1, 2 and 3
Figure 35., leaving the plug, item 4 out until after
the relief valve has been adjusted.
7. Check to ensure the motor turns freely without
binding. 4
IMPORTANT: The relief valve must be set to the
correct pressure setting after the motor has been
re--assembled. Follow the correct procedure as
detailed under ‘Pressure relief valve setting’, of this
Chapter. 1
2
8. After the relief valve has been correctly set
re--install the steering motor onto the mounting 3
bracket and tighten the securing bolts to a torque 60--41--006 TI
value of 10--15 lbf ft(13--20Nm). 35
9. Reconnect the steering hoses, tighten to a torque
value of 10--15 lbf ft (13--20Nm).
10. Purge the air from the system by operating the
steering system from lock to lock until the system
functions correctly.

STEERING COLUMN REMOVAL AND

INSTALLATION
NOTE: The component parts of the steering column as
listed are serviced separately.

Removal
1. Remove the steering wheel, if required.
2. Remove the lower steering column cover complete
with multi--function switches.
3. Remove the upper steering column cover on
mechanical transmission models. Prior to
removing the upper cover on Hi--Lo and 60--41--028 TI
semi--powershift models remove the shuttle lever 36
from steering column.
4. Remove the instrument console side panels.
5. Remove the four securing bolts securing the
column to the frame, Figure 36.

6. Lift the column clear of the steering shaft and clear

of the instrument console, Figure 37.

60--41--027 TI
37
7. Remove the pin from the spacer at the bottom of Inspection
the column and remove the steering shaft and
spacer, Figure 38.

41- 24
SECTION 41 -- STEERING -- CHAPTER 1
1. Inspect the steering shaft universal joint and lower
rubber coupling. Replace if any free play is evident.
2. Inspect the column assembly, if damaged or the
bushes are worn a new assembly will be required.

60--41--025 TI
38
Installation
1. Place spacer and steering shaft onto the steering
motor and install pin.
2. Carefully place the steering column through the
instrument console and over the steering shaft,
ensuring flat sides are aligned.
3. Replace the securing bolts at the top of the column.
Tighten to 23 Nm (17 [Link]).
4. Refit the upper and lower column covers and
shuttle switch if fitted.
5. Refit the instrument console panels.
6. Refit the steering wheel. 60--41--026 TI
39

41- 25
SECTION 41 -- STEERING -- CHAPTER 1
TWO WHEEL DRIVE STEERING CYLINDER -- REMOVAL AND INSTALLATION (OP. 41 216)

1
2

5
4
3
60--41--029 TI
1
Steering Cylinder Installation -- Two Wheel Drive

1. Nut 5. Cylinder Mounting Bracket

2. Washer 6. Spacer
3. Nut 7. Bolt
4. Washer

Removal 4. Remove the nut securing the cylinder rod ball joint
1. Stand the unit on a hard level surface and position to the steering arm and separate the joint, Figure
the front wheel in the straight ahead position. 1.
2. Disconnect flexible pipes, cap the open pipe ends 5. Remove the steering cylinder to axle pivot pin and
and remove hose clamps. remove the steering cylinder from the vehicle.
3. Position of flexible pipes and orientation of 6. Installation is the reversal of the removal
connectors must be the same upon re--assembly. procedure.

41- 26
SECTION 41 -- STEERING -- CHAPTER 1
Steering Cylinder Overhaul -- Two Wheel Drive

1 2
13
3

4
9 5
6
7
8

2
Steering Cylinder Assembly -- Two Wheel Drive
1. Cylinder 8. Gland Lockring
2. Lockring 9. Cylinder Rod
3. Bearing 10. Retaining Ring
4. Gland 11. Piston
5. ‘O’ Ring 12. Seal
6. Seal 13. Seal
7. Wiper Seal
1. Using appropriate circlip pliers, remove the gland
lockring.
2. Using a punch, push the steering cylinder gland
into the cylinder and remove the wire locking ring.
3. Pull the rod and gland assembly from the cylinder.
4. Remove the nut from the cylinder rod and
disassemble to replace seals.

60--41--030
3
5. Inspect the bore of the cylinder and replace if
scored.
6. Reassemble the cylinder in the reverse to
disassembly, lubricating all components as
assembled. Replace all seals supplied in the
service seal kit.
NOTE: The seal located in the centre of the gland is
replaceable.

41- 27
SECTION 41 -- STEERING -- CHAPTER 1
FOUR WHEEL DRIVE STEERING CYLINDERS -- REMOVAL AND INSTALLATION (OP. 41 216)

1 2

7
6

5
Steering Cylinder Installation -- Four Wheel Drive
1. Pivot Pin 5. Spacer
2. Pivot Pin 6. Circlip
3. D Shaped Washer 7. Spacer
4. Spacer

1. Stand the unit on a hard level surface and position

the front wheel in the straight ahead position.
2. Disconnect flexible pipes, cap the open pipe ends
and remove hose clamps.
NOTE: Position of flexible pipes and orientation of
connectors must be the same upon re--assembly.
3. Remove the snap ring retaining the steering arm to
the cylinder piston pivot pin, item 6, Figure 5 and
remove the pivot pin.
4. Remove the steering cylinder fixed end pivot pin
retaining bolt and withdraw the pivot pin, item 1,
Figure 5 . Remove the cylinder from the vehicle.
5. Installation is the reversal of the removal
6
procedure.

Steering Stop Adjustment

1. Turn the wheels to full lock and adjust steering stop

to ensure tyres or mudguards do not touch the side
of the tractor and that the steering cylinders have
not reached the end of their travel.

41- 28
SECTION 41 -- STEERING -- CHAPTER 1
Steering Cylinder Overhaul -- Four Wheel Drive
1 2

8
3

6 4

7
Steering Cylinder Assembly -- Four Wheel Drive
1. Cylinder 5. Cylinder Rod
2. Wiper Seal 6. Gland and Seal Assembly
3. Retaining Ring 7. Piston
4. Gland Nut 8. Nut

1. Using appropriate ‘C’ spanner, unscrew and

remove the gland nut.
2. Using a punch, push the steering cylinder gland
into the cylinder and remove the wire locking ring.
3. Pull the rod and gland assembly from the cylinder.
4. Remove the nut from the cylinder rod and
disassemble to replace seals.

8
5. Inspect the bore of the cylinder and replace if
scored.
6. Reassemble the cylinder in the reverse to
disassembly, lubricating all components as
assembled. Replace all seals supplied in the
service seal kit.
NOTE: The seal located in the centre of the gland is
replaceable.

41- 29
SECTION 41 -- STEERING -- CHAPTER 1
NOTES

41- 30
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
SECTION 44 -- FRONT AXLE AND WHEELS

Chapter 1 -- Front Axle and Wheels

CONTENTS

Section Description Page

44 000 -- SPECIFICATIONS -- TIGHTENING TORQUES -- TOOLS -- SECTIONAL VIEWS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING

SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrally pivoted U--type centre
beam with telescopic outer sections
Track settings (7 off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1545--1645--1745--1845--1945--
2045--2145
Wheel camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2°, corresponding to approx.
15 mm with 16” rims
Wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0 to 5
Swivel Pin Assembly
Swivel pin (3, Fig. 2) diameter at the bushes . . . . . . . . . . . . . . . . . . . . mm 49.961 to 50.000
Press--fit bush (4) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.050 to 0.140 (1)
Swivel pin to bush clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.050 to 0.179
Axle Pivot Pin Assembly
Pivot pin (9, Fig. 2) diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 37.961 to 38.000
Press--fit bush (8) inner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.050 to 38.140 (1)
Pivot pin to bush clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.050 to 0.179

(1) final dimension without reaming

44- 1
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
TIGHTENING TORQUES
DESCRIPTION Thread size Torque
Nm kgm
Front axle
Bolts or nuts, front axle carrier to housing (C1) . . . . . . . . . . . . . 3/4” -- 10UNC 333 to 373 34 to 38
Nut, track control rod clamp (C2) . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.25 49 5
Locknut, steering rod (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 20x1 176 18
Nut, RH and LH levers to swivel pins retaining screw (C4) . . . M 16x1.5 294 30
Nut, axle outer section (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5 211 21.5
Bolt, front wheel to hub (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18x1.5 314 32
Bolt, axle pivot pin (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.25 49 5

44- 2
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
SPECIAL TOOLS List of special tools necessary to carry out the different
CAUTION operations described in this Section.
Operations described in this Section of the Manual
X 293521 Swivel pin ring nut spanner.
must be performed using the following ESSENTIAL
tools marked with the identification code (X).
X 290793 Axle pivot pin adapter (M 12x1.25)
To work safely and achieve the best technical results
(use with 292927).
with additional savings of time and effort, these
mandatory tools should be used in conjunction with the
suggested special tools listed below and integrated 292927 Slide hammer.
with the Dealer made ones for which you will find the
necessary construction drawings and specifications in 292400 Wheel lifting hook.
this Manual.

TROUBLESHOOTING

Problem Possible Cause Correction

Premature tyre wear 1. Wrong inflation pressure. Inflate tyres to correct
pressure, refer to values
suggested in the Operator’s
Manual. Always comply with
values specified by the tyre
manufacturer.
2. Wrong front wheel toe--in. Adjust toe--in (see page 14).
Poor tractor stability 1. Wrong inflation pressure. Inflate tyres to correct pressure

DESCRIPTION AND OPERATION

The front axle for two wheel drive tractors is composed The front axle is controlled by the power steering
of a reversed U type centre beam with telescopic axle system through a cylinder attached to the axle housing
outer sections. and the swivel pin control lever. The two swivel pins are
The centre beam is attached to the front axle carrier by connected by an adjustable track control rod for toe--in
means of a single pivot which allows oscillation on both adjustment, if required.
sides. Axle centre beam and telescopic outer sections are
drilled to obtain 7 possible track settings.

44- 3
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

2
Front Axle and Carrier -- Sectional View
1. Adjustable track control rod 6. Swivel pin thrust bearing
2. Swivel pin control lever 7. Axle centre beam
3. Swivel pin 8. Axle pivot pin bushings
4. Swivel pin bushings 9. Axle pivot pin
5. Wheel hub tapered roller bearing. 10. Front axle carrier.

44- 4
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
FRONT AXLE
Removal -- Installation (Op. 44 101 30)
DANGER
Lift and handle all heavy components using lifting
equipment of appropriate capacity. Ensure that units or
parts are supported by suitable slings or hooks. Ensure
that no--one is in the vicinity of the load to be lifted.

Remove the front axle assembly from the tractor as

follows:
1. Open and raise engine hood.
2. Disconnect the negative cable (1) from the battery
and insulate.
3. Safely block rear wheels.
4. Remove front weights and weight support, where
fitted.

1
5. Jack up front of tractor and place a stationary stand
(1) under the sump.

2
6. Loosen retaining bolts and remove front wheels.

44- 5
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
7. Connect axle to a hoist using two nylon cables (2)
(one on each side). Disconnect steering cylinder
control lines (1).

4
8. Loosen the axle pivot pin locking bolt (1).

5
9. Using a slide puller (1) on the pivot pin (2) withdraw
the pivot pin.

6
10. Remove front axle using a hoist.
WARNING
Always use suitable tools to align holes. DO NOT USE
HANDS OR FINGERS.

11. Reinstall the front axle assembly to carrier

observing the following:
-- Reassembly follows disassembly procedure in
reverse, from step 10 back to step 1.
-- Tighten to correct torques as detailed on
page 2.

44- 6
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
FRONT WHEEL HUB
Removal--Installation (Op. 44 101 22)
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

Wheel hubs can be removed with the front axle on the

tractor. Proceed as follows for each hub:
1. Open and raise engine hood.
2. Disconnect the negative cable (1) from the battery
and insulate.
3. Safely block rear wheels.
4. Remove front weights and weight support, where
fitted.

1
5. Jack up front tractor and place a stationary stand
(1) under the sump.

2
6. Loosen retaining bolts and remove front wheels.

44- 7
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
7. Remove the wheel hub bearing grease cup (1)

4
8. Unstake locking tab on the wheel hub bearing
adjustment ring nut (1).

5
9. Using the socket spanner tool no. 293521 (1),
loosen the wheel hub bearing adjust ring nut.

6
10. Remove the wheel hub (2) and recover bearings (1
and 3).
11. Replace faulty seals and worn bearings using
suitable pullers and drifts.
12. Fill the wheel hub with AMBRA GR 75 MD grease.

44- 8
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
13. Re--assemble the wheel hub (2) complete with the
bearings (1 and 3).

8
14. Using a torque wrench and socket spanner tool no.
293521 (2), torque the ring nut to 196 Nm (20 kgm)
while turning the wheel hub to settle the bearings.
15. Loosen the ring nut and torque it again to 24 to 29
Nm (2.5 to 3 kgm) continuing to turn the wheel hub.
NOTE: The ring nut should be replaced at each
re--assembly.

9
16. Stake the locking tab on the ring nut (1).

10
17. Reassemble the wheel hub bearing grease cup (1).

44- 9
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
SPINDLE ASSEMBLY
Overhaul (Op. 44 101 46)
WARNING
Handle all components with the greatest care. Do not
insert hands or fingers between the parts. Wear
suitable protection clothing, including goggles, gloves
and footwear.

Swivel pins can be overhauled with the front axle on the

tractor. Proceed as follows for each wheel:
1. Open and raise engine hood.
2. Detach the negative cable (1) from the battery and
insulate.
3. Safely block rear wheels.
4. Remove front ballast and ballast support, if
present.

1
5. Jack up front of tractor and place a stationary stand
(1) under the sump.

2
6. Loosen retaining bolts and remove front wheels.

44- 10
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
7. Place an hydraulic jack under the spindle assembly
and loosen the swivel pin control lever (1) retaining
screw.

4
8. Slide out the control lever (1) from the spindle
assembly.

5
9. Lower the hydraulic jack and remove the spindle
and hub assembly (1).

6
10. Loosen the axle outer section (1) attaching bolts.

44- 11
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
11. Remove the axle outer section (1).

8
12. Fix the axle outer section in a vice and using a slide
puller remove the swivel bearing bushings (1).

9
13. Reinstall the spindle assembly to the front axle
following the disassembly procedure in reverse
and using a suitable drift to install new bushings (1)
on the axle outer section.

10
14. Reinstall axle outer section (1).
15. Reinstall the spindle assembly to the axle outer
section.

44- 12
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
16. Place the control lever (1) on the spindle assembly
(2) and torque retaining bolt.

44- 13
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
FRONT WHEEL SETTING TESTS
(Op. 44 511 80)
Wheel camber test
Check the front wheel camber considering that, when
the tractor moves along a straight line, wheels should
be tilted by 2° relative to the ground, corresponding to
a difference (X) of approximately 15 mm between the
rim edges (with 16” rims).

1
Front wheel toe--in test
When the tractor moves along a straight line, wheels
should be parallel to the tractor centre line or slightly
toe--in until a max. of 5 mm, measured between the rim
edges.
Check correct toe--in as follows:
1. Inflate front tyres to a pressure of 2.5 bar (kg/cm2).
2. Place the steering wheel at mid--travel, with one
spoke along the tractor centre line.
3. Check if wheels are parallel to the tractor centre
line.
4. Measure the distance (B) between the wheel inner
rims at hub height at the front of the wheels. 2
5. Measure the distance between the wheel inner
rims at hub height at the rear of the wheels. The
measurement taken should be the same as (B) or
greater by up to 5 mm max.
6. Should it be necessary to adjust the front wheel
toe--in, proceed as follows:
1
-- Loosen the locknuts (1) on both end of the track
control rod.
-- Turn the track control rod hex end (2) in or out
to shorten or lengthen the track control rod until
0--5 mm toe--in is achieved.
-- Torque the locknuts (1) to the specified torque
(see on page 2).

24440 2

44- 14
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
SECTION 50 -- AUXILIARY UNITS

Chapter 1 -- Air Conditioning

CONTENTS

Section Description Page

50 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Finding and System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Leak Testing, Charging, Discharging and System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . 31
Component Overhaul (excluding compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
50 200 Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
50 200 Compressor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

50 000 SPECIFICATIONS
Refrigerant Specification New Holland Specification 82000810 (R134a)
Refrigerant Charge 1.4 kg (3.1 lbs)
Compressor Oil Specifications New Holland Specification 82008750 (PAG Type)
(ISO 100 Viscosity)
Sanden SP20
Refrigerant Oil Capacity
(Compressor and system) 186 cc--228 cc
Cooling capacity @ 22° C -- 49° C (75° F -- 120°F) ambient. 4.5 kW Typical
(Actual capacity dependent on system control operator settings)
Combined High/Low Pressure Switch (Mounted Adjacent to Compressor)
Low Pressure Switch
On 2.06 bar (29.9 lbf/in2)
Off 1.96 bar (28.4 lbf/in2)
High pressure switch
On 21 bar (299 lbf/in2)
Off 26 bar (384 lbf/in2)
Low Pressure Cut Out Switch (Mounted in Cab Roof)
On 2.3 bar (34 lbf/in2)
Off 0.7 bar (10 lbf/in2)
Temperature Cycling Control Switch
Switch Setting On Off
Minimum Cooling 21° C 18° C
Maximum Cooling 5° C 2° C

COMPRESSOR
Manufacturer and Type Sanden SD7H15 (model 7890)
Compressor Clutch and Pulley Air Gap 0.4--0.8 mm (0.016 and 0.031″)
Drive Belt Tension Automatic Belt Tensioner

50- 1
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
TORQUES
Compressor Cylinder Head Bolts 24.5--26.5 Nm (18--19.5 [Link])
Compressor Clutch Front Plate retaining Bolt 11.0--14.0 Nm (8--10 [Link])
Self--sealing Couplings small 40--54 Nm (29--40 lbf ft)
large 54--68 Nm (40--50 lbf ft)
Compressor Mounting Bolts 20.5--25.5 Nm (15--19 [Link])
SPECIAL TOOLS
Certified Refrigerant Recover,Recycling and Recharge Equipment suitable for the type of refrigerant gas used on
tractor are required when servicing air conditioning systems.
This special equipment is available through recognised suppliers of air conditioning equipment. Refer to the Tool
supplier for details on the latest equipment available for servicing the air conditioning system.
Vacuum/charge Portable system New Holland Tool No.294030
Recovey/recharge Portable system New Holland Tool No.294048
Evaporator and condenser cleaner New Holland Tool No.293831
Expansion valve tape New Holland Tool No.293826
Electronic Gas Leak Detector New Holland Tool No.294036
Manifold Gauge Set (Where required) OTC/V.L Churchill Ltd Part No FNH00172
Quick Release Coupling Tool New Holland Tool No.295031
COMPRESSOR TOOLS:
Sanden SDH715 KIt OTC/V.L Churchill Ltd Part No. NH.50--100

SAFETY PRECAUTIONS refrigerant recovery unit operated by a certified

WARNING technician must be used.
• When discharging the refrigerant in the system
Before overhauling an air conditioning system read
make sure you are operating in well--ventilated
and observe the following Safety PrecautionsIf a repair
premises with good air circulation and far away
or replacement becomes necessary, ensure that only
from open flames.
certified Air Conditioning technicians are employed,
using approved equipment to effect repairs. Do not • When charging and discharging the system always
attempt to disassemble the air conditioning system, It wear goggles and take suitable precautions to
is possible to be severely frostbitten or injured by protect the face in general and the eyes in
escaping refrigerant. particular, from accidental spillage of the
refrigerant fluid.
IMPORTANT: Do not allow refrigerant to escape into • The oil and refrigerant mixture inside the air
the atmosphere. conditioning system is pressurized.
Refrigerant must be handled with care in order to Consequently, never loosen fittings or tamper with
AVOID HAZARDS. lines unless the system has been properly
discharged.
Undue direct contact with liquid refrigerant can
produce freezing of skin and eyes. • Before loosening any connection, cover the fitting
in question with a cloth and wear gloves and
Keep the refrigerant container and air conditioning
goggles in order to prevent refrigerant from
system away from flame or heat sources, the resulting
reaching the skin or eyes.
pressure increase can cause the container or system
to explode. • In the event of an accident, proceed as follows:--
If in direct contact with open flames or heated metal If the refrigerant has reached the eyes, wash them
surfaces, the refrigerant will decompose and produce immediately with copious amounts of sterilised
products that are toxic and acidic. water or mains pressure tap water and transfer to
hospital for immediate medical help.
Make sure to comply with the following indications and
simple precautions to avoid any risk of injury: If the refrigerant has touched the skin, wash with
cold water and transfer to hospital for immediate
• Never discharge refrigerant into the atmosphere.
medical help.
When servicing air conditioning units a certified

50- 2
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PRINCIPALS OF AIR CONDITIONING
The function of the air conditioning system is to
improve the operator’s comfort by cooling the air
temperature inside the cab and reducing the humidity
level.
This temperature control is achieved by absorbing the
heat within the cab into a refrigerant and then allowing
the heat absorbed by the refrigerant to be transferred
to the outside air
In order to achieve this heat transfer the following
principals of heat generation and transfer are applied
within the air conditioning system. 60--50--001 TI
1. When two bodies of different temperature come
together heat is transferred from one to another. 1
On air conditioning systems an evaporator is used
to hold the low temperature refrigerant which
absorbs the heat from the air within the cab.
2. When a gas is pressurised the temperature of the
gas will rise. In air conditioning systems the
increase in pressure is achieved using a
compressor.
3. When a gas is cooled it will condense into a liquid.
In the air conditioning system a condenser is used
to cool the gas and the resulting liquid is stored in
a receiver dryer.
4. When a liquid is atomized through an orifice, the 60--50--002 TI
temperature of the resultant vapour will drop. The
low temperature of the atomized liquid will then 2
absorb heat from its surroundings. On air
conditioning systems the refrigerant is atomized
using an expansion valve.
It can now be seen that the principal components of an
air conditioning system are:--
• Refrigerant
• Evaporator
• Compressor
• Condenser
• Receiver Dryer
• Expansion Valve 60--50--003 TI

Figure 5, uses the examples above to illustrate the air

3
conditioning cycle.

60--50--004 TI

50- 3
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

2 1

O
C

60--50--005 TI

5
Air Conditioning Principal of Operation
1. Expansion Valve -- Atomizes Liquid Refrigerant Before Passing to Evaporator
2. Evaporator-- Absorbs Heat From Air In Cab
3. Compressor -- Compresses and Raises Temperature Of Refrigerant Gas
4. Condenser, Evaporator and Dryer -- Converts Refrigerant from Gas to a Liquid

50- 4
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

LOW PRESSURE SIDE HIGH PRESSURE SIDE

EXPANSION VALVE

LOW TEMPERATURE
HIGH PRESSURE LIQUID
FILTERED AND MOISTURE REMOVED
LOWER TEMPERATURE
LOW PRESSURE
ATOMIZED LIQUID
RECEIVER DRYER

LOWER TEMPERATURE
EVAPORATOR HIGH PRESSURE LIQUID

CONDENSER

WARM
LOW PRESSURE VAPOUR
HIGH TEMPERATURE
HIGH PRESSURE VAPOUR

COMPRESSOR
HEAT FROM INSIDE CAB HEAT MOVES TO OUTSIDE AIR
MOVES TO REFRIGERANT FROM REFRIGERANT

6
Air Conditioning Flow Diagram
Figure 6, shows in schematic form the flow of high pressure liquid to a low pressure atomized liquid
refrigerant through the five major components of an air with a lower temperature.
conditioning system. Refer to, Figure 6, for the This low pressure, low temperature, atomized liquid
location of these components on the tractor. enters the evaporator coils and absorbs heat from the
Refrigerant is drawn into the compressor as a cool, low cab warm air blown across the coils and fins by the cab
pressure vapor which is compressed and then pumped blower motor. The refrigerant now changes from a cold
out as a hot, high pressure vapor to the condenser. low pressure atomized liquid to a warm low pressure
As the hot, high pressure vapor passes through the vapor and leaves the evaporator outlet, moving to the
condenser core it gives off heat to the cooler outside suction (low pressure) side of the compressor to repeat
air, being drawn past the fins by the engine cooling fan. the cycle.
By giving off heat to the outside air, the vapor is As this heat loss is taking place, moisture (humidity) in
condensed to a liquid which moves under high the cab air will condense on the outside of the
pressure to the receiver dryer where it is stored until evaporator and drain off as water through the drain
released to the evaporator by the temperature sensing hoses attached to the evaporator drain pan, thereby
expansion valve. reducing the humidity level of the cab.
As liquid refrigerant passes through the metered orifice
in the expansion valve the refrigerant changes from a

50- 5
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

A B

D C

60--50--006 TI
7
Air Conditioning Component Layout
A. Blower Motor, Expansion Valve and Evaporator C. Compressor
B. Quick Release Self Sealing Couplings D. Condenser and Receiver Dryer

50- 6
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
SYSTEM COMPONENTS -- DESCRIPTION AND equipment will be of two different sizes as recognised
OPERATION and specified by the air conditioning industry.
WARNING
Refrigerant
R--134a refrigerant is not compatible with R--12
To achieve the absorption and the release of heat refrigerant. Do not attempt to replace R134a
which is, in essence, the function of an air conditioning refrigerant with R--12 refrigerant or test the system
system, requires the use of a suitable “refrigerant” - a using gauges or equipment previously used with R12
liquid that has a relatively low temperature boiling as damage to the system will result.
point, plus certain desirable safety and stability
features. R-134a refrigerant is stable at all operating
The refrigerant used in the air conditioning system is temperatures and able to absorb great quantities of
refrigerant R-134a. heat.
NOTE: To help protect the environment legislation has The boiling point of R-134a is -22° C (-15° F) at
been introduced in most territories banning the release atmospheric pressure.
into the atmosphere of refrigerants,including R134a. If the pressure is increased, R-134a will readily
All service procedures contained in this manual can be vaporize to absorb heat at temperatures between
carried out without the need to release refrigerant into -11.7° C (11° F) at 1.9 bar (27.5 lbf/in2) and 0°C (32°
the atmosphere. F) at 42 lbf/in2 (2.9 bar) in the evaporator.
In order to prevent the incorrect type of refrigerant At higher pressures, R-134a will condense and give off
being charged to the system the service valves fitted heat at temperatures between 48° C (118° F) at 12.4
to the tractor and necessary to connect up refrigerant bar (180 lbf/in2) and 58° C (136° F) at 15.85 bar (230
recovery, evacuation and recycling/recharging lbf/in2 ) in the condenser.

50- 7
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

6
5 4 3
TA6050007

8
Air Conditioning Refrigerant Compressor
1. Electro--magnetic Clutch 6. Suction Chamber
2. Clutch Bearing 7. Discharge Chamber
3. Cam Rotor 8. Cylinder Head
4. Wobble Plate 9. Static Gear
5. Piston
Compressor Pump Refrigerant is drawn in on the downward stroke of a
The tractor air conditioning unit compressor pump is piston through the reed valves located either end of the
mounted on the left hand side of the engine and is belt cylinder assembly. Refrigerant enters the cylinder
driven by the crankshaft pulley, Figure 7. assembly through a gallery in the outer circumference
of the cylinder assembly.
The compressor separates the low and high pressure
sides of the system and is basically a pump which has The upwards stroke of the piston compresses the
two functions: refrigerant and expels it through another reed valve
into an inner gallery in the cylinder assembly and out
(1) To raise the refrigerant temperature by
into the refrigerant circuit.
compression to a higher degree of temperature than
the ambient (outside air) temperature. The compressor is lubricated with a Polyalklene Glycol
(PAG) oil. This oil is totally miscible with the refrigerant
(2) To circulate the required volume of refrigerant
and is carried around the refrigerant circuit.
through the system.
The compressor is activated by an electro-magnetic
The refrigerant compressor is a seven cylinder wobble
clutch which functions to engage or disengage the
plate unit housed in a die cast aluminium housing.
compressor as required in the operation of the air
Drive to the wobble plate is from the pulley, through the conditioning system.
electro magnetic clutch to the main driveshaft.
The clutch is primarily activated by the:--
Attached to the driveshaft is a cam rotor which
oscillates the wobble plate. The wobble plate is • Temperature cycling control switch
prevented from rotating by a static gear engaging with • Combined high/low pressure cut--out switch
teeth formed in the face of the plate. The seven pistons • Low pressure cut--out switch
are connected to the wobble plate by rods located in
ball sockets.

50- 8
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Air Conditioner Temperature Cycling Control
Switch
The air conditioner temperature cycling control switch
is mounted on the left hand side of the evaporator
housing and close to the expansion valve, Figure 9.
The switch is a device which turns the compressor
clutch on and off to maintain a constant average
evaporator temperature and senses the evaporator
temperature using a thermistor positioned within the
evaporator fins, Figure 10.
The temperature cycling control switch compares the
voltage of the thermistor, which is dependent on the
temperature of the evaporator, with the voltage across 60--50--009 TI
the potentiometer of the ‘in cab’ temperature control 9
switch.
The switch upon comparing the two voltages
determines whether the compressor clutch should be
switched ‘on’ or ‘off’ in order to maintain the desired in
cab temperature control.

60--50--010 TI

10
Low Pressure Cut-out Switch
The low pressure switch, Figure 11, is in the
evaporator outlet line and located in the cab roof next
to the evaporator and temperature cycling control
switch.
The purpose of the switch is to shut off the compressor
pump in the event of low pressure in the refrigerant
system.
Low refrigerant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve orifice
or refrigerant loss. Low refrigerant pressure may result
in damage to the compressor pump. 60--50--011 TI
The low pressure switch is factory set and cannot be
adjusted. 11

50- 9
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Combined High/Low Pressure Cut--out Switch
The combined high/low pressure switch, (1) Figure 1
12, is located in the condenser inlet line from the
compressor. The switch shuts off the compressor
pump in the event of a restriction in the high pressure
line or excessively low pressure due to lack of
refrigerant in the system.
Loss of refrigerant in the system will result in
insufficient cooling and lubrication and continuous
operation will cause damage to the compressor pump.

60--50--089 TI
12
System Pressure Relief Valve
A relief valve is located at the discharge port on the 1
compressor, (1) Figure 13. This allows the system
refrigerant to be discharged into the engine bay
(atmosphere) instead of in the cab, if the system
pressure became such that a hose might fail in the cab
and cause injury to the operator. This secondary safety
feature will only operate in extreme conditions, for
example, if the high pressure cut out switch were to fail,
or in the event of an engine fire.

60--50--089 TI
13
Condenser And Receiver Dryer
The condenser, (1) located at the front of the tractor, 2 1
Figure 14, consists of a number of turns of continuous
coil mounted in a series of thin cooling fins to provide
a maximum of heat transfer in a minimum amount of
space.
The condenser receives the hot, high pressure
refrigerant vapour from the compressor. The hot
vapour passes through the condenser coils and
outside air is pushed through the condenser by the
engine cooling fan.
Heat moves from the hot refrigerant vapour into the
60--50--006A TI
cooler outside air flowing across the condenser coils
and fins. 14
When the refrigerant vapour reaches the pressure and
temperature that will induce a change of state, a large
quantity of heat is transferred to the outside air and the
refrigerant changes to a high pressure warm liquid.
The warm liquid refrigerant continues onto the
receiver/drier where it is filtered and desiccated, to
remove any moisture, before passing through an outlet
line to the thermostatic expansion valve.
The receiver/dryer(2) stores the liquid refrigerant to be
sure a steady flow to the thermostatic expansion valve
is maintained under widely different operating
conditions.

50- 10
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
The drier section contains a desiccant (Molecular
sieve) to absorb any moisture within the system and a
filter prevents the entry of foreign particles.
NOTE: Any moisture in the air conditioning system is
extremely harmful. Moisture not absorbed by the
dehydrator will circulate with the refrigerant and
droplets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the
refrigerant flow and stop the cooling action. Moisture
will also react with refrigerant R-134a and the lubricant
to form a corrosive acid.
The desiccant can only absorb a limited amount of
moisture before reaching saturation point. Because of
this, after any system component replacement or
repairs requiring entry into the system, the
receiver/dryer should be replaced.

Expansion Valve
The expansion valve, Figure 15, is located next to the
evaporator, in the pressure line leading from the
receiver/dryer and performs the following functions:
1. METERING ACTION -
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liquid.
2. MODULATING ACTION -
A thermostatically controlled valve within the
expansion valve body controls the volume of liquid
refrigerant passing through the orifice and makes
sure the refrigerant is fully vaporized within the
evaporator. Liquid refrigerant would damage the
compressor reed valves or freeze the pistons.
3. CONTROLLING ACTION -
The valve responds to changes in the cooling 60--50--013 TI
requirements. When increased cooling is 15
required, the valve opens to increase the
refrigerant flow and when less cooling is required
the valve closes and decreases the refrigerant
flow.

50- 11
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Expansion Valve - Operation
All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic unit
and no external tubes are required for these purposes.
The refrigerant from the condenser and receiver dryer
enters the thermostatic expansion valve as a high
pressure warm liquid. Upon passing through the ball
and spring controlled metering orifice, the pressure
and temperature of the refrigerant is reduced and the
refrigerant leaves the thermostatic expansion valve as
a low pressure, lower temperature atomized liquid.
The atomized liquid now passes through the
60--50--014 TI
evaporator where it absorbs heat before returning via
the expansion valve to the compressor as a warm Low 16
pressure vapour.
There are two refrigerant passages in the valve. One
passage is in the refrigerant line from the condenser to
the evaporator and contains the ball and spring type
orifice valve. The other passage is in the refrigerant
line from the evaporator to the compressor and
contains the valve’s temperature sensing element.
Liquid refrigerant flow from the condenser and receiver
dryer is controlled by a push-rod forcing the orifice
valve ball off its seat and the spring exerting pressure
on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the
pressure on the bottom of the expansion valve
diaphragm rises above the pressure on the top of the
diaphragm allowing the valve spring to close the
orifice.
When the system is started, the pressure on the
bottom of the diaphragm drops rapidly, allowing the
orifice to open and meter atomized liquid refrigerant to
the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized
refrigerant out of the evaporator and back through a
gallery in the top of the valve which passes the
temperature sensor.

50- 12
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
The temperature sensor reacts to variations in
1
refrigerant gas pressure returning from the evaporator.
When heat from the passenger compartment is
absorbed by the refrigerant the pressure of the gas 2
increases causing a differential pressure above and
below the temperature sensor diaphragm. The
diaphragm reacts to this pressure differential and a
push rod forces the ball in the expansion valve orifice
further off its seat. This reaction allows an increase in
the atomized refrigerant to flow through the valve, to
the evaporator, so that more heat can be absorbed by
the air conditioning system.
Similarly when the temperature of the gas returning 60--50--015 TI
from the evaporator decreases the pressure of the gas
17
decreases. This causes the diaphragm to react
accordingly and allow the ball in the orifice to move
closer towards its seat thus reducing the flow of
refrigerant through the valve to the evaporator.
Evaporator
The evaporator, Figure 17, is located in the cab roof
and consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator absorbs
heat from the hotter air in the operator’s compartment,
thereby cooling the air.

60--50--016 TI

18
Blower Fan
The blower fan, (2) Figure 17, draws warm air from
outside the cab through the intake filters, Figure 18
and forces it across the evaporator before entering the
cab through louvered vents.
The blower motor is controlled by a three-speed
switch, Figure 19. The switch uses a variable resistor
to change the fan speed.
High blower speed provides the greatest volume of
circulated air, however, a slower speed will allow the air
to contact the cooling fins and coils of the evaporator
for a longer period resulting in the warm air giving up 60--50--017 TI
more heat to the cooler refrigerant. Therefore, the
coldest air temperature is obtained when the blower 19
fan is operated at the lowest speed.

50- 13
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
FAULT FINDING AND TESTING THE AIR Preliminary Fault Finding
CONDITIONING SYSTEM Always conduct the preliminary fault finding checks
before performance testing the system.
General 1. Run the engine at 1000-1200 rev/min for 10
Overhaul of the air conditioning system should only be minutes with the air conditioner set at maximum
undertaken by a certified specialist refrigeration cooling and the blower on high speed.
engineer using a comprehensive air conditioning test 2. Check that the heater temperature control is
kit, including a gas leak detector, suitable for R134a switched OFF.
refrigerant gas.
3. Close the heater shut--off valve on the rear of the
WARNING inlet manifold.
Before dismantling an air conditioning system for 4. Check that the blower fan is operating at all
repair the gas within the system must be discharged speeds.
and recovered using a certified recovery unit 5. Check that the compressor clutch engages when
designed for the type of refrigerant gas used in the the temperature control switch is turned from
system. “OFF” to “ON” position. A clicking sound indicates
NEVER release refrigerant gas into the atmosphere. the clutch is engaging. If the clutch fails to operate
ALWAYS wear safety goggles and gloves when it may indicate an electrical problem in the high low
servicing any part of the air conditioning system. pressure cut out switches or malfunction of the
electric drive clutch on the compressor.
To prevent the entry of any foreign material, observe 6. Check the engine cooling fan is drawing cool air
the following points: through the condenser
• Ensure all tools, gauges, hoses and replacement 7. Check the compressor drive belt tension.
parts are kept clean and dry and are suitable for the 8. Check the condenser core and grid is clean and
type of refrigerant gas used in the system. free of obstruction.
• Clean all hoses and fittings before disconnecting. 9. Check the cab air filters are clean and free of
Cap or plug all openings when disconnected. obstruction.
• When adding lubricating oil to the system always 10. Check the evaporator fins are not plugged or
uncap and re-cap the oil container immediately excessively dirty.
before and after use. Always ensure the oil
remains free of moisture.

50- 14
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

3
6

5 4
60--50--018

20
Attaching Manifold Gauge Set to the Tractor
1. Low Side Gauge 6. Test Hose to Low Side Service Connector
2. High Side Gauge 7. Shut-off Valve
3. Shut-off Valve 8. Low Pressure Side Service Valve
4. Test Hose to High Side Service Connector 9. High Pressure Side Service Valve
5. Center Hose (Not Used)
Performance Testing The Air Conditioning Operating Precautions
System IMPORTANT: Always ensure the shut--off valves are
The manifold gauge set is the most important tool used closed (turn clockwise until seated) during all test
in testing and servicing the air conditioning system. operations.
It should be noted however that for those dealers who In the closed position, refrigerant circulates around the
posses the latest design level of refrigerant recovery, valve stems to the gauges. Therefore, when the
recycling and recharging station these gauges are an manifold gauge set is connected into a system,
integral part of the machine. pressure is registered on both gauges.
The following instructions for performance testing the • NEVER open the HIGH SIDE shut off valve when
air conditioning system is based on the use of the the system is operating.
gauge set shown in Figure 20. The principal of • ALWAYS open the LOW SIDE shutoff valve when
operation is however similar when testing the system adding refrigerant.
using a recovery and recharging station with integral
gauges.
When using this type of equipment always consult the
manufacturers operating instructions.

50- 15
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Attaching The Gauge Set To The Tractor 2. Apply the parking brake, check the gear shift levers
WARNING are in neutral and close the cab windows and
doors.
To avoid personal injury, stop the tractor engine during
connection of the manifold gauge set. 3. Run the engine at 1000-1200 rev/min.
4. Turn the heater temperature control ‘off’
1. Check that the gauge set shut off valves are closed 5. Operate the system at maximum cooling, with the
(turned fully clockwise). blower fan at high speed for 10 minutes to stabilize
2. Connect the high side gauge hose (normally red) all components.
to the high pressure side service valve and the low 6. Check the manifold low pressure gauge reading is
side gauge hose (normally blue) to the low within the specified range of approximately 4-36
pressure side service valve on the tractor, Figure lbf/in2 (0.28-2.48 bar) (0.28-2.53 kgf/cm 2).
20. Ensure the hose connections are fully 7. Check the manifold high pressure gauge reading
tightened. and compare the reading to the pressure indicated
IMPORTANT: Prior to connection of the manifold on the pressure temperature chart below.
gauge set, identify the suction (low pressure) and 8. Measure and compare the temperature of
discharge (high pressure) service gauge ports. The conditioned air entering the cab through the
high pressure service valve is always in the line from louvered air vents with the ambient air at the air
the compressor to the condenser. intake filters on the outside of the cab.
The high and low pressure service valves on the tractor If the system is operating correctly the conditioned
are spring loaded valve and will be automatically air entering the cab should be 6--9° C (10--15° F)
opened when the test hose is connected. cooler than the ambient temperature of the outside
NOTE: The test hose must incorporate a valve air.
depressor to actuate this type of valve. 9. If it is confirmed that the system is not operating
The service valves have a protective cap. This cap correctly refer to the fault diagnostic charts and
must be removed for test gauge connections and performance test gauge reading examples on the
replaced when service operations are completed. following pages for possible corrective action.
WARNING
Test Procedure A significant amount of refrigerant vapour may have
After the manifold gauge set has been connected and condensed to a liquid at the service fitting at the high
before pressure tests can be made, the system must side of the compressor. Use a cloth or other protective
be stabilized as follows: material when disconnecting the manifold hose from
1. Re--check that both the high and low side shut off this fitting to prevent personal injury to hands and face.
valves on the manifold gauge set are fully closed.

APPROXIMATE HIGH PRESSURE GAUGE READINGS

Ambient Air Temperature High Pressure Gauge Reading

Degrees F Degrees C bar kgf/cm2 lbf/in 2
80 27 10.0/11.6 10.3/11.8 147/168
85 29 11.2/12.7 11.4/12.9 162/184
90 32 12.3/13.8 12.5/14.0 179/200
95 35 13.3/15.2 13.6/15.5 194/221
100 38 14.5/16.7 14.8/17.0 210/242
105 41 16.0/18.3 16.3/18.6 231/265
110 43 17.3/20.9 17.7/20.3 252/289

50- 16
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST DIAGNOSIS
Gauge Readings:-- Low Pressure - Low
High Pressure - Low
PROBLEM POSSIBLE CAUSES CORRECTION
Evaporator air not cold Low refrigerant charge. Perform leak tests and repair
(Refer to Example 1) Evacuate system
Charge system, re--test system
Evaporator air warm Extremely low refrigerant charge. Perform leak tests and repair
Evacuate system
Charge system, re--test system
Evaporator air cool but not Expansion valve not permitting Check expansion valve as follows:
sufficiently cold. sufficient flow.
Low pressure switch cutting out Stuck valve Set a max. cooling
Expansion valve to evaporator tube Low pressure gauge should drop
shows considerable condensation slowly
or frost.
Too cold to touch If expansion valve is defective:
Discharge system
Replace expansion valve
Evacuate system
Charge system
Re--test

50- 17
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST DIAGNOSIS CHART
Gauge Readings:-- Low Pressure - High
High Pressure - High
PROBLEM POSSIBLE CAUSES CORRECTION
Evaporator air warm Improper operation of condenser Inspect for dirty condenser
restricting air flow and cooling
Liquid line hot (condenser outlet to Overcharged with refrigerant Check operation of condenser
expansion valve tube) cooling fans. Repair or replace as
needed.
High pressure switch cutting out Air in system Check for overcharge as follows:
Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the the system with the
correct quantity of refrigerant,
replacing any lost lubricant.
Recheck performance of air
conditioning system.
Evaporator air not cold Expansion valve allowing too much Check expansion valve as follows:
refrigerant to flow through the
evaporator Set for Maximum cooling.

Low pressure gauge should drop

slowly
If expansion valve is defective:
Discharge System
Replace Expansion Valve
Evacuate System
Charge System
Re--test

50- 18
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST DIAGNOSIS CHART
Gauge Readings:-- Low Pressure - Low
High Pressure - High
PROBLEM POSSIBLE CAUSES CORRECTION
Insufficient cooling Restriction in liquid line Discharge the system
Replace the receiver/drier
Inspect all lines and tubing from
compressor outlet to expansion
valve.
Replace if needed.
Evacuate the system
Charge the system
Re--test

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - High
High Pressure - Low

PROBLEM POSSIBLE CAUSES CORRECTION

Evaporator air not cold Internal leak in compressor. (reed Discharge the system
valves gasket,
valves, gasket worn or scored
piston rings or cylinder) Replace the compressor

Evacuate the system

Charge the system
Re--test

50- 19
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST DIAGNOSIS CHART
Gauge Readings:-- Low Pressure - Normal
High Pressure - Normal
PROBLEM POSSIBLE CAUSES CORRECTION
Insufficient cooling Low pressure System low on charge Air or Perform leak test
reading does not fluctuate with moisture present in system
changes in temperature control Discharge system
switch (pressure should drop until Repair leaks
compressor cycles) Evaporator air
not cold. Replace receiver/drier
Check oil level
Evacuate system
Charge the system
Re--test

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - High
High Pressure - Normal

PROBLEM POSSIBLE CAUSES CORRECTION

Compressor cycles “on” and “off” Defective temperature control Stop engine and shut off A/C
too frequently (thermostatic) switch
Replace temperature control switch
Re--test system and check
compressor cycling

EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS

The following examples show typical low and high The recommended corrective action is based on a
pressure gauge readings obtained when performance similar fault as identified in the performance test
testing the air conditioning system with an ambient diagnosis charts.
temperature of 35° C (95° F).

50- 20
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 1

7 1

6 2

5 4 3
60--50--019
1

21
Performance Test Example 1
1. High Side Low 5. Low Side Hose Connected to Low Side Service
2. High Side Hand Valve Closed Connector
3. High Side Hose Connected to High Side Service 6. Low Side Hand Valve Closed
Connector 7. Low Side Low
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

Little or no cooling. 1. Leak test the system.
2. Repair leaks. (Discharge and recover the
CAUSE: refrigerant from the system; replace lines or
Refrigerant slightly low. components).
3. Check compressor oil to ensure no loss.
CONDITIONS* 4. Evacuate the system.
Low side pressure too low. 5. Charge the system.
Gauge should read 1--2 bar (15-30 lbf/in2). 6. Performance test the system.
High side pressure too low. DIAGNOSIS: System refrigerant is low. May be
Gauge should read 13.3--14.8 bar caused by a small leak.
(194--215 lbf/in2).
NOTE: Test procedure based upon ambient
Evaporator air not cold. temperature of 35°C (95° F). For proper high side
gauge reading for other ambient temperatures, refer to
the pressure temperature chart.

50- 21
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 2

7 1

6 2

5 4 3

60--50--020

22
Performance Test Example 2
1. High Side Low 5. Low Side Hose Connected t
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

Insufficient cooling. 1. Leak test the system.
2. Discharge and recover the refrigerant from the
CAUSE: system.
Refrigerant excessively low. 3. Repair leaks.
4. Check compressor oil to ensure no loss.
CONDITIONS* 5. Evacuate the system.
Low side pressure very low. 6. Charge the system.
Gauge should read 1--2 bar (15-30 lbf/in2)
7. Performance test the system.
DIAGNOSIS: System refrigerant is extremely low. A
High side pressure too low.
serious leak is indicated.
Gauge should read 13.3--14.8 bar
(194--215 lbf/in2). NOTE: Test procedure based upon ambient
temperature of 95° F. For proper high side gauge
reading for other ambient temperatures, refer to the
Evaporator air warm.
pressure temperature chart.
Low pressure switch cutting out

50- 22
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 3

7 1

6 2

5 4 3
60--50--021

23
Performance Test Example 3
1. High Side Normal 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: 2. Discharge and recover the refrigerant from the

Insufficient cooling. system.
3. Repair leaks.
CAUSE: 4. Replace the receiver/dryer.
Air in system. 5. Check compressor oil to ensure no loss.
6. Evacuate the system.
CONDITIONS* 7. Charge the system.
Low side pressure reading does not change when 8. Performance test the system.
compressor cycles “on” and “off”.
DIAGNOSIS: Air or moisture in system. System not
High side pressure slightly high or slightly low. Gauge fully charged.
should read 13.3--14.8 bar (194--215 lbf/in2).
NOTE: Test procedure based upon ambient
Evaporator air not cold. temperature of 35°C (95° F). For proper high side
gauge reading for other ambient temperatures, refer to
CORRECTIVE PROCEDURES the pressure temperature chart.
1. Leak test the system. Give special attention to the
compressor seal area.

50- 23
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 4

7 1

6 2

5 4 3
60--50--022

24
Performance Test Example 4
1. High Side Low 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side High
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

28
Performance Test Example 8
1. High Side Low 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: Insufficient cooling. Check the low side gauge. The pressure should
CAUSE: Improper operation of thermostatic drop slowly.
expansion valve (stuck closed). 2. If the procedure outlined in Step 1 shows that the
CONDITIONS* expansion valve is defective, proceed as follows:
Low side pressure too low (zero or vacuum). Gauge Discharge system
should read 1--2 bar (15-30 lbf/in2). Replace expansion valve
High side pressure low. Gauge should read Evacuate the system.
13.3--14.8 bar (194--215 lbf/in2). Charge the system.
Evaporator air cool, but not sufficiently cold. Performance test the system.
Evaporator inlet pipe surface shows considerable DIAGNOSIS: Expansion valve is not permitting a
moisture or frost. sufficient flow of refrigerant. May be caused by valve
Low pressure switch cutting out. stuck in restricted or closed position.
CORRECTIVE PROCEDURES NOTE: Test procedure based upon ambient
1. Place finger on expansion valve to evaporator temperature of 35°C (95° F). For proper high side
tube. If too cold to touch, proceed as follows: gauge reading for other ambient temperatures, refer to
the pressure temperature chart.
Operate the system at maximum cooling.

50- 28
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 9

7 1

6 2

5 4 3
60--50--027

29
Performance Test Example 9
1. High Side Low 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

Insufficient cooling. 1. Discharge and recover the refrigerant from the
system.
CAUSE: 2. Replace the liquid lines, receiver/dryer, or other
Restriction in high side of system. obstructed components.
3. Evacuate the system.
CONDITIONS* 4. Charge the system.
Low side pressure too low. Gauge should read 5. Performance test the system.
1--2 bar (15-30 lbf/in2). DIAGNOSIS: Restriction in the liquid line and/or
High side pressure too low. Gauge should read receiver/dryer resulting in a “starved” evaporator
13.3--14.8 bar (194--215 lbf/in2). (compressor moving refrigerant from the evaporator
NOTE: A normal or high reading of the high side faster than it can enter).
pressure gauge under these conditions indicates the NOTE: Test procedure based upon ambient
system is overcharged or the condenser or temperature of 95° F. For proper high side gauge
receiver/dryer is too small. reading for other ambient temperatures, refer to the
Evaporator only slightly cool. pressure temperature chart.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.

50- 29
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
PERFORMANCE TEST EXAMPLE 10

7 B A 1

6 2

5 4 3
60--50--028

30
Performance Test Example 10
1. High Side Normal 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Gauge
4. Not Used Compressor Cycles on at 34 lbf/in 2 (2.3 bar)
Compressor Cycles off at 28 lbf/in 2 (1.9 bar)

PROBLEM: CORRECTIVE PROCEDURES

Compressor cycles (cuts in and out) too rapidly. 1. Stop the engine and shut off A/C system.
2. Replace thermostatic switch with switch of same
CAUSE: type.
Thermostatic switch defective. 3. Make sure the switch’s temperature sensor is
installed in the same position and depth (in
CONDITIONS* evaporator core) as previous.
Low side pressure readings too high during both “on” 4. Performance test the system.
and “off” compressor cycles and between cycles. DIAGNOSIS: Defective thermostatic switch.
Readings should be: NOTE: Test procedure based upon ambient
0.8--1.0 bar (12-15 lbf/in2) - cycle “off” temperature of 35°C (95° F). For proper high side
2.5--2.7 bar (36-39 lbf/in2) - cycle “on” gauge reading for other ambient temperatures, refer to
the pressure temperature chart.
1.7--1.9 bar (24-27 lbf/in2) - between cycles
High side pressure normal. Gauge should read
13.3--14.8 bar (194--215 lbf/in2).

50- 30
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
LEAK TESTING, DISCHARGING and CHARGING
THE AIR CONDITIONING SYSTEM

Leak Testing
To perform a leak test if refrigerant leakage is
suspected, use an electronic leak detector, Figure 31
following manufacturer’s instructions.
Electronic leak detectors use flashing lights or sound
to alert the operator to a leak. If the leak detector’s
sensitivity is adjustable, be sure you calibrate the
detector according to the manufacturer’s instructions
before use.
60--50--029 TI
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley area 31
is normal and does not necessarily indicate a repair is
required.
When a leak is located, follow these steps.
• Discharge the system using a certified freon
recovery system.
• Repair the leak.
• Evacuate the system.
• Partially charge system with 400 grammes
(14 ozs) of refrigerant.
• Check system for leaks.
• Fully charge the system.
Always check the system for leaks as a final test after
evacuating and before recharging. Refer to Evacuating
the system.
Discharging The System
Legislation has been introduced banning the release of
refrigerant into the atmosphere.
Whenever overhauling the air conditioning system or
performing other tasks which require the air conditioning
system to be dismantled it is necessary to discharge the
refrigerant gas before commencing repair.
Before you can dismantle an air conditioning system
for repairs, you must discharge and recover the
refrigerant using a certified recovery unit in
accordance with the manufacturers instructions.
Figure 32 shows a combined refrigerant recovery,
evacuation and recycling/charging station. This
equipment removes R--134a refrigerant from the air
conditioning system, recycles and recharges all in one
hook up. The unit is designed to be used with the
manifold gauge set built into the control panel.

60--50--030 TI

50- 31
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

4 1

3 2
60--50--031

33
Connecting Recovery Evacuation and recycling/Charging Station to the Tractor
1. High Side Service Valve (Red Hose) 3. Recovery/Recharging Unit
2. Built In Manifold Gauge Set 4. Low Side Service Valve (Blue Hose)

Other recovery systems are available where the blue (low side) hose to the low side fitting, Figure
manifold gauges are not an integral part of the 33.
machine. When this type of equipment is used a NOTE: If a unit requiring the manifold gauge set is
separate manifold gauge set must be used. being used, the low and high sides of the manifold set
The following is a summary of the steps for discharging are connected to the low and high sides of the tractor
the system using a recovery/recycling unit air conditioning system. The hose from the recovery
WARNING unit is then connected to the manifold centre port.
Refer to Figure 34.
Never discharge refrigerant gas into the atmosphere.
3. To recover refrigerant, open both high and low side
Always where safety goggles and gloves when
valves on the control panel or the valves on the
working with refrigerant. Only use authorised
manifold gauge set if being used, Figure 34.
refrigerant tanks.
4. Open the valves labeled “gas” and “liquid” on the
IMPORTANT: Always follow the manufactures recovery unit refrigerant tank, Figure 35.
instructions when operating recovery equipment. 5. Plug in the units power cord
1. Run the vehicle’s air conditioning system for a few 6. Operate the recovery system in accordance with
minutes. the manufacturers instructions.
2. Set up the recovery unit following manufacturer’s The compressor will shut off automatically when the
instructions. Ensure that the units red (high side) recovery is complete.
hose is connected to the high side fitting and the

50- 32
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
FLUSHING THE SYSTEM A B
Air conditioning systems may occasionally become 7 1
contaminated with solid particles. This contamination
may be the result of allowing dirt to enter the system
while it was open, from aluminum corrosion or sludge, 6
or from disintegrated compressor reed plates.
Contamination of this nature can result in plugged 2
evaporators, condensers and expansion valves.
5
Contaminated systems must be flushed with a special
flushing solvent to remove the unwanted material.
Prior to flushing, the system must be discharged as
4 3
described in “Discharging the System”.
60--50--032 TI
Each individual component must be flushed after
disconnecting every hose fitting. 34
The compressor and expansion valve can not be Manifold Gauge Set
flushed, therefore, the compressor should be 1. High Side Gauge
disassembled and cleaned or replaced and the 2. High Side Shut--off Valve
expansion valve should be replaced. When flushing 3. High Side Hose
the system always replace the receiver/drier. 4. Centre Service Hose
NOTE: Never use any solvent for flushing an air 5. Low Side Hose
conditioning system other than a special flush solvent 6. Low Side Shut--off Valve
made specifically for air conditioning systems. Always 7. Low Side Gauge
follow the manufacturer’s recommendations and
directions for using the flushing equipment and
solvent.
Re--assemble and evacuate the system to remove air
and moisture as described in “Evacuating the System”.

60--50--033 TI

50- 33
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
EVACUATING THE SYSTEM 1. If the manifold gauge set FNH00172 is being used
IMPORTANT: A system in which the refrigerant has connect the low and high sides of the manifold to
been recovered to facilitate repairs, must be the low and high sides of the tractor air conditioning
evacuated before new refrigerant is installed. system as described for discharging the system.
Air and moisture are removed by evacuating the Connect the manifold centre hose to the vacuum
system using a vacuum pump. pump suction port as per the manufacturers
instructions.
The automatic recycling, recharge and evacuation
stations or evacuating and charging stations available Fully open both the low and high side gauge shutoff
throughout the air conditioning industry incorporate a valves.
vacuum pump within the assembly. If this type of 2. If a combined recovery/evacuation unit is to be
equipment is not available a separate vacuum pump used attach the unit to the air conditioning system
and manifold gauge set must be used. in accordance with the manufacturers instructions.
As the system is evacuated the boiling point of any Be sure to read all installation and operating
moisture within the system is similarly lowered. As the instructions carefully before starting the unit.
vacuum increases the boiling reduces to below that of 3. After starting the evacuation cycle, note the low
the ambient temperate and the moisture is side gauge to be sure the system pulls down into
subsequently boiled away. a vacuum.
The relationship of system vacuum to the boiling 4. Time the evacuation for a minimum of 20 minutes
temperature at which the water vapor is removed from from the point when lowest vacuum is attained.
the system is as follows: 5. When the low side gauge attains the lowest steady
vacuum, stop the evacuation process.
System Vacuum Temperature
NOTE: The vacuum pump achieves ultimate vacuum
In Cm. of °F °C with the vented exhaust valve closed.
Mercury Mercury 6. Check the system by closing the gauge shut--off
28.0 71.0 100 37 valves, turning the vacuum pump off and noting the
low side gauge reading. A loss of more than 2″ (5
28.9 73.4 80 27 cm) of vacuum in 5 minutes indicates either a leak
or moisture in the system.
29.4 74.6 60 16
7. If the gauge needle remains stationary and the
29.7 75.4 40 5 vacuum is maintained for 3-5 minutes, close both
29.8 75.7 20 --7 the high and low side manifold hand valves, turn off
and disconnect the center hose from the pump.
29.9 75.9 0 --18 The system is now ready for charging.
8. If a leak is detected, charge the system with
NOTE: For every 1000 feet (305 m) above sea level, approximately 14 ozs (400 g) of refrigerant, see
the vacuum gauge reading must be corrected by charging the system and identify leak using a leak
adding 1″ (2.54 cm) of mercury to compensate for the detector.
change in atmospheric pressure.
9. Once the leak is located discharge and recover the
IMPORTANT: Be sure the system is completely refrigerant in the system, repair the leak, then
discharged as refrigerant will damage the vacuum repeat the evacuation procedure.
pump.

50- 34
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
CHARGING THE SYSTEM 5. If the refrigerant charge will not completely transfer
IMPORTANT: Be sure there are no leaks in the system to the air conditioning system, recover and
and the system has been fully evacuated. recharge the system.
Observe all safety recommendations when handling 6. Close the high and low side valves on the units
refrigerant R-134a, see “Precautions when Handling control panel, or manifold gauge set if being used
Refrigerant R-134a” in this Section. and test the air conditioning as detailed in
1. Ensure the charging unit is correctly connected to Performance Testing The Air Conditioning System
the tractor air conditioning system in accordance on Page 15.
with the manufacturers instructions. NOTE: After charging a system use the following start
2. If a charging unit, in conjunction with the manifold up procedure to ensure the lubricating oil is properly
gauge set is used, open the high and low side hand dispersed around the system:
valves on the manifold. • Ensure air conditioning is switched OFF.
3. Charge the system with 1.4kg (3.1lbs) of • Start the engine and bring speed down to idle.
refrigerant as per the manufacturers instructions. • Turn the air conditioning ON and allow system to
4. If the charging rate becomes very slow close the operate for at least one minute before increasing
high side valve, start the tractor and set engine engine speed.
speed to idle. Turn ‘ON’ the air conditioning so that
the compressor can pull the remainder of the
refrigerant into the system.

4 1

3 2
60--50--031

36
Connecting Recovery Evacuation and Recycling/Charging Station to the Tractor
1. High Side Service Valve (Red Hose) 3. Recovery/Recharging Unit
2. Built In Manifold Gauge Set 4. Low Side Service Valve (Blue Hose)

50- 35
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
COMPONENT OVERHAUL (EXCLUDING
COMPRESSOR)

GENERAL
WARNING
Before disconnecting components in the air
conditioning system the refrigerant gas must be
discharged and recovered using a certified recovery
system. Refer to Discharging the system on Page 31.
Do Not discharge the gas into the atmosphere.

If an air conditioning component is to be replaced

during a system overhaul it is necessary to drain any
refrigerant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean refrigerant oil equivalent to that
removed from the replaced component must then be
added to the new item before being installed onto the
tractor.
Upon completion of the repair evacuate, recharge, leak
test and performance test the system to ensure correct
operation.
Disconnection and Reconnection Of Air
Conditioning Spring Lock Couplings A
1. The spring lock couplings, Figure 37(A), can be
separated using Special Tools reference
No.295031, which are available for 3/8, 1/2, 5/8, 3/4 B C
inch diameter air conditioning tubes.
2. To separate the connection position the tool
around the connector and slide the tool into the
coupling, Figure 37(B), The sleeve on the tool will
then release the retaining spring in the connector.
3. Pull the connector tubes to separate the coupling
Figure 37(C).
60--50--034 TI
4. Prior to reconnecting the connections examine the
‘O’ ring seals for damage and replace as 37
necessary.
5. Coat the ‘O’ rings with compressor oil.
6. To reconnect the connector install the plastic ring,
(1), (not part of the tool but supplied with the 1
tractor) into the bulbous section of the coupling,
(2), Figure 38.
7. Push couplings firmly together until they ‘lock’ at
which time the plastic ring will be ejected from the
bulbous section of the tube.

60--50--035 TI
38

50- 36
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
EXPANSION VALVE
The expansion valve is not a serviceable item and must
be replaced if defective.

1. Fully discharge the air conditioning system.

60--50--013 TI
39
2. Remove roof access hatch and evaporator cover
plate to gain access to the valve, Figure 39.

60--50--036 TI
40
3. To gain access to the expansion valve spring lock
couplings partially lift the evaporator core from its
position in the cab roof.
4. Disconnect the two spring lock couplings to the
expansion valve.
5. Remove Allen screw securing the inlet and outlet
connections to the valve, Figure 40 and pull valve
from tubing.
6. Replace the ‘O’ ring seals and lubricate with
refrigerant oil prior to installing the valve using
disassembly procedure in reverse, Figure 41.
7. Evacuate, leak test and recharge the system.
60--50--037 TI
41

50- 37
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
EVAPORATOR
1. Close the heater shut--off valve on the rear of the
inlet manifold, Figure 42.
2. Turn the cab heater temperature control to
maximum heat.
3. Apply a clamp to the heater return hose at the left
side of the engine. Disconnect the hose and drain
the heater system of coolant, Figure 43.
4. Discharge and reclaim refrigerant gas using
certified recovery systems.
5. Remove the black cover plate to reveal evaporator
assembly.
6. Partially lift evaporator and heater core from plastic 42
housing to improve access to hoses, Figure 44.
7. Remove temperature cycling control
thermocouple, Refer to Figure 45.
8. Disconnect tubing to expansion valve.
9. Disconnect heater hoses and remove evaporator
and heater core assembly.
10. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
11. Clean the evaporator core of all foreign material to
be sure it is free of obstructions.
12. Check the evaporator assembly for indications of
refrigerant leakage. If damage or leaks are evident, 60--50--038 TI
replace the evaporator core.
43
13. If a new evaporator is to be installed drain the
refrigerant oil in the evaporator into a clean
calibrated container. Measure the quantity of oil
obtained and add the same quantity of new
refrigerant oil directly into the replacement
evaporator core.
14. Install evaporator using disassembly procedure in
reverse.
15. Evacuate, leak test and recharge the system.

60--50--015 TI
44

60--50--010 TI

50- 38
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
AIR CONDITIONER TEMPERATURE CYCLING
CONTROL SWITCH
1. Remove the black evaporator cover plate.
2. Partially lift evaporator and heater core and
remove temperature cycling control switch
thermistor from left hand end of evaporator, Figure
46.
3. Carefully pull and disconnect the switch wiring
connector from beneath the plastic housing which
holds the evaporator and blower motor assembly.
Refer to Figure 52.
60--50--010 TI
46
4. Remove temperature cycling control switch,
Figure 47.

60--50--009 TI
47
LOW PRESSURE CUT--OUT SWITCH

1. With the engine ‘Off’ check continuity across the

switch contacts, Figure 48. If the switch shows
‘Open Circuit’ replace as detailed below.
NOTE: The switch can be replaced without
discharging the system.
2. Remove switch, Figure 48, by unscrewing from
self sealing schrader valve.
3. Replace with new switch and connect to harness.

60--50--011 TI

48
BLOWER MOTOR and FAN ASSEMBLY
The blower motor can if required be removed without
discharging the system as follows:--
1. Remove the cab heater temperature control knob,
Figure 49 and then unscrew the control shaft
retaining nut.

60--50--017 TI

50- 39
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
2. Remove the 3 head lining studs situated close to
the air louvre vents inside the front of the cab.
3. Raise the cab roof and withdraw the heater control
mechanism, Figure 50, from the control panel.
4. Remove the visible screws which attach the motor
to the plastic air conditioning housing in the cab
roof.
5. Remove the 2 retaining bolts from the plate which
covers the evaporator and then remove the 2 bolts
securing the plastic evaporator housing to the cab
roof.
60--50--039 TI
50
6. Carefully lift the front of the plastic evaporator
housing and turn the complete assembly over
towards the rear of the cab Refer to Figure 51 and
Figure 52.
NOTE: Take care not to damage hoses during this
operation or spill any water onto the cab roof.
If the cab heater hoses restrict movement of the
housing drain the heater assembly and disconnect the
hoses.
7. Disconnect the motor wiring connector block.
8. Remove the remaining motor securing screws and
withdraw motor.
60--50--015 TI
51
9. Re--assembly follows the disassembly procedure
in reverse. During re--assembly ensure the 4 drain
hoses are reconnected to the plastic air
conditioning housing, Figure 52.

60--50--040 TI

50- 40
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
RECEIVER DRYER and CONDENSER
The receiver/dryer, (2) Figure 53, cannot be
overhauled and must be replaced as an assembly. The
receiver/dryer assembly should be replaced if it is
suspected that moisture is in the system.
The receiver dryer must also be replaced if the system
has been discharged and the air conditioning joints
disconnected.
1. Discharge and reclaim refrigerant gas using
certified recovery systems.
2. Slide condenser, (1) Figure 53, to side of tractor.
3. Separate the air conditioning tube spring lock 2 1
couplings to the receiver dryer.
4. Remove the dryer from the tractor.
5. Disconnect the connections to the condenser.
6. Cap and plug all fittings to prevent any dirt entering
the system.
7. Remove condenser from tractor.
8. Inspect the condenser assembly fins for damage
and be sure they are not plugged.
9. Check the condenser for signs of leakage. If the
60--50--006A TI
condenser is damaged or leaking, install a new
condenser assembly. 53
10. Drain the refrigerant oil from the receiver dryer into
a clean calibrated container. Measure the quantity
of oil obtained and add the same quantity of new
refrigerant oil directly into the new item.
11. If the condenser is to be replaced, drain the
refrigerant oil from the condenser into a clean
calibrated container. Measure the quantity of oil
obtained and add the same quantity of new
refrigerant oil directly into the new condenser.
12. Soak new tubing connector ‘O’ rings in clean
refrigerant lubrication oil and install onto tubing
13. Install condenser and a new receiver dryer.
14. Evacuate, leak test and recharge the system.

50- 41
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
COMPRESSOR HIGH LOW CUT--OUT SWITCH
1. With the engine ‘Off’ check continuity across the
switch contacts, (1), Figure 54. If the switch shows 1
‘Open Circuit’ replace as detailed below.
NOTE: The switch can be replaced without
discharging the system.
2. Remove switch by unscrewing from self sealing
schrader valve.
3. Replace with new switch and connect the harness.

60--50--089 TI
54
CAB AIR FILTERS
1. Before servicing the filters, switch off the blower
and close the roof hatch, all windows and one door.
Slam the final door closed and the resulting back
pressure will dislodge most of the loose dirt from
the underside of the filters.
2. Remove filter element(s), Figure 55 and clean by
blowing with compressed air not exceeding 2 bar
(30 lbf/in2).
Blow the dust from the upper surface through the
element to the underside. Hold the nozzle at least
60--50--016 TI
12 in (300 mm) from the element to prevent
damage to the paper pleats.
55
3. Clean both filter chambers with a damp, lint free
cloth.
4. Replace the filter elements with the rubber seal
uppermost and re--install the covers.

50- 42
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
COMPRESSOR -- OVERHAUL

Compressor Removal
1. Discharge and reclaim refrigerant gas using
certified recovery systems. Record the amount of
oil discharged as (X).
2. Disconnect tubing to compressor.
3. Disconnect wiring connector to compressor clutch.
4. Disconnect drive belt, remove the four mounting
bolts and remove compressor from tractor.

60--50--008 TI

56
5. Drain the refrigerant oil from the old compressor
into a clean calibrated container. Measure and
record the quantity of oil as (Y). This information is
required during installation of the new or
overhauled unit.
NOTE: It is necessary to rotate the compressor drive
shaft several times to completely expel all the oil.

Compressor Installation
1. Installation is the reversal of the removal but the
following points should be noted:--
• Torque the mounting bolts to 40--51Nm
([Link]).
57
NOTE: It is recommended that a new receiver / drier
assembly is installed after any system component
replacement or any repair that requires entry into the
system.
• Drain the oil from the new compressor to be fitted
into a clean container, or if the old compressor is
to be refitted, obtain a new can of refrigerant oil.
• Calculate the amount of oil to be installed as,
(x)+(y). Add this quantity of the new oil into the fill
port on top of the compressor.
NOTE: Refer to the following page regarding Oil Level
Measurement to determine if the system oil quantity
is correct.
After charging a system use the following start up
procedure to ensure the lubricating oil is properly
dispersed around the system:
• Ensure air conditioning is switched OFF.
58
• Start the engine and bring speed down to idle.
• Turn the air conditioning ON and allow system to
operate for at least five minutes before increasing
engine speed.

50- 43
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Oil Level measurement (on vehicle)
Oil level in the compressor should be checked when a
system component is removed or replaced or when an
oil leak is suspected.
Use the following procedure to determine if the oil
quantity is correct.
1. Start the engine and allow to idle. Switch on air
conditioning and run the compressor for 10
minutes.
2. Recover the refrigerant from the system, very
slowly so as not to lose any oil.
3. Carefully remove the oil filler plug. Turn the
armature retaining nut to allow full insertion of the
oil dipstick (1) Figure 59, supplied with kit
NH.50--100.
1
4. Remove the dipstick and count the notches
covered by the oil. An acceptable level of oil is
when 5--7 notches are covered.
5. Add or subtract oil through the filler plug to obtain
the correct level.
6. Ensure the filler hole seat and filler plug seal are
clean and not damaged and Install the oil plug.
Tighten to 15--25Nm ([Link]).

59
Oil Retained in System Components
After replacement of individual system components it
will be necessary to add some oil to the system to make
up the amount lost in the removed component. The
table, on the right, shows some typical volumes for the
components. It is, however, still recommended that the
on vehicle oil level measurement procedure, described
above, is carried out after a new component has been
installed to establish correct oil quantity.

60
Component Typical oil amount
[Link]. cc
Evaporator 2.0 60
Condenser 1.0 30
Receiver / drier 0.5 15
Hoses 0.3 10

50- 44
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using the A
+ --
rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 volt battery check current drawn by the
field coil which should be between 3.6-- 4.2 Amps.

TA605057

61
Very high current readings indicate a short circuit
in the field coil and no current reading indicate an
open circuit. Replace coil with either fault.
Resistance of the coil using an ohmmeter should
be approximately 3.0Ω at 20°C.
A poor earth (ground) connection of the field coil
will result in a low voltage.
3. Ensure clutch is disengaged and rotate pulley by
hand. If roughness in the bearing is felt, it will be
necessary to replace the pulley and bearing as an
assembly.

TA605058

62
Clutch Disassembly

Removal
All clutch servicing should be done with the
compressor removed from the vehicle:
1. Support the compressor. If using a vice, do not hold
on to the housing.
2. Remove the cover on the front of the clutch plate.
3. Using the front plate tool hold the clutch plate
stationary and remove the retaining nut from the
end of the shaft. Figure 63.
6050092TAG
63
4. Place a thread protector over the end of the
driveshaft and using a puller remove the clutch
front plate, Figure 64.

6050093TAG
64

50- 45
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
5. Carefully remove the bearing dust cover, if fitted.

TA605088

65
6. Remove the clutch shims

TA605062

66
7. Remove the shaft key

TA605063
67
8. Remove the pulley bearing external snap ring

TA605064
68

50- 46
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
9. With a shaft protector over the exposed shaft, use
a suitable puller to remove the clutch pulley.

6050094TAG

69
10. Inspect the pulley bearing for wear and replace
where necessary.

TA605066

70
11. Remove the field coil wire retaining clip.

TA605067
71
12. Remove the field coil retaining snap ring and lift the
coil from the housing.

TA605068
72

50- 47
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Clutch Reassembly
1. Install the field coil, ensuring that the lug on the
compressor housing locates in the cut out on the
back of the coil housing, secure with the snap ring.

TA605071
73
2. Position the pulley on the housing hub.

TA605069
74
3. Using a suitable adaptor that rests firmly on the
inner race of the pulley bearing, tap the pulley onto
the front hub of the compressor.

TA605070
75
4. Install the bearing snap ring.
5. Replace the original shims, key and a new bearing
dust cover.

TA605064
76

50- 48
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
6. Install the clutch front plate and using a suitable
adaptor, tap into position.

TA605073
77
7. Replace the retaining nut and tighten to a torque of
18Nm ([Link]).

6050092TAG
78
8. Check the clearance between the clutch front plate
and pulley. This should be consistent around the
circumference and be between 0.4--0.8mm
(0.016--0.031in.)
9. If the air gap is not consistent, lightly pry up on the
counter weighted front plate at the low spots or
lightly tap down at the high spots.

TA605074

79
10. If the clearance is not within specification the shims
under the front plate, Figure 80, should be added
to or subtracted from until the correct clearance is
obtained.
NOTE: New shims are available in sizes 1.00, 0.50 and
0.13 mm, (0.040, 0.020 and 0.005 in.).

TA605062

50- 49
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
Shaft Seal Replacement
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior to
replacing the shaft seal.

Removal
1. Remove the clutch front plate, as detailed in steps
1 to 7 of clutch disassembly.
2. Using a suitable lever or pair of snap ring pliers,
remove the felt ring.

TA605076

81
3. Remove the shaft seal retaining snap ring.

TA605075
82
4. Insert the seal remover/installer tool. Twist the tool
to engage the slots in the seal. Pull up to remove.
Discard the seal.
NOTE: If seal remover tool is not available, insert a
suitable piece of hooked wire into the seal slot and pull
out seal.

6050095TAG
83
Installation
1. Thoroughly clean the seal cavity in the hub. Use
‘lint free’ cloth only.
2. Position the seal protector over the driveshaft.

TA605077
84

50- 50
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
3. Ensure the shaft seal ‘O’ ring is installed onto the
seal assembly.

TA605079

85
4. Dip the new seal assembly in clean refrigerant oil
and attach to the seal remover/installer tool.
5. Insert the new seal fully into the hub.
NOTE: If remover/installer tool is not available,
position the seal squarely in the hub and tap gently until
fully seated.

TA605080

86
6. Install the seal snap ring. If the snap ring has a
beveled edge this should face outwards.

TA605082
87
7. Install a new felt seal and gently tap into position.
8. Remove the shaft protector and position the shims
over the shaft.
9. Reinstall the clutch front plate as described in
clutch reassembly.

TA605083
88

50- 51
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1
CYLINDER HEAD SERVICING

Disassembly
1. Drain the refrigerant oil from the compressor into
a clean calibrated container. Measure and record
the quantity of oil obtained. This information is
required during installation of the new or
overhauled unit.

TA605084

89
2. Remove the six cylinder head bolts and using a
hide mallet, gently tap the cylinder head free. The
use of a gasket scraper may also be required to
free cylinder the cylinder head from the
compressor body.
3. If the valve plate and/or cylinder head are to be
reused, carefully remove the gasket using a
suitable scraper.

TA605085

90
4. Gently pry the valve plate free from the cylinder
block and remove the gasket.
5. Inspect the valve plate for damage.

TA605086

91
Reassembly
1. Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the
reverse of the disassembly procedure.
2. When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
3. Install the cylinder head bolts and tighten using the
sequence shown in Figure 92. Torque initially to
20Nm ([Link]) then finally to 32Nm (24 [Link]).
4. When the overhaul is complete add to the
compressor a volume of oil equivalent to that TA605087
drained prior to disassembly.
92

50- 52
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 1 -- Electrical Introduction

CONTENTS

Section Description Page

55 100 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 000 System Precautions For Battery Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 100 Temporary Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
ELECTRICAL SYSTEM AND FUSES
The electrical system of all tractors consists of various
wiring harnesses, instrument clusters, touch panels
and various switches. Models fitted with Power
Command, Range Command or Dual Command
transmissions also use a number of micro--processors
to control the transmission and an electronically
controlled hydraulic lift system, where fitted.
There are three instrument clusters available,
Electronic Instrument Cluster (EIC),
Analogue/Electronic Instrument Cluster (AEIC) and an
Analogue Instrument Cluster (AIC).
The Key start switch has five positions:
1. Thermostart
2. ‘Off’
3. Accessory ‘on’
4. Warning lamp and instruments ‘on’
5. Start

1
There are two battery options.
Standard 1 x 1200 CCA
Cold start 2 x 900 CCA

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Fuses and Relays
The Main Distribution Panel (MDP), or fuse box, is
located behind the right hand instrument cluster
console side panel.

3
For primary protection the main supplies from the
starter solenoid are fitted with maxi fuses.
These are located behind the left hand instrument
cluster console side panel.

4
There are two fuse links fitted:--
1. In the main battery to alternator lead.

5
2). In the 12v supply lead from the alternator B+
terminal to the starter relay (C005 pin 1 FM--150U--N)

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

7
Relay Function Relay Function
A Blank (Air Brakes -- Germany/With Cab only) III Thermostart Relay
B Worklamp Relay -- Front (Roofline) IV Front Intermittant Wipe
C Worklamp Relay -- Rear (Roofline) V Blank
D Worklamp Relay -- Lower Front VI Rear Intermittant Wipe
E Worklamp Relay -- Lower Rear VII
F Bridge Link or Fuel Shut Off Relay VIII
} Front Hitch Control Module
G Stoplamp Relay IX Trailer Brake Relay
H Trailer Brake Relay X Blank
I Ignition Relay XI
II Hydraulic Diverter Valve Relay XII
} ISO Module or NASO Module (Indicators)
NOTE: Indicator relay is located separately behind the
No. Amps. Circuit MDP.
1 15 Headlamp -- Main
No. Amps. Circuit
2 15 Headlamp -- Dip
3 10 Sidelamp -- Right Hand 16 25 Heater Fan
4 10 Sidelamp -- Left Hand 17 20 Wiper Washer/Front Wiper/Rear Wiper/
Temperature Control/Console Lamp
5 30 Worklamp -- Front & Rear (Cab Roof)
18 10 Turn Indicators
6 15 Worklamp -- Rear (Fenders)
19 25 Thermostart
7 30 Worklamp -- Front
20 5 Keep Alive Memory for Transmission and
8 15 Fuel Shut--Off/Fuel Pump/Water in Fuel EDC Processors, EMU and Radio, Supply for
9 10 Gauges/External Switches/Radar Diagnostic Connectors
10 20 Hazard Lights 21 25 Transmission Control Module/Clutch
11 30 Horn/Headlamp Flasher/Cigar Lighter/Roof Switch/Gear Shift Indicator/Limp Home
Beacon 22 5 Radio
12 10 EDC 23 25 Accessory Socket/Interior Lamp/Cigar Lighter
13 25 Diff Lock/PTO/4WD/Worklamps 24 5 Implement Socket
14 10 Transmission Shuttle 25 20 Stop Lamp relay (G) Supply
15 30 EMU Module/Stoplamps/Seat Pump/ Front 26 5 Starter fuse -- Power Command Only
Hitch Trailer Brake/Diverter Valve
NOTE: Fuses 25 and 26 are located in a separate
holder attached to the maxi fuses.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Micro Processors
The tractor can have a maximum of 4 processors
(including an Electronic Instrument Cluster, where
fitted). With 3 processors connected to the instrument
cluster by a serial link for cluster display.
Electronic Management Unit

8
Electronic Instrument Cluster

9
GCM

Dual Command
Transmission and EDC Control

Range Command
EDC and Suspended

Power Command
Suspended Front Axle Control

10
TCM

Range Command
Transmission Control

Power Command
Transmission and EDC Control

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
PROTECTING THE ELECTRONIC/ELECTRICAL SYSTEMS DURING CHARGING OR WELDING
PRECAUTIONS be removed from the tractor. It is recommended
To avoid damage to the electronic/electrical systems, that this procedure be carried out by an
always observe the following: authorised dealer.
1. Never make or break any of the charging circuit • Never allow welding cables to lay on, near or
connections, including the battery connections, when across any electrical wiring or electronic
the engine is running. component while welding is in progress.
2. Never short any of the charging components to 6. Always disconnect the negative cable from the
earth. batteries when charging the batteries in the tractor
with a battery charger.
3. Do not use a slave battery of higher than 12 volts
nominal voltage. WARNING
4. Always observe correct polarity when installing the Batteries contain sulphuric acid. In case of contact with
batteries or using a slave battery to jump start the skin, flush the affected area with water for five minutes.
engine. Follow the instructions in the operator’s Seek medical attention immediately. Avoid contact
manual when jump starting the tractor. Connect with the skin, eyes or clothing. Wear eye protection
positive to positive and negative to negative. when working near batteries.
5. Always disconnect the earth cable from the
batteries before carrying out arc welding on the IMPORTANT: Failure to disconnect the two earth
tractor or on any implement attached to the tractor. cable connections at the battery prior to charging the
batteries or welding on the tractor or attached
• Position the welder earth cable clamp as close
implement will result in damage to the electronic and
to the welding area as possible.
electrical systems.
• If welding is to be carried out in close proximity
to a computer module, then the module should

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Temporary Wiring Harness Repair
The following method to repair wiring is a temporary
expedient only. Wiring should be replaced as soon as
possible. Replacement of temporary repaired cables
with new is particularly important if the tractor is to be
used for spraying as chemicals can enter the repaired
area, travel up the cable and damage electrical
components. Do not attempt to repair the wire on any
system sensors as these are sealed and should only
be replaced with a new component.
NOTE: When conducting a cable repair it is important
that only RESIN CORED SOLDER is used. Use of
other types of solder may result in further cable
damage.
To carry out a temporary repair, proceed as follows:--
1. Locate damaged portion of cable then cut away
outer protective cover on both sides of the
damaged area, Figure 12.

12
2. Peel back the cable from both ends of the
damaged area and carefully cut away the inner
cable cover at the damaged area and strip about
13 mm (1/2 inch) of insulation from the wires. Do
not cut away any wire strands.
3. Using a suitable solvent, clean about 2 inches (50
mm) from each cover end. Clean the grey cable
cover and the individual leads.
4. Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape,
Figure 13.
13

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
5. Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section. Make
a paper trough, Figure 14, then apply silicon
rubber compound (non hardening sealant) over the
repaired section up to the cover ends. Sufficient
sealant must be used to fill the ends of the cut away
area.

14
6. Allow the compound to cure then cover the area
with insulating tape taking the tape well over each
end of the repair. An overlap of at least 2 inches
(50 mm) of tape at each end is necessary, Figure
15.

7. Check to ensure the repair is satisfactory and

secure the repaired cable so that repeat damage
is avoided.
NOTE: This is a temporary repair only. Ensure the
damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 2 -- Electronic Management Unit

CONTENTS

Section Description Page

55 440 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Worklamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Functions controlled by the Electronic Management Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electronic Management Unit with Terralock t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electronic Management Unit without Terralock t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

B
A

1
There are three types of Electronic Management Unit used on the TM Series tractor:--
• With cab Electronic Management Unit with Terralockt. (A)
• With cab Touch Panel Unit t. (B)
• With cab Electronic Management Unit with Terralockt for Supersteer (A)
These units are located on the right hand console.

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
FUNCTIONS CONTROLLED BY THE ELECTRONIC MANAGEMENT UNIT
The Electronic Management Units control,
1. 4WD
2. Diff Locks
3. Rear PTO operation, including Softstart
4. Rear PTO brake operation
5. Measurement of rear PTO speed
6. Thermostart
7. Measurement of tractor ground speed if analogue electronic instrument cluster (AEIC) fitted
8. PTO and handbrake warning system
9. Worklamps

Handbrake Released Handbrake Engaged

Seat unoccupied/ Intermittent alarm for 2.5 minutes No alarm
PTO disengage *FWD on
Seat unoccupied/ 5 second continuous then 5 second continuous alarm
PTO engaged intermittent alarm for 2.5 minutes *FWD on
Seat occupied/ No alarm No alarm
PTO disengaged *FWD on
Seat occupied/ No alarm No alarm
PTO engaged *FWD on

NOTES:
1) ‘*’ Overrides all other commands from MAN and AUTO functions on the Electronic Management Unit.
2) ‘PTO’ refers to rear PTO.

WORKLAMP OPERATION
Worklamps are selected with the Touch Pads in the
lower section.
With cab -- 4 sets of worklamps
The worklamps will only operate with the tractor lights
on.
During operation, if the tractor lights are switched off,
the worklamps will be extinguished. However, if the
lights are then turned on again the same worklamps
will re--illuminate.
If the key switch and side lights are switched off the
worklamps will be permanently extinguished until
reselected.

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ELECTRONIC MANAGEMENT UNIT WITH
TERRALOCK T

1. Auto Differential Lock

2. Manual Differential Lock
3. Worklamps
4. Manual FWD
5. Auto FWD

3
Auto Differential Lock
The Differential Lock will be temporarily disengaged
when :
• either or both brake pedals are applied
• steering angle is greater than 20° (14° for
supersteer) and speed less than 10 Km/h (6 mph)
• steering angle is greater than 10° (7° for
supersteer) and speed is between 10--15 Km/h
(6--9 mph)
• When the raise/work switch is operated.
Differential lock will permanently disengage if tractor
speed exceeds 15 Km/h (9 mph).
If the keystart is switched off when auto differential lock 4
is engaged, the auto Differential lock will re engage
when the engine is restarted.

Manual Differential Lock

The Differential Lock is permanently engaged until
either;
the Differential Lock switch is operated
or
the brakes (latched or unlatched) are operated
or
tractor speed exceeds 15 Km/h (9 mph).

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
Auto FWD
The FWD will temporarily disengage when:--
• ground speed exceeds 20 km/h (12 mph)
• steering angle is greater than 25° (17.5° for
supersteer) and tractor speed is between 10--20
km/h (6--10 mph)
• steering angle is greater than 30° (21° for
supersteer) and tractor speed is less than 10 km/h
(6 mph)
If the keystart is switched off when Auto FWD is
engaged, the Auto FWD will re-engage when the
engine is re-started.
6
Manual FWD
The FWD remains engaged until the switch is
operated.
FWD also engaged during braking with latched pedals
or when parking brake is applied.
If the keystart is switched off when Manual FWD is
engaged, the Manual FWD will re-engage when the
engine is re-started.

7
The Terralock functions can be switched off by holding
both manual diff and 4WD buttons, keying ON, and
holding the buttons for 1 minute. The LEDs will flash at
double speed. This procedure returns the unit to a
three button touch panel. Repeat the procedure to
switch back on.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ELECTRONIC MANAGEMENT UNIT
WITHOUT TERRALOCK T

1. Semi Automatic Differential Lock

2. Manual Differential Lock
3. Cab Worklamps
4. FWD

8
Semi Automatic Differential Lock (1), Figure 9
The Differential Lock will temporarily disengage
when:--
• either or both brake pedals are applied
• the lift is operated by the raise/work switch or
Lift-O-Matic lever.
Differential Lock will permanently disengage if tractor
speed exceeds 15 Km/h (9 mph).
If the keystart is switched off, the semi auto Differential
lock will re engage when the engine is restarted.

9
Manual Differential Lock (2), Figure 10
The Differential Lock is permanently engaged until
either;
the Differential Lock switch is operated
or
the brakes (latched or unlatched) are operated
or
tractor speed exceeds 15 Km/h (9 mph).

10
Manual FWD (3)
The FWD remains engaged until the switch is
operated.
FWD also engaged during braking with latched pedals
or when parking brake is applied.
If the keyswitch is switched off, the Manual FWD will
re-engage when the engine is re-started.

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
CALIBRATION

Ground speed selection

When analogue electronic instrument cluster (AEIC) is
fitted metric or imperial speed display may be selected:
• From mph to km/h, depress manual diff lock touch
pad whilst turning key start on.
• From km/h to mph , depress manual FWD touch
pad whilst turning key start on.

12
Wheel speed sensor (all tractors) and steering
angle sensor Electronic Management Unit
calibration.
Mark out 100m track.
Ensure that tractor side lights are turned off.
Enter mode by holding both manual FWD and
Differential Lock touch pads and start tractor.

13
Approach start and press manual Differential Lock
touch pad.
Drive 100 metres in straight line.

14
Press manual Differential Lock touch pad at end of 100
metres and switch off tractor to enter calibration into
memory.

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
Brake Pedal Switches Adjustment
Locate a 2.5mm (0.10 inch) thick gauge bar between
the switch and brake pedal. Loosen the switch
retaining screws.
Push the switch towards the brake pedal to the limit of
the plunger travel whilst ensuring that the pedal
remains stationary. Tighten the retaining screws and
remove the gauge. Repeat for the other switch.
After adjustment ensure that both switches can be
heard operating and operating simultaneously.

60--33--020 TI
16
ELECTRONIC MANAGEMENT UNIT
REMOVAL AND INSTALLATION
Removing Electronic Management Unit from right
hand console.

17
Electronic Management Unit connection (C105).
NOTE: A new Electronic Management unit or a unit
taken from another tractor must be calibrated after
installation. Refer to previous page for calibration
details.

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ELECTRONIC MANAGEMENT UNIT ERROR CODES
The Electronic Management Unit has an inbuilt self diagnostic system to assist with the detection of faults should
they occur.
If a fault occurs that is related to the Electronic management Unit a two digit code prefixed with a ‘P’ will be displayed
on the instrument cluster. Should more than one fault occur at any one time, the fault with the highest priority will
be displayed followed by the lower priority error code. Error codes present at key ON will similarly be displayed.
PRIORITY ERROR ERROR DESCRIPTION
(1 = Highest) CODE
1 P01 Rear PTO brake solenoid stuck off
2 P02 Rear PTO brake solenoid stuck on
3 P03 Rear PTO brake output open circuit
4 P04 Rear PTO brake driver over temperature
5 P05 Not used
6 P06 Not used
7 P07 Rear PTO solenoid stuck off
8 P08 Rear PTO solenoid circuit overcurrent
9 P09 Not used
10 P10 Not used
13 P13 Not used
14 P14 Not used
15 P15 Diff lock solenoid stuck off
16 P16 Diff lock solenoid stuck on
17 P17 Diff lock output open circuit
18 P18 Diff lock driver overtemperature
19 P19 Not used
20 P20 Not used
21 P21 FWD solenoid stuck off
22 P22 FWD solenoid stuck on
23 P23 FWD output open circuit
24 P24 FWD driver overtemperature
25 P25 Not used
26 P26 Not used
27 P27 PTO speed sensor open circuit
28 P28 Not used
29 P29 Not used
30 P30 Not used
31 P31 Steering sensor out of range -- maximum voltage
32 P32 Steering sensor out of range -- minimum voltage
33 P33 Rear PTO cab switch momentary contact open circuit
34 P34 Fender mounted rear PTO switch (if fitted) open circuit or short circuit to
ground
35 P35 Fender mounted rear PTO switch (if fitted) input short to 12V or short across
fender switch wires

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
PRIORITY ERROR ERROR DESCRIPTION
(1 = Highest) CODE
36 P36 PTO failure to start (further qualification required)
37 P37 Rear PTO cab switch momentary switch stuck closed (greater than 30
seconds)
38 P38 Cab and fender rear PTO controls operated within 2 seconds of each other.
39 P39 Incorrect voltage on fender mounted rear PTO switch input (if fitted)
40 P40 PTO relay coil short to +12V or open circuit
41 P41 PTO relay coil short circuit to ground

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P01 -- REAR PTO BRAKE SOLENOID STUCK OFF

With the Key start off, disconnect the rear PTO

brake solenoid connector C033. Turn the key start
on,

Error P01 displayed Error P02 or P02 & P03

With the keystart off Check resistance of solenoid. Is

disconnect connector C105 Repair short resistance between 5--11Ω ?
from electronic management to ground
unit. Using a multimeter
check for a short circuit Replace solenoid valve
between C105--35 and
ground. Is a short indicated?

Substitute the electronic

Substitute the electronic management unit
management unit

ERROR CODE P02 -- REAR PTO BRAKE SOLENOID STUCK ON

Turn the keystart ON, ensure the FWD and
Differential lock are disengaged. Turn the keystart
OFF, set the PTO brake switch to the brake Refer to fault finding flow
applied position, set the front and rear PTO chart for Error code P03.
engagement switches to be disengaged. Turn the
keystart ON again, are errors P02 and P03
displayed?

Turn the keystart OFF and ON again. Set the PTO

brake switch to the OFF position, P02 should be
displayed. Disconnect the rear PTO brake
connector, C033 and electronic management unit Trace short circuit in wiring
connector C105. With the keystart ON check for a and repair
short to +12v on C105--35. With the keystart OFF,
check for a short from C105--35 and the other
C105 connector pins. Is a short circuit indicated?

Substitute Electronic Management Unit

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P03 -- REAR PTO BRAKE OUTPUT OPEN CIRCUIT

Is C033 connected correctly? Refit correctly

Disconnect connector C033 from

solenoid. Using a suitable
multi--meter check across solenoid Replace
terminals. Is an open circuit solenoid
indicated?

Check wiring at connector C033.

Check for continuity between C033 -- Trace and repair
RM57N--B and ground. fault in ground
Is an open circuit indicated? circuit

Disconnect Electronic Management Trace open circuit in wiring.

Unit Connector (C105). Check wiring Disconnect connector C19.
from C105--35 to C033--RM2130--B/N/S Check between C19--20 and
Is an open circuit indicated? C105--35 and between C19--20 and
C033--RM2130--B/N/S to determine
Check and clean connectors in circuit which harness is faulty.
(C105, C19, C033). Recheck for error
code. If error code persists substitute
Electronic Management Unit.

C105 C19 C033

2130 2130 2130
35 20

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P04 -- REAR PTO BRAKE DRIVER OVER TEMPERATURE

Check for low resistance in rear PTO brake

solenoid circuit

Disconnect connector C033. Check coil

resistance is approx. 5--11Ω at 20_C. Replace
coil if outside specification.

Check for short circuit between C105--35 and

Trace and repair short to earth
ground. Is a short circuit indicated?

Check for a short circuit between C105--35 and

the other pins of C105. Is a short circuit Trace and repair short circuit
indicated?

Inspect the connector pins on C105. Refit

connector, if error persists substitute the
electronic management unit.

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P07 -- REAR PTO SOLENOID STUCK OFF (ELECTRICALLY)
ERROR CODE P08 -- REAR PTO SOLENOID CIRCUIT OVERCURRENT

C116 C19 C041

CM2049 O/P 18 RM--2049 O/P
C105
18 CM2045 O/G
RM--57K--B
13 CM2048 O/Y

Disconnect PTO solenoid connector, C041.

Check coil resistance is approx. 5--11Ω Replace coil
20_C. Is coil within specification?

Check each coil terminal to ground. Replace coil

Is a short/partial short to ground indicated?

Disconnect PTO switch connectors C116

and check solenoid connector C041, Trace and repair
terminal, RM2049--O/P, to ground. faulty wiring
Is a short to ground indicated?

Disconnect E.M.U. connector C105. Check

the PTO switch connectors C116, Trace and repair
CM2045--O/G and CM2048--O/Y to ground. faulty wiring
Is a short to ground indicated?

Substitute Electronic Management Unit

55- 13
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P15 -- DIFF. LOCK SOLENOID STUCK OFF

C105 C19 C042

36 CM--7080--B/LG 22 RM--7080--B/LG
57J--B

Disconnect differential lock solenoid

connector, C042. Turn the keystart ON and
select manual differential lock
NOTE: Keep foot off brake pedals

Error P15 Error P16 or P16

displayed and P17 displayed

Check diff lock

solenoid
resistance. Is Replace solenoid
resistance
5--11Ω?

With the keystart off, disconnect

C105 from electronic management Substitute
unit. Using a multi--meter, is a Electronic
short to ground indicated at Management Unit
C105--36?

Disconnect connector C019. Trace and repair short

Check again for short to ground at to ground between
C105--36. Is a short to ground C042--RM7080--B/LG
indicated? and C019

Trace and repair short to ground

between C105--36
(CM7080--B/LG) and C019.

55- 14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P16 -- DIFF. LOCK SOLENOID STUCK ON

Turn keystart ON, ensure

differential lock is deselected.
Key OFF and ON again, P16 Refer to error P17 fault
should be displayed. Select finding flow chart
Manual differential lock, is
P17 displayed?

Disconnect differential lock connector,

C042, and electronic management
unit connector, C105. Turn the Trace short to
keystart ON, using a multimeter check +12v and repair
for +12v on C105--36. Is a short to
+12v indicated?

With the keystart OFF, check for a

short circuit to one of the other C105 Trace short in
connector pins, is a short circuit harness and repair
indicated?

Substitute
Electronic
Management Unit

C105 C19 C042

36 CM--7080--B/LG 22 RM--7080--B/LG
57J--B

55- 15
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P17 -- DIFF. LOCK OUTPUT OPEN CIRCUIT

Is C042 connected correctly? Refit correctly

Disconnect connector C042 from the

diff. lock solenoid. Using a suitable
multi--meter check across solenoid Replace
terminals. Is an open circuit solenoid
indicated?

Check wiring at connector C042. Trace and repair

Check for continuity between C042 -- fault in ground
RM57J--B and ground. circuit
Is an open circuit indicated?
Trace open circuit in wiring.
Disconnect Electronic Management Disconnect connector C19.
Unit Connector (C105). Check wiring Check between C19--22 and
from C105--36 to C042--RM7080--B/LG. C042--RM7080--B/LG and between
Is an open circuit indicated? C19--22 and C105--36 to determine
which harness is faulty.
Check and clean connectors in circuit
(C105, C19, C042). Recheck for error
code. If error code persists substitute
Electronic Management Unit.

55- 16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P18 -- DIFF. LOCK DRIVER OVER TEMPERATURE

Check for low resistance in

differential lock solenoid circuit

Disconnect connector C042. Check coil

resistance is approximately 5--11Ω at
20_C. Replace coil if outside
specification.

Check for short circuit between C105--36 and

Trace and repair short to earth
ground. Is a short circuit indicated?

Check for a short circuit between C105--36 and

the other pins of C105. Is a short circuit Trace and repair short circuit
indicated?

Inspect the connector pins on C105. Refit

connector, if error persists substitute the
electronic management unit.

55- 17
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P21 -- 4WD SOLENOID STUCK OFF

With the keystart OFF, disconnect the FWD connector, C034.

Turn the keystart ON and ensure that 2WD is selected.
Key OFF and ON again.

P21 displayed P22 or P22 and

P23 displayed

With the keystart Substitute Electronic

OFF, disconnect Management Unit Check solenoid
connector C105 from resistance is
the electronic between 5--11Ω
management unit at 20°C, replace
and check for a short if outside
to ground on specification.
C105--14. Is a short
circuit indicated?

Disconnect connector Trace and repair

C19 and check for a short to ground
short to ground on between
C105--14. Is a short C034--RM3025--Y/U
indicated? and C105--14

Trace and repair

short to earth
between C105--14
and ground.

C105 C19 C034

14 CM--3025--Y/U 19 RM--3025--Y/U

RM--57M--B

55- 18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P22 -- 4WD SOLENOID STUCK ON

turn keystart ON, select manual FWD and

turn keystart OFF. Depress both brake
pedals and turn the keystart ON and Tractor okay or possible
momentarily crank the engine (no need to intermittent fault.
start engine). Is error P22 displayed?

Release brake Refer to Error code

pedals, is error P23 P23 fault finding flow
displayed? chart.

Disconnect the FWD solenoid connector,

C034 and electronic management unit
connector C105. Using a multimeter Trace short circuit
check for a short to +12v on C105--14 or and repair
a short to one of the other terminals on
C105. Is a short circuit indicated?

Substitute Electronic
Management Unit

C105 C19 C034

14 CM--3025--Y/U 19 RM--3025--Y/U

RM--57M--B

55- 19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P23 -- 4WD OUTPUT OPEN CIRCUIT

Is connector C034 connected correctly? Refit correctly

Disconnect connector C034 from the

4WD solenoid. Using a suitable
multi--meter check across solenoid Replace
terminals. Is an open circuit solenoid
indicated?

Check wiring at C034. Check for

continuity between C034 -- Trace and repair
RM57M--B and ground. fault in ground
Is an open circuit indicated? circuit

Disconnect Electronic Management Trace open circuit in wiring.

Unit Connector (C105). Check wiring Disconnect connector C19.
from C105--14 to C034--RM3025 -- Y/U. Check between C19--19 and
Is an open circuit indicated? C034--RM3025--Y/U and between
C19--19 and C105--14 to determine
Check and clean connectors in circuit which harness is faulty.
(C105, C19, C034). Recheck for error
code. If error code persists substitute
Electronic Management Unit.

C105 C19 C034

14 CM--3025--Y/U 19 RM--3025--Y/U

RM--57M--B

55- 20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P24 -- 4WD DRIVER OVER TEMPERATURE

Check for low resistance in FWD solenoid

circuit.

Disconnect connector C034. Check coil

resistance is approximately 5--11 Ω at 20_C.
Replace coil if outside of specification.

Check for short circuit between C105--14 and

Trace and repair short to earth
ground. Is a short circuit indicated?

Check for a short circuit between C105--14 and

the other pins of C105. Is a short circuit Trace and repair short circuit
indicated?

Inspect the connector pins on C105. Refit

connector, if error persists substitute the
electronic management unit.

C105 C19 C034

14 CM--3025--Y/U 19 RM--3025--Y/U

RM--57M--B

55- 21
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P27 -- PTO SPEED SENSOR OPEN CIRCUIT

Is the speed sensor connector (C054) Refit correctly

connected correctly?

Disconnect C054. Using a suitable multi meter

Replace speed
check access the speed sensor terminals. Is an
sensor
open circuit indicated?

Check wiring at C054. Check for continuity Trace and repair fault
between C054 -- RM57R--B and ground. Is an in ground wiring
open circuit indicated?

Disconnect electronic management unit Trace open circuit in wiring.

connector (C105) check wiring from C105--23 to Disconnect connector C19.
C054 -- RM2140 -- B/O/S. Is an open circuit Check between C19--14
indicated. and C054 -- RM2140 --
B/O/S and between
C19--14 and C105--23 to
Check and clean connectors in circuit (C105, determine which harness is
C19, C054). Recheck for error code. If error faulty.
persists, substitute electronic management unit.

C19 C054
C105 14 RM2140 B/O/S
2140
23
RM57R--B

55- 22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P31 -- STEERING SENSOR OUT OF RANGE -- (MAXIMUM VOLTAGE)

Disconnect connector C014. With

the keystart ON, check for a short to
+12V on the Red, yellow or black Locate short and repair
wires of the steering sensor. Is a
short indicated?

With the Keystart OFF, check for a

short circuit between the red, yellow Locate short and repair if
and black steering sensor wires. Is possible or replace steering
sensor assembly
a short indicated?

Visually inspect the steering sensor

Check resistance between red and wires, connector and connector
black wires of steering sensor. Is the terminals, if no fault evident replace
resistance 5kΩ--6kΩ? steering sensor.

Inspect connector C014 for correct

terminal installation. Reconnect Tractor okay
C014, is the error code still present?

Disconnect connectors C014 and

C105. Turn ON keystart, Are Trace and repair short circuit
C105--28, C105--4 and C105--27
indicating 0 volts?

With the Keystart OFF is an open

circuit indicated between Trace and repair short circuit
connector C105 pins, 4, 27 and 28? between C105 pins, 4, 27 and 28.

Is there continuity between :--

C105--28 and C014--1
C105--4 and C014--2 Trace and repair open circuit
C105--27 and C014--3?

Substitute the Electronic Management Unit.

Recalibrate after installation

+5V
1
2
3
0V
4
C105 C001 C014
CM3100 B/G/S FM3100 B/G/S R Steering Sensor
+5V 28 13
Input 4 CM3120 B/K/S
14 FM3120 B/K/S Y
CM3140 B/LG/S FM3140 B/LG/S B
0V 27 15

55- 23
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P32 -- STEERING SENSOR OUT OF RANGE -- (MINIMUM VOLTAGE)
Disconnect connector C014. With
the keystart OFF, check for a short
to ground on the Red, yellow or Locate short and repair
black wires of the steering sensor. Is
a short indicated?

With the Keystart OFF, check for a

Locate short and repair if
short circuit between the red, yellow
possible or replace steering
and black steering sensor wires. Is
sensor assembly
a short indicated?

Visually inspect the steering sensor

Check resistance between red and wires, connector and connector
black wires of steering sensor. Is the terminals, if no fault evident replace
resistance 5kΩ--6kΩ? steering sensor.

Inspect connector C014 for correct

terminal installation. Reconnect Tractor okay
C014, is the error code still present?

Disconnect connectors C014 and

C105. With keystart OFF, Are Trace and repair short to ground.
C105--28, C105--4 and C105--27
shorted to ground?

With the Keystart OFF is an open

circuit indicated between Trace and repair short circuit
connector C105 pins, 4, 27 and 28? between C105 pins, 4, 27 and 28.

Is there continuity between :--

C105--28 and C014--1
C105--4 and C014--2 Trace and repair open circuit
C105--27 and C014--3?

Substitute the Electronic Management Unit.

Recalibrate after installation

+5V
2
1
3
0V
4
C105 C001 C014
CM3100 B/G/S FM3100 B/G/S R Steering Sensor
+5V 28 13
Input 4 CM3120 B/K/S
14 FM3120 B/K/S Y
CM3140 B/LG/S FM3140 B/LG/S B
0V 27 15

55- 24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P33 -- REAR PTO CAB SWITCH MOMENTARY CONTACT OPEN CIRCUIT

Remove switch from right hand console

panel. Does the switch read 15 kΩ across Replace switch
momentary contact pins (blue and black assembly
wires)?

Check wiring to momentary contacts of the

PTO switch.
Disconnect touch panel connector C105 and
PTO connectors (C116). Check for open
circuit between C105--13 (2048 O/Y) and
C116, 2048 (O/Y). Repair or replace faulty
wiring as required.

55- 25
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P34 -- FENDER MOUNTED REAR PTO SWITCH OPEN CIRCUIT OR
SHORT TO GROUND

Disconnect and check operation of switches Replace switch,

using a multi-meter. Are the switches key off, key on and
operating correctly? ensure error is
eliminated

Check the wiring to the fender switches.

Disconnect the touch panel connector, C105
and the two switch connectors C257 and Inspect wiring for
C258. Using a suitable multi-meter check for short to ground,
a short circuit to ground at C105--31 repair or replace
(2059--W/U). wiring as required.
Is a short to ground indicated?

With a suitable multi-meter check the wiring

between C105--31 (2059--W/U) and
connectors C257, C258, for an open circuit. If
no fault is indicated attempt to ’wiggle’ the
harness in case the fault is intermittent and
inspect the connector terminals.
Repair or replace wiring as required.

55- 26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P35 -- FENDER MOUNTED REAR PTO SWITCH INPUT SHORT TO +12V
OR SHORT ACROSS FENDER SWITCH WIRES

Disconnect and check the operation of the Replace faulty

fender switches using a suitable multi-meter. switch, key
Are the switches operating correctly? OFF/ON to ensure
error is eliminated

With the C105 (touch panel) connector Trace the short circuit to
connected and the fender switch connectors +12V between C105--31 and
disconnected, is +0V indicated on the switch connector.
2059--W/U wire terminal at either connector Repair/Replace wiring as
C257 or C258? required.

If no fault is indicated attempt to ’wiggle’ the

harness in case the fault is intermittent and
inspect the connector terminals for possible
short across terminals/wires.
Repair/replace wiring as required.

55- 27
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P36 -- REAR PTO FAILURE TO START -- RELAY OR SWITCH WIRING FAULT

Remove the rear PTO switch from the right

hand console. Remove the connector and Fault in connector or connector
inspect each terminal and wire connection. wiring. Ensure connector is
Refit the connector. Does the error code P36 permanently corrected.
still show?

Substitute relay KX (Fender Switch Relay) for Relay faulty. Install

one of known performance. Does the error now. Relay and
code P36 still show? clear error code

Inspect wiring to relay socket. Repair or

replace wiring as required.

55- 28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P37 -- REAR PTO CAB MOMENTARY SWITCH STUCK CLOSED (LONGER
THAN 30 SECONDS)

Remove and inspect the switch. Repair or replace

Is the switch stuck on? the switch

Using a multi--meter, are the PTO switch

(momentary contacts) internally short Replace the switch
circuited?

Remove the PTO switch connector (C116)

and Electronic Management Unit Connector
(C105). Using a suitable multi-meter check
for a short to ground on C105--18
(orange/green) wire.
Repair/replace wire as required.

55- 29
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P38 -- CAB AND FENDER REAR PTO CONTROLS OPERATED WITHIN 2
SECONDS OF EACH OTHER

Operator error.
Leave for 10 seconds then operate.

ERROR CODE P39 -- INCORRECT VOLTAGE ON FENDER MOUNTED REAR PTO

SWITCH INPUT (IF FITTED)

Is Fuse 15 okay? Replace Fuse

Is there +12V at the switch connectors

(C257--LH & C258--RH) on wire R/LG/P Trace fault in wiring
(Red/Light Green/Purple)? back to fuse 15
and repair
Remove the switches (S51 & S52) and check
operation using a multi-meter.
The switch should indicate: 1015Ω in the Replace switches
open (off) position and 15Ω in the closed (on) as required.
position. Are the switches operating
correctly?

Check wiring from the switch to pin No. 31 of

C105 (W/U wire) for open circuit.
Repair as required.

55- 30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P40 -- PTO RELAY COIL SHORT TO +12V OR OPEN CIRCUIT

Is the fender switch relay (kx) installed / Install/Reinstall

installed correctly? Relay

Is the relay operating correctly? Replace with one of

known performance
Disconnect the Electronic Management Unit
Connector (C105) and remove relay, kx.
Check wire C105--12 (O/LG) for an open
circuit or short to +12V.
Repair as required.

55- 31
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2
ERROR CODE P41 -- PTO FENDER SWITCH RELAY COIL SHORT TO GROUND

Remove the relay and check the operation. Is

Replace the relay
the relay operating correctly?

Disconnect the Electronic Management Unit

Connector (C105) and remove the relay (kx).
Check wire C105--12 (O/LG) for a short to
ground. Repair as required.

55- 32
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- Electronic Instrument Cluster

CONTENTS

Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Senders, sensors, & switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Programming central LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Programming performance monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fault code charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fault finding flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1
The Electronic Instrument Cluster consists of five
distinct areas:
1. Indicator and Warning Lamps
2. Tractor Condition Bar Graph
3. Central Display
4. Tractor Performance Monitor
5. Function Buttons

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
AREA 1: INDICATOR AND WARNING LAMPS

Condition Indicator/ Central LCD Audible Alarm

Warning Lamp Display
1 Coolant level low ON Stop Critical
2 Engine oil pressure ON Stop Critical
3 Battery voltage:
Below 10 volts ON Non critical
above 16 volts Non critical
4 Air filter restriction ON
5 Thermostart ON
6 Parking brake on Flashing
Key on (stopped)
Parking brake on Flashing Critical
Ground speed +0.8 kph (0.5 mph)
Parking brake off OFF Critical 2 minutes
Key off
7 Water in fuel ON Non critical
8 Transmission oil filter blocked ON Non critical
Charge pressure low (CCLS pump Flashing
only)
9 Transmission oil pressure low ON Stop Critical
10 Trailer brake pressure low Flashing Critical
11 Left turn indicator Flashing
12 Single trailer indicator Flashing
13 Second trailer indicator Flashing
14 Main beam on ON
15 Side lights on ON
16 Hi (power shuttle only) ON
17 Lo (power shuttle only) ON
18 Four wheel drive engaged ON
19 Differential lock engaged ON
20 Brake fluid low ON
21 Right hand indicator Flashing

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
CRITICAL ALARMS

Coolant Temperature High

With engine running:
Critical audible alarm, stop and left hand display will
flash.
With engine off, key on:
The left hand display continues to display maximum
bars and coolant symbol.

3
Engine Oil Pressure Low
With engine running:
Critical audible alarm, stop and left hand display will
flash. Alarm pressure function will vary with engine
speed.

OIL PRESSURE RPM ALARM

Bar lbf/in2 Less than 500 OFF
0.6 8 500--1500 ON
1.1 16 1500--2000 ON
1.7 24 2000--3000 ON

With engine off, key on: 4

The left hand display continues to display minimum
bars and oil pressure symbol.
NOTE: If both coolant and oil pressure alarms are
activated together, both symbols, high and low
symbols and all 12 segments of left hand display flash.

Fuel Level Low

Display and alarm are activated as bargraph changes
from:--
3 to 2 Segments
2 to 1 Segment
Or when Key switched on (with low fuel).
5 second non critical alarm.

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
AREA 2: TRACTOR CONDITION BAR
GRAPHS

Fuel Level
Each segment indicates 1/12 of total fuel capacity.
A low fuel level alarm is activated if the display drops
from 3 to 2 segments, and from 2 to 1 segment.

6
Engine Oil Pressure
Each segment indicates approximately 0.56 bar
(8 lbf/in2).
SEG Bar lbf/in2 SEG Bar lbf/in2
1 0--0.5 0--8 7 3.4--3.9 48--56
2 0.5--1.1 8--16 8 3.9--4.5 56--64
3 1.1--1.7 16--24 9 4.5--5.0 64--72
4 1.7--2.2 24--32 10 5.0--5.6 72--80
5 2.2--2.8 32--40 11 5.6--6.1 80--88
6 2.8--3.4 40--48 12 6.1--6.7 88--96

A low oil pressure alarm will be activated at 0.5--1.7 7

(8--24 lbf/in2) depending on engine rpm.

Engine Coolant Temperature

Each segment indicates approximately 5-6ûC, the first
segment is always displayed when temperature below
66ûC.

SEG ûC SEG ûC
1 60--66 7 93--99
2 66--71 8 99--104
3 71--77 9 104--110
4 77--82 0 110--116
5 82--88 11 116--121
6 88--93 12 Over 121 8

Coolant over heating alarm is activated when the

display changes from 11 to 12 segments.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
AREA 3: CENTRAL DISPLAY

Battery Voltage
Digital display indicating to nearest 0.1volt.
Alarm system activated if voltage is less than 10 volts
or above 16 volts.

9
Engine Hours
Digital display of actual hours of engine running,
automatically selected when Key Start switch turned
’ON’.
Readouts 0--1000 hours in 0.1 increments and above
1000 hours in 1 hour increments to maximum 9999
hours.
Recorded hours are stored in the permanent memory
and not affected by battery removal.

10
Engine RPM
Digital display to nearest 10 rpm.
Display automatically selected on engine start up.
Permanent 18 segment rpm bargraph display
indicates 800--2500 rpm in 100 rpm steps.

11
Ground Speed
Digital display of ground speed km/h or mph
(programming). In ’ERPM’, display will automatically
select ground speed over 20 km/h.
Ground speed provided by Radar (if fitted) or
transmission speed sensor.
Ground speed calibration must be correct to provide
accurate ground speed.

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
PTO Speed
PTO speeds are actual speeds measured by the PTO
sensor picking up a signal from the output shaft.
The PTO engaged/overspeed lamp will flash for 10
seconds as the shaft speed rises above 650 rev/min to
indicate that if 540 speed is selected, the shaft speed
is too high.

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
AREA 4: TRACTOR PERFORMANCE
MONITOR

Area Per Hour

Area per hour being worked based on last 5 seconds
of operation.
Display will read .0 if either the implement is raised or
the tractor is stopped.

14
Area
Total accumulated area (since last display reset).
Area accumulation is automatically switched ’OFF’ or
’ON’ when the implement is raised or lowered in work,
or manually by touching the ON/OFF (ground speed
button).
Area display can be set to ZERO by holding down
AREA function button for 3 seconds.

15
Slip (With Radar Option Only)
Wheel slip percentage (%).
Based on difference between radar (ground speed)
sensor and transmission (wheel speed) sensor
signals.
To ’zero’ slip, hold down SLIP function button for 3
seconds (alarm tone) while tractor speed is less than
16 km/h (10 mph).

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
AREA 5: FUNCTION KEYS

17
1. Engine Oil Pressure 8. Engine RPM Digital Readout
2. Fuel Tank Level 9. Ground Speed
3. Engine Coolant Temperature 10. PTO RPM 540/1000
4. Battery Voltage 11. Area/Hour
5. Engine Hours 12. Area Worked
6. Programming & Diagnostic Functions 13. Slip %
7. Programming & Diagnostic Functions

The liquid crystal displays are selected by touching the An audible bleep confirms each function button
appropriate touch sensitive function buttons as shown command.
above. The selected displays are shown on the following
pages.
The function buttons are disabled during critical and
non--critical alarm sequences.

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SENDERS, SENSORS & SWITCHES

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
A. ENGINE COOLANT LEVEL SWITCH
Operates as engine coolant level drops to illuminate warning lamp. Uses a normally closed switch.
B. ENGINE OIL PRESSURE SWITCH
Operates as engine oil pressure drops below 0.68 bar (10 lbf/in2) to illuminate warning lamp. Uses a normally
closed switch.
C. ALTERNATOR
Provides a square wave signal of 142.5 -- 855.0 Hz (480 -- 3060 ERPM) for instrument cluster and
microprocessor operations.
D. AIR CLEANER RESTRICTION SWITCH
Operates when the vacuum in the air intake system rises above 46.7 mm Hg (25 in H2O) to illuminate warning
lamp. Uses a normally open switch.
E. PARKING BRAKE SWITCH
Switch is closed with parking brake applied, a warning lamp and audible alarm with key switch on.
Sounds an alarm when wheel movement is detected above 0.8 km/h (0.5 mph).
Sounds an alarm for 2 minutes with key switch off and park brake released.

NOTE: FWD is always engaged when park brake is applied.

F. WATER IN FUEL
Operates when water is detected in the fuel to illuminate warning lamp.
G. INTAKE FILTER RESTRICTION SWITCH (Open Centre System)
Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to illuminate warning lamp.
Switch is normally open.

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SENDERS, SENSORS & SWITCHES

19
H. INTAKE FILTER OIL TEMPERATURE SWITCH
Operates as the transmission oil temperature rises above 40oC (104oF) to allow the intake filter restriction switch
to function. Switch is normally open.
I.
J. INTAKE FILTER RESTRICTION SWITCH
Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to operate warning lamp.
Switch is normally open.

K. CHARGE PRESSURE SWITCH

Operates as charge pressure drops below 0.8 bar (12 lbf/in2) to illuminate warning lamp. Switch is normally
closed.

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SENDERS, SENSORS & SWITCHES

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SENDERS, SENSORS & SWITCHES
L. TRANSMISSION OIL PRESSURE SWITCH
Operates as transmission oil pressure drops below 11 bar (160 lbf/in2) to operate warning lamp. Switch is
normally closed.

M. ITALIAN TRAILER BRAKE SWITCH

Operates when trailer brakes are applied to illuminate warning lamp.

N. FWD OIL PRESSURE SWITCH

S. ENGINE COOLANT TEMPERATURE SENDER

The temperature sender resistance changes proportionally with coolant temperature causing a modulated signal
voltage to be sent back to the instrument cluster to operate the gauge.

SENDER RESISTANCE GAUGE INDICATION

710 -- 580 ohms Cold
Less than 100 ohms Hot

T. FUEL TANK SENDER

Signal from sender potentiometer determines fuel level displayed on the gauge.

SENDER RESISTANCE GAUGE INDICATION

31 -- 49 ohms Full
230 -- 250 ohms Empty

U.
V. ENGINE OIL PRESSURE SENDER
The oil pressure sender resistance changes proportionally with engine oil pressure causing a modulated signal
voltage to be sent back to the instrument panel to operate the gauge.

DISPLAY PRESSURE
Bar lbf/in2
1 Bar 0 -- 0.5 0 -- 8
12 Bars 6.1 -- 6.7 88 -- 96

55- 13
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SENDERS, SENSORS & SWITCHES

21
W. PTO SPEED SENSOR
Sensor output modulates as signal voltage to the instrument cluster to display PTO speed.
X. TRANSMISSION SPEED SENSOR
Senses transmission output (wheel) speed and generates a signal for cluster ground speed display, distance
displays, and to compute area accumulations.
When a radar is fitted the transmission speed sensor is used only to compute % slip display.
Y. RADAR SENSOR (Optional)
Senses true ground speed and generates a signal for cluster ground speed, % slip, distance displays and to
compute area accumulations.

55- 14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
SERVICE ALERT SETUP
The next service alert is indicated by the hourmeter
symbol flashing for up to 10 hours when the service is
due.
The warning can be cancelled by pressing the
hourmeter and ground speed function buttons
together.

22
To enter the program press and hold the hour function
button for 3 seconds, (1) Figure 23.

23
To program the next service alert use the digit set (3)
and digit select, (2) Figure 24, function buttons.

24
GROUND SPEED CALIBRATION SETUP
Ground speed calibration number is related to the rear
wheel rolling radius (under load) for tractors less
Radar. The calibration number is programmed into the
centre display using digit select and set buttons.
For tractors with Radar the calibration number is 4018.

55- 15
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
Should tyres of a different size be fitted, then the
computer module may be recalibration to display a
more accurate ground speed
Using the table select the required calibration number.

REAR EMU CODE DIC CODE

TYRE
SIZE RADIUS TM 115 / 125 TM 135 / 150 TM 165
INDEX
(mm) All Transmissions All Transmissions Semi P/S Full P/S

18.4 x 34 770 7643 N/A N/A N/A

16/9 x 38 795 7403 7712 N/A N/A
480/70R38 795 7403 N/A N/A N/A
18/4 x 38 820 7177 7476 8716 7923
520/70R38 820 7177 7476 8716 7923
600/65R38 820 7177 7476 8716 7923
20.8 x 38 855 N/A 7170 8359 7599
580/70R38 855 N/A 7170 8359 7599
650/65R38 855 N/A 7170 8359 7599
18.4 x 42 870 N/A 7047 8215 7468
14.9 x 46 865 6804 7088 8262 7511
12.4 x 54 920 6397 6664 7768 7062
320/90R54 920 6397 6664 7768 7062

NOTE: For tractors fitted with RADAR use a Radius Index value of 100 for programming the EMU and a DIC
calibration value of 4018.

ALTERNATIVE CALIBRATION PROCEDURE

Start engine and enter ground speed calibration mode.
Measure suitable 122 m (400 ft) course. Drive over
course, touch speed button at start and end of course.
Number displayed is new CALIBRATION number, turn
off Key Start switch to enter into memory.

55- 16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
TRACTOR PERFORMANCE MONITOR
SETUP

1 Implement Width
Hold Set Up button to enter programming mode and
display implement width.
Use digit select and digit set buttons to revise width
setting.
Units:
M = metric ; FT = imperial

27
2 Slip Alarm
Touch Set Up button to display slip alarm* setting
(where Radar fitted).
Use digit set and select buttons to revise slip alarm
setting.
Set display to ’0’ ’0’ if alarm not required.
*Units without Radar will show AREA PRESET.

28
3 Area Preset
Touch Set Up button to display area accumulation
reading.
Use digit select and set buttons to preset area reading.

55- 17
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
TRACTOR PERFORMANCE MONITOR
SETUP

4 Distance Measurement

30
Touch Set Up button to enter distance measuring
mode.
(M or FT will be displayed indicating metric/imperial
units).
To measure travelled distance in this mode use
ON/OFF switch to start and stop display.

5 Setting Metric Or Imperial Units

31
Touch Set Up button to display units ’M’ or ’FT’.
Touching either reset button will change the units
displayed.
To exit programming mode hold down Set Up button
until the display changes to AREA/HOUR display.

55- 18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
EIC SERVICEABILITY
Removing Electronic Instrument Cluster

32
Rear Cover removed

33
Bulb replacement

55- 19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
FAULT CODE CHART These error codes appear when any one of the listed
errors occurs. The alarm sounds continuously for a
ERROR CODES critical alarm and for 5 seconds with a non critical
alarm.
The Electronic Instrument Cluster (EIC) features an
integral fault diagnosis system which displays error
codes on the LCD as shown in the following Table.

EIC DISPLAY
SENSOR CONDITION ALARM
Less than 500 rev/min More than 500 rev/min
Error Code No.
Oil Sender
Critical
Short to Ground/Open Circuit
Oil Sender
Critical
Short to a +ve Voltage
Fuel Sender
Non Critical
Short to Earth/Ground
Fuel Sender
Non Critical
Open Circuit or Short to a +ve Voltage
Axle Sender
Non Critical
Short to Earth/Ground
Axle Sender
Non Critical
Open Circuit or Short to a +ve Voltage
Coolant Temperature Sender
Non Critical
Short to Earth/Ground
Electronic Draft Control error
Serial Link Failure
Transmission error
Serial Link Failure
Battery Calibration error

Slip Alarm, Slip constant,

Non Critical
Width and Service Hours check
Coolant Temperature Sender
Critical
open circuit or shorted to a +ve Voltage
Engine Shutdown error

Non EIC Errors -- only displayed Read Your Manual (RYM)

in the Diagnostic Memory.

55- 20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 1 -- Engine Oil Pressure Sender Short or Open Circuit

Turn keystart OFF and

disconnect connector C003
from sender

Short Signal Out, FM--31--Y/S Does Error Code

and +5, FM--2014--G/K, pins on disappear and oil
connector C003 pressure display indicate
Is Error Code 1 still maximum?
displayed?

At connector, C003,
measure voltage between Replace
Check for faulty cable between cable
C001--FM2014--G/K/C081--CM2014--G/K, +5 and Ground pins
C001--FM31--Y/S/C081--CM31--Y/S and Is voltage approx. 5v?
C001--FM2095--G/W/B / C081--CM2095--G/W/B,
Is cable O.K?
Replace
sender
Replace Replace
EIC cable

55- 21
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 2 -- Engine Oil Pressure Sender Short to +ve Voltage

Disconnect connector C003

from sender

Using a suitable multi--meter Substitute

test for a voltage at each of the Inspect instrument Instrument panel
three terminals, with the keystart panel connectors. Are for one of known
ON. There should only be +5V connectors okay? performance.
at FM2014--G/K and 0V at the
remaining pins. Are voltage
readings correct? Repair connector as
required.

Disconnect engine
harness at connector
C002. Test voltage Trace and repair faulty
at C002--CM31--Y/S, wiring between connector
CM2014--G/K and C002 and connector
CM2095--G/W/B. C081
Are voltages
correct?

Trace and repair wiring

in Engine harness

55- 22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 3 -- Fuel Tank Level Sender Short to Earth/Ground
ERROR CODE 4 -- Fuel Tank Level Sender Open Circuit or Short to +12V

Inspect level sender, are the

connectors on the terminals clean Repair/replace and recheck
and tight?

Disconnect wires from sender unit

and connector C079 from the
instrument panel. With a suitable Locate and repair open circuit in sender
multi--meter, check ground wire
C022--RM2095--G/W/B to ground. Is
resistance <10Ω ?

Check the terminals of the sender to Remove sender, repair/replace and

ground. Is a short to ground indicated ensure there is no short to ground on
on either terminal? reassembly

Check the operation of the sender. Is

the resistance within the range: Renew sender
Full 30Ω and Empty 250Ω ?

Check C022--RM29--G/B to ground.

Is a short to ground indicated? Trace and repair fault in wiring

Check between C022--RM29--G/B Trace and repair open circuit fault in

and C079--16. Is resistance <10Ω ? wiring

Inspect instrument
panel connectors. Are Substitute instrument panel for one of
connectors okay? known performance and recheck.

Repair connector as
required.

55- 23
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 5 -- Axle Speed Sender Short Circuit
ERROR CODE 6 -- Axle Speed Sender Open Circuit

Is connector
Is Transmission Error code E49 C122 fitted Reconnect
also displayed? correctly? and recheck

Disconnect EDC and Hi--Lo

transmission processor Disconnect C081
connector C127 and wheel and C122. Is a
short or open Trace and
speed connector C046. Test repair fault
wiring between C127--6 and circuit indicated
between C081--1 in wiring
C046--RM5135--TQ. Is a short or
open circuit indicated? and C122?

Reconnect the Trace and Leave connector

two connectors repair/replace C122
carefully. Check fault in wiring disconnected and
that they are disconnect C127. Trace and
correctly fitted Test for a short or repair fault
and recheck. Is open circuit in wiring
error code 5 or 6 between C122
still displayed? and C127--8. Is a
fault indicated?

With the sender Reconnect the connectors

installed check for carefully. Check that they are
a short circuit to correctly fitted and recheck. Is error
ground on each code 5 or 6 still displayed?
sender terminal or
for an open circuit
of the sender. Substitute Instrument
Replace sender if panel for one with
either condition is known performance
indicated.

55- 24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 7 -- Coolant Temperature Sender Short Circuit

Remove the connector, C012, from the

sender. Ensure the end of the wire is not
contacting any metallic part. Turn keystart Renew sender and
ON, engine OFF recheck function.
Is Error Code 7 displayed?

Remove the instrument panel, disconnect

plug C079. Disconnect the signal wire Locate and repair
from the sender. Measure the resistance short circuit in signal
between pins C079--CM39--G/U and wire
C079--CM57N--B
Is the resistance less than 5000Ω?

Replace instrument cluster with one of

known performance

55- 25
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 8 (EDC serial link failure) and 9 (transmission serial link failure) --
Communications Error

The Electronic Management Unit module and the combined Electronic Draft Control and Hi--Lo
Transmission control module send their display information over a two wire serial communications
connection.

Communications errors (8&9) occur when the message received by the instrument panel is not
correct. This can be caused by an intermittent connection on the signal wires (LN/O or N/R/B). If
these errors are accompanied by reports of intermittent or blank displays in the transmission or hitch
position areas, then the circuit wires should be investigated for open circuits, short circuits and
intermittent connections.

C128--35

EDC/TRANS.
C128--14

C80--19 LN/O

EIC
C80--20 LN/TQ

C105--6

EMU
C105--10

ERROR CODE 10 -- Memory Retention Error of Battery Calibration Constant

Compare the voltage display of instrument panel to a voltmeter reading at the battery. If the readings
differ by more than 2.0 volts, then install a new instrument panel and recheck.

ERROR CODE 11 -- Memory Retention Error of Operator Setting for Slip Alarm, Slip
Zero Reference Constant, Implement Width and Service Hours

If Error Code 11 persists then replace the instrument panel.

Re--programme the constants listed above using the instructions detailed earlier in this Section. Turn
keystart OFF and re--check the programmed values. If the values are not correct then replace the
instrument panel

55- 26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 12 -- Coolant Temperature Sender Short Circuit

Inspect the connection at connector C012

at the sender. Rectify poor
Are the terminal and connector clean connection and
and do they fit together firmly? recheck function

With the connector removed from the

Remove the connector C012 from the sender measure the resistance between the
sender and hold it firmly against a good sender terminal and body
ground Is the resistance between 80Ω (hot) and
Does the display indicate Code 7? 800Ω (cold) ?

Remove the instrument panel, disconnect

connector C079. At the sender ,earth the signal Sender has poor Renew sender and
wire and measure the resistance between ground to engine. recheck function.
C079--CM39--G/U and C079--CM57N--B Remove sender and
Is the resistance less than 10Ω? clean threads

Clean the connector pins with Find and repair an open circuit fault in wiring
contact cleaner spray Apply a between connectors C079 (instrument panel)
dielectric grease. Reconnect and connector C012 (sender)
plugs to the instrument cluster
and turn keystart switch on
Does the cluster function Install a new Instrument Panel and recheck
correctly? function.

55- 27
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
ERROR CODE 13 -- Engine Shut--Down Output Short to a + Voltage

1 Figure 1

1. Fuel Shut--Off Solenoid

2. Relay ’F’
3. EIC
4. Fuse Panel
5. Fuel Pump

C081--CM2070--O/U/B

C081--CM2080--O/R

Remove the Fuel Shut--Off relay (F) from

the fuse panel. Measure the resistance of Renew relay
the relay coil at terminals 85 and 86.
Is resistance less than 95 Ω?

Remove instrument panel, disconnect

connector C081. With relay removed, Locate and repair
measure resistance between harness pins short in circuit
C081--2080--O/R and C081--2070--O/U/B between C081 and
Is resistance showing open circuit ? Relay F holder

Check instrument panel

connectors if okay Install a new
Instrument Panel

55- 28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
Common Test Procedure for ALL of the Switch Circuits Connecting to Ground

Disconnect the harness at the Check the ground path of the switch and
sender/switch, and connect signal wire to recheck function.
ground Is the resistance to ground less than
Is the warning light illuminated? 10 Ω?

Unplug wiring harness from instrument Renew the switch

cluster. Ground the signal wire at and recheck
switch/sender and measure resistance function.
between the signal pin and the tractor
frame at the panel connector
Is resistance less than 10 Ω? Locate
and repair
open Check and clean
circuit in connectors. Is
Clean wiring harness to instrument signal wire
cluster connector pins with contact spray switch
Reconnect the plugs to instrument panel functioning?
Remove the signal wire at the switch and
connect to ground
Is the warning light illuminated? Locate and
repair the open
circuit
Renew
the
warning
bulb

Is the
warning
light
illuminated?

Renew the Instrument Panel

and recheck function

55- 29
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
Instrument Cluster Inoperative
No display on instrument cluster when the keystart switch is turned on.

Ensure the gear levers are in the neutral

[Link] the keystart switch to crank
Charge the
the engine
battery
Is the battery sufficiently charged to
crank the engine?

Turn keystart off. Remove Fuse 9 from

the fuse box. Renew fuse
Is fuse blown? and recheck
function.

Remove the instrument cluster. Clean wiring loom to instrument cluster

Disconnect plug C079. Turn keystart connector pins with contact spray. Rejoin
switch on and measure voltage between connector C079 and switch ignition on.
C079--57N--B and C079--CM1003A--G Does instrument cluster display?
terminals
Is approximately 12v measured?
lnstall a new central
Digital Display
Turn keystart switch on and measure Module into the
voltage between connector terminal instrument cluster
C079--CM1003A--G and the battery and recheck
negative (ground) terminal. function.
Is approximately 12v measured?

Fault in ground wiring Fault in 12V power wiring

Locate and repair locate and repair

55- 30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
DIAGNOSTIC MEMORY
To enter diagnostic memory mode hold down digit set
button during key ’ON’ and self test sequence.
Touching the digit set button will cycle the display
through the memory.

36
The error codes will appear on the appropriate display,
together with engine hours recorded. Typical examples
are illustrated.
NOTE: Transmission E codes relate only to hi/Lo
transmission.

37
The memory can be erased by holding down the digit
set button for 10 seconds (while in diagnostic memory
mode).
To exit mode touch any other display and function
button.
The cluster stores up to 10 diagnostic error codes in a
permanent memory. The stored ’Services History’ can
be displayed by entering the Diagnostic Memory
Mode.
When in this mode, touching the digit set button will
cycle the display through the stored memory.
When 10 error codes are already stored, further error
codes occurring will cancel the oldest error code in the
memory or update the hours if that code is already 38
stored.

55- 31
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
INSTRUMENT PANEL BYTE LEVELS
To set bytes, press and hold the battery function button
and turn key to ON (Engine off). The display will show
’0’ ’7’
’7’ = Byte number
’0’ or ’1’ = Function
Use the DIGIT SELECT function switch to select next
Byte (15 -- 0).
Use the DIGIT SET function switch to select function
of Byte (’0’ or ’1’).

BYTE No.

7 EDC Gain -- Both should be switched to ’0’.

6
5 Reserved -- No effect whether switched to ’0’ or ’1’.
4

3 Bar Graph Displays -- Both should be switched to ’1’.

2
1 Units : Imperial ’1’ : Metric ’0’.
0 Panel Type -- should be switched to ’1’.
15
14
13
12 Reserved -- No effect whether switched to ’0’ or ’1’.
11
10

9 Radar Normally switched to ’0’

If switched to ’1’ the Tractor Performance Monitor display will be blank when radar not
fitted.

8 PTO Switched to ’0’ .

Engine Speed Constant -- depress Engine Speed function switch.

Constant = 017.1

55- 32
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
Checking DIC Software Revision Level
Displays the DIC software revision level for four
seconds after the KEY ON self check has completed.
To view software revision level, press and hold the
ERPM button whilst the key is switched on.
NOTE: This is a view only mode and software is not
upgradable.

55- 33
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3
NOTES

55- 34
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 4 -- Analogue Electronic Instrument Cluster

CONTENTS

Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Senders, sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1
The Analogue Electronic Instrument Cluster consists
of four distinct areas:
1. Indicator and Warning Lamps
2. Tractor Condition Gauges
3. Main Tachometer
4. LCD Displays

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
AREA 1: INDICATOR AND WARNING LAMPS

2
Condition Indicator/Warning Lamp Audible Alarm
1 Coolant level low Flashing Critical
2 Engine oil pressure low ON Critical
3 Battery charge low ON Non critical
4 Air filter restriction ON
5 Thermostat activated ON
6 Parking brake on/Key on ON
Parking brake off/Key off None 2 minutes continuous
7 Water in fuel ON
8 Transmission oil filter blocked ON Non critical
9 Transmission oil pressure low Charge ON
pressure low (CCLS pump only) Flashing
10 Trailer brake pressure low Flashing
11 Left turn indicator on Flashing
12 Single trailer indicator on Flashing
13 Second trailer indicator on Flashing
14 Headlamp main beam on ON
15 Side lights on ON
16 Direct drive selected ON
17 Under drive selected ON
18 Four wheel drive engaged ON
19 Differential lock engaged ON
20 Brake/clutch fluid low ON
21 Right hand indicator on Flashing

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
AREA 2: TRACTOR CONDITION GAUGES
The Analogue panel has two gauges:
Coolant Temperature

3
Fuel Level

4
AREA 3 : MAIN TACHOMETER
The central display is the tachometer showing engine
speed and the correct engine speeds for 540/1000
PTO operation, as well as economy 540.
Also in this area is the proof meter for engine hours.

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
AREA 4 : LCD DISPLAYS
Area 4 is the liquid crystal display, which is split into two
displays and is also used to display EDC, Electronic
Management Unit and Hi/Lo Transmission
calibrations.

6
When the PTO is operated the arrow will point at the
PTO symbol to show PTO shaft speed as detected by
the sensor.

7
With the PTO disengaged the arrow will point to the
EDC symbol and give the three point hitch linkage
position. EDC errors are also displayed.

8
If the Hi/LO Transmission develops a fault the arrow
will be displayed under the transmission symbol and
the fault code displayed in the display.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES
A. ENGINE COOLANT LEVEL SWITCH
Operates as engine coolant level drops to illuminate warning lamp. Uses a normally closed switch.
B. ENGINE OIL PRESSURE SWITCH
Operates as engine oil pressure drops below 0.68 bar (10 lbf/in2) to illuminate warning lamp. Uses a normally
closed switch.
C. ALTERNATOR
Provides a square wave signal of 142.5 -- 855.0 Hz (480 -- 3060 ERPM) for instrument cluster and
microprocessor operations.
D. AIR CLEANER RESTRICTION SWITCH
Operates when the vacuum in the air intake system rises above 46.7 mm Hg (25 in H2O) to illuminate warning
lamp. Uses a normally open switch.
E. PARKING BRAKE SWITCH
Switch is closed with parking brake applied, a warning lamp and audible alarm with key switch on.
Sounds an alarm when wheel movement is detected above 0.8 km/h (0.5 mph).
Sounds an alarm for 2 minutes with key switch off and park brake released.
NOTE: FWD is always engaged when park brake is applied.
F. WATER IN FUEL
Operates when water is detected in the fuel to illuminate warning lamp.
G. INTAKE FILTER RESTRICTION SWITCH (Open Centre System)
Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to illuminate warning lamp.
Switch is normally open.

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES

11
H. INTAKE FILTER TEMPERATURE SWITCH
Operates as the transmission oil temperature rises above 40ûC (104ûF) to allow the intake filter restriction switch
to function. Switch is normally open.
I.
J. INTAKE FILTER RESTRICTION SWITCH
Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to operate warning lamp.
Switch is normally open.

K. CHARGE PRESSURE SWITCH

Operates as charge pressure drops below 0.8 bar (12 lbf/in2) to illuminate warning lamp. Switch is normally
closed.

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES
L. TRANSMISSION OIL PRESSURE SWITCH
Operates as transmission oil pressure drops below 11 bar (160 lbf/in2) to operate warning lamp. Switch is
normally closed.

M. ITALIAN TRAILER BRAKE SWITCH

Operates when trailer brakes are applied to illuminate warning lamp.

N. FWD OIL PRESSURE SWITCH

Operates when transmission pressure 16 bar (240 lbf/in2) is absent in FWD line (FWD engaged) to illuminate
warning lamp. Switch is normally closed.
O.
P. DIFFERENTIAL LOCK PRESSURE SWITCH
Operates when transmission oil pressure 16 bar (240 lbf/in2) is present in differential lock supply lines to
illuminate warning lamp. Switch is normally open.
Q.
R. BRAKE/CLUTCH FLUID LEVEL SWITCH
Operates as fluid level drops below minimum to operate warning lamp. Switch is normally closed.
S. ENGINE COOLANT TEMPERATURE SENDER
The temperature sender resistance changes proportionally with coolant temperature causing a modulated signal
voltage to be sent back to the instrument cluster to operate the gauge.

SENDER RESISTANCE GAUGE INDICATION

710 -- 580 ohms Cold
Less than 100 ohms Hot

T. FUEL TANK SENDER

Signal from sender potentiometer determines fuel level displayed on the gauge.

SENDER RESISTANCE GAUGE INDICATION

31 -- 49 ohms Full
230 -- 250 ohms Empty
U.
V.

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SENDERS, SENSORS & SWITCHES

13
W. PTO SPEED SENSOR
Sensor output modulates as signal voltage to the instrument cluster to display PTO speed.

X. TRANSMISSION SPEED SENSOR

Senses transmission output (wheel) speed and generates a signal for cluster ground speed display, distance
displays, and to compute area accumulations.
When a radar is fitted the transmission speed sensor is used only to compute % slip display.

Y. RADAR SENSOR (Optional)

Senses true ground speed and generates a signal for cluster ground speed, % slip, distance displays and to
compute area accumulations.

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4
SERVICEABILITY
Instrument Cluster removed.

14
Rear cover removed.

15
Dip switch position.
1-5 Set to OFF
6 Set to ON.

16
Bulb replacement.
As well as the bulbs, the gauges and liquid crystal
displays can also be replaced seperately.

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 5 -- Analogue Instrument Cluster

CONTENTS

Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Senders, sensors & switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Servicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1
The Analogue Instrument Cluster has four display
areas:
1. Indicator and Warning Lamps
2. Fuel Level
3. Main Tachometer Display
4. Engine Temperature

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
AREA 1: INDICATOR AND WARNING LAMPS

2
Condition Indicator/ Audible
Warning Lamp Alarm
1 Coolant level low Flashing
2 Engine oil pressure low ON
3 Battery charge low ON
4 Air filter restriction ON
5 Thermostart activated ON
6 Parking brake on/key on ON
Parking brake off/key off None 2 minutes continuous
7 Water in fuel ON
8 Transmission oil filter blocked ON Non critical
9 Transmission oil presssure low ON
10 Trailer brake pressure low Flashing
11 Left turn indicator on Flashing
12 Single trailer indicator on Flashing
13 Second trailer indicator on Flashing
14 Headlamp main beam on ON
15 Side lights on ON
16 Direct drive selected ON
17 Under drive selected ON
18 Four wheel drive engaged ON
19 Differential lock engaged ON
20 Brake/clutch fluid low ON
21 Right hand indicator on Flashing

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
Fuel Level

3
Tachometer
Displays engine speed and indicates correct speeds
for 540/1000 PTO operation.

4
Coolant Temperature

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SENDERS, SENSORS & SWITCHES

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SENDERS, SENSORS & SWITCHES
A. ENGINE COOLANT LEVEL SWITCH
Operates as engine coolant level drops to illuminate warning lamp. Uses a normally closed switch.

B. ENGINE OIL PRESSURE SWITCH

Operates as engine oil pressure drops below 0.68 bar (10 lbf/in2) to illuminate warning lamp. Uses a normally
closed switch.

C. ALTERNATOR
Provides a square wave signal of 142.5 -- 855 Hz (480 -- 3060 ERPM) for instrument cluster and microprocessor
operations.

D. AIR CLEANER RESTRICTION SWITCH

Operates as the vacuum in the air intake system rises above 46.7mm Hg (25in H2O), to illuminate warning lamp.

E. PARKING BRAKE SWITCH

Switch is closed with parking brake applied, a warning lamp and audible alarm with key switch on.
Sounds an alarm when wheel movement is detected above 0.8 km/h (0.5 mph).
Sounds an alarm for 2 minutes with key switch off and park brake released.
NOTE: FWD is always engaged when park brake is applied.

F. WATER IN FUEL
Operates when water is detected in the fuel to illuminate warning lamp.

G. INTAKE FILTER RESTRICTION SWITCH (Open Centre System)

Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to illuminate warning lamp.

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SENDERS, SENSORS & SWITCHES

7
H. INTAKE FILTER TEMPERATURE SWITCH
Operates as the transmission oil temperature rises above 40ûC (104ûF) to allow the intake filter restriction switch
to function. Switch is normally open.
I.
J. INTAKE FILTER RESTRICTION SWITCH
Operates as the transmission intake vacuum rises above 406mm Hg (228.8 in H2O) to operate warning lamp.
Switch is normally open.

K. CHARGE PRESSURE SWITCH

Operates as charge pressure drops below 0.8 bar (12 lbf/in 2) to illuminate warning lamp. Switch is normally
closed.

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SENDERS, SENSORS & SWITCHES

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SENDERS, SENSORS & SWITCHES
L. TRANSMISSION OIL PRESSURE SWITCH
Operates as transmission oil pressure drops below 11 bar (160 lbf/in2) to operate warning lamp. Switch is
normally closed.

M. ITALIAN TRAILER BRAKE SWITCH

Operates when trailer brakes are applied to illuminate warning lamp.

N. FWD OIL PRESSURE SWITCH

S. ENGINE COOLANT TEMPERATURE SENDER

The temperature sender resistance changes proportionally with coolant temperature causing a modulated signal
voltage to be sent back to the instrument cluster to operate the gauge.

SENDER RESISTANCE GAUGE INDICATION

710 -- 580 ohms Cold
Less than 100 ohms Hot

T. FUEL TANK SENDER

Signal from sender potentiometer determines fuel level displayed on the gauge.

SENDER RESISTANCE GAUGE INDICATION

31 -- 49 ohms Full
230 -- 250 ohms Empty

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5
SERVICABILITY
Removing Analogue Instrument Cluster.

9
Rear cover removed.

10
Bulb replacement.
As well as the bulbs, the gauges can also be replaced
seperately.

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- Starting System

CONTENTS

Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 201 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

55 000 SPECIFICATIONS
Starter Type Bosch / Iskra 3 Kw Gear Starter
Maximum No Load Current Draw at 11.5 volts and 120 amps
4000 rev/min.
Minimum Brush Length 12 mm
Minimum Commutator Diameter 34.2 mm

TORQUE SPECIFICATIONS
[Link]. Nm
Starting Motor to Engine Block Retaining Bolts 25 34
Solenoid Cable Nuts 12 18
Starting Motor End Housing Bolts 4.8 6.8
Solenoid Retaining Screws 3.5 4.1
Brush Gear Plate Screws 3.5 4.1

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
OPERATION
The type of starting system is dependant on the
transmission installed in the tractor. All systems
consist of a key start switch, heavy duty wiring, starter At this point one end of the ‘pull--in’ coil is connected to
motor and solenoid assembly, a starting relay and a battery positive through the starter switch while the
clutch pedal switch, these are the components of the other end is connected to positive through the solenoid
basic circuit which is used on the mechanical contacts. The ‘pull--in’ coil is thus by--passed, drawing
transmission. Other components are included on the no current and the ‘hold--in’ coil alone keeps the
more sophisticated transmissions to ensure that the solenoid plunger engaged.
engine can only be started under the correct
conditions.

The starter incorporates a single set of contacts and a

two piece solenoid plunger which completely closes
There are four basic types of transmission, the contacts even if the pinion and ring gear teeth are
Synchro-Command (mechanical), Dual-Command misaligned. When this happens, an engagement
(Hi/Lo), Range Command (semi-powershift) and spring is compressed which forces the pinion into full
Power Command (full powershift). The Power engagement as soon as the starter begins to turn.
Command and Range Command share the same
starting circuit with Dual Command and Synchro
Command having their own unique starting circuits.

The gear type starter incorporates an epicyclic gear

reduction unit. The rotation from the armature drives
into the epicyclic and then onto the pinion. The ratio is
There are two starting motors available. A Bosch or an approximately 3.75:1 (3.75 armature rotations to 1
Iskra which are both four pole four brush type starters output rotation). This enables the engine to be cranked
with integral solenoid and with geared drive over easier, using less battery power compared with
engagement assemblies. Both are rated at 3Kw. non-geared starters, this is especially useful in cold
conditions. The starter is also more efficient and
maintains its initial cranking speed longer than
conventional direct drive starters.
The integral solenoid incorporates two windings
connected in parallel. One winding is the low
resistance ‘pull--in’ coil, grounded through the motor,
while the other is the high resistance ‘hold--in’ coil When the key start switch is released, power to the
grounded via the solenoid body. solenoid and motor is removed. The solenoid return
spring acting through the pivoted linkage mechanism
pulls the drive pinion out of mesh and reopens the
solenoid contacts.
When the key start switch is closed with the clutch
pedal depressed and the transmission in neutral
(except mechanical) the solenoid coils are energised
and the solenoid plunger is magnetically attracted into Incorporated in the drive pinion assembly is a roller
the solenoid core. This movement, transmitted through clutch device. This device prevents the armature from
a pivoted linkage mechanism forces the drive pinion rotating excessively if the pinion remains in mesh with
into mesh with the flywheel ring gear. At ring gear to the flywheel ring gear after the engine has started.
pinion abutment, the solenoid plunger closes a set of
contacts to give a direct feed from the battery to all four
field coils, providing full power to the starting motor.

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

1
Starter Circuit -- Power Command and Range Command Transmission
FL1 Fuse Link KIII Thermostart Relay
FL2 Fuse Link KF Fuel Shut Off Relay
G1 Battery R1 Thermostart Coil
K1 Ignition Relay Y1 Shut Off Solenoid
K2 Start Relay Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch MF1 Maxi Fuse 1 50A
MF2 Maxi Fuse 2 60A
G2 Alternator
F26 Fuse 26, 5A
F8 Shut off Solenoid Fuse
F19 Fuse S4 Forward/Reverse Shuttle Lever

MM7
2 3
Starter Relay Location Shuttle Lever Switch

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

4
Starter Circuit -- Hi/Lo Transmission
FL1 Fuse Link KIII Thermostart Relay
FL2 Fuse Link KF Fuel Shut Off Relay
G1 Battery R1 Thermostart Coil
K1 Ignition Relay Y1 Shut Off Solenoid
K2 Start Relay Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch MF1 Maxi Fuse 1 50A
MF2 Maxi Fuse 2 60A
G2 Alternator
F26 Fuse 26, 5A
F8 Shut off Solenoid Fuse
F19 Fuse S4 Forward/Reverse Shuttle Lever

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

5
Starter Circuit -- Synchro-Command Transmission
FL1 Fuse Link KIII Thermostart Relay
FL2 Fuse Link KF Fuel Shut Off Relay
G1 Battery R1 Thermostart Coil
K1 Ignition Relay Y1 Shut Off Solenoid
K2 Start Relay Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch MF1 Maxi Fuse 1 50A
MF2 Maxi Fuse 2 60A
G2 Alternator
F26 Fuse 26, 5A
F8 Shut off Solenoid Fuse
F19 Fuse S4 Forward/Reverse Shuttle Lever

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Engine Does Not Turn Over When Key Start Is Operated, Transmission In Neutral

Is the battery Charge or replace

fully charged? NO battery. Does engine
turn over OK?

Inspect starter circuit wiring. Are all

connections tight, is the battery Repair wiring
negative to ground connection O.K, are as required
any wires broken or frayed, possibly
causing a short circuit?

Is the engine Investigate

seized? engine failure

Operate key start switch, is there Can the Suspect faulty

+12v at the starter solenoid input solenoid be motor windings,
wire (white/red stripe) heard brushes or
‘clicking’? mechanical
failure
Suspect faulty starter solenoid,
remove starter and inspect
Inspect starter relay, operate key
start switch, can the relay be Replace relay
felt/heard operating?

Remove connector to relay is there

+12v on pin 4, (white/red stripe wire) Replace relay
when the key start switch is operated?

Inspect wiring to shuttle lever and/or clutch Reconnect wiring

NO Check
pedal switch, are wires connected? to switch
wire from
relay
Check operation of switches, are switches O.K.? Replace switch through
NO
(Use menu mode H5 where applicable) connector
C001--1 to
Check continuity of the shuttle
Is there +12v on the white/yellow white/red wire from clutch
wire to the clutch switch? NO lever
switch to pin 4 at starter switch,
relay connector, wire OK? where
Is there continuity of white/yellow wire from clutch fitted
NO Repair/replace
switch to key start switch, connector pin 6?
wiring

Do the displays in the instrument panel Check the main feed to the key
NO start switch from the battery.
illuminate when the key start is operated?
Pin 1 of key start connector.

Inspect the key start switch, if wiring

to switch is O.K. replace switch

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
STARTER SYSTEM TESTING ON TRACTOR
For easier and rapid diagnosis and for most conclusive
test results, it is recommended that a battery--starter
tester (high rate discharge tester) incorporating a 0--20
volt voltmeter and a 0--500 amp ammeter be used to
diagnose starting system problems.
When using test equipment follow the manufacturers
recommended test procedures. If test equipment is not
available the following test procedure, using a
standard 0--20 volt voltmeter and 0--500 amp ammeter
can be used to determine the correct operation of the
starter without removing it from the engine.
Before testing:
• Check that the battery is fully charged.
• Check the complete starting system wiring circuit
for frayed or broken wires or loose terminal
connections.
• Check the engine is not seized.

Starter Motor Circuit Current Draw

1. Disconnect the Battery (3) ground (negative) cable
from the battery.
2. Disconnect the battery positive cable from the
starter solenoid. Connect the ammeter(1) positive
lead to the battery positive terminal and the
negative lead to the solenoid input terminal.
3. Reconnect the battery ground (negative) cable to
the battery negative terminal.
4. Connect the voltmeter(2) positive lead to the
battery positive terminal and the voltmeter
negative lead to the battery negative terminal.
5. Disconnect the wire from the fuel injection pump 6
shut off solenoid.
6. Crank the engine while observing the voltmeter
and ammeter readings. The voltage should remain
steady at around 12 volts with between 250--300
amps being drawn.
• If the current draw is within specification the
starting motor (4) is functioning correctly. If the
voltage drops during the test proceed to ‘Starting
System Circuit Resistance’.
• If the current draw is greater than specified, check
the circuit as outlined below. If the starting system
circuit tests are satisfactory the starting motor is
defective and must be disassembled to determine
the cause.
• If the current draw is less than specified, the
starting motor is defective and must be
disassembled to determine the cause.

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
STARTING SYSTEM CIRCUIT RESISTANCE
(VOLTAGE DROP)
If there is an excessive current draw the circuit should
be checked by recording voltage drops across the
individual components in the circuit
IMPORTANT: Disconnect the fuel injection pump fuel
shut off solenoid wire.

Battery Positive Cable:

1. Connect the voltmeter positive lead to the battery V
positive terminal.
2. Connect the voltmeter negative lead to the starting
motor solenoid battery terminal.
3. Crank the engine while observing the voltmeter
reading. If the voltage exceeds 0.2 volts, check
and tighten the cable connections. Recheck the
voltage, if still excessive install a new cable.

60--55--002 mm
7
Starting Motor Ground Connections:
1. Connect the voltmeter positive lead to the starting
motor frame.
2. Connect the voltmeter negative lead to the engine
block.
3. Crank the engine while observing the voltmeter
reading. If the voltmeter reading exceeds 0.2 volts
check the ground connections between the
starting motor flange and the rear engine plate.

60--55--003 mm
8
Battery Ground Cable:
1. Connect the voltmeter positive lead to the engine
block. V
2. Connect the voltmeter negative lead to the battery
negative terminal.
3. Crank the engine while observing the voltmeter
reading. If the reading exceeds 0.2 volts, check
and tighten the ground cable connections.
Recheck the voltage, if it is still excessive install a
new ground cable.

60--55--004 mm
9

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
10 201 STARTER MOTOR REMOVAL AND
INSTALLATION
1. Disconnect the battery ground (negative) cable
from the battery.
2. Remove the protective cover from the solenoid
assembly and disconnect the positive cables to the
solenoid and the solenoid coil feed wire.
3. Remove the three starting motor mounting bolts
and remove the starting motor.
4. Installation is the reverse of the removal
procedure.

11
Starter Motor -- Exploded View
6. Front housing 16. Brush plate
7. Solenoid screws 17. Armature housing bolts
8. Plunger 18. Motor casing
9. Spring 19. Armature
10. Solenoid 20. Snap ring and collar
11. Engagement lever 21. Spring
12. Circlip 22. Spring cap
13. Reduction gear unit 23. Engagement lever plate
14. Screws 24. Washer
15. End housing

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
DISASSEMBLY 7. Withdraw the drive engagement lever pivot pin
With reference to Figure 11. from the drive end housing.
1. Support the starting motor in a soft jawed vice. 8. Withdraw the drive assembly and lever together
from the front housing.
2. Disconnect the thick braided wire from the field coil
housing to the solenoid assembly. 9. Remove the drive assembly and reduction unit
retaining snap ring from the armature shaft by
3. Remove the three screws from the front housing driving the securing thrust collar squarely off the
assembly and withdraw the solenoid assembly. snap ring with a suitable diameter tube and then
The plunger may be left behind. In this case, pull levering the snap ring from the groove.
the plunger from the front housing.
10. Separate the reduction unit from the drive
• Mark the starter casing at each end prior to assembly.
disassembly to ensure correct alignment of
components during reassembly. 11. The drive assembly can be further dismantled to
replace the pinion gear. Remove the circlip from
4. Remove the two armature housing bolts and the the drive assembly, relieving the pressure of the
two screws retaining the end cap and brush plate spring and disassemble the drive assembly.
to the end housing, withdraw the end housing,
leaving the brush gear on the commutator.
RE--ASSEMBLY
5. At this stage of disassembly inspect the brushes
and commutator. Check for sticking brushes. If 1. Re--assembly of the starting motor follows the
necessary, clean brushes and brush channels disassembly procedure in reverse, observing the
using a suitable cleaning solvent. Check brushes folloiwng points:
for wear. If worn below the minimum length • Ensure the marks made before disassembly are
specified, of 7.00mm, it will be necessary to aligned before final tightening of the two armature
replace the complete starter motor. housing bolts.
NOTE: The brushes are not serviced separately. They • To aid brush installation over the commutator,
are spot welded into position and not intended to be insert a thin blade screwdriver under the brush
replaced during the starter motors service life. spring to allow the brushes to move freely in their
6. Withdraw the brush box and the motor casing from holders.
the armature and drive end housing. Prior to installation the starting motor no load function
must be tested.

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
Starting Motor No--Load Test:
NOTE: A fully charged battery and a battery starter
tester (high rate discharge tester) with a carbon pile
(variable load resistor) should be used to perform this
test.
1. Secure the starting motor in a vice equipped with
soft jaws.
2. Connect the battery negative cable (4) to the
starting motor mounting flange.
3. Connect a short jumper lead (6) between the
solenoid battery and solenoid switch terminals.
4. Connect a voltmeter (3) positive lead to the battery
positive terminal, the voltmeter negative lead to the
12
battery negative terminal, the ammeter (1) positive
lead to the battery positive terminal and the
ammeter negative lead to the solenoid battery or
starting motor terminal.
5. Hold a hand tachometer (5) on the end of the
armature shaft. Actuate the starting motor by
adjusting the carbon pile (2) to give 11.7 volts.
When the armature rotates between 7500 and
8500 rev/min. the maximum current draw should
not exceed 160 amperes.
6. If the starting motor does not perform to
specification, check for grounded field coils, a
rubbing armature or a distorted armature shaft.

BENCH TESTS
Armature
1. The commutator face should be clean and free
from burnt spots. If necessary remove any burnt
spots using fine glass paper, not emery cloth.
Finally clean the commutator with a petrol
moistened cloth.
2. If it is necessary to skim the commutator ensure
the diameter is not reduced below the minimum
specified diameter of 42.5mm. Following skimming
the commutator should be polished with a fine
glass paper and then wiped clean with a petrol
moistened cloth.
NOTE: Do not cut into the commutator metal when
recutting insulation slots.

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6
3. Armature insulation can be checked by connecting
an ohmmeter between the commutator segments
and the armature shaft. There should be an infinity
reading, i.e, no continuity.
4. To test the armature for short circuits it is
necessary to use suitable armature testing
equipment, the only alternative is to check the
armature by substitution.
5. If there is evidence that the armature
circumference has been in contact with the pole
pieces, then the armature bearings are probably
excessively worn. First check that the pole pieces
are tight and that the armature runs true in a lathe,
then if necessary renew the armature bearings. 13

Field Coils
1. To test the insulation of the field coils connect an
ohmmeter in turn between each of the field winding
brushes and a clean unpainted part of the housing.
There should be no reading, i.e, no continuity.
2. To test the field winding continuity connect an
ohmmeter in turn between each of the field winding
brushes and the main feed terminal (thick braided
wire). A reading of 1 MΩ should be indicated.
3. If a fault is indicated in the field windings it will be
necessary to replace the complete field coils and
housing assembly.

14
Bearing Bushes
1. Inspect the bushes in the brush end plate
assembly and pinion drive end housing for wear.
Install the armature shaft and observe the free
play, replace bushes where free play appears
excessive. Inspect the field poles for signs of
rubbing by the armature which may also have been
caused by worn bushes.

Drive Pinion Assembly

1. Check the operation of the roller clutch. The pinion
should rotate clockwise only. If the pinion is stuck
or rotates in both directions, or if the pinion teeth
are damaged install a new drive assembly.
If damaged pinion teeth are evident, check the flywheel
ring gear teeth as described in Section 10, Engine
Systems.

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 7 -- Charging System

CONTENTS

Section Description Page

55 000 SPECIFICATIONS
Alternator Type
A127--100 A127--120
(Optional)
Polarity Negative Ground
Nominal Voltage 12.0 v
Maximum Rev/Min. 18,000
Maximum Output 100 Amps 120 Amps
Regulator Controlled Voltage 13.6 -- 14.4 v
Rotor Field Winding Resistance 2.6 Ω
Stator Field Winding Resistance 0.075 Ω
New Brush Length 20.0 mm
Minimum Brush Length 5.0 mm
Brush Spring Pressure 1.3 -- 2.7 N (4.7 -- 9.8 oz)

TORQUE SPECIFICATIONS
[Link] Nm
Alternator Through Bolts 4.0 5.5
Pulley Retaining Nut 52.0 70.0
Rectifier Attaching Screws 3.0 4.0
Regulator and Brushbox Screws 2.0 2.7
Terminal Nuts 2.0 2.7
Mounting Bolt 16.0 23.0
Adjusting Bolt 8.0 12.0

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
Description and Operation
Magnet Marelli (Lucas) A127 type alternators are fitted
to all models. Used in 100 and 120 Amp form with an
internal cooling fan. The alternator is mounted high at
the front of the engine and is driven from a crankshaft
pulley via a ‘poly vee’ drive belt. The alternators feature
integral regulators.

100 and 120 Amp Alternators

1. Earth (Ground) Connection
2. Engine Speed Sensor Connection (W Terminal)
3. Warning Lamp (D+ terminal)
4. Output Connection (B+ Terminal)
5. Protective Terminal Sleeve

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

2
Alternator Charging Circuit
G1 To Starter Motor S1 Ignition Switch
G2 Alternator MF1 Maxi--Fuse 1
M1 Starter Motor MF2 Maxi--Fuse 2
K1 Ignition Relay FL1 & FL2 Fuse Links
K2 Start Relay F9 Fuse 9--10A

Alternator Operation This direct current is fed back to supplement the

With reference to Figure 2. current flowing through the rotor field winding.
When the key start switch is turned on a small current This action results in an ever increasing magnetic
flows from the battery through the rotor field wiring. The influence of the rotor along with an associated rapid
circuit is made via the charge indicator warning lamp, rise in generated output current and voltage.
alternator terminal ‘D+’ the rotor field winding, the During the rise in generated output voltage (reflected
alternator regulator and ground. at the ‘D+’ terminal) the brilliance of the warning lamp
At this stage the warning light is illuminated and the is reduced and when the voltage at the ‘D+’ terminal
rotor partially magnetised. equates to that at the battery side of the warning light
the lamp is extinquished.
When the engine is started and the partially
magnetised rotor revolves within the stator windings a The voltage continues to rise until the predetermined
3--phase alternating current is generated. A constant regulated voltage level is reached.
portion of the generated current is converted to direct In the event of drive belt breakage the voltage will not
current by the three field diodes incorporated in the build up within the alternator and so the charge
rectifier pack. indicator light will remain on to indicate failure.

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

8
1
7

4 3
TA6010093A TA6010093B
3
Fan Belt Tensioner
A. Fan Belt Less Air Conditioning B. Fan Belt With Air Conditioning

1. Water Pump Pulley 5. Tensioner Attaching Bolt

2. Air Conditioning Compressor (optional) 6. 1/2 inch Square Drive Hole
3. Crankshaft Pulley 7. Alternator
4. Tensioner Pulley 8. Idler Pulley

SYSTEM TESTING AND FAULT FINDING

Service Precautions Preliminary Checks

To avoid damage to the components of the alternator Prior to electrical testing thoroughly inspect the
charging system, service precautions must be charging and electrical system.
observed as follows: Check all leads and connections for continuity and
• NEVER make or break any of the charging circuit tightness.
connections, including the battery, when the
engine is running. 1. Check the battery
• NEVER short any of the charging components to Using a hydrometer check the individual battery cells.
ground. The battery should be at least 70% charged and in
• ALWAYS disconnect the battery ground cable good condition.
(negative) when charging the battery on the tractor
using a battery charger. 2. Check the drive belt
• ALWAYS observe correct polarity when installing Inspect the alternator drive belt and pulley, ensuring
the battery or using a slave battery to start the that both are clean, free from oil and grease and in
engine. good condition.
CONNECT POSITIVE TO POSITIVE AND The alternator drive belt is automatically tensioned by
NEGATIVE TO NEGATIVE a spring tensioner mounted at the front of the engine,
shown in Figure 3. If the the belt tension is suspect,
check the tensioner assembly as follows:

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
Fan Belt Tensioner Removal 3. Check the Warning Lamp
1. The fan belt should be removed in the following Turn on the key start switch and check that the warning
manner. Place a lever with 1/2 inch square drive lamp is fully illuminated.
attachment into the 1/2 inch square hole of the If the warning lamp is not fully illuminated check the
tensioner arm and rotate the lever clockwise. bulb. If the bulb is not the cause of the fault carry out
Remove the fan belt from the pulley and allow the the Alternator wiring connections test as detailed under
tensioner to return to its untensioned position once ‘initial tests’ in this section.
the belt has been removed.
If the warning lamp is illuminated start the engine and
2. Remove the tensioner from the pump by loosening run above idling speed. The lamp should go out.
and removing the centre attaching bolt, item 6
If the lamp does not go out, stop the engine and remove
Figure 3.
the wire from the D+ terminal. If the lamp now goes out
a faulty alternator component is indicated. Conduct the
Inspection and Repair ‘Alternator components tests’ as detailed in this
1. Checking of the tensioner assembly operation section.
should be carried out, with the tensioner assembly If the warning lamp remains illuminated, check for a
still attached to the front plate fuel injection pump short circuit to earth (ground) between the ‘D+’ cable
gear cover. To check the spring load, place a end and the warning lamp.
‘‘break back” torque bar pre--set to, 52 -- 63 lbf. ft
(70 -- 85 Nm) (7.1 -- 8.7 kgf.m), into the pulley arm
INITIAL TESTS
1/2 inch squre drive hole. Raise the lever up
through an arc of 20° maximum. If the torque bar The initial tests may be performed without removing
does not ‘‘break” within the range a new tensioner any of the charging circuit components from the tractor
assembly is required. and enable the following items to be checked:
2. Ensure the tensioner pulley rotates freely by hand. • Alternator wire connections
If not replace with new parts. • Alternator charging current and controlled voltage
• Alternator charging circuit volt drops
Re--Assembly • Alternator maximum output performance
1. Fit a new pulley to the assembly if required, and
torque the attaching bolt to, 34.5 -- 44 [Link] (46.5 -- Test equipment required:
60 Nm), (4.7 -- 6.1 kgf.m)
• Voltmeter (0--30 volts moving coil type
2. To re--assemble the arm assembly, position the
tensioner on to the front plate fuel injection pump • Millivoltmeter (0--1 volt)
gear cover, fit the mounting bolt through the • Ammeter (0--110 Amperes moving coil type)
assembly, and torque the bolt to, 34.5 -- • 1.5 Ohm 110 Amperes variable load resistor
44 [Link] (46.5 -- 60 Nm), (4.7 -- 6.1 kgf.m). NOTE: Most commercial test equipment incorporates
3. Refitment of the fan belt is the reverse of the several testing devices within a single unit . Use such
removal procedure, but ensure the ‘‘Poly V’’ belt, is equipment in accordance with the manufacturers
positioned correctly onto all of the pulleys. instructions.

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
1. Alternator Wiring Connections Test
With reference to Figure 4. 4
1
1. Disconnect the battery
+ V --
2. Disconnect the B+(2) and D+(3) terminals from the
alternator.
3. Reconnect the battery and turn the key start on but 3
do not start the engine. Connect a voltmeter(4)
between each terminal and earth (ground), (1).
Battery voltage should be registered.
If battery voltage is not registered a continuity fault in
the external cable circuitry must be traced and
remedied, refer to the circuit diagram shown in Figure 2
2.
4
4. Connect the D+ terminal, warning lamp
(brown/yellow) wire, to earth (ground). The
warning lamp should illuminate.
5. Disconnect the battery and reconnect the removed
alternator cable connections to the alternator.
NOTE: If the warning lamp fails to illuminate when the
cable is reconnected to the alternator, a fault is
indicated in the alternator regulator or rotor circuits.
Ensure that the D+ terminal is clean and then conduct
the alternator component tests as detailed in this
section.

2. Charging Current And Controlled Voltage

Tests
With reference to Figure 5.
1. Ensure all tractor electrical components are 4
switched off and the key start switch is in the ‘off’
position.
2. Disconnect the battery negative terminal and 3
disconnect the B+ terminal(4) of the alternator. 1
3. Connect an ammeter(1), between the removed
(brown) cable(3) and the B+ alternator terminal. -- + -- +
4. Connect a voltmeter(2) between the alternator B+ 2
terminal and earth (ground) V A
5. Reconnect the battery. Start and run the engine at 5
2000 rev/min. and observe the ammeter and
voltmeter readings.
The voltmeter should register in excess of battery
voltage and when the ammeter reading falls below 10
Amperes the voltmeter reading should stabilise at
13.6--14.4 volts.
If the voltmeter reading exceeds 14.4 volts the
alternator regulator must be replaced as described in
this section. (when a new regulator has been installed
conduct tests 4 and 5).

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
If the voltmeter reading is below 13.6 volts a faulty
alternator component or a high resistance fault in the
external connections of the charging system is
indicated.
If the ammeter registers zero amperes a faulty
alternator component is indicated. Turn off the engine
and conduct the ‘alternator component tests’ as
detailed in this chapter.

3. Charging Circuit Volt Drop Tests

(a) Insulated--Side Volt Drop Tests 4
With reference to Figure 6.
Ensure the key start switch is in the ‘off’ position. -- +
1. Disconnect the battery negative cable and
V
5
disconnect the B+ cable(1) from the alternator 1
2. Connect a millivoltmeter(4) between the battery
positive terminal and the B+ cable(5). (Positive -- 2
side to cable). -- +
3. Securely connect an ammeter(2) between the B+ A
terminal of the alternator and the B+ cable 3 Figure 2
(negative side to cable)
4. Reconnect the battery negative cable and connect 6
a variable load resistor(3), with the slider in the
minimum current draw position (maximum
resistance), across the battery terminals.
5. Start the engine and increase the speed to 2000
rev/min.
6. Slowly increase the current loading of the resistor
(decrease resistance) until the ammeter registers
100 or 120 Amperes depending on alternator type.
7. Observe the millivoltmeter reading which should
not exceed 400 millivolts.
If the reading is in excess of 400 millivolts, a high
resistance fault is indicated in the external circuitry.
If the required alternator output cannot be achieved
and the millivoltmeter reading is less than 400
millivolts, then a faulty alternator component is
indicated. Conduct the‘ alternator component tests’ as
detailed in this section.
8. Stop the engine.

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
(b) Ground--Side Volt Drop Test
With reference to Figure 7.
1. Ensure the key start switch is in the ‘off’ position. -- +
2. The circuit is the same as that used in the previous
V
test except for the millivoltmeter(4) which is now 5
connected between the battery negative terminal 4 1
and the alternator frame (negative side to frame).
NOTE: Ensure the variable load resistor(3) is in the --
minimum current draw position (maximum resistance). -- +
2
3. Start the engine and increase the speed to A
2000rev/min. 3
4. Slowly increase the current loading of the resistor
(decrease resistance) until the ammeter (2) 7
registers 100 or 120 Amperes depending on
alternator type.
5. Observe the voltmeter reading which should not
exceed 200 millivolts.
If the reading is in excess of 200 millivolts a high
resistance fault is indicated in the external circuitry.
If the required alternator output cannot be achieved
and the millivoltmeter reading is less than 200 millivolts
then a faulty alternator component is indicated.
Conduct the alternator component tests as detailed in
this section.
6. Stop the engine.

4. Alternator Maximum Output Performance Test

With reference to Figure 8.
1. Ensure the key start switch is in the ‘off’ position. 4
2. Disconnect the battery negative cable and -- +
disconnect the B+ cable (5) from the alternator. 5
V
3. Securely connect an ammeter(2) between the B+ 1
terminal(1) of the alternator and the B+ cable
(negative side to cable).
-- 2
4. Connect a voltmeter(4) between the alternator B+ -- +
terminal and earth (ground). A
5. Reconnect the battery, start and increase the 3 Figure 3
engine speed to 2000 rev/min.
6. Slowly increase the the current loading of the 8
resistor(3) (decrease resistance) until the
ammeter registers either 100 or 120 Amperes
depending on alternator type.
7. Observe the voltmeter reading which should not
fall below 13.6 volts
If the reading falls below 13.6 volts a faulty alternator
component is indicated. Conduct the ‘alternator
component tests’ as detailed in this section.

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
ALTERNATOR COMPONENT TESTS
The component tests which should only be conducted
if the INITIAL TESTS have indicated a faulty alternator
component, will enable the following items to be
checked:
• Regulator
• Rotor Field Winding Continuity
• Brushes and Springs and Rotor Slip Rings
NOTE: The component tests detailed previously may
be performed with the alternator installed on the
tractor. Testing of the other alternator components will
necessitate removal of the alternator from the tractor.
Refer to the ‘Overhaul’ section of this Chapter.
IMPORTANT: Prior to removal of the alternator cables
from the alternator ensure that the key start switch is
in the ‘off’ position and the battery negative cable is
disconnected.
Test equipment required:
• 12 volt battery
• Multimeter
• 2.2 Watt Test Lamp

1. Regulator and Rotor Field Circuit Test

With reference to Figure 9 --
1. Disconnect all of the alternator cables.
2. Connect a 12 volt battery and a 2.2 Watt test
lamp(2) in series between the D+(1) and the
alternator frame (negative side to frame).
2
3. The test lamp should illuminate.
If the test lamp is not illuminated a fault is indicated in
the rotor circuit. Check brushes, slip rings and
continuity of rotor field windings.
If examination indicates these parts to be satisfactory 1
the regulator may be suspect.
9

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
2. Rotor Field Winding Continuity Test
With reference to Figure 10
1. Remove the regulator and brushbox assembly as
described in this chapter.
2. Connect an ohmmeter(3) between the two slip
rings(2). The resistance should read 2.6 ohms at
20°C.
If the resistance is outside of the specification renew
the rotor(1) as detailed in the following overhaul
section.

10
3. Brushes--and--Springs and Rotor Slip Rings
1. Remove the regulator and brushbox assembly as
5 mm
described in this Chapter.
2. Ensure the brushes and slip rings are clean and
check for freedom of movement of the brushes in
the brushbox moulding.
3. Check the brush spring pressure with a push type
spring gauge and record the spring pressure when
the brush end face is flush with the moulding.
Install a new regulator and brushbox assembly if
the pressure is less than specified.
If the visible length of the brushes(1) in the free position
is less than 0.25 in. (5mm) this is a probable cause of
open circuit in the field circuit and the regulator and 11
brushbox assembly should be renewed, Figure 11.
NOTE: The brushes are an integral part of the
regulator and brushbox assembly and cannot be
replaced as individual items.

55 301 ALTERNATOR OVERHAUL AND

COMPONENT TESTING
Alternator Removal
With reference to Figure 12
1. Disconnect the battery negative cable.
2. Disconnect the four cables from the rear of the
alternator.
3. Remove the alternator drive belt in the following
manner. Place a lever with socket attachment,
onto the tensioner retaining bolt and gently lever
the tensioner up, Figure 3. Remove the fan belt
from the pulley, and allow the tensioner to return to
its untensioned position once the belt has been 12
removed.
4. Remove the alternator arm(2) and the lower
mounting through bolts and remove the
alternator(1) from the engine bracket(3).

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

13
100 and 120 Amp Alternator Components
1. Rectifier and Housing Assembly 5. Rotor Assembly
2. Pulley Retaining Nut 6. End Cover
3. Spacer 7. Regulator and Brushbox Assembly
4. Stator and Housing Assembly

Disassembly -- 100 and 120 Amp Alternator 4. Remove the three nuts securing the two halves of
With reference to Figure 13 the outer casing. Mark each half of the casing to aid
reassembly and carefully pull the casing apart, it
1. Remove the three nuts securing the plastic end
may be necessary to gently tap the casing on the
cover.
mounting lugs.
2. Remove the nut securing the blue wire to the
5. Remove the nut securing the pulley to the rotor
warning lamp terminal and disconnect the wire.
shaft and withdraw the rotor from the casing.
Remove the two bolts and two nuts securing the
regulator and brushbox assembly, withdraw the 6. It is not necessary to remove the rectifier from the
assembly from the alternator. casing as these are serviced as one unit.
3. Using a suitable soldering iron, unsolder the six
wires from the stator to rectifier.

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
COMPONENT TEST
Rectifier Assembly -- Diode Testing
With reference to Figure 14.
1. Test each of the nine diodes separately, using a
multimeter with a diode check facility or a
multimeter set on the resistance scale.
2. Connect one test lead onto the lower plate(3) and
the other to the diode pin(1).
On a multimeter(2) with the diode check facility,
note if a reading of 0.49 (volts) is shown. Reverse
the test lead connections. The meter should
indicate 0.49 (volts) during one half of the test and
0 volts with the leads reversed. Repeat this test on
14
all nine diodes. If any one diode fails this test it will
be necessary to replace the rectifier and housing
assembly.
3. Where only an ohmmeter is available repeat the
above test observing the following results, 0 ohms
with leads in one direction and when the test leads
are reversed a reading of between 900--1000KΩ,
again if any one diode fails this test it will be
necessary to replace the rectifier and housing
assembly.

Rectifier Insulation
With reference to Figure 15.
1. Check the insulation of the rectifier to the casing.
With an ohmmeter (2), connect the test leads
between the alternator casing(3) and the positive
plate of the diodes(1). An infinity reading should be
displayed, therefore indicating an open circuit. If a
resistance of any kind is indicated, i.e, a short
circuit, the rectifier and housing assembly should
be replaced.

15
Stator Test -- Winding Continuity
Figure 4 1
With reference to Figure 16.
1. Connect the ohmmeter (2) test leads between the
pairs of wires, A, B and C. There should be a small
resistance of 0.1Ω, between each pair of wires. If
A
a resistance higher than this is registered it will
indicate a possible break within the winding, i.e, an B
open circuit. A lower reading, for example 0.0Ω will
C
indicate a short circuit within the winding. If any one -- +
of the three pairs of wires fail the test a new
stator(1) and housing assembly will be required.
Ω
2
16

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
Stator Test -- Insulation
With reference to Figure 17.
1. Check the insulation of each pair of windings to
each other and then each pair to the alternator
casing. There should be no continuity between the
three pairs of windings and no continuity to the
casing. If any ohmmeter(2) reading other than
open circuit is indicated in any test it will be
necessary to replace the stator(1) and housing -- +
assembly.
Ω 1
2

17
Rotor Test
Prior to performing component tests on the rotor the
following slip ring inspection should be carried out.
1. Ensure the slip rings are clean and smooth. If
necessary the slip rings may be cleaned with a
petrol moistened cloth. If the slip rings are burnt
and require re--finishing use very fine glass paper
(not emery cloth) and wipe clean.
NOTE: Ensure the re--finishing glass paper is
sufficiently fine to produce a highly polished slip ring
surface otherwise excessive brush wear will occur.
2. If the slip rings are excessively worn a new rotor
must be installed.

Rotor Field winding Continuity

with reference to Figure 18
1. Connect an ohmmeter(3) between the two slip
rings(2). The resistance should read 2.6 ohms at
20°C.
If the resistance is outside of the specification renew
the rotor(1).

18
Rotor Field Winding Insulation
With reference to Figure 19.
1. Using an ohmmeter(3) test between each of the
slip rings(2) and the rotor poles(1). An infinity
reading should be indicated in each case. If any
resistance reading is indicated the rotor assembly
must be replaced.

55- 13
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7
INSPECTION AND REPAIR
1. Inspect the rotor poles and stator for signs of
rubbing. Areas of rubbing indicates possible worn
bearings, misaligned housings or a bent rotor
assembly shaft.
NOTE: The end bearings are not serviced separately.
It will be necessary to either obtain a new rectifier and
housing or stator assembly to renew worn bearings.

20
RE--ASSEMBLY
1. Re--assembly of the alternator follows the
disassembly procedure in reverse.

INSTALLATION
1. Installation of the alternator is the removal
procedure in reverse.
On installation observe the following:
• Ensure the battery ground (negative) cable is
disconnected from the battery when installing the
alternator.
• Adjust the alternator drive belt as previously
described in this Chapter.

55- 14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 8 -- BATTERY

CONTENTS

Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 300 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Common Causes of Battery Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

55 000 SPECIFICATIONS
Dual Battery Single Battery
Option Option
Capacity (Ampere hour at 20 hour rate) 95 140
Cold Cranking Ampere Rating 900 1200
Voltage 12 12
Cells 6 6
Ground Terminal Negative Negative

55 000 DESCRIPTION AND OPERATION

All models have the option of either a single 1200cca • To furnish current when the electrical demands
or dual 900cca [Link] options employ negative exceed the alternator output.
ground, ‘maintenance free’ lead calcium (Pb--Ca) type • To support quiescent loads from radio and micro
batteries, of six cell construction. processor memory.
NOTE: ‘Maintenance Free’ means that under normal The battery is constructed in such a manner that each
charging conditions the battery does not loose water cell contains positive and negative plates placed
from the electrolyte. Conditions that may cause water alternatively next to each other. Each positive plate is
loss include prolonged charging above 14.4volts separated from a negative plate by a non--conducting
where gassing occurs as it approaches full charge. porous envelope separator. If any of the positive plates
This can be caused by a faulty charging system or should make contact with negative plates within a cell,
boost/recovery charging equipment. the cell will short circuit and suffer irrepairable damage.
The batteries are mounted in front of the radiator on all All of the positive plates are welded to a bus--bar,
models, one on top of the other for the dual option, and forming a positive terminal and all of the negative
are wired in parallel. Wiring the batteries in parallel plates are welded to a similar bus--bar forming a
adds the c.c.a. capacity of the batteries. negative terminal.
The single battery option occupies the lower position. Each positive plate is composed of a lead grid with lead
The battery has four major functions: peroxide pasted into the grid openings. The negative
plates are composed of a lead grid with spongy lead
• To provide a source of current for starting, lighting
pasted into the grid openings.
and instrumentation.
The plates are submerged in a liquid electrolyte
• To help control the voltage in the electrical system.
solution of diluted sulphuric acid.

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
REMOVAL AND INSTALLATION
Top Battery
1. Lift the engine hood.
2. First disconnect the earth lead from the tractor
frame to the lower battery negative terminal and
secure away from frame.
3. Disconnect the positive and negative leads from
the top battery and secure away from battery.
4. Loosen the bolts of both clamps and slide one
clamp away.
5. Using the flexible handles at each end of the
battery, lift the battery from the tractor.
1
Lower Battery
Remove the top battery tray and supports.
1. Disconnect the positive lead from the battery
terminal and secure out of the way.
2. Loosen the bolts securing both battery clamps and
slide one clamp out of the way.
3. Using the flexible handles at each end of the
battery, lift the battery from the tractor.

Installation
1. Installation of the battery is the removal procedure
in reverse, observing the following points:
• Ensure that the battery is clean and dry and that the
vent caps are fully installed. Smear the terminals
with petroleum jelly, do not use conventional
lubricating greases as these can promote
electrolytic corrosion.
• Ensure the battery tray and clamps are clean and
free from stones or small objects which may
puncture the battery casing.
• Ensure that the battery terminal polarity is correct
and that the terminal connections are sufficiently
tight, but not overtightened. 2
• The radio, if fitted, will lose its stored information
and will require re--programming. It should be
noted that on models with electronic instrument
panel and micro--processors, that these
components will not lose their memories, i.e,
electronic draft control and transmission
calibrations will not be affected.

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
BATTERY MAINTENANCE AND TESTS Maximum battery life will be obtained if the correct care
Specific Gravity and periodic inspection is given. It is important that
output capacity should not be exceeded by constant
The specific gravity of the battery electrolyte indicates and excessive overloading and that charging
the state of charge. Fully charged the specific gravity requirements are maintained.
of the electrolyte is 1.280 minimum at 25°C.
Alternatively the approximate state of charge can be Servicing The Battery
measured by using an accurate digital volt meter (+/--
0.01V) as follows:-- WARNING
Less than 10.5V Battery un--serviceable* Batteries contain sulphuric acid and during charging
Less than 11.8V Battery discharged generate a highly explosive mixture of hydrogen and
Less than 12.3V Battery 1/2 charged oxygen gases.
Better than 12.6V Battery fully charged • Never use equipment that generates flames or
* See note under tests for possible recovery of a mildly sparks in order to control electrolyte level
sulphated battery. • Do not remove the battery cover plugs without
Battery voltage to be taken with the battery unloaded protection for eyes and hands.
and:--
U. After the battery has rested unloaded for at least 4 When servicing a battery the following steps should be
hours. observed:
V. If the vehicle has recently run or battery has 1. Maintain the electrolyte to the recommended level
recently been charged, switch on headlamps for 2 of 17 mm (0.67 in.) above the plates. If this is not
minutes. observed the acid will reach a high concentration
that will damage the separators and impair the
When a battery discharges, sulphuric acid in the
performance of the plates.
electrolyte combines chemically with the plates and
this action lowers the specific gravity of the solution. 2. Use only distilled or de--mineralised water, do not
overfill and never use tap water or water from a rain
A battery hydrometer will determine the specific gravity
barrel or other source.
of the electrolyte in a cell and the amount of unused
sulphuric acid in the solution is a measure of the degree 3. Always keep the battery at least 75% charged
of charge of that cell. otherwise the plates will become sulphated and
loss of efficiency will result with possible damage
The lower the temperature at which a battery is
from freezing at low temperatures.
required to operate, the more necessary it is that the
battery is maintained in a fully charged condition. For 4. Avoid overcharging the battery as excessive
example a battery with a low specific gravity of 1.225 charging will create high internal heat that will
at 27°C (80°F) will operate the starting motor at warm cause plate grid deterioration and produce water
ambient temperatures but may not, due to lower loss.
battery efficiency at a low temperature. 5. When fast charging ensure the battery
Table 1 shows the effect of temperature on the temperature does not exceed 50°C.
efficiency of a typical battery. 6. Do not add sulphuric acid to a cell unless the
Table 1 electrolyte has been lost through spilling. Before
replenishing ensure the solution is at the correct
Temperature Efficiency of a Fully specific gravity. A slow charge is the only method
Charged Battery to be employed to fully charge a battery. A high rate
25.0°C (77.0°F) 100% charger can be used to quickly boost the battery
--4.5°C (23.9°F) 82% capacity but this must be followed by a slow charge
--24.0°C (--11.2°F) 64% rate to bring the battery to full capacity.
--27.5°C (--17.5°F) 58%
--31.0°C (--23.8°C) 50%
--34.5°C (--30.1°C) 40%
--37.5°C (--35.5°C) 33%

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Dry Charged Batteries 3. Re--check the level of electrolyte in each cell and
Dry charged batteries must be prepared for service as add distilled water as necessary.
follows: WARNING
1. Remove the battery cell vent plugs. When a battery is being charged an explosive gas is
2. Fill each cell to the recommended level with produced. Do not smoke or use an exposed flame
electrolyte of 1.260 specific gravity. when checking the electrolyte level and ensure the
NOTE: The electrolyte must be diluted sulphuric acid charger is switched off before connecting or
preferably at a temperature of 21° --32°C (70° --90°F). disconnecting to avoid sparks which could ignite the
gas.
3. After filling, allow the battery to stand for 15
minutes then re--check the electrolyte level and top
up if necessary. Recharging Deeply Discharged Batteries
4. Charge the battery for 4 hours at a rate of 5--8 The recommended method to recharge a maintenance
amperes and check that all cells are gassing freely. free Pb--Ca battery is to use a constant voltage
5. Install the battery cell vent plugs. charger. For deeply discharged batteries a 48 hours
charging period at 16volts is recommended, with
Charging The Battery current limitation, (47.5A for 95Ah and 70A for 140Ah).
Before charging a battery: This system is self regulating: high current is delivered
1. Thoroughly clean the battery casing and cell at the beginning (when battery voltage is low), lower
covers with dilute ammonia or hot water and clean and lower current is then absorbed when battery
the terminals. reaches full charge (and its voltage is high).
2. Check the level of the electrolyte in each cell and, If only constant current chargers are available it is
if below plates, add distilled water to bring above recommended to use the current levels and times
plate level. shown Table 2 below. The figures are intended for
deeply discharged batteries. If the battery is only 50%
discharged use one half of the time listed (slow charge
Normal (Top--up) Charging
programs). For other states of discharge reduce
1. With a slow charger use a rate of 3 to 6 amperes proportionally the time of charge. Whenever possible
for the time necessary to bring the battery to full use the slowest charge program to increase the
charge. This may take 36 hours or more if the battery’s life.
battery is heavily discharged. A severely sulphated
If when charging the battery, violent gassing or
battery might not accept a charge. When the
spewing of electrolyte occurs, or the battery case feels
battery is fully charged the cells will gas freely and
hot (50°C or greater), reduce or temporarily halt
the specific gravity will remain constant. Remove
charging to avoid damaging the battery.
the charger after three consecutive hydrometer
readings taken at hourly intervals indicate that the Table 2
specific gravity has stopped rising. Battery Type
2. When using a fast or high rate of charge carefully
follow the manufacturers instructions. High rate 140Ah 95Ah
(1200 cca) (900 cca)
charging raises the temperature of the electrolyte
and unless the charger is equipped with an Slow Charge 36hrs at 5A 25hrs at 5A
automatic time or temperature device, the Programs 18hrs at 10A 12.5hrs at 10A
electrolyte temperature could exceed 50°C , which Fast charge 10hrs at 18A 7hrs at 18A
may cause violent battery gassing and damage to Program
internal components. (emergencies
only)

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Tests NOTE: Specific gravity should not vary more than
Before commencing battery tests check the battery for 0.025 points between cells.
clogged vents, corrosion, raised vent plugs or a 4. If the specific gravity is 1.280 or more the battery
cracked case. is fully charged and in good operating condition.
Test equipment required: 5. Should the corrected specific gravity be below
• Hydrometer 1.280, charge the battery and inspect the charging
system to determine the cause of the low battery
• Battery starter tester (High rate discharge tester)
charge.
• Thermometer
NOTE: If distilled water has recently been added the
• Battery Charger battery should be recharged for a short period
otherwise accurate hydrometer readings will not be
Specific Gravity: This test will determine the state of obtained.
battery charge. If the battery has been charged under static conditions,
1. With the float in the vertical position take the denser electrolyte will accumulate at the bottom of the
reading. cells. The battery should be shaken periodically to mix
the electrolyte, this will improve the charge rate and
2. Adjust the hydrometer reading for electrolyte
provide a more accurate hydrometer reading when
temperature variations by subtracting 4 points
tested.
(0.004 specific gravity) for every 5.5°C (10°F)
below the temperature at which the hydrometer is
calibrated and by adding 4 points (0.004 specific Performance Test: The performance test is to
gravity) for every 5.5°C (10°F) above this determine if the battery has adequate capacity to turn
temperature. the engine. The voltage reading obtained is used to
determine the battery condition. Prior to testing,
The following examples are calculated using a
ensure the electrolyte level is correct and the open
hydrometer calibrated at 30°C (86°F). circuit voltage is 12.5V or more. The battery may be
Example 1: tested on or off the tractor.
Temperature below 30°C (86°F) 1. Set the current control switch of the battery starter
Electrolyte temperature 19°C (66°F) tester (high rate discharge tester) to the ‘off’
Hydrometer reading 1.270 position and the voltage selector switch equal to,
Subtract 11.0 x 0.004 0.008 or slightly higher than, the rated battery voltage.
5.5 Connect the tester positive leads to the battery
Corrected specific gravity = 1.262 positive terminal and the negative leads to the
Example 2: negative battery terminal.
Temperature above 30°C (86°F) 2. Turn the current control knob until the ammeter
Electrolyte temperature 40°C (104°F) reading is half the CCA rating of the battery and
Hydrometer reading 1.220 take the voltage reading.
Add 10.0 x 0.004 0.007
• If the reading is 9.6 volts or more after 15 seconds,
5.5
the battery has an acceptable output capacity and
Corrected specific gravity = 1.227
will readily accept a normal charge.
3. Use the following table to determine the state of
• If however the reading is below 9.6 volts, the
charge.
battery is considered unsatisfactory for service
State of Corrected Corrected Average and should be test charged as described below.
Charge Specific Specific Battery CAUTION
Gravity Gravity Voltage
@15°C @25°C Do not leave the high discharge load on the battery for
100% 1.295 1.287 12.76 periods longer than 15 seconds.
75% 1.253 1.246 12.52
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
Discharged 1.137 1.130 11.84

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8
Test Charging: This test is designed only for batteries Common Causes of Battery Failures
that have failed the previous capacity test. 1. Internal open circuit.
1. Attach the battery starter (high rate discharge 2. Internal short circuit.
tester) positive leads to the battery positive
3. Loss of electrolyte.
terminal and the negative leads to the battery
negative terminal. 4. Separation of active materials from grids.
2. Connect the battery charger positive lead to the 5. Accumulation of sulphate crystals too large to
battery positive terminal and the negative lead to disperse.
the battery negative terminal. These failures are normally caused by the following:
3. Turn the charger timer past a ‘3 minutes’ charge 1. Failure of inter cell components.
indication and then back to the ‘3 minutes’ mark. 2. Excessive crystal growth may puncture the
4. Set the charging rate as close as possible to 40 separators and cause short circuits.
amperes. 3. Excessive over charging (charging system
5. After 3 minutes at this fast charge take the malfunction, boost/recovery techniques with high
voltmeter reading. voltage, operation in very high temperatures.
• If the total voltage is over 15.5 volts the battery is 4. Freeezing of electrolyte.
unsatisfactory and is probably sulphated or worn A fully charged battery does not freeze until --65°C.
out and should be replaced. A 50% charged battery freezes between --17°C
NOTE: A mildly sulphated battery can be recovered by and --27°C. Fully discharged electrolyte freezes at
using a multiple battery type charger, with an open --3°C to --11°C.
circuit upper voltage limit of 50 volts. Owing to the high Excessively high boost charging and gassing will
resistance of a sulphated battery, it will primarily also cause separation of active materials from the
require a high voltage setting to overcome the grids. Separation destroys the chemical function of
resistance of the sulphation. initially there may be no the battery.
visible acceptance of the charge. After a few minutes 5. Crystal growth occurs whenever batteries are left
of inactivity a small charge will be apparent, followed discharged. High temperatures and extended
by a rapid increase in the charge rate. The charge rate discharged periods increase this condition. At
must not exceed 14.0 amperes or the electrolyte room temperature after one week the battery is
temperature 50°C. When the ampere rate has unlikely to recover on the vehicle. Recharge will
stabilised, reset the volts until the charge rate is a require a higher constant voltage. After 3 weeks
steady 5 amperes. Continue at this rate until the the battery will have suffered permanent
electrolyte specific gravity stops rising at degradation and the procedure detailed previouly
approximately 1.275--1.280 at 20°C (68°F), this can for charging a ‘Deeply Discharged’ battery should
take up to 48 hours of charging. Stand the battery for be followed.
24 hours and then conduct the capacity test detailed When fully charged, batteries have a long shelf life.
previously. The lead calcium type batttery self discharges at 3%
• If the total voltage is under 15.5 volts, test the per month. This means that it will take 16 months to
specific gravity of each cell and re--charge the drop to 50% charged. On the tractor the quiescent load
battery to the following scale: is about 50mA. To predict rundown on a static vehicle
this should be added as approximately 8Ah per week.
Specific Gravity Fast charge up to: It is worth stressing that when cranking, if a battery
1.150 or less 60 minutes starts to fade, it is beneficial to stop and allow two
minutes for the battery to recover. The recovery time
1.151 to 1.175 45 minutes should be increased as the temperature decreases.
1.176 to 1.200 30 minutes With the dual battery set up, an old battery should not
1.201 to 1.225 15 minutes be used with a new one. One battery will always fail
(Slow charge only) first. If the battery has given the service life expected,
change both batteries. If one has failed early, i.e,
NOTE: When battery problems are experienced the through manufacturing defect, then it is acceptable to
fan belt tension and the complete charging system replace just one battery.
should be checked.

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM
Chapter 9 -- Wiring Diagrams
CONTENTS

Description Page

Wiring diagram circuit descriptions (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How to use the linear wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component identification and wiring diagram location key . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wiring Diagrams:
Power Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Range Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Dual Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Shuttle Command Transmission, With Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Wire identification key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Electrical system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Wiring Diagrams Circuit Description -- All Models Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0--380
Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390--1760
Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1770--2770
Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2780--3060
Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3070--3880
Circuit 6 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3890--4250
Circuit 7 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4260--4850
Circuit 8 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4860--5640
Circuit 9 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5650--5940
Circuit 10 Trailer Braking system circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5950--6450
Circuit 11 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6460--6860
Circuit 12 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6870--7160
Circuit 13 Diagnostic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7170--7530
Circuit 14 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7540--7920
Circuit 15 Air--Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7930--8290

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
HOW TO USE THE LINEAR WIRING DIAGRAMS
The wiring diagrams have been drawn in a linear style.
This means that the complete wiring diagram has been
drawn over a number of pages but if joined together
would make a complete diagram.

There are a number of guides to help assist in reading

and understanding the wiring diagrams.
1. The wiring diagrams (1) are located at the top of
each page. The title and key (2) are located below
the diagram and the wire colour code table (3) is
located below the key.

The title under the diagram details the models of

the range that are applicable, the model
configuration, ie, transmission type, with or less
cab and the serial number of the tractor to which
the diagrams apply. The key then details all the
components used within that particular page.

2. Every component and connector has its own

unique reference number. 1

3. Every wire has a code assigned to it (1) this code

refers to its function, the code is not marked on the
actual wire. A key of all wire codes can be found at
the rear of this section. Letters (2), (3) and (4)
indicate the wire colour. The first letter (2) indicates
the main wire colour. The second letter (3)
indicates tracer wire colour, the third letter (4)
indicates the band colour, for example wire
reference (5) and number 57 is an earth wire, letter
(6) B indicates its a solid black wire.

4. Each component and connector pin appears only 2

once in the electrical drawings and has its own
location point on the page.

5. The wiring diagrams are drawn in sections.

However where a single component is used in a
number of circuits such as a processor or multi
function switch, it is drawn either on its own or on
the circuit which it influences the most.

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
6. The wiring is drawn between four lines three
across the top of the page and one at the bottom of
the page.

The two upper most lines (1) marked +30A and

+30B are the constant live lines.
Below the +30 line is the +15 (2) which is the
ignition key on live line.
The lowest line is the ground/earth line.
On the lower part of the page (3) a line is marked
with numbers increasing by ten (10--20--30, etc.).
This is the line used to reference wires and
components.

Example 3
Figures 4 and 5 show a basic circuit drawn over two
pages.

Power comes in from the ignition on live line +15

through fuse F3, which is located at point 230.

Power comes to switch S10. If the switch is operated,

power continues up and stops with an arrow (1) and a
number. The arrow indicates the wire continuing to 4
another page. The Number 780 refers to the line
reference where it appears on a new page. Note the
line reference directly below the wire being traced ie.
260. Following the line reference until 780 is found.
Using either the index or following the page reference
line. When 780 is located on the reference line the
number 260 will be observed at the top of the page.
Note the arrow points back to the previous part of the
circuit. From this point follow the wire down to solenoid
EV6. The diagram now indicates that power goes to
ground.

5
Where a circuit originates or terminates at a processor,
ie, Transmission processor, EDC processor,
Electronic Management Unit or Instrument cluster, the
wire in the diagram is ended with a small circle and a
connector reference number. A white circle (1)
indicates a processor, a black circle (2) indicates an
instrument cluster.
The diagrams have been constructed to ensure the
minimum number of pin--outs, detailed above, are
used. Due to this, many diagrams have been spread
across 2 sheets and it will be necessary to follow from
one page across to the next to complete a circuit.
6

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
Symbols

Fuse

Horn

Relay

Diode

Motor

Switch

Earth/ground point

Resistor

Sensor

Electro--Valve/solenoid
Potentiometer

Temperature Switch
Lamp

Pressure Switch
Speaker

Processor
Connector pin

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
(A) PROCESSORS,
MODULES AND PANELS
A001 1020 Gear Shift Display Module
A002 1880 EDC Panel
A003 & 4 4800 Radio
A005 7510 Transmission Diagnostic Plug (C125) -- White
A006 7170 EDC/Trans./suspension Diagnostic Plug (C126) -- Black
A007 7550 Instrument Cluster A (C079)
A008 7550 Instrument Cluster B (C080)
A009 7550 Instrument Cluster C (C081)
A010 7740 Transmission Module
A011 7640 EDC/Trans./suspension Module
A012 7900 Electronic Management Unit
A013 2170 EDC Control Unit
A014 3420 Front PTO Module
(B) SENSORS, SENDERS
AND POTENTIOMETERS
B1 470 Medium/Reverse Potentiometer
B2 510 High/Low Potentiometer
B3 700 Clutch Potentiometer
B4 470 Transmission Mid--Speed Sensor
B5 500 Transmission Output Speed Sensor
B7 2540 Transmission Oil Temperature Sender
B8 2680 Axle Speed Sensor
B8 2680 Rear Axle Speed Sensor
B9 2570 Left Hand Draft Pin
B10 2640 Right Hand Draft Pin
B11 3120 Front lift height controller
B12 3220 Front Lift Potentiometer
B13 3650 PTO Speed Sensor
B14 4270 Horn
B17 4780 Speaker, Right Hand
B18 4840 Speaker, Left Hand
B19 6840 Radar
B20 8240 Temperature Control Potentiometer
B21 2080 Lift Cross Shaft Potentiometer
B22 1880 Height Limit Potentiometer
B23 1880 Slip Limit Potentiometer
B24 1880 Drop Rate Potentiometer
B25 1880 Draft control Frequency Potentiometer
B26 8510 Water in Fuel Sensor
B27 6560 Steering Sensor
B28 6650 Engine Cooling Sensor
B29 6700 Engine Oil Pressure Sender
B30 6730 Fuel Tank Sender
B31 1290 Synchro. Position Potentiometer
B32 530 Engine Torque/RPM Sensor
B33 740 Throttle Potentiometer
B34 4100 Axle Height Sensor

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
(E) MISCELLANEOUS
E1 4320 Left Hand Beacon
E2 4360 Right Hand Beacon
E3 8110 Air Con Compressor Clutch
(F) FUSES
F1 5080 Headlight Main Beam 15A
F2 5060 Headlight Dipped Beam 15A
F3 5140 Side Lights, R.H. and Console Lamp 10A
F4 5220 Side Lights, L.H. 10A
F5 5680 Work Lamps (Cab Roof Mounted) 30A
F6 5800 Work Lamps (Lower Rear) 15A
F7 5860 Work Lamps (Lower Front) 30A
F8 250 Fuel Shut--Off / Fuel Pump 15A
F9 6260 Gauges / External Switches / Radar 10A
F10 4880 Hazard Lights 20A
F11 4900 Horn/Headlight Flasher/Cigar Lighter/Roof Beacon 30A
F12 3880 EDC Valve Supply 10A
F13 3860 Transmission Feed 25A
F14 880 Transmission Control Supply 10A
F15 5960 Air Seat Compressor/EMU/Front Hitch/Stop Lamps 30A
F16 7940 Heater Fan 25A
F17 6950 Washer Wiper 20A
F18 4870 Turn Indicators 10A
F19 330 Thermostart 25A
F20 7700 Processor / EMU KAM Supply 5A
F21 3520 P.T.O. 25A
F22 4750 Radio and Clock feed 5A
F23 4690 Accessory Sockets & Interior Lamp 25A
F24 4720 Clock and Radio KAM Supply 5A
F25 5500 Tractor/Trailer (7--pin Socket) Stop Lamps 20A
F26 800 Clutch Starter Fuse (Power Command Only)
(H) LAMP AND LIGHTS
H1 3360 PTO Engaged Lamp, Front
H2 3790 PTO Engaged Lamp, Rear
H3 3390 PTO Brake Engaged Lamp (Shuttle Command)
H4 4400 Console Lamp
H5 4690 Interior Lamp
H6 5280 Fender Rear Lights LH
H7 5280 Fender Rear Lights RH
H8 5320 Headlamp LH
H9 5360 Headlamp RH
H10 5540 Licence Plate Lamp
H11 5560 Front Indicator LH
H12 5580 Rear Indicator LH
H13 5600 Front Indicator RH
H14 5620 Rear Indicator RH
H15 5570 Side Lamp LH

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
H16 5600 Side Lamp RH
H17 5680 Upper Work Lamp & Licence Plate Lamp LH
H18 5710 Upper Work Lamp & Licence Plate Lamp RH
H19 5750 Upper Front Work Lamp LH
H20 5780 Upper Front Work Lamp RH
H21 5810 Work Lamp LH Fender
H22 5840 Work Lamp RH Fender
H23 5900 Work Lamp RH
H24 5930 Work Lamp LH
H25 5870 Work Lamp Lower Front RH
H26 5900 Work Lamp Lower Front LH
H28 1870 EDC Status Lamp
H29 1900 EDC Slip Lamp
H30 1880 EDC Raise Lamp
H31 1880 EDC Lower Lamp
H32 4190 Front Suspension Engaged Lamp
(G) CHARGING
G1 0 Battery
G2 70 Alternator
(K) RELAYS
KI 90 Ignition Relay
KII 4430 Remote Valve Relay
KIII 320 Thermostart Relay
KIV 7120 Rear Wiper Relay
KV -- Not Used
KVI 6980 Intermittent Wiper Relay
KVII 3090 Front Hitch Control Module
KVIII 3150 Front Hitch Control Module
KIX 6010 Trailer Brake Relay
KX 3290 PTO Fender Switch Relay
KXI / KXII 5210 ISO / NASO Module
KA 6230 Air Brake Relay
KB 5750 Front Work Lamp Relay
KC 5680 Upper Rear Work Lamps Relay
KD 5880 Lower Front Work Lamp Relay
KE 5820 Lower Rear Work Lamp Relay
KF 250 Fuel Shut--Off Relay
KG 5490 Stop Lights Relay
KH 6010 Trailer Brake Relay
K2 150 Starter Relay
K3 4900 Flasher Unit Relay
K4 4980 Indicator ON Buzzer Module
(M) MOTORS
M1 30 Starter Motor
M2 5960 Air Seat Pump
M3 6980 Front Wiper Motor
M4 7010 Front Washer Pump
M5 7100 Rear Wiper Motor
M6 7050 Rear Washer Pump
M7 8050 Blower Motor

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
(MF) MAXI FUSE
MF1 40 50 Amp. Ignition, and Fuses 9, 15, 16, 17, 18
MF2 280 60 Amp. Fuses 10, 11, 19 and 20
MF3 5070 30 Amp. Light Switch Feed
MF4 5660 60 Amp. Fuses 5, 6 and 7
MF5 4720 30 Amp. Fuses 23 and 24
MF6 4480 40 Amp. Rear Implement Sockets
MF7 4460 40 Amp. Front Implement Socket
(P) CLOCKS
P1 4750 Clock
P2 6220 Air Pressure Gauge and Backlight
(R) RESISTORS
R1 330 Thermostart Coil
R2 4560 Cigar Lighter
R3 8000 Blower Speed Resistor
R4 8050 Speed Resistor
(S) SWITCHES
S1 310 Ignition Switch
S2 410 Creeper Switch
S3 640 Gear Shift Selector
S4 850 Shuttle Switch
S5 870 Clutch Pedal Switch
S6 950 Transmission Oil Pressure Switch
S7 2460 Hydraulic OIl Temperature Switch
S8 2460 Hydraulic Charge Pressure Warning Switch
S9 2500 Hydraulic Oil Pressure Warning Switch
S11 2700 EDC Fender Switch LH
S12 2750 EDC Fender Switch RH
S13 2810 FWD Engaged Switch
S14 3010 Brake Switch RH
S15 3010 Brake Switch LH
S16 3330 PTO Switch, Rear
S17 3520 PTO Switch, Front
S18 3710 Ground Speed PTO Engaged Switch
S19 3790 PTO Brake Switch
S20 4330 Beacon Switch
S21 4450 Remote Valve Lock--out Switch
S22 4710 Door Switch LH
S23 4730 Door Switch RH
S24 4890 Hazard Lights Switch
S25 5080 Indicator Switch
S26 6080 Handbrake Switch
S27 3810 Seat Switch
S28 6470 Brake Fluid Reservoir Switch
S29 6600 Air Filter Vacuum Switch

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
S30 6620 Engine Coolant Level Switch
S31 6670 Oil Pressure Switch
S32 6790 Radar / Speed Sensor Selector
S33 6900 Front Wiiper / Washer Switch
S34 7120 Rear Wiper / Washer Switch
S35 7980 Blower Speed Switch
S36 8110 Low Pressure Cut--Out Switch
S37 8110 High / Low Pressure Cut--Out Switch
S38 8240 Temperature Exchange Control Switch
S39 2850 Differential Lock Engaged Switch
S40 440 3--4 Neutral Switch (Dual Command)
S41 460 1--2 Neutral Switch (Dual Command)
S42 480 1--4 Range Switch
S43 500 5--8 Range Switch
S44 520 Clutch A Pressure Switch
S45 520 Clutch B Pressure Switch
S46 4430 Divertor Valve Switch
S47 650 Hi Range Switch (Dual Command)
S48 650 Lo--Range Switch (Dual Command)
S49 2460 Hyd. Oil Blocked Filter Switch (Shuttle Command Only)
S50 3840 Lift--O--Matic Switch
S51 3630 PTO Fender switch, Left Hand
S52 3600 PTO Fender Switch, Right Hand
S53 3580 PTO Soft Start Switch
S54 1170 High Range Pressure Switch
S55 1200 Mediujm Range Pressure Switch
S56 1180 Low Range Pressure Switch
S57 1150 Reverse Range Pressure Switch
S58 4230 Front Suspension Switch
S59 1370 Transmission Auto Function Switch
S60 970 Clutch Fluid Reservoir Switch (Shuttle Command Only)
(X) POWER SOCKETS / CONNECTORS
XI 4470 Implement Socket, Front
X2 4490 Implement Socket, Rear
X3 4660 Accessory Socket
X4 4520 Accessory Terminals
X5 4620 Implement Status Socket
X6 5400 Trailer Socket
X7 6050 Italian Trailer Brake Harness Connector
X8 6200 Air Brake Harness Connector
X9 4640 Rear Accessory Panel Connector
(Y) SOLENOID VALVES
Y1 240 Fuel Shut--Off Solenoid
Y2 290 Fuel Lift Pump
Y3 1420 PWM Valve A
Y4 1450 PWM Valve B
Y5 1500 PWM Valve C
Y6 1530 PWM Valve D
Y7 1560 PWM Valve E

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SYMBOL DRAWING DESCRIPTION
LOCATION
Y8 1600 Transmission Low Range Solenoid
Y9 1630 Transmission Medium Range Solenoid
Y10 1670 Transmission High Range Solenoid
Y11 1710 Transmission Reverse Range Solenoid
Y12 2430 EDC Raise Solenoid
Y13 2430 EDC Lower Solenoid
Y14 2790 FWD Solenoid
Y15 2830 Diff Lock Solenoid
Y16 3200 Front Lift Solenoid Valve
Y17 3240 Front PTO Solenoid
Y18 3330 Rear PTO Solenoid
Y19 4420 Divertor Valve
Y20 4450 Hydraulic Remote Valve Solenoid
Y21 1160 Reverse Synchroniser Solenoid
Y22 1200 Forward Synchroniser Solenoid
Y23 1330 Clutch A Solenoid (low)
Y24 1370 Clutch B Solenoid (high)
Y25 1260 Dump Solenoid
Y26 1120 PTO Lube Solenoid
Y27 3920 Suspension Lower Solenoid
Y28 3960 Suspension Lower Lockout Solenoid
Y29 4010 Suspension Raise Solenoid
Y30 4050 Suspension Raise Lockout Solenoid
Y31 3670 PTO Brake Solenoid

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
WIRING DIAGRAMS:

Models: TM150 and TM165 with POWER COMMAND Transmission

Wiring Diagrams Circuit Description Line Reference Range

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 20
TM150 & TM165 Power Command Transmission, W/Cab,

H1 Front PTO Engaged Lamp Y17 Front PTO Solenoid
Y18 Rear PTO Solenoid
KVll Front Lift Relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 37
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 38
TM150 & TM165 Power Command Transmission, W/Cab,

CAB ACCESSORIES
Line 4510--4850
MF5 Maxi Fuse 5 -- 30A
P1 Clock
F22 Fuse 22 -- 5A
F23 Fuse 23 -- 25A R2 Cigar Lighter
F24 Fuse 24 -- 5A
S22 Left Hand Door Switch
A003 Radio -- A S23 Right Hand Door Switch
A004 Radio -- B
X3 8 Amp Accessory Socket
B17 Left Hand Speaker X4 40 Amp Accessory Terminals
B18 Right Hand Speaker X5 Implement Status Socket
X9 Right Hand Console Accessory Harness
H5 Interior Lamp

55- 39
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

(C2
61)
(C2
60)

55- 40
TM150 & TM165 Power Command Transmission, W/Cab,

INDICATORS AND HAZARDS

Line 4860--5240

F1 Fuse 1, 15Amp K3 Flasher Unit Relay

F2 Fuse 2, 15Amp K4 Indicators ‘ON‘ Buzzer Module
F3 Fuse 3, 10Amp KXI ISO/NASO Module
F4 Fuse 4, 10Amp KXII ISO/NASO Module
F10 Fuse 10, 20Amp
F11 Fuse 11, 30Amp S24 Hazards Lights Switch
F18 Fuse 18, 10Amp S25 Indicator Switch

MF3 Maxi--fuse 3, 30Amp

WIRE COLOUR CODES

55- 41
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 42
TM150 & TM165 Power Command Transmission, W/Cab,

INDICATORS AND HAZARDS

Line 5250--5640

F25 Fuse 25, 20A H13 Front Indicator, Left Hand

H14 Rear Indicator, Right Hand
H6 Fender, Rear Lights, Left Hand H15 Side Lamp, Left Hand
H7 Fender, Rear Lights, Right Hand H16 Side Lamp, Right Hand
H8 Headlamp, Left Hand
H9 Headlamp, Right Hand KG Stop Lights Relay
H10 Licence Plate Lamp
H11 Front Indicator, Left Hand X6 Trailer Socket
H12 Rear Indicator, Right Hand

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 43
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

H2
6

(C085

H24
)
H2
5

(C084

H23
)

55- 44
TM150 & TM165 Power Command Transmission, W/Cab,

WORKLAMPS
Line 5650--5940
MF4 Maxi Fuse 4 -- 60A H21 Fender Worklamp, Left Hand
H22 Fender Worklamp, Right Hand
F5 Fuse 5 -- 30A H23 Front Worklamp, Upper Rail, Right Hand
F6 Fuse 6 -- 15A H24 Front Worklamp, Upper Rail, Left Hand
F7 Fuse 7 -- 30A H25 Front Worklamp, Lower Right Hand
H26 Front Worklamp, Lower Left Hand
H17 Rear Upper Worklamp/licence Plate Lamp,
Left Hand KB Front Upper Worklamp Relay
H18 Rear Upper Worklamp/licence Plate Lamp, KC Rear Upper Worklamp Relay
Right Hand KD Front Lower Worklamp Relay
H19 Front Upper Worklamp, Left Hand KE Rear Lower Worklamp Relay
H20 Front Upper Worklamp, Right Hand

WIRE COLOUR CODES

55- 45
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 46
TM150 & TM165 Power Command Transmission, W/Cab,

TRAILER BRAKE SYSTEMS

Line 5950--6450
F9 Fuse 9 -- 10A
F15 Fuse 15 -- 30A P2 Pressure Gauge and Backlight

KA Air Brake Relay S26 Handbrake Switch

KH Trailer Brake Relay
KIX Trailer Brake Relay X7 Italian Trailer Brake Harness
X8 Air Brake Harness Connector
M2 Air Seat Pump

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 47
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 48
TM150 & TM165 Power Command Transmission, W/Cab,

SENSORS
Line 6460--6860
B19 Radar
S28 Brake Fluid Reservoir Switch
B26 Water in Fuel Sensor S29 Air Filter blocked -- Vacuum Switch
B27 Steering Angle Sensor S30 Engine Coolant Level Switch
B28 Engine Coolant Sender S31 Engine Oil Pressure Switch
B29 Engine Oil Pressure Sender S32 Radar Speed Selector connector
B30 Fuel Tank Sender

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 49
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 50
TM150 & TM165 Power Command Transmission, W/Cab,

WASHERS AND WIPERS

Line 6870--7160
F17 Fuse 17 -- 20A M4 Front Washer Pump
M5 Rear Wiper Motor
KIV Rear Wiper Relay M6 Rear Washer Pump
KVI Intermittent Wiper Relay
S33 Front Wiper/washer Switch
M3 Front Wiper Motor S34 Rear Wiper/washer Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 51
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 52
TM150 & TM165 Power Command Transmission, W/Cab,

DIAGNOSTIC PLUGS
Line 7170--7530

A005 C125 Transmission/EDC diagnostic plug (white)

A006 C126 Suspension diagnostic plug (black)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 53
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 54
TM150 & TM165 Power Command Transmission, W/Cab,

PROCESSOR FEEDS AND GROUNDS

Line 7540--7920

F20 Fuse 20 -- 5A

A007 Instrument Cluster A (C079)

A008 Instrument Cluster B (C080)
A009 Instrument Cluster C (C081)
A010 (TCM) Transmission Processor (C100, C101 & C239)
A011 (GCM) Suspension Processor (C127)
A012 Electronic Management Unit (C105)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 55
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 56
TM150 & TM165 Power Command Transmission, W/Cab,

AIR CONDITIONING AND CAB HEATING

Line 7930--8290
F16 Fuse 16 -- 25A
S35 Blower Speed Switch
B20 Temperature Control Potentiometer S36 Low Pressure Cut Out Switch
S37 High/Low Pressure Switch
M7 Blower Motor S38 Temperature Exchange Control Switch

R3 Blower Speed Resistor E3 Compressor Clutch

R4 Speed Resistor

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 57
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

55- 58
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
WIRING DIAGRAMS:

Models: TM115, TM125, TM135, TM150 and TM165 with RANGE COMMAND Transmission

Wiring Diagrams Circuit Description Line Reference Range

55- 65
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this model

55- 66
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

TRANSMISSION SYSTEM
Line 1150--1410

Not Applicable to this Model

WIRE COLOUR CODES

55- 67
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 68
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 69
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 70
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

ELECTRONIC DRAFT CONTROL

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 71
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 72
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

ELECTRONIC DRAFT CONTROL

Line 2140--2510
A013 EDC Control
Y12 EDC Raise Solenoid
S7 Hydraulic Oil Temperature Switch Y13 EDC Lower Solenoid
S8 Charge Pressure Switch
S9 Hydraulic Oil Warning Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 73
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 74
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

ELECTRONIC DRAFT CONTROL

Line 2520--2770
B7 Transmission Oil Temperature Sender
B8 Rear Axle Speed Sensor
B9 Left Hand Draft Pin
B10 Right Hand Draft Pin

S11 Raise/Lower Fender Switch -- Left Hand

S12 Raise/Lower Fender Switch -- Right Hand

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 75
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 76
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

FOUR WHEEL DRIVE AND DIFFERENTIAL LOCK

Line 2780--3060
S13 FWD Engaged Switch Y14 Four Wheel Drive Solenoid
S14 Brake Switch -- Right Hand Y15 Differential Lock Solenoid
S15 Brake Switch -- Left Hand
S39 Differential Lock Engaged Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 77
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 78
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

POWER TAKE OFF

Line 3070--3470
A014 Front PTO Module KVIII Front Lift Relay
KX PTO Fender Relay
B11 Front Lift Height Control
B12 Front Lift Potentiometer S16 Rear PTO Switch

Y16 Front Lift Solenoid Valve

H1 Front PTO Engaged Lamp Y17 Front PTO Solenoid
Y18 Rear PTO Solenoid
KVll Front Lift Relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 79
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 80
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

POWER TAKE OFF

Line 3480--3880
B13 Rear PTO Speed Sensor S18 Ground Speed PTO Engaged Switch
S19 PTO Brake Switch
F12 Fuse 12, 10A S27 Seat Switch
F13 Fuse 13, 25A S51 PTO Fender Switch -- Left Hand
F21 Fuse 21, 25A S52 PTO Fender Switch -- Right Hand
S53 PTO Soft Start Switch
H2 Rear PTO Engaged Lamp
Y31 PTO Brake Solenoid
S17 Front PTO Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 81
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

(C084

H23
)

55- 92
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

WIRE COLOUR CODES

55- 93
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 94
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

TRAILER BRAKE SYSTEMS

Line 5950--6450
F9 Fuse 9 -- 10A
F15 Fuse 15 -- 30A P2 Pressure Gauge and Backlight

KA Air Brake Relay S26 Handbrake Switch

KH Trailer Brake Relay
KIX Trailer Brake Relay X7 Italian Trailer Brake Harness
X8 Air Brake Harness Connector
M2 Air Seat Pump

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 95
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 96
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 97
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 98
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

WASHERS AND WIPERS

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 99
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

A00
C12

TC
M
5

5
GCM
A006
C126

55- 100
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

DIAGNOSTIC PLUGS
Line 7170--7530

A005 C125 Transmission diagnostic plug (white)

A006 C126 Suspension/EDC diagnostic plug (black)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 101
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 102
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

PROCESSOR FEEDS AND GROUNDS

Line 7540--7920

F20 Fuse 20 -- 5A

A007 Instrument Cluster A (C079)

A008 Instrument Cluster B (C080)
A009 Instrument Cluster C (C081)
A010 (TCM) Transmission Processor (C101)
A011 (GCM) Suspension/EDC Processor (C127)
A012 Electronic Management Unit (C105)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 103
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 104
TM115, TM125, TM135 Range Command Transmission, W/Cab,
TM150 & TM165

AIR CONDITIONING AND CAB HEATING

R3 Blower Speed Resistor E3 Compressor Clutch

R4 Speed Resistor

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 105
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

55- 106
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
WIRING DIAGRAMS:

Models: TM115, TM125 and TM150 with DUAL COMMAND Transmission

Wiring Diagrams Circuit Description Line Reference Range

55- 107
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 108
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 109
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

(C14
1)
S47

B Black R Red LG Light Green K Pink

55- 115
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this Model

55- 116
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

TRANSMISSION SYSTEM
Line 1420--1760

Not Applicable to this Model

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 117
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 118
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

ELECTRONIC DRAFT CONTROL

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 119
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 120
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

ELECTRONIC DRAFT CONTROL

Line 2140--2510
A013 EDC Control
Y12 EDC Raise Solenoid
S7 Hydraulic Oil Temperature Switch Y13 EDC Lower Solenoid
S8 Charge Pressure Switch
S9 Hydraulic Oil Warning Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 121
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 122
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

ELECTRONIC DRAFT CONTROL

Line 2520--2770
B7 Transmission Oil Temperature Sender
B8 Rear Axle Speed Sensor
B9 Left Hand Draft Pin
B10 Right Hand Draft Pin

S11 Raise/Lower Fender Switch -- Left Hand

S12 Raise/Lower Fender Switch -- Right Hand

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 123
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 124
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

FOUR WHEEL DRIVE AND DIFFERENTIAL LOCK

Line 2780--3060
S13 FWD Engaged Switch Y14 Four Wheel Drive Solenoid
S14 Brake Switch -- Right Hand Y15 Differential Lock Solenoid
S15 Brake Switch -- Left Hand
S39 Differential Lock Engaged Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 125
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 126
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

POWER TAKE OFF

Line 3070--3470
A014 Front PTO Module KVIII Front Lift Relay
KX PTO Fender Relay
B11 Front Lift Height Control
B12 Front Lift Potentiometer S16 Rear PTO Switch

Y16 Front Lift Solenoid Valve

H1 Front PTO Engaged Lamp Y17 Front PTO Solenoid
Y18 Rear PTO Solenoid
KVll Front Lift Relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 127
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 128
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

POWER TAKE OFF

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 129
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this Model

55- 137
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 138
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

INDICATORS AND HAZARDS

Line 5250--5640

F25 Fuse 25, 20A H13 Front Indicator, Left Hand

WIRE COLOUR CODES

55- 139
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

H2
6

(C085

H24
)
H2
5

(C084

H23
)

55- 140
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

WIRE COLOUR CODES

55- 141
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 142
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

TRAILER BRAKE SYSTEMS

Line 5950--6450
F9 Fuse 9 -- 10A
F15 Fuse 15 -- 30A P2 Pressure Gauge and Backlight

KA Air Brake Relay S26 Handbrake Switch

KH Trailer Brake Relay
KIX Trailer Brake Relay X7 Italian Trailer Brake Harness
X8 Air Brake Harness Connector
M2 Air Seat Pump

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 143
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 144
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 145
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 146
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

WASHERS AND WIPERS

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 147
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

C126
A006

GC
M

55- 148
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

DIAGNOSTIC PLUGS
Line 7170--7530

A006 C126 Transmission/EDC diagnostic plug (black)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 149
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

(A01
1)

55- 150
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

PROCESSOR FEEDS AND GROUNDS

Line 7540--7920

F20 Fuse 20 -- 5A

A007 Instrument Cluster A (C079)

A008 Instrument Cluster B (C080)
A009 Instrument Cluster C (C081)
A011 (GCM) Transmission/EDC Processor (C127)
A012 Electronic Management Unit (C105)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 151
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 152
TM115, TM125, TM135 Dual Command Transmission, W/Cab,

AIR CONDITIONING AND CAB HEATING

R3 Blower Speed Resistor E3 Compressor Clutch

R4 Speed Resistor

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 153
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

55- 154
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
WIRING DIAGRAMS:

Models: TM115 and TM125 with SHUTTLE COMMAND Transmission

Wiring Diagrams Circuit Description Line Reference Range

55- 155
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 156
TM115, TM125 Shuttle Command Transmission, W/Cab,

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 157
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this Model

55- 158
TM115, TM125 Shuttle Command Transmission, W/Cab,

TRANSMISSION SYSTEM
Line 390--780

Not Applicable to this Model

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 159
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 160
TM115, TM125 Shuttle Command Transmission, W/Cab,

TRANSMISSION SYSTEM
Line 790--1140
S5 Clutch Pedal Switch
S6 Transmission Oil Pressure Switch
S60 Clutch Fluid Reservoir Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple

55- 161
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this model

55- 162
TM115, TM125 Shuttle Command Transmission, W/Cab,

TRANSMISSION SYSTEM
Line 1150--1410

Not Applicable to this Model

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 163
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this Model

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 167
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

S
4
9

55- 168
TM115, TM125 Shuttle Command Transmission, W/Cab,

Line 3070--3470
A014 Front PTO Module KVIII Front Lift Relay
KX PTO Fender Relay
B11 Front Lift Height Control
B12 Front Lift Potentiometer S16 Rear PTO Switch

Y16 Front Lift Solenoid Valve

H1 Front PTO Engaged Lamp Y17 Front PTO Solenoid
H3 PTO Brake Lamp Y18 Rear PTO Solenoid

KVll Front Lift Relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 175
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

S50

55- 176
TM115, TM125 Shuttle Command Transmission, W/Cab,

POWER TAKE OFF

Line 3480--3880
B13 Rear PTO Speed Sensor S19 PTO Brake Switch
S27 Seat Switch
F12 Fuse 12, 10A S51 PTO Fender Switch -- Left Hand
F13 Fuse 13, 25A S52 PTO Fender Switch -- Right Hand
F21 Fuse 21, 25A S53 PTO Soft Start Switch

H2 Rear PTO Engaged Lamp S50 Lift--O--Matic

S17 Front PTO Switch Y31 PTO Brake Solenoid

S18 Ground Speed PTO Engaged Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 177
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Not Applicable to this Model

55- 178
TM115, TM125 Shuttle Command Transmission, W/Cab,

FRONT AXLE SUSPENSION SYSTEM

Line 3890--4250

Not Applicable to this Model

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White

55- 179
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 180
TM115, TM125 Shuttle Command Transmission, W/Cab,

CAB ACCESSORIES
Line 4260--4500
MF6 Maxi Fuse 6 40A S20 Beacon Switch
MF7 Maxi Fuse 7 40A S21 Remote Valve Lockout Switch

B14 Horn
X1 Implement Socket Front
E1 Left Hand Beacon X2 Implement Socket Rear
E2 Right Hand Beacon

H4 Console Lamp Y20 Hydraulic Remote Valve Solenoid

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 181
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 182
TM115, TM125 Shuttle Command Transmission, W/Cab,

55- 183
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 184
TM115, TM125 Shuttle Command Transmission, W/Cab,

INDICATORS AND HAZARDS

Line 4860--5240

F1 Fuse 1, 15Amp K3 Flasher Unit Relay

MF3 Maxi--fuse 3, 30Amp

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink

55- 185
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 186
TM115, TM125 Shuttle Command Transmission, W/Cab,

INDICATORS AND HAZARDS

Line 5250--5640

F25 Fuse 25, 20A H13 Front Indicator, Left Hand

WIRE COLOUR CODES

55- 187
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

H2
6

(C085

H24
)
H2
5

(C084

H23
)

55- 188
TM115, TM125 Shuttle Command Transmission, W/Cab,

WIRE COLOUR CODES

55- 189
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 190
TM115, TM125 Shuttle Command Transmission, W/Cab,

TRAILER BRAKE SYSTEMS

Line 5950--6450
F9 Fuse 9 -- 10A
F15 Fuse 15 -- 30A P2 Pressure Gauge and Backlight

KA Air Brake Relay S26 Handbrake Switch

A007 Instrument Cluster A (C079)

A008 Instrument Cluster B (C080)
A009 Instrument Cluster C (C081)
A012 Electronic Management Unit (C105)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 199
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 200
TM115, TM125 Shuttle Command Transmission, W/Cab,

AIR CONDITIONING AND CAB HEATING

R3 Blower Speed Resistor E3 Compressor Clutch

R4 Speed Resistor

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
TN Light Brown Y Yellow TQ Turquoise

55- 201
S Slate G Green L Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

55- 202
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
CIRC. COLOUR DESCRIPTION

10 G STOPLAMP SWITCH FEED

12 U/W MAIN BEAM HEADLAMP FUSE SUPPLY

13 U/R DIP BEAM HEADLAMP FUSE SUPPLY

15 U LIGHTING SWITCH SUPPLY

28 Y/LG WIPER MOTOR (PARK RETURN)

29 G/B MAIN FUEL SENDER SIGNAL

31 Y/S ENGINE OIL PRESSURE SENDER SIGNAL

39 G/U TEMPERATURE GAUGE SIGNAL

44 LG/N FLASHER UNIT (49A)

49 G/W RIGHT HAND TURN SIGNAL

50 G/R LEFT HAND TURN SIGNAL

56 W/LG WIPER MOTOR--HIGH

57 B EARTH (ALL)

58 R/LG WIPER MOTOR--LOW

63 U/LG WIPER MOTOR--PARK FEED

65 W DUAL POWER/4 WHEEL DRIVE SWITCH FEED

71 W IGNITION SWITCHED FEEDS (UNFUSED)

84 G WINDSHIELD WASHER SWITCH FEED

90 G DUAL POWER / FOUR WHEEL DRIVE SWITCH

97 LG/B WINDSHIELD WASHER FEED

137 W/K RADIO FEED

138 P RADIO KAM

150 N BATTERY FEED (ALL)

181 G BLOWER MOTOR FEED

182 P/LG THERMOSTATIC SWITCH FEED

252 N/G ALTERNATOR FIELD

365 G/O LOW FUEL WARNING LAMP (DELAY ON)

366 O/U LOW FUEL WARNING LAMP (DELAY SWITCH)

376 P/N HORN FEED

587 LG/O W1NDSHIELD WIPER INTERMITTENT DELAY

649 B/O COOLANT TEMPERATURE SWITCH

666 P/W DOMELAMP SWITCH FEED

787 G AUXILIARY FUEL PUMP SUPPLY

810 G/P STOPLAMPS

820 B/R/S STOPLAMP SWITCH LH

830 B/U/S STOPLAMP SWITCH RH

840 G/O R & L STOPLAMP SIGNAL

979 G/S BLOWER MOTOR HIGH SPEED

980 N/U THERMOSTAT SWITCH SUPPLY

981 G/P/B A/C CLUTCH RELAY FEED

55- 203
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
982 G/S/B BLOWER MOTOR FEED

984 P/G TEMPERATURE CONTROL POT. INPUT

986 P/K TEMPERATURE CONTROL POT. OUTPUT

989 P/G BLOWER MOTOR MEDIUM SPEED

997 G/N WORK LAMP--REAR FEED (OUTER)

998 G/LN WORK LAMP--REAR FEED (INNER)

999 G/Y BLOWER MOTOR LOW SPEED

1000 W/Y SAFETY START SWITCH SUPPLY

1001 W/R STARTER SOLENOID FEED

1002 P IMPLEMENT LAMP SWITCH SUPPLY

1003 G SUPPLY TO GAUGES

1004 G SUPPLY TO HORN AND HEADLAMP FLASH

1005 B/S AIR CLEANER WARNING LAMP

1006 N/Y ALTERNATOR WARNING LAMP

1007 W ETHER START BUTTON SUPPLY

1008 N/K ETHER START SOLENOID SUPPLY

1009 N/P ALTERNATOR FIELD

1010 G IGNITION RELAY (COIL)

1011 Y/W SUPPLY TO FUSES

1013 R RIGHT HAND LAMPS

1014 R/B LEFT HAND LAMPS

1015 P DOME LAMP SWITCH FEED

1016 P/N HORN FEED

1017 LG/G AIR CON. THERMOSTATIC SWITCH FEED

1018 LG/W AIR CONDITIONER CLUTCH

1019 G WINDSHIELD WIPER FEED

1020 G HAZARD SWITCH SUPPLY

1021 P HAZARD SWITCH SUPPLY (BATTERY)

1022 N/R THERMOSTART

1023 N LIGHT SWITCH FEED

1024 R RIGHT & LEFT HAND SIDELAMP FEED

1025 G HZD SWITCH IGN FEED

1026 U/W HIGH BEAM INDICATOR LAMP

1027 U/W HEADLAMP MAIN BEAM

1028 U/W HEADLAMP MAIN BEAM FUSE

1029 U/R HEADLAMP DIP BEAM FUSE

1030 U/R HEADLAMP DIP BEAM

1031 R/W INSTRUMENT ILLUMINATION

1032 LG/P TURN SIGNAL WARNING LAMP (TERM C)

1033 LG/Y TURN SIGNAL WARNING LAMP (TERM C2)

1034 LG/R TURN SIGNAL WARNING LAMP (TERM C3)

55- 204
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
1035 W/N ENGINE OIL PRESSURE WARNING LAMP

1036 N IGNITION SWITCH (BATTERY)

1037 LG/N FLASHER UNIT (TERM 49A)

1040 LG/K FLASHER SWITCH TO RELAY--RHS CUT OUT

1041 LG/U FLASHER SWITCH TO RELAY--LHS CUT OUT

1050 G ACCESSORY FEED

1070 R FRONT WORKLAMP SWITCH FEED

1071 P WORKLAMP FRONT FEED

1072 P/U WORKLAMP FRONT RELAY SUPPLY

1073 P WORKLAMP FRONT FEED

1090 R REAR WORKLAMP RELAY SIGNAL

1091 R FRONT WORKLAMP LOWER RELAY SIGNAL

1092 R FRONT WORKLAMP RELAY SIGNAL

1093 R FENDER WORKLAMP RELAY SIGNAL

1096 R/Y WORKLAMP FENDER MOUNTED

1097 R/S FEED FRONT WORKLAMP OUTER

1098 W/B FRONT WORKLAMP RELAY GROUND

1099 R/O FEED FRONT WORKLAMP INNER

1119 G/R/B RR WINDSHIELD WIPER

1120 G/O/B RR WINDSHIELD WIPER PARK RETURN

1121 G/Y/B RR WINDSHIELD WASH

1130 N/S ENGINE HEATER CONTROL TO IGN SWITCH

1135 G/K/B THERMOSTART WARNING LAMP

1140 K/W/S THERMOSTART INITIATE SIGNAL TO RELAY

2001 N/G BATTERY TEMPERATURE SENSOR

2002 N/P BATTERY TEMP SENSOR (ALT OUTPUT)

2003 W/R STARTER SOLENOID FEED

2006 U/O DE--ICING SWITCH -- AIR CONDITIONER

2009 G FUEL PUMP SUPPLY

2010 LG/W AIRCON PLUG TO DE--ICING SWITCH

2011 P/B HORN RETURN

2012 Y/O TRANS OIL PRESSURE WARNING LAMP

2013 Y/R PTO OVERSPEED WARNING LAMP

2014 G/K ENGINE OIL PRESSURE SENDER (+5 VOLT)

2015 W/S TACHOMETER SENSOR--SIGNAL

2016 Y/G REAR AXLE SPEED SENSOR--SIGNAL

2017 B/P BULB TEST (EIC)

2018 B/R RADAR PRESENT

2019 B/K ENGINE RPM (TACHO MODULE TO TPM)

2020 Y/K ENGINE SHUT DOWN (TACHO MODULE TO TPM)

2021 Y/P AXLE GROUND SPEED (TACHO MODULE TO TPM)

55- 205
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
2022 B/Y PTO 540/1000 RPM (TACHO MODULE TO TPM)

2023 S TPM TO EIC (AXLE SPEED DRIVE)

2024 S/N RADAR SIGNAL DRIVE

2025 S/U AUDIO ALARM CONTROL

2026 S/R IMPLEMENT SWITCH SIGNAL

2027 R RADAR ASSEMBLY (GUN) POWER

2028 G RADAR ASSEMBLY (GUN) SIGNAL

2029 P INSTRUMENT MEMORY SUPPLY

2030 N/O ELECTRONIC DRAFT CONTROL

2040 LG/G/S WATER IN FUEL SENSOR

2041 P/Y FUEL SHUT OFF

2042 O/S PTO SOLENOID--REAR

2043 O/K PTO SOLENOID--FRONT

2045 O/G PTO SWITCH TO MODULE

2046 O/LG PTO SWITCH (VCC)

2047 O/W PTO SWITCH (VCCO)

2048 O/Y PTO SWITCH (VCCS)

2049 O/P PTO SWITCH 1000RPM WARNING LAMP

2050 G PTO SUPPLY

2052 W/R/B PTO LUBE SOL

2053 P/W/B PTO LUBE SOL RETURN

2055 B/W/S PTO SYNCHRO GROUND SPEED ENGAGED

2060 O/LG PTO 540/1000 SWITCH

2065 N/G/B PTO ENGAGED

2070 O/U/B ENGINE SHUT OFF RELAY +12V

2080 O/R ENGINE SHUT OFF RELAY

2090 W/U STARTER RELAY TO START INHIBIT SWITCH

2095 G/W/B INSTRUMENT SIGNAL GROUND

2100 G/U/B A/C CONDENSER MOTOR FEED

2120 B/LN/S PTO BRAKE SIGNAL

2130 B/N/S PTO BRAKE SOLENOID

2140 B/O/S PTO SPEED SENSOR

2150 B/P/S PTO EXT. SWITCH OFF

2200 G/N/B SERVICE MODE INITIATE

2245 K/LN/S PTO FRONT -- SWITCH TO MODULE (MOM)

2248 K/N/S PTO FRONT -- SWITCH (VCCS)

225O K/O/S PTO FRONT -- SUPPLY

2500 N/B/S FRONT HITCH SOLENOID

2510 N/G/S FRONT HITCH POSITION SIGNAL

2520 N/K/S FRONT HITCH SET POSITION SIGNAL

2530 N/LG/S FRONT HITCH V REF

2540 N/O/S FRONT HITCH +12v IGN

55- 206
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
2550 N/P/S FRONT HITCH OVERIDE SWITCH

2560 N/R/S FRONT HITCH 0v REF

2600 Y/G/S REAR AXEL SPEED MONITOR

3000 G/LG FLASHER UNIT SUPPLY (TERMINAL 49)

3001 G/R LEFT HAND FLASHER CIRCUIT

3002 G/W RIGHT HAND FLASHER CIRCUIT

3003 W/K RADIO FEED

3004 G/W RIGHT HAND TURN SIGNAL WARNING LAMP

3005 G/R LEFT HAND TURN SIGNAL WARNING LAMP

3006 G/S AUXILIARY FUEL TANK SENDER

3007 G/B FUEL GAUGE FEED

3008 U/B WORKLAMP WARNING LIGHT

3010 R/Y FOGLAMP FEED

3011 R/Y FOGLAMP FEED

3012 G HANDBRAKE WARNING FEED

3013 LG/S AUXILIARY FUEL TANK SIGNAL

3014 R/K HANDBRAKE WARNING LAMP SIGNAL

3015 P/K ACCESSORY SOCKET (POWER)

3020 Y DUAL POWER SOLENOID SUPPLY

3022 Y/N DUAL POWER (HIGH) WARNING LAMP

3025 Y/U FOUR WHEEL DRIVE SOLENOID

3030 W/K ACCESSORY RELAY SIGNAL

3045 Y/U/S FOUR WHEEL DRIVE WARNING LAMP

3050 P AUXILIARY FEED CONNECTOR SUPPLY

3051 P CIGAR LIGHTER SUPPLY

3052 P/W DOME LAMP TO DOOR SWITCH

3053 S/O SPEAKER RIGHT HAND

3054 S/Y SPEAKER NEGATIVE RH

3055 S/K SPEAKER LEFT HAND

3056 N/B SPEAKER NEGATIVE LH

3060 P IMPLEMENT SOCKET RELAY

3061 P/S IMPLEMENT SOCKET

3062 P/O IMPLEMENT SOCKET SWITCH

3070 P ’B’ PILLAR SKT SUPPLY

3075 O TRAILER SOCKET (ACCESSORY FEED)

3076 O/N ACCESSORY SWITCH FEED

3080 P/LN CONSOLE LAMP

3090 Y/LN SEAT PUMP SUPPLY

3100 B/G/S STEERING SENSOR +5v

3120 B/K/S STEERING SENSOR SIGNAL

3140 B/LG/S STEERING SENSOR GROUND

55- 207
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
3150 W/O HANDBRAKE SWITCH (N.C CONTACT) OFF SIG

3155 W/G HANDBRAKE TRANS INTERLOCK

4001 R/U TRANSMISSION OIL WARNING LAMP (TEMP)

4002 R/U TRANSMISSION OIL WARNING LAMP SWITCH

4010 N/W RETURN TO DIG

4011 P/G ROTATING BEACON SWITCH SUPPLY

4012 P/R ROTATING BEACON FEED

4013 U/N TRANS CONTROL FEED

4014 U/G FORWARD CLUTCH SOLENOID FEED

4015 U/Y REVERSE CLUTCH SOLENOID FEED

4016 U/K TORQUE CONVERTOR LOCK--UP RELAY FEED

4017 U/S TORQUE CONVERTOR LOCK--UP LAMP

4018 S/P TORQUE CONVERTOR LOCK--UP SOLENOID FEED

4019 S/G HYDRAULIC FILTER BY--PASS SWITCH FEED

4020 S/LG HYDRAULIC FILTER BY--PASS LAMP

4021 S/W BACK--UP ALARM RELAY FEED

4022 S/B BACK--UP ALARM FEED

4025 Y/LN 4 IN 1 BUCKET FEED

4040 G LINK LEVEL SWITCH SUPPLY

4050 W/P LINK LEVEL RAISE

4051 W/G LINK LEVEL LOWER

4100 TQ/Y TRANS RANGE ENABLE SWITCH SUPPLY

4101 TQ/B TRANS RANGE ENABLE

5000 P EDC MEMORY POWER

5005 N/O EDC KEY SWITCH FEED

5010 B EDC EARTH

5011 B EDC EARTH CASE RFI

5015 R EDC CONTROLS BACKLIGHTING

5020 LN EDC PROC +5V REF VOLTAGE DROP POSN/RATE

5021 K/Y EDC PROCESSOR REF VOLT (+5V) ROCKSHAFT

5022 K/B EDC PROCESSOR REF VOLT +5V QUADRANT

5023 K/S EDC PROCESSOR REF VOLT +5V HEIGHT LIMIT

5025 LN/U EDC LOWER SIGNAL

5030 LN/R EDC RAISE SIGNAL

5035 LN/G EDC RETURN REF. VOLTAGE EARTH

5040 LN/W EDC DRAFT POSITION

5045 LN/Y EDC DROP RATE

5050 LN/B EDC QUADRANT

5055 LN/S EDC CLOCK LINE TO DISPLAY

5060 LN/O SERIAL DATA TO CLUSTER

55- 208
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
5065 LN/P EDC RIGHT PIN

5070 LN/LG EDC LEFT PIN

5075 K EDC VOLTAGE TO PINS

5080 K/N EDC ROCKSHAFT

5085 K/U EDC VALVE UP

5087 K/U/B EDC VALVE UP RETURN

5090 K/R EDC VALVE DOWN

5095 K/G EDC EXTERNAL SWITCH DOWN

5097 K/G/B EDC VALVE DOWN RETURN

5100 K/W EDC EXTERNAL SWITCH UP

5105 S/R EDC IMPLEMENT STATUS SWITCH

5110 K/LG EDC LAMP SIGNAL

5115 K/P EDC SLIP SIGNAL

5120 K/O EDC HEIGHT LIMIT SIGNAL

5125 TQ/W EDC RAISE SIGNAL--RAISE WORK SWITCH

5130 TQ/P EDC WORK SIGNAL--RAISE WORK SWITCH

5135 TQ EDC +WHEEL SPEED SIGNAL

5140 TQ/N EDC --WHEEL SPEED SIGNAL

5145 TQ/R EDC SLIP LIMIT POT

5150 G EDC EXTERNAL SWITCH SUPPLY

5155 B/U EDC LOWER LIMIT POT

5160 TQ/O EDC HEIGHT LIMIT POT FEED

5170 LN/TQ SERIAL DATA FROM CLUSTER

5180 TQ/G EDC SLIP INDICATOR LAMP

5190 R/W/B HPL INTERLOCK

5200 N/R/B EDC VALVE SUPPLY

5210 N/S/B EDC VALVE ENABLE

5300 K/W/B ECU FLASH PROGRAM SIGNAL

5820 B EDC ROCKSHAFT POT

6000 K/LG/S ENGINE SPEED SIGNAL

6010 B/TQ/S THROTTLE POSITION SWITCH

6100 U ENGINE COLD ADVANCE CONTROL

7000 U/R/B TRANS CONTROL SUPPLY

7001 U/0/B TRANS DISPLAY ILLUMINATION

7002 U/Y/B TRANS MAIN CLUTCH SOL (C3/C4)

7003 U/G/B TRANS DUMP SOL

7004 U/B TRANS FRONT CLUTCH SOL (C1/C2)

7005 U/P/B TRANS CREEPER GR SOL

7007 R/P/B TRANS DUAL POWER PRESSURE SWITCH HIGH

7008 R/S/B TRANS DUAL POWER PRESSURE SWITCH LOW

55- 209
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
7010 U/N/B TRANS RANGE INDICATOR SWITCH (GR 1--4)

7020 U/W/B TRANS RANGE INDICATOR SWITCH (GR 5--8)

7030 U/LG/B TRANS RANGE INDICATOR SWITCH COMMON

7035 N/LG/B TRANS DUMP SOLEN0ID FEED

7040 U/LN/B TRANS CREEPER SWITCH

7050 R/G/B TRANS RELAY SUPPLY -- RUN

7060 R/K/B TRANS RELAY SUPPLY -- START

7070 R/LG/B TRANS FEED

7071 N/K/B FEED HYD FILTER RESTRICTION IND LAMP

7080 B/LG DIFF--LOCK SOLENOID FEED

7090 LG DIFF--LOCK SWITCH TO BRAKE SWITCH

7100 N/LG DIFF--LOCK RELAY TO BRAKE SWITCH

7110 R/Y/B PTO INHIBITOR SWITCH TO TRANS

7120 Y/B DIFF--LOCK WNG LP

7130 B/N HYD FILTER WNG LP

7140 O/B DIFF--LOCK OFF SOLENOID

7150 S/G/B LOW OIL PRESSURE WRN FEED

7160 R/N/B HYD LOW CHARGE WARNING

7170 B/W DIFF LOCK SWITCH OUTPUT

7180 U/TQ CREEPER SWITCH MOM SIGNAL

7190 K/G/S TRANS SOLENOID VALVE SUPPLY

7195 K/U/S TRANS SOLENOID VALVE RETURN

7200 S/K/B TRANSMISSION SHIFT DOWN

7210 S/LG/B TRANSMISSION SHIFT UP

7220 S/N/B TRANSMISSION HIGH RANGE

7225 W/LG/B TRANS HI RANGE SOL -- RET

7230 S/O/B TRANSMISSION LOW RANGE

7235 Y/LN/B TRANS LOW RANGE SOL -- RET

7240 S/P/B TRANSMISSION DISPLAY SWITCH

7250 S/R/B TRANSMISSION FORWARD SIGNAL

7260 S/U/B TRANSMISSION REVERSE SIGNAL

7265 K/Y/S TRANS NEUTRAL SWITCH TO PROCESSOR ([Link] 1)

7267 LG/N/S TRANS NEUTRAL SWITCH 2 TO PROCESSOR

7270 R/G TCM SERIAL DATA IN--DISPLY DATA OUT

7275 W/U/B TCM SERIAL DATA OUT--DISPLY DATA IN

7280 W/G/B LIMP HOME SWITCH 18x18 TRANS.

7290 W/K/B DIRECTIONAL INTERRUPT RELAY TO SOLENOID

7300 W/LG/B SOLENOID 1 18x9 TRANSMISSION

7301 Y/LN/B SOLENOID 1 18x9 RETURN

7320 W/N/B SOLENOID 2 18x9 TRANSMISSION

7321 P/Y/B SOLENOID 2 18x9 RETURN

7330 W/P/B SOLENOID 3 18x9 TRANSMISSION

55- 210
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
7331 Y/S/B SOLENOID 3 18x9 RETURN

7340 W/R/B SOLENOID F1 18x9 TRANSMISSION

7341 Y/W/B SOLENOID F1 18x9 RETURN

7350 W/S/B SOLENOID F2 18x9 TRANSMISSION

7351 S/W/B SOLENOID F2 18x9 RETURN

7355 S/Y/B SOLENOID R 18x9 TRANSMISSION

7356 U/S/B SOLENOID R 18x9 RETURN

7360 W/Y/B SOLENOID A 18x9 TRANSMISSION

7361 P/LG/B SOLENOID A 18x9 RETURN

7370 Y/G/B SOLENOID B 18x9 TRANSMISSION

7371 P/N/B SOLENOID B 18x9 RETURN

7380 Y/K/B SOLENOID C 18x9 TRANSMISSION

7381 P/O/B SOLENOID C 18x9 RETURN

7390 Y/LG/B SOLENOID PMW (F1) 18x9 TRANSMISSION

7391 P/R/B SOLENIOD PWM (F1) 18x9 RETURN

7392 O/G/B SOLENOID PWM (F2) 18x9 TRANSMISSION

7393 O/N/B SOLENOID PWM (F2) 18x9 RETURN

7395 P/S/B SOLENOID CREEP 18x9 TRANSMISSION

7396 P/W/B SOLENOID CREEP 18x9 RETURN

7400 Y/N/B TRANS RPM SPEED SENSOR TO TCM INPUT

7401 P/B/G TRANS RPM SPEED SENSOR

7410 Y/O/B TRANS RPM SPEED SENSOR TO TCM OUTPUT

7420 Y/P/B TCM TO CLUTCH POSITION SWITCH

7430 Y/R/B CLUTCH POSITION SIGNAL

7431 TQ/W/B CLUTCH ’A’ SUPPY

7440 Y/U/B TCM TO TRACTOR EIC--AXLE OUTPUT

7450 W/LN/B TRANS CREEPER INTERLOCK SUPPLY

7460 W/O/B TRANS CREEPER CLUTCH ENGAGED

7470 S/LN/B TRANS CREEPER CLUTCH DISENGAGED

7480 G/K/S TRANS AUTO FUNCTION 1

7485 K/P/S TRANS AUTO FUNCTION LAMP 1

7490 G/LG/S TRANS AUTO FUNCTION 2

7495 K/R/S TRANS AUTO FUNCTION LAMP 2

7500 B/G TRANS OIL TEMP. SENSOR

7520 G/N/S TRANS SENSOR SUPPLY 8v

7525 G/B/S TRANS SENSOR SUPPLY 5v

7560 G/LN/S TRANS WARNING LAMP

7570 B SIGNAL GROUND

7580 U/K/B CREEPER SOLENOID MONITOR

7590 O/W/B TRANS CREEPER GEAR STATUS LAMP

7600 N/W/B TRANS FEATHERING SOLENOID

7620 N/Y/B TRANS FEATHERING SOL. MONITOR

55- 211
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
7630 N/U/B TRANS MAIN CLUTCH PRESSURE SWITCH

7640 B/LN DIAGNOSTIC PLUG RS232 IN

7650 W/LN DIAGNOSTIC PLUG RS232 OUT

7660 R/U/B TRANS CLUTCH DISCONNECT

7700 LN/N/B TRANS SHUTTLE DUMP SWITCH

7710 LN/O/B TRANS OIL TEMPERATURE SWITCH

7735 LN/P/B TRANS MID SPEED SIGNAL +

7740 LN/R/B TRANS MID SPEED SIGNAL --

7750 R/B/S TCM TO DOG 30/40 KPH SELECT

7760 W/N/B TORQUE SENSOR

7810 K/N/B TRANS PWM SOLENOID C1

7815 K/O/B TRANS PWM SOLENOID C1 RETURN

7820 K/P/B TRANS PWM SOLENOID C2

7825 K/R/B TRANS PWM SOLENOID C2 RETURN

7830 K/S/B TRANS PWM SOLENOID C3

7835 K/U/B TRANS PWM SOLENOID C3 RETURN

7840 K/W/B TRANS PWM SOLENOID C4

7845 K/Y/B TRANS PWM SOLENOID C4 RETURN

7850 G/P/S TRANS DIAGNOSTIC PROGRAM VOLTAGE

7855 G/R/S TRANS DIAGNOSTIC EA

7860 G/U/S TRANS DIAGNOSTIC RCV

7865 G/W/S TRANS DIAGNOSTIC XMT

7870 G/Y/S TRANS DIAGNOSTIC RTS

7875 K/B/S TRANS DIAGNOSTIC CTS

7880 B T C M SIGNAL GROUND

7900 TQ/K/B CLUTCH ’A’ SIGNAL

7910 TQ/N/B CLUTCH ’B’ SIGNAL

7915 P/O/S TCM CLUTCH B RETURN

7920 TQ/O/B CLUTCH ’C’ SIGNAL

7925 P/R/S TCM CLUTCH C RETURN

7930 TQ/R/B CLUTCH ’D’ SIGNAL

7935 P/N/S TCM CLUTCH D RETURN

7940 TQ/S/B CLUTCH ’E’ SIGNAL

7945 P/TQ/S TCM CLUTCH E RETURN

7950 TQ/Y/B CLUTCH SUPPLY

7960 P/K/B TRANS SLOW/FAST

7965 P/K/S HI/LO SYNCHRO SIGNAL

7970 P/TQ/B TRANS MED/REV

7980 K/LG/B TRANS MED RANGE

7982 W/P/B TRANS MED RANGE RET

7985 G/O/S TRANS REVERSE RANGE

7990 K/R/B TRANS BRAKE

55- 212
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

8000 N/TQ/B TRAILER BRAKE SOLENOID

8010 LN/W/B TRAILER BRAKE PRESSURE

8020 LN/K/B TRAILER BRAKE PRESSURE

8030 LG/O/S TRANS FWD SOLENIOD

8035 P/LG/S TRANS FWD SOL RET

8040 LG/P/S TRANS REV SOLENIOD

8045 P/LN/S TRANS REV SOL RET

9000 LN/S/B DIVERTER VALVE

9010 LN/U/B DIVERTER VALVE SUPPLY

9020 LN/Y/B HYDRAULIC REMOTE VALVE SOL

9025 LN/G/B HYDRAULIC REMOTE VALVE SWITCH

55- 213
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

55- 214
TM115, TM125, TM135 All Models
TM150, TM165

Revised wiring diagram colour codes -- use with all diagrams

55- 215
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

LN Light Brown Y Yellow TQ Turquoise

S Slate G Green P Purple
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 216
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
Fold out for Key to DUAL COMMAND Electrical System Diagram.

ELECTRICAL SYSTEM DIAGRAMS

POWER COMMAND, RANGE COMMAND AND

DUAL COMMAND MODELS

55- 217
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
DUAL COMMAND ELECTRONIC MANAGEMENT UNIT AND INSTRUMENT CLUSTER SYSTEM ELECTRONIC MANAGEMENT UNIT TERMINALS (C105)
1. +12V CONTINUOUS LIVE FROM FUSE 20
DIAGRAM
2. EXTERNAL BUZZER
1. BATTERY 13. STEERING ANGLE SENSOR
3. THERMOSTART INITIATE/PTO SOFT START
2. MAXI FUSES 14. REAR PTO SOLENOID
4. STEERING SENSOR
3. IGNITION SWITCH 15. TO RELAY A -- AIR BRAKE RELAY
4. IGNITION RELAY 16. TO TRAILER SOCKET 5. GROUND SPEED PTO SWITCH
5. RELAY E -- REAR LOWER WORKLIGHTS 17. RELAY G -- BRAKE LAMP RELAY 6. EMU DATA IN
6. RELAY D -- FRONT LOWER WORKLIGHTS 18. ELECTRONIC MANAGEMENT UNIT 7. BRAKE SWITCH -- RIGHT
7. RELAY C -- REAR UPPER WORKLIGHTS 19. SENSOR SIGNAL GROUND 8. SIDELIGHT DETECT
8. RELAY B -- FRONT UPPER WORKLIGHTS 20. CHASSIS GROUND
9. SEAT SWITCH
9. RELAY III -- THERMOSTART 21. POWER GROUND
10. EMU DATA OUT
10. DIGITAL INSTRUMENT CLUSTER 22. TRANSMISSION OIL PRESSURE
SWITCH TO C128--25 11. CASE GROUND
11. FRONT PTO SWITCH AND MODULE 23. FUEL SHUT--OFF SOLENOID 12. REAR PTO RELAY
12. PTO FENDER SWITCHES (IF FITTED) 24. TO ITALIAN TRAILER BRAKE CIRCUIT 13. REAR PTO SOLENOID
25. BRAKE FLUID LEVEL SWITCH 14. FOUR WHEEL DRIVE SOLENOID
INSTRUMENT CLUSTER -- TERMINALS 15. REAR PTO ON/OVERSPEED LAMP
C079 -- 1. ENGINE COOLANT TEMPERATURE C080 -- 1. ENGINE RPM 16. FRONT LOWER WORKLAMP
2. SIGNAL GROUND 2. HANDBRAKE LAMP +12V FEED
17. REAR LOWER WORKLAMP
3. +12V SWITCHED IGNITION LIVE FROM FUSE 9 3. HANDBRAKE SWITCH 18. REAR PTO MOMENTARY SWITCH
4. LEFT TURN 4. LOW RANGE LAMP
19. STARTER RELAY CRANKING INPUT
5. NOT USED 5. TRANSMISSION OIL TEMPERATURE
20. BRAKE SWITCH -- LEFT
6. TRAILER 1 6. FOUR WHEEL DRIVE PRESSURE SW.
21. ENGINE RPM
7. ENGINE OIL PRESSURE LAMP 7. HYD OIL TEMP / BLOCKED OIL FILTER
22. HANDBRAKE SWITCH
8. TRAILER 2 8. FOUR WHEEL DRIVE LAMP +12V FEED
23. REAR PTO SPEED SENSOR
9. FUEL GAUGE SENSOR 9. DIFFERENTIAL LOCK
24. +12V SWITCHED IGNITION LIVE FROM FUSE 15
10. +12V CONTINUOUS LIVE FROM FUSE 20 10. STEERING / TRANS. PRESSURE
25. POWER GROUND
11. BACKLIGHT POWER 11. SERIAL DATA OUT
26. WHEEL SPEED
12. HIGH RANGE LAMP 12. SERIAL DATA IN
27. STEERING ANGLE SENSOR RETURN
13. THERMOSTART LAMP 13. POWER GROUND
28. STEERING ANGLE SENSOR +5V FEED
14. AIR FILTER 14. EXTERNAL ALARM TRIGGER
29. EDC WORK SWITCH INPUT
15. MAIN BEAM 15. POWER GROUND
30. REAR PTO BRAKE
16. ALTERNATOR LAMP 16. LOW HYD. OIL CHARGE PRESSURE 31. REAR PTO FENDER SWITCH
17. RIGHT TURN
32. THERMOSTART RELAY
18. POWER GROUND
33. REAR UPPER WORKLAMP
19. POWER GROUND
34. FRONT UPPER WORKLAMP
20. NOT USED
35. REAR PTO BRAKE SOLENOID

C081 -- 1, ENGINE OIL PRESSURE GAUGE 36. DIFFERENTIAL LOCK SOLENOID

2. +5V REFERENCE
3. RADAR
4. RADAR SENSE
5. IMPLEMENT STATUS
6. WHEEL SPEED
7. POWER GROUND
8. ENGINE OIL PRESSURE GAUGE GROUND
9. CHASSIS GROUND
10. FUEL GAUGE GROUND
11. SHUTDOWN RELAY RETURN
12. SHUTDOWN RELAY +12V FEED

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 220
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
PROCESSOR TERMINALS (C127=Red connector / C128=Black connector / C242=Black at other end)
DUAL COMMAND EDC AND TRANSMISSION SYSTEM DIAGRAM
C127 -- 1. SENSOR GROUND C128 -- 1. MED--LO IN GEAR SWITCH
2. -- 2. 3--4 IN GEAR SWITCH
1. EDC/TRANS PROCESSOR
3. -- 3. 1--2--4 IN GEAR SWITCH
2. SENSOR SIGNAL GROUND
4. -- 4. A AND B CLUTCH PRESSURE SWITCH
3. CHASSIS GROUND
5. +5 VOLT REFERENCE LINE 5. HI--RANGE BUTTON
4. POWER GROUND
5. SYSTEM DIAGNOSTICS CONNECTOR 6. WHEEL SPEED INPUT 6. FUSE 21 +12V SENSE

6. EDC CONTROL PANEL 7. IMPLEMENT STATUS 7. SHUTTLE LEVER REVERSE SWITCH

7. IMPLEMENT DEPTH AND DRAFT CONTROL UNIT 8. WHEEL SPEED OUTPUT 8. HPL CROSS--SHAFT LIFT SENSOR
8. RAISE/WORK SWITCH 9. CASE GROUND 9. DROP RATE
9. SHUTTLE LEVER NEUTRAL SWITCH 10. DUMP SOLENOID 10. DRAFT SENSITIVITY
10. START RELAY 11. FORWARD SOLENOID 11. RIGHT DRAFT PIN
11. FROM TURN SIGNAL CIRCUIT 12. HI--PWM RETURN 12. PROGRAMME ENABLE -- DIAGNOSTICS
13. REVERSE SOLENOID RETURN 13. RS232 -- OUT
14. REVERSE SOLENOID 14. SERIAL IN
15. LO--LAMP 15. RADAR
16. HI--LAMP 16. WHEEL SLIP
17. HI--PWM 17. SYNCHRO--POSITION POTENTIOMETER
18. LO--PWM 18. TRANS OIL TEMPERATURE
19. LOWER PWM 19. CLUTCH PEDAL
20. RAISE PWM 20. SHUTTLE LEVER FORWARD SWITCH
21. LOWER LAMP 21. HITCH FENDER SWITCH -- RAISE
22. RAISE LAMP 22. SERVICE -- DIAGNOSTIC CONNECTOR
23. SLIP WARNING 23. HI--MED IN GEAR SWITCH
24. LIFT STATUS LAMP 24. LO--RANGE BUTTON
25. + 8.5 VOLTS FOR DRAFT PINS 25. TRANS OIL PRESSURE SWITCH
26. -- 26. RAISE SWITCH
27. LOWER--PWM RETURN 27. NEUTRAL POSITION SWITCH INPUT
28. RAISE PWM RETURN 28. HITCH FENDER SWITCH -- DOWN
29. FUSE 12 +12V INPUT (+12VH) 29. WORK SWITCH
30. FUSE 14 +12V INPUT (+12VD) 30. POSITION CONTROL
31. FUSE 20 (CONTINUOUS + 12v SUPPLY) 31. HEIGHT LIMIT
32. POWER GROUND 32. DRAFT CONTROL
33. POWER GROUND 33. LEFT DRAFT PIN
34. FUSE 14 +12v INPUT (+12VF) 34. ENGINE RPM
35. FUSE 14 +12v INPUT (+12VF) 35. SERIAL OUT
36. FORWARD SOLENOID RETURN 36. RS232 -- IN

C242 3. SEAT SWITCH

4. HANDBRAKE ON INPUT
18. EXTERNAL BUZZER

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
RANGE COMMAND ELECTRONIC MANAGEMENT UNIT AND INSTRUMENT CLUSTER ELECTRONIC MANAGEMENT UNIT TERMINALS (C105)
1. +12V CONTINUOUS LIVE FROM FUSE 20
SYSTEM DIAGRAM
2. EXTERNAL BUZZER
1. BATTERY 13. STEERING ANGLE SENSOR
3. THERMOSTART INITIATE/PTO SOFT START
2. MAXI FUSES 14. REAR PTO SOLENOID
4. STEERING SENSOR
3. IGNITION SWITCH 15. TO RELAY A -- AIR BRAKE RELAY
4. IGNITION RELAY 16. TO TRAILER SOCKET 5. GROUND SPEED PTO SWITCH
5. RELAY E -- REAR LOWER WORKLIGHTS 17. RELAY G -- BRAKE LAMP RELAY 6. EMU DATA IN
6. RELAY D -- FRONT LOWER WORKLIGHTS 18. ELECTRONIC MANAGEMENT UNIT 7. BRAKE SWITCH -- RIGHT
7. RELAY C -- REAR UPPER WORKLIGHTS 19. SENSOR SIGNAL GROUND 8. SIDELIGHT DETECT
8. RELAY B -- FRONT UPPER WORKLIGHTS 20. CHASSIS GROUND
9. SEAT SWITCH
9. RELAY III -- THERMOSTART 21. POWER GROUND
10. EMU DATA OUT
10. DIGITAL INSTRUMENT CLUSTER 22. TRANSMISSION OIL PRESSURE
SWITCH TO C128--25 11. CASE GROUND
11. FRONT PTO SWITCH AND MODULE 23. FUEL SHUT--OFF SOLENOID 12. REAR PTO RELAY
12. PTO FENDER SWITCHES (IF FITTED) 24. TO ITALIAN TRAILER BRAKE CIRCUIT 13. REAR PTO SOLENOID
14. FOUR WHEEL DRIVE SOLENOID
INSTRUMENT CLUSTER -- TERMINALS 15. REAR PTO ON/OVERSPEED LAMP
C079 -- 1. ENGINE COOLANT TEMPERATURE C080 -- 1. ENGINE RPM 16. FRONT LOWER WORKLAMP
2. SIGNAL GROUND 2. HANDBRAKE LAMP +12V FEED
17. REAR LOWER WORKLAMP
3. +12V SWITCHED IGNITION LIVE FROM FUSE 9 3. HANDBRAKE SWITCH 18. REAR PTO MOMENTARY SWITCH
4. LEFT TURN 4. NOT USED
19. STARTER RELAY CRANKING INPUT
5. NOT USED 5. TRANSMISSION OIL TEMPERATURE
20. BRAKE SWITCH -- LEFT
6. TRAILER 1 6. FOUR WHEEL DRIVE PRESSURE SW.
21. ENGINE RPM
7. ENGINE OIL PRESSURE LAMP 7. HYD OIL TEMP / BLOCKED OIL FILTER
22. HANDBRAKE SWITCH
8. TRAILER 2 8. FOUR WHEEL DRIVE LAMP +12V FEED
23. REAR PTO SPEED SENSOR
9. FUEL GAUGE SENSOR 9. DIFFERENTIAL LOCK
24. +12V SWITCHED IGNITION LIVE FROM FUSE 15
10. +12V CONTINUOUS LIVE FROM FUSE 20 10. STEERING / TRANS. PRESSURE
25. POWER GROUND
11. BACKLIGHT POWER 11. SERIAL DATA OUT
26. WHEEL SPEED
12. NOT USED 12. SERIAL DATA IN
27. STEERING ANGLE SENSOR RETURN
13. THERMOSTART LAMP 13. POWER GROUND
28. STEERING ANGLE SENSOR +5V FEED
14. AIR FILTER 14. EXTERNAL ALARM TRIGGER
29. EDC WORK SWITCH INPUT
15. MAIN BEAM 15. POWER GROUND
30. REAR PTO BRAKE
16. ALTERNATOR LAMP 16. LOW HYD. OIL CHARGE PRESSURE 31. REAR PTO FENDER SWITCH
17. RIGHT TURN
32. THERMOSTART RELAY
18. POWER GROUND
33. REAR UPPER WORKLAMP
19. POWER GROUND
34. FRONT UPPER WORKLAMP
20. NOT USED
35. REAR PTO BRAKE SOLENOID

C081 -- 1, ENGINE OIL PRESSURE GAUGE 36. DIFFERENTIAL LOCK SOLENOID

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
RANGE COMMAND TRANSMISSION SYSTEM DIAGRAM
PROCESSOR TERMINALS (C100=Black connector / C101=Red connector)
C100 -- 1. -- C101 -- 1. SENSOR GROUND
1. START RELAY
2. CREEPER DISENGAGED SWITCH 2. TRANS MID SPEED SENSOR
2. SHUTTLE LEVER NEUTRAL SWITCH
3. -- 3. --
3. CLUTCH PEDAL SWITCH
4. FUSE 12 +12V SENSE 4. --
4. CREEPER DISENGAGED SWITCH
5. GEAR DISPLAY MODULE 5. 5. +5V REFERENCE SUPPLY

6. SYSTEM DIAGNOSTICS CONNECTOR (WHITE) 6. DOWNSHIFT SWITCH 6. TRANS OUTPUT SPEED SENSOR

7. CHASSIS GROUND 7. REVERSE SELECT SWITCH 7. --

8. POWER GROUND 8. -- 8. NOT USED

9. SENSOR SIGNAL GROUND 9. -- 9. CASE GROUND
10. TRANS OIL PRESSURE SWITCH 10. -- 10. REVERSE RANGE SOLENOID
11. SHIFT SWITCH ASSEMBLY 11. LOW/HIGH SYNCHRO POSITION POTENTIOMETER 11. CLUTCH C PWM
12. FORWARD / REVERSE SHUTTLE LEVER 12. PROGRAMME ENABLE -- DIAGNOSTICS 12. CLUTCH B PWM RETURN
13. TRANS PROCESSOR 13. RS232 OUT 13. CLUTCH D PWM RETURN
14. SERIAL DATA IN 14. CLUTCH D PWM
15. ENGINE RPM INPUT 15. MEDIUM RANGE SOLENOID
16. -- 16. FAST RANGE SOLENOID
17. RANGE SELECT SWITCH 17. CLUTCH B PWM
18. TRANSMISSION OIL TEMPERATURE 18. CLUTCH A PWM
19. CLUTCH PEDAL POTENTIOMETER 19. SLOW RANGE SOLENOID
20. FORWARD SELECT SWITCH 20. CLUTCH E PWM
21. 21. --
22. SERVICE -- DIAGNOSTIC CONNECTOR 22. --
23. -- 23. --
24. -- 24. --
25. TRANSMISSION OIL PRESSURE SWITCH 25. +8V REFERENCE SUPPLY
26. 26. CLUTCH A PWM RETURN
27. NEUTRAL SWITCH 27. --
28. HANDBRAKE ON INPUT 28. CLUTCH E PWM RETURN
29. OPERATOR PRESENT INPUT (SEAT SWITCH) 29. FUSE 13 (IGN. SWITCH) +12V (12VH)
30. -- 30. FUSE 13 (IGN. SWITCH) +12V (12VD)
31. -- 31. FUSE 20 +12V CONTINUOUS LIVE FEED
32. UPSHIFT SWITCH 32. POWER GROUND
33. MED/REV SYNCHRO POSITION POTENTIOMETER 33. POWER GROUND
34. NOT USED 34. FUSE 13 (IGN. SWITCH) +12V (12VD)
35. SERIAL DATA OUT 35. FUSE 13 (IGN. SWITCH) +12V (12VD)
36. RS232 IN 36. CLUTCH C PWM RETURN

55- 225
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 226
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
PROCESSOR TERMINALS (C127=Red connector / C128=Black connector / C242=Black at other end)
RANGE COMMAND EDC AND FRONT SUSPENSION SYSTEM DIAGRAM
C127 -- 1. SENSOR GROUND C128 -- 1. --
2. -- 2. --
1. EDC/SUSPENSION PROCESSOR
3. -- 3. --
2. SENSOR SIGNAL GROUND
4. -- 4. --
3. CHASSIS GROUND
5. +5 VOLT REFERENCE LINE 5. --
4. POWER GROUND
5. SYSTEM DIAGNOSTICS CONNECTOR 6. WHEEL SPEED INPUT 6. --

6. EDC CONTROL PANEL 7. IMPLEMENT STATUS 7. --

7. IMPLEMENT DEPTH AND DRAFT CONTROL UNIT 8. WHEEL SPEED OUTPUT 8. HPL CROSS--SHAFT LIFT SENSOR
8. RAISE/WORK SWITCH 9. CASE GROUND 9. DROP RATE
10. -- 10. DRAFT SENSITIVITY
11. -- 11. RIGHT DRAFT PIN
12. -- 12. PROGRAMME ENABLE -- DIAGNOSTICS
13. -- 13. RS232 -- OUT
14. -- 14. SERIAL IN
15. -- 15. RADAR
16. -- 16. WHEEL SLIP
17. -- 17. --
18. -- 18. --
19. LOWER PWM 19. --
20. RAISE PWM 20. --
21. LOWER LAMP 21. HITCH FENDER SWITCH -- RAISE
22. RAISE LAMP 22. SERVICE -- DIAGNOSTIC CONNECTOR
23. SLIP WARNING 23. --
24. LIFT STATUS LAMP 24. --
25. + 8.5 VOLTS FOR DRAFT PINS 25. --
26. -- 26. RAISE SWITCH
27. LOWER--PWM RETURN 27. --
28. RAISE PWM RETURN 28. HITCH FENDER SWITCH -- DOWN
29. FUSE 12 +12V INPUT (+12VH) 29. WORK SWITCH
30. -- 30. POSITION CONTROL
31. FUSE 20 (CONTINUOUS +12v SUPPLY) 31. HEIGHT LIMIT
32. POWER GROUND 32. DRAFT CONTROL
33. POWER GROUND 33. LEFT DRAFT PIN
34. FUSE 14 +12v INPUT (+12VF) 34. ENGINE RPM
35. FUSE 14 +12v INPUT (+12VF) 35. SERIAL OUT
36. -- 36. RS232 -- IN

C242 9. SUSPENSION ON/OFF SWITCH 26. SUSPENSION LOWER SOLENOID

19. SUSPENSION ON/OFF SWITCH LAMP 27. LOWER LOCKOUT SOLENOID
21. SUSPENSION LOWER SOLENOID RETURN 28. SUSPENSION RAISE SOLENOID
22. SUSPENSION RAISE SOLENOID RETURN 29. RAISE LOCKOUT SOLENOID RETURN
23. LOWER LOCKOUT SOLENOID RETURN 32. SUSPENSION POSITION POTENTIOMETER
25. RAISE LOCKOUT SOLENOID

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
POWER COMMAND ELECTRONIC MANAGEMENT UNIT AND INSTRUMENT CLUSTER ELECTRONIC MANAGEMENT UNIT TERMINALS (C105)
1. +12V CONTINUOUS LIVE FROM FUSE 20
SYSTEM DIAGRAM
2. EXTERNAL BUZZER
1. BATTERY 13. STEERING ANGLE SENSOR
3. THERMOSTART INITIATE/PTO SOFT START
2. MAXI FUSES 14. REAR PTO SOLENOID
4. STEERING SENSOR
3. IGNITION SWITCH 15. TO RELAY A -- AIR BRAKE RELAY
4. IGNITION RELAY 16. TO TRAILER SOCKET 5. GROUND SPEED PTO SWITCH
5. RELAY E -- REAR LOWER WORKLIGHTS 17. RELAY G -- BRAKE LAMP RELAY 6. EMU DATA IN
6. RELAY D -- FRONT LOWER WORKLIGHTS 18. ELECTRONIC MANAGEMENT UNIT 7. BRAKE SWITCH -- RIGHT
7. RELAY C -- REAR UPPER WORKLIGHTS 19. SENSOR SIGNAL GROUND 8. SIDELIGHT DETECT
8. RELAY B -- FRONT UPPER WORKLIGHTS 20. CHASSIS GROUND
9. SEAT SWITCH
9. RELAY III -- THERMOSTART 21. POWER GROUND
10. EMU DATA OUT
10. DIGITAL INSTRUMENT CLUSTER 22. FUEL SHUT--OFF SOLENOID
11. CASE GROUND
11. FRONT PTO SWITCH AND MODULE 23. TO ITALIAN TRAILER BRAKE CIRCUIT
12. REAR PTO RELAY
12. PTO FENDER SWITCHES (IF FITTED)
13. REAR PTO SOLENOID

INSTRUMENT CLUSTER -- TERMINALS 14. FOUR WHEEL DRIVE SOLENOID

C079 -- 1. ENGINE COOLANT TEMPERATURE C080 -- 1. ENGINE RPM 15. REAR PTO ON/OVERSPEED LAMP
2. SIGNAL GROUND 2. HANDBRAKE LAMP +12V FEED 16. FRONT LOWER WORKLAMP
3. +12V SWITCHED IGNITION LIVE FROM FUSE 9 3. HANDBRAKE SWITCH 17. REAR LOWER WORKLAMP
4. LEFT TURN 4. LOW RANGE LAMP 18. REAR PTO MOMENTARY SWITCH
5. NOT USED 5. TRANSMISSION OIL TEMPERATURE 19. STARTER RELAY CRANKING INPUT
6. TRAILER 1 6. FOUR WHEEL DRIVE PRESSURE SW. 20. BRAKE SWITCH -- LEFT
7. ENGINE OIL PRESSURE LAMP 7. HYD OIL TEMP / BLOCKED OIL FILTER 21. ENGINE RPM
8. TRAILER 2 8. FOUR WHEEL DRIVE LAMP +12V FEED 22. HANDBRAKE SWITCH
9. FUEL GAUGE SENSOR 9. DIFFERENTIAL LOCK 23. REAR PTO SPEED SENSOR
10. +12V CONTINUOUS LIVE FROM FUSE 20 10. STEERING / TRANS. PRESSURE 24. +12V SWITCHED IGNITION LIVE FROM FUSE 15
11. BACKLIGHT POWER 11. SERIAL DATA OUT 25. POWER GROUND
12. HIGH RANGE LAMP 12. SERIAL DATA IN 26. WHEEL SPEED
13. THERMOSTART LAMP 13. POWER GROUND 27. STEERING ANGLE SENSOR RETURN
14. AIR FILTER 14. EXTERNAL ALARM TRIGGER 28. STEERING ANGLE SENSOR +5V FEED
15. MAIN BEAM 15. POWER GROUND 29. EDC WORK SWITCH INPUT
16. ALTERNATOR LAMP 16. LOW HYD. OIL CHARGE PRESSURE 30. REAR PTO BRAKE
17. RIGHT TURN 31. REAR PTO FENDER SWITCH
18. POWER GROUND 32. THERMOSTART RELAY
19. POWER GROUND 33. REAR UPPER WORKLAMP
20. NOT USED 34. FRONT UPPER WORKLAMP
35. REAR PTO BRAKE SOLENOID
C081 -- 1, ENGINE OIL PRESSURE GAUGE
36. DIFFERENTIAL LOCK SOLENOID
2. +5V REFERENCE
3. RADAR
4. RADAR SENSE
5. IMPLEMENT STATUS
6. WHEEL SPEED
7. POWER GROUND
8. ENGINE OIL PRESSURE GAUGE GROUND
9. CHASSIS GROUND
10. FUEL GAUGE GROUND
11. SHUTDOWN RELAY RETURN
12. SHUTDOWN RELAY +12V FEED

55- 228
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 229
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 230
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
PROCESSOR TERMINALS (C127=Red connector / C128=Black connector / C242=Black at other end)
POWER COMMAND FRONT SUSPENSION SYSTEM DIAGRAM
C127 -- 1. C128 -- 1. --
2. -- 2. --
1. EDC/SUSPENSION PROCESSOR
3. -- 3. --
2. SENSOR SIGNAL GROUND
4. -- 4. --
3. CHASSIS GROUND
5. +5 VOLT REFERENCE LINE 5. --
4. POWER GROUND
5. SYSTEM DIAGNOSTICS CONNECTOR 6. WHEEL SPEED INPUT 6. --
7. 7. --
8. WHEEL SPEED OUTPUT 8. --
9. CASE GROUND 9. --
10. -- 10. --
11. -- 11. --
12. -- 12. PROGRAMME ENABLE -- DIAGNOSTICS
13. -- 13. RS232 -- OUT
14. -- 14. SERIAL IN
15. -- 15. RADAR
16. -- 16. --
17. -- 17. --
18. -- 18. --
19. -- 19. --
20. -- 20. --
21. -- 21. --
22. -- 22. SERVICE -- DIAGNOSTIC CONNECTOR
23. -- 23. --
24. -- 24. --
25. -- 25. --
26. -- 26. --
27. -- 27. --
28. -- 28. --
29. FUSE 12 +12V INPUT (+12VH) 29. --
30. -- 30. --
31. FUSE 20 (CONTINUOUS +12v SUPPLY) 31. --
32. POWER GROUND 32. --
33. POWER GROUND 33. --
34. FUSE 14 +12v INPUT (+12VF) 34. ENGINE RPM
35. FUSE 14 +12v INPUT (+12VF) 35. SERIAL OUT
36. -- 36. RS232 -- IN

C242 9. SUSPENSION ON/OFF SWITCH 26. SUSPENSION LOWER SOLENOID

55- 231
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

55- 232
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9
PROCESSOR TERMINALS (C100=Black connector / C101=Red connector)
POWER COMMAND EDC AND TRANSMISSION SYSTEM DIAGRAM
C100 -- 1. CLUTCH PEDAL POTENTIOMETER C101 -- 1. SENSOR GROUND
2. -- 2. TRANS OUTPUT SPEED SENSOR
1. EDC AND TRANSMISSION PROCESSOR
3. -- 3. TRANS MID SPEED SENSOR
2. CHASSIS GROUND
4. CREEPER STATUS 4. SERIAL OUT -- B
3. POWER GROUND
5. NEUTRAL SWITCH 5. SERIAL IN -- B
4. SENSOR GROUND
5. TURN INDICATOR AND HANDBRAKE BUZZER 6. PTO STATUS 6. RS232 OUT

6. GEAR DISPLAY 7. SERVICE SWITCH -- DIAGNOSTIC PLUG 7. RS232 IN

7. DIAGNOSTIC CONNECTOR 8. -- 8. --
8. STARTER RELAY 9. HANDBRAKE STATUS 9. --
9. CLUTCH PEDAL SWITCH 10. TRANSMISSION OIL PRESSURE SWITCH 10. CHASSIS GROUND
10. EDC CONTROL PANEL 11. PC ENABLE -- DIAGNOSTIC PLUG 11. ENGINE RPM / TORQUE SENSOR
11. POSITION AND DRAFT CONTROL UNIT 12. POWER GROUND 12. +5V REFERENCE
13. MID RANGE SOLENOID RETURN 13. HIGH RANGE SOLENOID
PROCESSOR TERMINALS (C239=Red connector) 14. POWER GROUND 14. FUSE 20 +12V (12VP) CONTINUOUS
C239 1. HITCH LOWER SOLENOID 15. REVERSE RANGE PRESSURE SWITCH 15. FUSE 14 +12V (12VD)
2. +8V REFERENCE 16. WHEEL SPEED OUTPUT 16. FUSE 14 +12V (12VD)
3. -- 17. ENGINE RPM 17. FUSE 14 +12V (12VS)
4. SLIP CONTROL 18. -- 18. FUSE 14 +12V (12VS)
5. EXTERNAL HITCH SWITCH -- UP 19. DOWNSHIFT SWITCH 19. FUSE 14 +12V (12VF)
6. EXTERNAL HITCH SWITCH -- DOWN 20. TRANSMISSION OIL TEMPERATURE SENDER 20. FUSE 14 +12V (12VF)
7. POWER GROUND 21. SHUTTLE LEVER FORWARD SWITCH 21. FUSE 14 +12V (12VF)
8. HIGH/MEDIUM/LOW RANGE PRESSURE SWITCHES 22. SHUTTLE LEVER REVERSE SWITCH 22. EXTERNAL ALARM
9. -- 23. UPSHIFT SWITCH 23. HITCH RAISE LAMP
10. -- 24. -- 24. POWER GROUND
11. -- 25. PTO LUBE SOLENOID RETURN 25. HITCH LOWER LAMP
12. --
26. HITCH LOWER SOLENOID RETURN 26. CLUTCH A SOLENOID
13. HEIGHT LIMIT
27. HITCH RAISE SOLENOID RETURN 27. CLUTCH B SOLENOID
14. DRAFT PIN -- RIGHT
28. -- 28. CLUTCH D SOLENOID
15. ACCELERATOR PEDAL POTENTIOMETER
29. CLUTCH E SOLENOID RETURN 29. CLUTCH C SOLENOID
16. DRAFT POSITION SETTING
30. CLUTCH D SOLENOID RETURN 30. CLUTCH E SOLENOID
17. DRAFT PIN -- LEFT
31. CLUTCH C SOLENOID RETURN 31. --
18. OPERATOR PRESENCE -- SEAT SWITCH
32. CLUTCH A SOLENOID RETURN 32. --
19. RAISE SWITCH
33. CLUTCH B SOLENOID RETURN 33. PTO LUBE SOLENOID
20. RADAR
21. IMPLEMENT STATUS 34. HIGH RANGE SOLENOID RETURN 34. REVERSE RANGE SOLENOID

22. SLIP WARNING LAMP 35. LOW RANGE SOLENOID RETURN 35. MID RANGE SOLENOID

23. HITCH STATUS LAMP 36. REVERSE RANGE SOLENOID RETURN 36. LOW RANGE SOLENOID
24. HITCH RAISE SOLENOID
25. FUSE 12 +12V (12VH)
26. --
27. --
28. SERIAL IN -- A
29. SERIAL OUT -- A
30. HPL CROSS--SHAFT POSITION SENSOR
31. WORK SWITCH
32. SERVICE BRAKE STATUS (FROM RELAY G)
33. DRAFT SENSITIVITY CONTROL
34. --
35. DROP RATE CONTROL
36. LIFT POSITION SETTING

55- 233
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

ELECTRICAL SYSTEM DIAGRAMS

55- 234
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 10 -- Component Testing

CONTENTS

Section Description Page

55 000 Thermostart Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water in Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diff. Lock Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4WD Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Transmission Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handbrake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Filter Restriction Switch (open centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PTO Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Forward / Reverse Shuttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clutch Pedal Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Range Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dual Command Lever Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Range Command Lever Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PWM Valves A,B,C,D & E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure Switches -- Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Forward / Reverse Potentiometer -- Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transmission Side Cover Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
40 Degree Switch -- CCLS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Intake Filter Restriction Switch -- CCLS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Low Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Steering Angle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Transmission Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Load Sensing Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EDC Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EDC Raise & Lower Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lift Arm Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission Range Clutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Foot Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Engine Torque/RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
Electronic Draft Control (EDC) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Multi--function Switch, Lights, Indicators, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Multi--function Switch, Wipers and Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
1. THERMOSTART DEVICE
The thermostart which is efficient at ambient
temperatures of --18° C, comprises a heating element
fitted in the intake manifold. When the thermostart is
switched on it ignites fuel in the manifold, thus heating
the air before it enters the combustion chamber.
The thermostart is activated when the key is turned
anti-clockwise. It is actioned for 20 seconds.

1
TEST PROCEDURE

Voltage
Turn the ignition key to the thermostart position. 12V
between the BROWN / RED and EARTH wires (for 18
secs only).

2
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
2. COOLANT LEVEL SENSOR
When the level of the coolant in the header tank falls
below a pre-set level, the warning lamp is illuminated.
As the switch is a normally open type, the warning lamp
must illuminate when the two wires are connected, i.e.
closed circuit.

4
TEST PROCEDURE

Voltage
12V between the BLACK / ORANGE and BLACK wire
(once contact is made).

Resistance
0.22 Ω if the level is not correct.
Circuit is open when the level is correct.

5
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
3. COOLANT TEMPERATURE SENDER
The resistance of the temperature sender changes
proportionally to the temperature of the coolant, which
makes it possible to send a modulated voltage signal
to the instrument cluster to operate the bar graph.

7
TEST PROCEDURE

Voltage
5V between the GREEN / BLUE and EARTH.

Resistance
4500--6000 Ω Engine cold
Less than 650 Ω Engine hot

8
ASSOCIATED ERROR CODES/ E.I.C. 7 and 12
WARNING LAMPS

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
4. ALTERNATOR
This sends a square wave signal, the frequency of
which varies between 142.5 and 855 Hz
(480--3060 rpm) to the microprocessor and to the
instrument panel.
With the engine running, the warning light should go
out. If not, disconnect the wire connected to terminal
D+. When D+ is not connected and the warning light
goes out, there is a fault with the alternator. If it does not
go out, then check the bulb and the wiring loom.

9
TEST PROCEDURE

10
READING THE FREQUENCY ENGINE SPEED FREQUENCY
(AT TERMINAL W) (RPM) (Hz)
1000 300
1500 430
2000 560
2300 660

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
5. ENGINE OIL PRESSURE SWITCH
If the engine oil pressure drops below 0.68 bar, the
warning lamp is illuminated.
As the switch is a normally open type, the warning lamp
is illuminated when the ignition is switched on and the
engine is not running.

11
TEST PROCEDURE

Voltage
12V between the WHITE / BROWN and EARTH wires.

12
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
6. ENGINE OIL PRESSURE SENDER
The resistance of the oil pressure sender varies
proportionally with the engine oil pressure, which
makes it possible to send a modulated voltage signal
to the instrument cluster to operate the engine oil
pressure bar graph (EIC only).

13
TEST PROCEDURE

Voltage
5V between the GREEN / PINK and EARTH wires.
Resistance of sender:

A B

-- Between pins A and B 26 kΩ

-- Between pins B and C 34 kΩ
-- Between pins A and C 26 kΩ
14

ASSOCIATED ERROR CODES/ DISPLAY PRESSURE

WARNING LAMPS
1 bar 0--0.5 bar
Relationship between Engine Oil Pressure and the
Instrument Cluster Bar Graph Display. 12 bar 6.1--6.7 bar

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
7. AIR FILTER RESTRICTION SWITCH
The warning lamp will illuminate when the switch has
been closed for 5 seconds.
When the vacuum pressure on the engine side of the
air intake filter exceeds 46.7 mm Hg. the warning lamp
is illuminated. This is a normally open switch.

15
TEST PROCEDURE

Voltage
12V between the BLACK / GREY and BLACK wires.

Checking the Switch

Removing the rubber plug and pressing against the
bottom of the switch with a suitable probe should cause
the switch to close.

16
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
8. BATTERIES
The batteries fitted to the tractor are LEAD/CADMIUM
batteries.
If the batteries become discharged to such an extent
that the voltage is less than 7V, then they should be
re-charged using the procedure outlined in the table
below.

CHARACTERISTICS 70 Ah Batteries 95 Ah Batteries

(750 cca) (900 cca)
30 minutes at 35 30 minutes 48A
then then
18 hours at 5A 25 hours at 5A
or or
9 hours at 10A 12 hours at 10A

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
9. WATER IN FUEL SENSOR
The sensor illuminates a warning lamp when water is
sensed in the fuel filter.
Whenever the warning lamp is illuminated, stop the
tractor and service the fuel filters, to prevent damage
to the injection circuit.

Checking the Sensor

Place the shuttle lever in neutral, the clutch pedal
must be released, then turn the start key to the run
position and release the key.
Placing the sensor in a metal container which is filled
with water and earthed to the tractor, this should cause
the warning lamp to illuminate.
19
TEST PROCEDURE

Voltage
12V between the BLACK wire and an EARTH.

20
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
10. DIFFERENTIAL LOCK PRESSURE
SWITCH
When the differential lock is engaged, the supply pipes
are pressurised with oil at 16 BARS pressure causing
the warning lamp to illuminate. This is a normally open
pressure switch.
With the ignition switched on and the engine not
running, the warning lamp should not illuminate,
irrespective of whether or not the diff. lock has been
selected.
With the engine running and manual diff. lock feature
selected, the warning lamp should illuminate.

23
TEST PROCEDURE

Voltage
12V between the YELLOW / BLACK and BLACK
wires.

24
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
11. FOUR WHEEL DRIVE PRESSURE
SWITCH
When the four wheel drive is engaged, pressure oil at
16 bar will be absent in the supply line to the four wheel
drive clutch and the warning lamp will be illuminated.
This is a normally closed pressure switch.
With the ignition switched on and the engine not
running, the warning lamp should be illuminated,
irrespective of whether or not the four wheel drive has
been selected.

26
With the engine running, the four wheel drive may be
either engaged or disengaged dependant on:
(1) whether the parking brake is applied,
(2) the brake pedals applied
(3) the four wheel drive is selected on the EMU.

27
TEST PROCEDURE

Voltage
12V between the YELLOW / BLUE / GREY and
BLACK wires.

28
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 13
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
12. LOW TRANSMISSION OIL PRESSURE
SWITCH
If the transmission oil pressure drops below 11 bars,
the warning lamp will be illuminated. This is a normally
closed pressure switch.
When there is no pressure in the system, contact is
made between the 2 terminals of the switch.

31
TEST PROCEDURE

Voltage
12V between the YELLOW / ORANGE and BLACK
wires.

32
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
13. BRAKE FLUID LEVEL SWITCH
When the fluid level drops below the minimum level, a
warning lamp is illuminated. This is a normally open
switch.

Checking the Switch

Place the shuttle lever in neutral, the clutch pedal
must be released, then turn the start key to the run
position and release the key.

34
TEST PROCEDURE

Voltage
12V between the PINK / RED / BLACK and the
PURPLE / GREY wires.

Resistance
If the level is correct, the circuit is open.
If the level is too low, the circuit is closed.

35
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 15
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
14. HAND BRAKE SWITCH
When the handbrake has been applied, the switch will
be closed and the warning lamp is illuminated.
An alarm will be triggered if wheel movement of more
than 0.8 km/h is detected when the handbrake has
been applied and the ignition is switched on.
This alarm is also activated for 2 minutes when the
ignition has been switched off and the handbrake has
not been applied.
NOTE: The four wheel drive is always engaged when
the handbrake has been applied.

36
TEST PROCEDURE

Voltage
NOTE: The orange and white wire (or blue on the side
of the switch) is only connected where the “Italian”
trailer braking system is fitted.

37
WIRE WIRE BRAKE RELEASED
HARNESS SWITCH
Ignition Ignition
SIDE SIDE
Off On
red/white-- grey--black 5V 12V
black
Testing the “Disconnected” Switch

Brake ’ON’ Brake ’Released’

Blue Blue
Black Black
Grey Grey

Continuity Black/Blue Continuity Black/Grey

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
15. FUEL SENDER
The signal from the fuel sender potentiometer
determines the fuel level displayed on the instrument
cluster gauge.

39
TEST PROCEDURE

Voltage
5 / 7 VOLTS between the GREEN / BLACK and the
EARTH wire OR the GREEN / WHITE / BLACK and
the EARTH wire.

40
Resistance TRANSMITTER GAUGE
RESISTANCE INDICATION
31 -- 49 Ω FULL
230 -- 250 Ω EMPTY

ASSOCIATED ERROR CODES/ 3 and 4

WARNING LAMPS E.I.C. Codes

55- 17
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
16. OIL FILTER RESTRICTION SWITCH
(OPEN CENTRE)
When the suction pressure on the pump side of the
filter exceeds 406 mm Hg (5812 mm H2O), the
vacuum switch illuminates the warning lamp. This is a
normally open switch.

41
TEST PROCEDURE

Voltage
12V between the BROWN / BLACK and EARTH
wires.

42
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
17. POWER TAKE-OFF SPEED SENSOR
This sensor sends a frequency signal to the instrument
cluster to display the speed of the power take-off.
The speed displayed is the actual power take-off speed
in RPM.

44
TEST PROCEDURE

Voltage
5 VOLTS between the BLACK / ORANGE / GREY and
the BLACK wires.

Resistance
680 Ω between the BLACK / ORANGE / GREY and
the BLACK wires.

45
Frequency SPEED FREQUENCY
RPM Hz
400 83
500 102
600 122
700 141
800 160
900 180
1000 200
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
18. FORWARD / REVERSE SHUTTLE LEVER
The shuttle lever is operated by lifting it against the
action of the return spring and moving it into one of two
positions: forward or reverse.
NOTE: Initial engagement of the transmission can only
be achieved when the clutch pedal is cycled.

47
TEST PROCEDURE
TEST AT THE MALE PLUG OF THE SHUTTLE
LEVER
Place shuttle lever in forward and measure the
resistance between:
Pins 1 and 2 : 560 Ω
Pins 1 and 3 : 2.7 -- 2.8 kΩ
Pins 2 and 3 : 0Ω
Pins 4 and 6 : 3.25 Ω
Place shuttle lever in neutral and measure between:
Pins 1 and 2 : 2.7 -- 2.8 Ω
Pins 1 and 3 : 2.7 -- 2.8 kΩ
Pins 2 and 3 : 5.4 kΩ 48
Pins 4 and 5 : 0Ω
Place shuttle lever in reverse and measure between:
Pins 1 and 2 : 2.7 -- 2.8 kΩ
Pins 1 and 3 : 560 Ω
Pins 2 and 3 : 3.25 kΩ
Pins 4 and 6 : 0Ω

55- 20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
18. FORWARD / REVERSE SHUTTLE LEVER

TEST PROCEDURE
Voltage PIN Approximate Voltage (V)
With the ignition switched ON Number
N mber
N F R
1 1.5 1.5 3.4
2 1.5 3.4 1.5
3 5.03 5.03 5.03
4 12.34 12.3 12.3
5 0.7 0.0 0.0
6 0.7 12.3 12.3
Resistance
-- When the lever is in neutral
Measure:
5.48 K Ω between pins 1 and 2
2.7 K Ω between pins 1 and 3
There should be continuity between pins 5 and 6
-- When the lever is in the forward or reverse position
There should be continuity between pins 5 and 6

ASSOCIATED ERROR CODES/ F59, F66, F67, F68, F69

WARNING LAMPS

55- 21
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
19. CLUTCH PEDAL POTENTIOMETER
Provides operator controlled engagement of the
fetahering clutches.

50
TEST PROCEDURE

Voltage
+5 volts between Pin 1 and EARTH.

Resistance
The resistance between Pins 2 and 3 varies between
900--1000 Ω when the pedal is depressed and 3.7 K
ohms when the pedal is released.

51
ASSOCIATED ERROR CODES/ F11 and F12
WARNING LAMPS CP -- F11 -- F12 -- F53 -- F54

55- 22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
20. CLUTCH PEDAL DISCONNECT SWITCH
Disengages the power to the clutch PWM valves.

52
TEST PROCEDURE

Switch
There should be continuity between the 2 central pins
(2 & 3) when the switch is not activated.
When activated, there should be continuity between
the 2 outer pins (1 & 4).

Voltage
With the ignition switched on, there should be 0.75 V
at pins 2 and 4.

54
ASSOCIATED ERROR CODES/ F37 -- F47 -- F48
WARNING LAMPS

55- 23
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
21. RADAR
This detects the forward and reverse speeds of the
tractor and sends a signal to the instrument cluster to
display the tractors speed, the percentage of wheel
slip, the distance and the cumulative total area worked.

56
TEST PROCEDURE

Voltage
Harness side
1 : Earth
2 : Frequency Signal
3 : Supply Voltage (1)
4 : Radar Diagnostics (2)
(3)
(4)

57
Relationship between Frequency and Speed FREQUENCY SPEED
Values can be read at connector C122 (located (Hz) (km/h)
beneath EDC panel) between the green wire with red 0 0
female end and earth.
550 15
1100 30
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
21. RANGE COMMAND POTENTIOMETER
TEST PROCEDURE

60
Voltage
Harness side
1 : 8V
2 : Earth
3 : Nothing
61
Resistance

62
Test between the following wires Red/Green Red/Yellow Yellow/Green
Potentiometer at rest against spring 1.8 kΩ 5.6 kΩ 4.6 kΩ
Potentiometer turned full travel 5.8 kΩ 1.2 kΩ 4.6 kΩ

ASSOCIATED ERROR CODES/ F41, F42, F43, F44, F45

WARNING LAMPS

55- 25
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
23 and 24. TRANSMISSION SPEED
SENSORS
The first of these sensors is located in the rear axle and
detects the transmission speed (wheel speed),
sending a signal to the instrument cluster so that the
forward speed, distance and cumulative total area
worked can be displayed.
If the tractor is fitted with a radar, the signal from the
transmission speed sensor is only used for the
calculation of the percentage wheel slip.

63
Two other sensors, which are identical to the first, are
located in the semi powershift transmission. One is
located in the speed section and the other in the range
section. These send frequency signals to allow the
microprocessor to manage the transmission.

64
TEST PROCEDURE

Resistance
There should be a resistance of between 800 Ω and
1.2 kΩ measured between wires 1 and 2.

65
ASSOCIATED ERROR CODES/
WARNING LAMPS
E3, E4, E5, E49
E.I.C : 9, 10
F49, F50, F75, F77 (speed sensors)
F73, F74, F75, F78 (intermediate sensors)

55- 26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
25. DUAL COMMAND (HI / LO) SELECTION
LEVER
1. Hare
2. Tortoise

67
TEST PROCEDURE

Continuity Check

68
Neutral Tortoise Hare
Red/Green Open Circuit Closed Circuit Open Circuit
Red/Blue Open Circuit Open Circuit Closed Circuit
Green/Blue Open Circuit Open Circuit Open Circuit

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 27
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
26. RANGE COMMAND (SEMI POWERSHIFT)
SPEED AND RANGE SELECTOR LEVER
1. Tortoise
2. Hare
3. Range Selector

70
TEST PROCEDURE

Resistance Check (at the male connector of the

gear control lever)

G
P
U
B

71
Released Pressed
Black/Blue (B/U) 2.7 -- 2.8kΩ 560Ω Range Button
Black/Green (B/G) 2.7 -- 2.8kΩ 560Ω Up Shift Button
Black/Purple (B/P) 2.7 -- 2.8kΩ 560Ω Down Shift Button

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
27. PWM SOLENOID VALVES A,B,C,D & E
RANGE COMMAND

TEST PROCEDURE

Resistance
The resistance of the solenoid coil, measured at the
terminals should be between 8 and 11 Ω .

Frequency
The supply signal has a frequency of 500 Hz which can
also be measured at the solenoid terminals.

Voltage/Current
CLUTCH: A and B
The average voltage is 7.5--8 VOLTS.
The average current is 300--800 MILLIAMPERES.
WARNING
These values may differ with filling time and clutch
calibration

73
ASSOCIATED ERROR CODES/ FC A, FC B, FC C, FC D, FC E,
WARNING LAMPS F1 A, F1 B, F1 C, F1 D, F1 E,
F2 A, F2 B, F2 C, F2 D, F2 E,
F21, F24

55- 29
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
28. PWM SOLENOID VALVES A,B,C,D & E
AND FAST/SLOW/MEDIUM/REVERSE
POWER COMMAND

74
TEST PROCEDURE

Resistance
The resistance of the solenoid coil, measured at the
terminals should be between 8 and 11 Ω .

Frequency
The supply signal has a frequency of 500 Hz which can
also be measured at the solenoid terminals.

Voltage/Current
The average clutch supply voltage is 7.5--8 VOLTS.
The average current is 300--800 MILLIAMPERES.
WARNING
These values may differ with filling time and clutch
calibration

75
ASSOCIATED ERROR CODES/ F21, F24, F84, F85, F1A, F1B, F1C, F1D, F1E, F1F,
WARNING LAMPS F1H, F1J, F1L, F1U, F2A, F2B, F2C, F2D, F2E, F2F,
F2H, F2J, F2L, F2U, FCA, FCB, FCC, FCD, FCE,
FCH, FCJ, FCL, FCU

55- 30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
29. PWM SOLENOID VALVES HIGH/LOW
DUAL COMMAND

76
TEST PROCEDURE

Resistance
The resistance of the solenoid coil, measured at the
terminals should be between 8 and 11 Ω .

Frequency
The supply signal has a frequency of 500 Hz which can
also be measured at the solenoid terminals.

Voltage/Current
The average clutch supply voltage is 7.5--8 VOLTS.
The average clutch supply current is 300--800
MILLIAMPERES.
WARNING
These values may differ with filling time and clutch
calibration

ASSOCIATED ERROR CODES/ F24

WARNING LAMPS

55- 31
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
30. PRESSURE SWITCHES A AND B
(DUAL COMMAND)

77
TEST PROCEDURE

Ignition ON
NOTE: Switch is normally closed.

Voltage
Pressure Switch A (C159):
12 volts between wires TQ/N/B and earth
Pressure Switch B (C160):
12 volts between wire G and earth.

78
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 32
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
31. FORWARD / REVERSE SYNCHRONISER
POTENTIOMETER

79
TEST PROCEDURE

Voltage
5 volts between the LIGHT BROWN (LN) wire and
EARTH.

Resistance
The resistance of the potentiometer when manually
operated and measured between the GREEN and
ORANGE wires varies between 1.0 k Ω and 3.7 k Ω.

80
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 33
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
32. SOLENOID VALVES
All models
Transmission, FWD, PTO, PTO Brake, Diff. Lock, PTO
Lube, Creep, Dump

81
TEST PROCEDURE

Voltage
When energised the voltage, measured at the
terminals should be 12V and when de-energised
should read 0V.

Resistance
The resistance of the solenoid coil, measured at the
terminals should be between 6 Ω and 8 Ω.

83
ASSOCIATED ERROR CODES/ All models
WARNING LAMPS PTO: P07, P08, P11
PTO Brake: P01, P02, P03, P04
Diff. Lock: P15, P16, P17, P18
4WD: P21, P22, P23, P24

Range Command
F1P, F1L, F1U, F1H

55- 34
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
33. 40 DEGREE SWITCH -- CCLS PUMP
When the transmission oil temperature exceeds 40° C,
this switch enables the oil filter restriction switch. This
is a normally open thermocontact.

84
TEST PROCEDURE
To check the switch, submerge it in oil. If the
temperature of the oil is in excess of 40° C, the switch
should close and there should be continuity between
the two terminals.

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 35
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
34. INTAKE FILTER RESTRICTION SWITCH
(CCLS PUMP)
When the suction pressure on the pump side of the
filter exceeds 406 mm Hg. the switch illuminates a
warning lamp. This is a normally open switch.
NOTE: This switch will not operate the warning lamp
until the oil has reached 40 degrees centigrade
(i.e. when the 40 degree switch closes to complete the
circuit).

86
TEST PROCEDURE

Voltage
There should be 12V between the BROWN / BLACK
and EARTH wires.

Switch
To check the switch, dismantle it and check that there
is not contact between its two pins.

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 36
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
35. LOW CHARGE PRESSURE SWITCH
(CCLS PUMP)
If the charge pressure drops below 0.8 BAR, it will
cause the warning lamp to flash. The warning lamp will
flash when the switch has been closed for 5
SECONDS. This is a normally closed switch.

87
TEST PROCEDURE

Voltage
The voltage measured between RED / BROWN and
EARTH should be 12 V.

Pressure Switch
Contact must be established between the connection
socket and pressure switch.

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 37
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
36. STEERING ANGLE POTENTIOMETER
(supply voltage = 5V)

TEST PROCEDURE
Resistance
Using a multimeter, check that the resistances
between the wires of the potentiometer are as follows:
90
The values in the table have been read off with the
steering stops in contact and adjusted to 45 mm.

Cables Resistance (kΩ)

Red/Black 4.75kΩ
Black/Yellow 30 Ω to 4.75kΩ
Yellow/Red 4.75 kΩ to 30Ω

ASSOCIATED ERROR CODES/

WARNING LAMPS

55- 38
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
37. BRAKE SWITCHES
When either brake pedal is applied, the relevant switch
closes, causing the brake lights to illuminate. These
switches, when closed, also send a signal to the EMU
for the operation of the four wheel drive, diff. lock and
air brakes. This is a normally open switch.

92
TEST PROCEDURE

Voltage

93
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 39
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
38. TRANSMISSION OIL TEMPERATURE
SENSOR

94
TEST PROCEDURE

Resistance

Temp 0° C 25° C 40° C

Resistance Ω 1140 min -- 1339 max 460 min -- 540 max 285 min -- 334 max

ASSOCIATED ERROR CODES/ F51

WARNING LAMPS

55- 40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
39. LOAD SENSING PINS
-- 60 kN pins
-- The fixing flange ensures correct pin orientation.

96
TEST PROCEDURE
1. Supply 8.5 V
Resistance
Between:
1 and 3 9.17 kΩ
1 and 2 178 kΩ
2 and 3 178 kΩ 2. Signal
NOTE: These values will change slightly with
temperature.
The signal voltage is always 1/2 of the supply voltage,
when there is no load on the pin. 3. Earth

97
ASSOCIATED ERROR CODES/ -- right side : 14, 15
WARNING LAMPS -- left side : 16, 17
: 18, 19 and 20
(load/pressure control)

55- 41
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
40. EDC CONTROL UNIT
-- The resistance of the potentiometer changes as
the lever is moved
-- Its signal is continuously monitored by the
microprocessor.

TEST PROCEDURE
Continuity Between Pins E & F for Raise and Lower
Switches.
Continuity Between Pins G & F for Work Switch.
Resistance for Draft Wheel, between Pins B & D,
wheel on Zero = 0.1 KΩ Ω
wheel on 10 = 0.45KΩ Ω
Resistance for Position lever, between Pins A & D, 98
Lever at Zero = 0.15KΩ Ω
Lever at 10 = 0.52KΩ Ω

99
Voltage at C240
+12v on Pin F (R/LG/B)
+5v on Pin C (LN)

100
ASSOCIATED ERROR CODES/ E 25, E 26
WARNING LAMPS

55- 42
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
41. LOWERING SOLENOID -- EDC VALVE

42. RAISING SOLENOID -- EDC VALVE

101

102
TEST PROCEDURE

Resistance
The resistance of each of the solenoids should be
between 6 and 8 Ω

Frequency
The signal frequency should be 83 Hz.

Voltage/Intensity
The average voltage, amperage and cyclic ratio
change in relation to the position of the lift arm lowering
speed potentiometer. 103
ASSOCIATED ERROR CODES/
WARNING LAMPS

55- 43
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
43. LIFT ARM (CROSS SHAFT)
POTENTIOMETER
-- Mounted on the lift arm
-- Informs the microprocessor of the lift arm position.

104

-- C052

105
TEST PROCEDURE
Resistance (at potentiometer connector)

Between Arms Arms

Pins: Lowered Raised
1&3 4.4 Ω 4.4 Ω
1&2 3.9 Ω 1.5 Ω
2&3 1.2 Ω 3.7 Ω
ASSOCIATED ERROR CODES/ E 24, E 27, E 28
WARNING LAMPS

55- 44
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
44. TRANSMISSION RANGE CLUTCH
PRESSURE SWITCH
When a range clutch supply gallery pressure drops
below 16 Bar the switch closes and triggers an error
code. This is a normally open switch.

106

107

108
ASSOCIATED ERROR CODES/ F84, F85
WARNING LAMPS

55- 45
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
45. FOOT THROTTLE POTENTIOMETER
Determines a preset throttle.
Position, only functional when in auto function mode to
assist in determining auto shifts.

109
TEST PROCEDURE

Voltage
+5 volts between Pin 1 and EARTH.

Resistance
The resistance between Pins 2 and 3 varies between
900--1000 Ω when the pedal is depressed and 3.7 K
ohms when the pedal is released.

110
ASSOCIATED ERROR CODES/ F82, F83
WARNING LAMPS

55- 46
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
46. ENGINE TORQUE/RPM SENSOR
Measures torque by means of flywheel damper spring
deflection.
Depending on the torque being transmitted will assist
in determining when gear shift will occur.

111
TEST PROCEDURE
Resistance
There should be a resistance of between 800 Ω and 1.2
kΩ measured between pins 1 and 2.

112
ASSOCIATED ERROR CODES/ F27, F70, F71, F72, F76, F79
WARNING LAMPS

55- 47
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
47. ELECTRONIC DRAFT CONTROL PANEL

Potentiometer Connector (C120)

Voltage Check
5V between LIGHT BROWN and EARTH 12V
between RED/LIGHT GREEN/BLACK and EARTH.

113
Slip Connection (C121)
No voltage is present from loom.

Resistance
Panel connector -- see table for typical approximate
values.

114
Panel Light Connector (C122)
Voltage when EDC solenoids function.

115

116

55- 48
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
ASSOCIATED ERROR CODES EDC 12 Drop rate control potentiometer/circuit -- open
EDC 2 Poor or no signal from tractor performance circuit or shorted to chasses.
monitor radar. EDC 13 Drop rate control potentiometer/circuit
EDC 6 Slip control potentiometer failure, open circuir shorted to supply voltage.
or shorted to chasses. EDC 21 Position/draft control sensitivity control
EDC 7 Slip control potentiometer failure or circuit potentiometer/circuit -- open circuit or shorted
shorted to supply voltage. to chassis.
EDC 10 Height limit control potentiometer/circuit -- EDC 22 Position/draft control sensitivity control
open circuit or shorted to chassis. potentiometer/circuit shorted to supply
voltage.
EDC 11 Height limit control potentiometer/circuit
shorted to supply voltage. EDC 30 Circuit failure to EDC controlpanel.

EDC Panel Potentiometer and Printed Circuit Board Check, With and Less Slip
EDC Panel EDC Panel Potentiometer Typical Resistance Ω
Connecting, Connection, Potentiometer Setting
Pin No. Pin No. Anti-Clockwise -- Clockwise
C120, 1 C121, 1 Slip (1) 333¦10 95¦10
C120, 1 C120, 2 Drop Rate (3) 333¦10 95¦10 W/Slip
418¦10 95¦10 L/Slip
C120, 3 Draft Position 333¦10 95¦10 W/Slip
Mix (2) 418¦10 95¦10 L/Slip
C120, 7 Height (4) 333¦10 95¦10 W/Slip
505¦15 180¦10 L/Slip
C120, 1 C120, 4 -- 341¦100 W/Slip
455¦100 L/Slip
C120, 5 C120, 8 Read Manual Light 13¦5
C121, 3 C120, 5 Slip Light 14¦5
C120, 8 Slip and Read Manual Light 27¦5
C122, 1 C122, 2 Up light 13¦5
C122, 3 C122, 4 Down Light 13¦5

55- 49
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
48. MULTIFUNCTION SWITCH
LIGHTS/INDICATORS/HORN
Multifunction switch controls lights and indicators

117

118
TEST PROCEDURE

Voltage
12V at BROWN, GREEN, LIGHT GREEN/BROWN
wires to EARTH.
Pin Loom Switch Function
No. Side Side
C074 C074
1 R R Side light
2 G/W LU Right hand indicator
3 G/R LU/B Left hand indicator
119
4 U/W B Main beam
5 N 12V S Supply -- side lights,
dip, main
6 LG/N 12V W/B Supply -- indicators
7 U/R S/B Dip beam
8 G 12V P/B Supply -- Horn,
Flash
9 P P Horn

120

55- 50
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
49. MULTIFUNCTION WIPER/WASHER
SWITCH
Multifunctions switch controls wipers, washer and horn

121

122

123

124

55- 51
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
TEST PROCEDURE

Voltage Test

Pin No. Wire Colour Wire Colour Function Voltage at C073

Connector Connector Multifunction Switch
C073 C073
Loom Side Switch Side With C088, With C088,
Wiper Motor Wiper Motor
Connected Disconnected
1 LG/O N Intermittent Wipe 1.5 1.5
2 R/LG S Slow Wipe 12 0
3 W/LG U Fast Wipe 12 0
4 G/O/B W Park Wipers 0 0
5 LG/U U/R Easher 12 12
6 B R Earth 0 0

Continuity Test
Pin No. Function Selected Continuity to Pin
6 Intermittent Wipe 1
6 Slow Wipe 2
6 Fast Wipe 3
6 Wash 5
5 Wash in Intermittent 1
5 Wash in Slow Wipe 2
5 Wash in Fast Wipe 3
2 Off 4
2 Intermittent 4

55- 52
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 11 -- Diagnostic H Routines

CONTENTS

Section Description Page

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Range Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dual Command Transmission “H” Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electronic Draft Diagnostic Test Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

55- 1
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
INTRODUCTION
The TM Range of tractors has a built in diagnostic
system.
To gain access to the diagnostic “H” menu mode
routine it is necessary to use the diagnostic test switch,
Tool 4FT950, in the tractor diagnostic connectors
(C125) located behind the Electronic Draft Control
panel.

1
The information for the “H” menus is displayed in one
of the following displays.
1. Power Command -- Gear Display
2. Range Command -- Gear Display
3. Dual Command --
EIC Lower Central Display
AEIC Upper LCD Display
4. Electronic Draft Control --
EIC -- Upper Right Hand LCD Display
AEIC -- Upper LCD Display

2
Connect Tool No. 4FT950 to the diagnostic connector
and turn the key start switch to ON.
The relevant display will show “HH” to indicate that the
“H” menu has been activated.

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Power Command Transmission “H” Routine
The “H” Routine consists of the following menu codes:
HH Transmission Service Menu
H1 Clutch calibration
H2 View clutch calibration
H3 Clutch calibration temperature review
H4 Software revision level
H5 Switch test
H6 External Hand Brake Loud Buzzer
Control 4
H7 Not used
H8 Non volatile memory reset
H9 Voltmeter
HA Clutch pedal position view (%)
HB Display of stored Error Codes
HC Clear stored Error Codes
HD Display of Live Error Codes
HE Quickfill duration adjustment
HF Not used
HJ Clutch pressure test mode
HL Clutch calibration adjustment mode

55- 3
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H1 CLUTCH AND SYNCHRONISER
CALIBRATION
Used to calibrate the 9 clutch packs. See Transmission
Calibration section for details.

5
Park the tractor on level ground, away from obstacles
(in case of unexpected tractor movement).
Apply handbrake, switch off all electrical equipment
and air conditioning if fitted. Stop the engine and place
remote levers in neutral and lower hydraulic equipment
to the ground.
Place the shuttle in neutral.
Either, (i) Install tool 4FT.950 into the diagnostic plug
or (ii) press and hold both Up/down shift buttons and
start the engine. Select H1 by depressing the
diagnostic switch once.

6
Release the buttons. The display will change to show
transmission temperature. Press the up or downshift
button to proceed.
If the temperature is less than 10°C Error Code ‘U19’
will be displayed. If the temperature is between 10°C
and 60°C ‘‘CL” will be displayed. If the temperature is
to high, above 105°C, ‘‘CH” will be displayed.
If ‘U19’ is displayed calibration will not be possible and
the oil will have to be warmed before proceeding.

7
If ‘CL’ or ‘CH’ are displayed after 4 seconds the display
will return to oil temperature and the tractor may be
operated to obtain the correct transmission oil
temperature. If it is not practical to wait for the oil
temperature to change press either of the up or down
shift buttons while ‘CL’ or ‘CH’ is being displayed. The
display will then show an ‘A’ and calibration can
proceed.
Move the shuttle lever to forward and release the
clutch pedal.
Set engine speed to 1200 ERPM ±100.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
The transmission is now ready for calibration.
Press and hold the downshift button to calibrate clutch
A.
If the start up procedure was incorrect a ‘‘U” code will
appear.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

9
Release the downshift button, the display will change
to ‘b’, indicating that clutch B is ready for calibration.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

10
Repeat the above steps for clutches C, D, E and F1(S),
F2(M), F3(F) and R. After clutch R has been calibrated,
release the downshift button and the display will
change to F.
Turn the key start switch off for at least 2 seconds to
store the calibration values.
NOTE: Transmission output speed, seat switch, hand
brake switch and clutch pedal position are constantly
monitored. Calibration cannot proceed unless the
tractor is stationary and the clutch pedal released.
Repeatedly depressing the upshift button will cycle
through each clutch mode, enabling a particular clutch
to be calibrated several times if required.
11

55- 5
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
AUTOMATIC CALIBRATION SEQUENCE
MODE:
When the tractor is set up correctly for the calibration
sequence, ie, H1 selected or upshift and downshift
buttons applied simultaneously, forward selected and
the display showing ’A’, (to calibrate clutch A), pressing
the AUTO FUNCTION pushbutton will start the
automatic calibration sequence.
Both the FIELD and TRANSPORT indicator lamps will
flash while in this mode. The clutches will be calibrated
one by one without the need to keep the downshift
button depressed.

12
If an error occurs while in auto mode the sequence is
stopped and the relevant code displayed. Press the
auto function pushbutton or the upshift/downshift
pushbuttons to clear the error.
NOTE: In ’automatic calibration sequence’ the seat
switch is constantly monitored, if the operator leaves
the seat the sequence will be stopped.
CAUTION
The tractor is drivable even if calibration has not been
completed. Pay attention in this condition as the tractor
could be jerky or sluggish. Always pull away using the
clutch pedal very carefully.

13
CALIBRATION ERRORS
U19 Oil temperature below 10°C
U21 Engine RPM too low
U22 Engine RPM too high
U23 Shuttle lever is in neutral
U26 Clutch pedal is not released
U31 Output speed sensed -- tractor is moving
U33 Handbrake not applied
U34 Seat switch not activated
U36 Maximum allowed clutch calibration value exceeded
U37 ERPM dropped too soon during clutch cal
CALIBRATION MESSAGES
CH Oil temperature above 105°C -- Press upshift to proceed
CL Oil temperature between 10 and 60°C -- press upshift to proceed

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H2 VIEW CLUTCH CALIBRATIONS
Here each clutch calibration is displayed

14
Clutch “A” and then its calibration number is displayed.

15
Progress through by pressing the upshift button.

55- 7
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H3 CLUTCH CALIBRATION TEMPERATURE
VIEW
Shows the transmission temperature when each
clutch was last calibrated.

17
Displays “A” first with temperature

18
To progress through press the upshift button.

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H4 SOFTWARE REVISION LEVEL
Display the software installed into the processor.

20
The display shows four figures consecutively:
BA Full Powershift
01 Production software level
00 Prototype software level
30/40 Transmission type, 30 or 40 kph

21
H5 SWITCH TEST
It is possible in “H5” to test the function of all switches
used in the transmission electrical system.

22
The display will show a code number.

55- 9
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
When a switch is operated, its code will be displayed
and an audible tone heard to indicate correct function.
If a switch’s code is not displayed and the tone not
heard, then the switch is not functioning correctly or the
wiring to it is at fault.

Identifier Switch/Input Special Requirements

d20 Clutch pedal potentiometer
d21 Clutch pedal switch Shuttle lever in forward
d22 Forward switch Clutch pedal down
d23 Reverse switch Clutch pedal down
d24 Downshift switch
d25 Upshift switch
d29 Oil Temperature switch (transmission) Disconnect and bridge circuit
d30 Oil pressure switch (transmission) Disconnect and bridge circuit
d31 Creeper switch
d36 Seat switch
d37 Automatic function switch
d38 Brake pedal switches
d39 Handbrake switch
d40 Accelerator potentiometer
d41 PTO switch
d42 Forward pressure switch
d43 Reverse pressure switch

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H6 HANDBRAKE LOUD BUZZER CONTROL
This mode is used to switch ON/OFF the external
handbrake Loud buzzer.

25
0 HB: Buzzer disabled
1 HB: Buzzer enabled
Use the up/down shift push buttons to change the
selection.

26
H7 NOT USED
H7 will be displayed when cycling through the H menu
but does not have a function.

27
H8 NON VOLATILE MEMORY RESET
Used to reset (clear) all calibration figures in the
processor.

55- 11
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
With H8 selected the procedure is automatic.
The display changes from “H8” to “EE” to “HH”,
indicating the processor is now reset.
NOTE: All calibrations will need to be performed
following an H8 operation.

29
H9 VOLT METER
Allows various voltage tests to be carried out on the
inputs and outputs of the Transmission Control Module
(TCM).
If an intermittent fault is exhibited within a particular
circuit, a ’wiggle’ test can be performed on the related
wiring whilst watching the display for sudden changes
in values, to help isolate the area where the fault lies.

30
There are 26 channels which can be accessed.
Use the upshift button to select the required channel.
NOTE: Channels 21 through to 26, inclusive, are spare
channels which have no function.

31
On entering the desired channel a value will be
displayed. Compare the value displayed with the value
shown in the table on the following page.
NOTE: The value is the output voltage from the
processor displayed as a percentage. This cannot be
directly translated into a voltage due to the internal
processes of the module. A zero equates to 0 volts.
If the value displayed varies by more than 10% to that
in the table a fault is indicated in either the component
or the wiring relevant to that channel.
NOTE: It is worthwhile checking the connectors of the
affected circuit, including the processor connectors,
prior to replacing any components.
32

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Channel Description Typical Value Notes
0 Clutch pedal position 91% released
25% depressed
1 Upshift switch 30% released
67% depressed
2 Downshift switch 30% released
67% depressed
3 Forward switch 30% released
67% depressed
4 Reverse switch 30% released
67% depressed
5 Temperature sender 71% @ 0°C
46% @ 30°C
26% @ 60°C
14% @ 90°C
6 Accelerator Pedal volts 20% released,
55% depressed
7 ERPM/Torque sensor 50%
8 Trans. mid speed sensor 50%
9 Trans. output speed sensor 50%
10 +12v supply (vd) 43% CP up, FNR in gear Tractor will drive if engine is
0% CP down, FNR in neutral running
11 +12v supply (vf) 43%
12 +12v supply (VH) 43%
13 +12v supply (VS) 43%
14 5 volt sensor supply 50%
15 8 volts sensor supply 80%
16 Clutch A current* 0% Clutch off See note 1
40--60% Clutch on
17 Clutch B current* 0% Clutch off See note 1
40--60% Clutch on
18 Clutch C current* 0% Clutch off See note 1
40--90% Clutch on
19 Clutch D current* 0% Clutch off See note 1
40--90% Clutch on
20 Clutch E current* 0% Clutch off See note 1
40--90% Clutch on
21 Clutch L current* 0% Clutch off See note 1
40--90% Clutch on
22 Clutch M current* 0% Clutch off See note 1
40--90 Clutch on
23 Clutch H current* 0% Clutch off See note 1
40--90% Clutch on
24 Clutch R current* 0% Clutch off See note 1
40--90% Clutch on
26 PTO Lube solenoid 0%CP up, 99% CP down 99% for 5--10 seconds after CP
release

*Engine must be running

NOTE: Enter the relevant channel by press and HOLDING either the upshift or downshift button. Release when
the LED on the gear display is in a gear which uses the clutch (eg. clutch A -- release when LED is in either
gear 1, 3 or 5). Depress the clutch pedal, select forward and gradually release the clutch pedal (THE
TRACTOR WILL DRIVE!). Note the reading in the gear display as the clutch is engaged.

55- 13
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HA CLUTCH PEDAL POSITION
This mode allows the tractor to be driven while showing
the clutch pedal position or oil temperature.

33
The clutch pedal position display is a percentage of
trave (0--99), and is indicated by ’C’ in the first display
digit.
The clutch pedal safety start/disconnect switch can be
adjusted in this mode. This switch should be set so that
it is heard to “click” when the pedal is being raised,
somewhere between 8--14%.
Incorrect adjustment of this switch will cause error
codes to be displayed when operating the clutch pedal.

34
Oil temperature in ° C can be displayed when the clutch
pedal is fully depressed or fully released by pressing
the upshift or downshift switch. Also, when the clutch
is fully released the display will change to oil
temperature after five seconds.

35
HB DISPLAY OF STORED ERROR CODES
This mode displays the error codes stored in the
memory of the micro processor.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Up to 10 error codes can be stored. This display mode
sorts the error codes so that the errors which occurred
most recently are displayed first.

37
To view the hours since the last occurrence depress
and hold the upshift button.

38
Continue to hold the upshift button and after 2 seconds
of displaying the hours, the screen will go blank then
the number of occurrences will be displayed.

39
To select the next stored error code press the
downshift.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
To return to the ’top’ of the list depress both up and
downshift buttons together.

41
When there are no more error codes to select the
display will show two dashes.

42
HC CLEAR STORED ERROR CODES
This mode functions like ’H8’ but only clears stored
error codes. Calibration values are not affected.
Select HC with the test switch.

43
The display will go blank, show ’EE’ go blank again and
then return to ’HH’.

55- 16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HD DISPLAY OF LIVE ERROR CODES
Select HD with the test switch.
After a few seconds the display will revert to normal
operating mode.
This mode allows normal tractor operation, but any
detected errors will cause an error code to be
displayed, whether they are disabling or not.
Key off, then on, to reset system to normal operation,
i.e. only disabling error codes displaying.

45
HE QUICK FILL ADJUSTMENT
Allows the amount of time to fill the clutch pack to be
adjusted.
This can be carried out with the engine running.

46
’A’ appears in the display followed by the quick fill
calibration figure.

47
Adjust the quick fill time using the upshift/downshift
buttons.

55- 17
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Change clutch by depressing the clutch pedal and
cycling the shuttle lever into forward and back to
neutral. To select reverse, cycle the shuttle lever to
reverse and back to neutral.
To test the quickfill, leave the shuttle lever in forward,
or reverse and fully release the clutch pedal.
To re-test the same clutch, depress the clutch pedal
slightly and release it again.
NOTE: When reducing quickfill values the first clutch
engagement may not be representative. Try at least
twice.

49
HF -- NOT USED

50
HJ CLUTCH PRESSURE TEST MODE
This test mode is for use in pressure testing the
transmission clutches, A, B, C, D, E, L, M, H and R.
It enables each clutch to be energised independently
and allows operation of the clutch pedal to control the
pressure.
Refer to the pressure testing section of the
transmission chapter for details of full operating
instructions.

55- 18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HL MANUAL CLUTCH CALIBRATION
ADJUSTMENT
Allows the clutch bite to be manually adjusted. This can
be carried out with the engine running.

52
’A’ appears followed by the clutch calibration figure
obtained in ’H1’.

53
Adjust the calibration figure using the upshift or
downshift buttons.

54
Change clutch by depressing the clutch pedal and
cycling the shuttle lever into forward and back to
neutral. To select reverse, cycle the shuttle lever to
reverse and back to neutral.
To test the quickfill, leave the shuttle lever in forward,
or reverse and fully release the clutch pedal.
To re-test the same clutch, depress the clutch pedal
slightly and release it again.
NOTE: When reducing quickfill values the first clutch
engagement may not be representative. Try at least
twice.
MM7
55

55- 19
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Range Command Transmission ’H’ Routines
The “H” Routine consists of the following menu codes:

HH Transmission Service Menu

H1 Clutch and synchronizer calibration
H2 View clutch calibration
H3 Clutch calibration temperature review
H4 Software revision level
H5 Switch test
H6 Synchronizer calibration view
H7 Not used
H8 Non volatile memory reset
H9 Voltmeter
HA Clutch pedal position view (%)
HB Display stored error codes
HC Clear stored error codes
HD Display live error codes
HE Quickfill duration adjustment
HF Manual clutch calibration adjustment
HJ Clutch pressure test mode
HL Synchroniser shift/position mode

55- 20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H1 CLUTCH AND SYNCHRONISER
CALIBRATION
Used to calibrate the 5 clutch packs and the position of
2 synchronisers.
See CALIBRATION section of this chapter for full
details.

57
Release the buttons. The display will change to show
transmission temperature. Press the up or downshift
button to proceed.
If the temperature is less than 10°C Error Code ‘U19’
will be displayed. If the temperature is between 10°C
and 20°C ‘‘CL” will be displayed. If the temperature is
to high, above 50°C, ‘‘CH” will be displayed.
If ‘U19’ is displayed calibration will not be possible and
the oil will have to be warmed before proceeding.

58
If ‘CL’ or ‘CH’ are displayed after 4 seconds the display
will return to oil temperature and the tractor may be
operated to obtain the correct transmission oil
temperature. If it is not practical to wait for the oil
temperature to change press either of the up or down
shift buttons while ‘CL’ or ‘CH’ is being displayed. The
display will then show an ‘A’ and calibration can
proceed.

59
Move the shuttle lever to forward and release the
clutch pedal.
Set engine speed to 1200 ERPM ±100.
The transmission is now ready for calibration.
Press and hold the downshift button to calibrate clutch
A.
If the start up procedure was incorrect a ‘‘U” code will
appear.

55- 21
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.
Release the downshift button, the display will change
to ‘b’, indicating that clutch B is ready for calibration.
Hold the downshift button until the engine speed
decreases by 50 RPM and the calibration number
stops increasing.

61
Repeat the above steps for clutches C, D and E. After
clutch E has been calibrated, release the downshift
button and the display will change to F.
Press the downshift button again. The synchronisers
will be shifted to neutral and synchroniser stroke
relationship will be checked. If satisfactory the display
will show ’CF’.

62
Pressing the downshift button again will select mode
’N’. This mode engages clutches A and C with the
synchronisers in neutral. This can be used to ’free’
transmission components that may be suspected of
sticking, i.e. synchronisers. It should be noted that if a
synchroniser is not actually in neutral, this mode can
cause the tractor to move.
When the display alternates between ’N’ and ’750’ this
indicates that the mode has completed.
Turn the key start switch off for at least 2 seconds to
store the calibration values.

63
NOTE: Transmission output speed and clutch pedal
position are constantly monitored. Calibration cannot
proceed unless the tractor is stationary and the clutch
pedal released.
Repeatedly depressing the upshift button will cycle
through each clutch mode, enabling a particular clutch
to be calibrated several times if required.

55- 22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
During each clutch calibration the synchroniser
positions are also calibrated.
• During Clutch A -- Mid range synchroniser
calibrated.
• During Clutch B -- Reverse range synchroniser
calibrated.
• During Clutch C and D -- High range synchroniser
calibrated.
• During Clutch E -- Low range synchroniser
calibrated.

65
H2 VIEW CLUTCH CALIBRATIONS
Here each clutch calibration is displayed.

66
Clutch ‘‘A” and then its calibration number is displayed.

67
Progress through by pressing the upshift button.

55- 23
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H3 CLUTCH CALIBRATION TEMPERATURE
VIEW
Shows the transmission temperature when each
clutch was last calibrated.

69
Displays ‘‘A” first with temperature.

70
To progress through press the upshift button.

55- 24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H4 SOFTWARE REVISION LEVEL
Display the software installed into the processor.

72
The display shows 4 figures consecutively.
CB Semi Powershift
01 Production software level
00 Prototype software level
30/40 Transmission type, 30 or 40 kph

73
H5 SWITCH TEST
It is possible in ‘‘H5” to test the function of all switches
used in the transmission electrical system.

74
The display will show a code number.

55- 25
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
When a switch is operated, its code will be displayed
and an audible tone heard to indicate correct function.
If a switch’s code is not displayed and the tone not
heard, then the switch is not functioning correctly or the
wiring to it is at fault.

Identifier Switch/Input Special Requirements

d20 Clutch pedal potentiometer
d21 Clutch pedal switch Shuttle lever in forward
d22 Forward switch Clutch pedal down
d23 Reverse switch Clutch pedal down
d24 Downshift switch
d25 Upshift switch
d26 Range switch
d27 Mid/Reverse synchro pot
d28 Low/High synchro pot
d29 Oil Temperature switch
d30 Oil pressure switch
d31 Creeper switch

55- 26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H6 SYNCHRONISER CALIBRATION VIEW
Displays the values stored in the microprocessor

77
‘1’ is displayed first, followed by its calibration number.
There are 6 views:
1 Slow (low) 362--912
2 Medium (mid) 50--601
3 Fast (high) 50--601
4 Reverse 362--912
5 Slow/Fast (neutral) 242--722
6 Med/Reverse (neutral) 242--722

78
Progress through by pressing the upshift button.

55- 27
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H7 NOT USED
H7 will be displayed when cycling through the H menu
but does not have a function.

80
H8 NON VOLATILE MEMORY RESET
Used to reset (clear) all calibration figures in the
processor.

81
With H8 selected the procedure is automatic.
The display changes from ‘‘H8” to ‘‘EE” to ‘‘HH”,
indicating the processor is now reset.
NOTE: All calibrations will need to be performed
following an H8 operation.

55- 28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H9 VOLT METER
Allows various voltage tests to be carried out on the
inputs and outputs of the Transmission Control Module
(TCM).
If an intermittent fault is exhibited within a particular
circuit, a ’wiggle’ test can be performed on the related
wiring whilst watching the display for sudden changes
in values, to help isolate the area where the fault lies.

83
There are 26 channels which can be accessed.
Use the upshift button to select the required channel.
NOTE: Channels 21 through to 26, inclusive, are spare
channels which have no function.

84
On entering the desired channel a value will be
displayed. Compare the value displayed with the value
shown in the table on the following page.
NOTE: The value is the output voltage from the
processor displayed as a percentage. This cannot be
directly translated into a voltage due to the internal
processes of the module.

85
If the value displayed varies by more than 10% to that
in the table a fault is indicated in either the component
or the wiring relevant to that channel.
NOTE: It is worthwhile checking the connectors of the
affected circuit, including the processor connectors,
prior to replacing any components.

60--55--011 TI
86

55- 29
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Channel Description Typical Value Notes
0 Clutch pedal position 91% released
26% depressed
1 Low/High synchro* 24% High range See note 1
45% Neutral Shuttle lever in neutral
71% Low range See note 2
2 Med/Rev synchro 24% Med range See note 3
45% Neutral Shuttle lever in neutral
71% Reverse range Shuttle lever in reverse
3 Upshift switch 30% Released Go to channel 2, press and hold
67% Depressed the upshift button
4 Downshift switch 30% Released Go to channel 5, press and hold
67% Depressed the downshift button
5 Range shift switch 30% Released
67% Depressed
6 Forward switch 30% Released
67% Depressed
7 Reverse switch 30% Released
67% Depressed
8 Temperature sender 71% @ 0ûC
46% @ 30ûC
26% @ 60ûC
14% @ 90ûC

9 +12v supply (vf) 43%

10 +12v supply (vd) 43%
11 Clutch pedal switch 43% Pedal up, forward Tractor will drive if engine is
0% pedal down, neutral running
12 5 volt sensor supply 50%
13 8 volts sensor supply 80%
14 Clutch A current* 0% Clutch off See note 4
40--60% Clutch on
15 Clutch B current* 0% Clutch off See note 4
40--60% Clutch on
16 Clutch C current* 0% Clutch off See note 4
40--90% Clutch on
17 Clutch D current* 0% Clutch off See note 4
40--90% Clutch on
18 Clutch E current* 0% Clutch off See note 4
40--90% Clutch on
19 Rear speed diagnostic volts 49%
20 Mid speed diagnostic volts 49%
*Engine must be running
Note 1: Go back to channel 0. Press and HOLD the upshift button to move onto channel 1. Only release the upshift
button when the LED on the gear display unit is in the C range. With the clutch pedal depressed, move the shuttle
lever into the forward position. The high range synchroniser (C range) should have been selected giving a reading
of approximately 25%.
Note 2: Go into channel 2, then press and HOLD the downshift button to take you back to channel 1. Only release
the downshift button when the LED on the gear display is in the A range. With the clutch pedal depressed, move
the shuttle lever into the forward position. The low range synchroniser (A range) should have been selected giving
a reading of approximately 75%.
Note 3: Follow the same procedure as notes 1 and 2, ensuring that the upshift button is only released when the LED
on the gear display unit is in the B range (medium range).
Note 4: Enter the relevant channel by pressing and HOLDING either the upshift or downshift button. Release when
the LED on the gear display is in a gear which uses the clutch (eg. clutch A -- release when LED is in either gear
1, 3 or 5). Depress the clutch pedal, select forward and gradually release the clutch pedal (THE TRACTOR WILL
DRIVE). Note the reading in the gear display as the clutch is engaged.

55- 30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HA CLUTCH PEDAL POSITION
This mode allows the tractor to be driven while showing
the clutch pedal position or oil temperature.
The clutch pedal position display is a percentage of
travel (0--99) and is indicated by ’C’ in the first display
digit.
The clutch pedal safety start/disconnect switch can be
adjusted in this mode. This switch should be set so that
it is heard to “click” when the pedal is being raised,
somewhere between 8--14%.

87
Incorrect adjustment of this switch will cause error
codes to be displayed when operating the clutch pedal.

88
Oil temperature in °C can be displayed when the clutch
pedal is fully depressed or fully released by pressing
and holding either the upshift or downshift switch. Also,
when the clutch is fully released the display will change
to oil temperature after five seconds.

89
HB DISPLAY STORED ERROR CODES
This mode displays the error codes stored in the
memory of the transmission processor.
Up to 10 error codes can be stored. The display mode
sorts the error codes so that the error codes which
occurred most recently are displayed first.

55- 31
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Whilst in this mode the transmission upshift and
downshift switches are used to control the display.

91
To select the next stored error code, press the
downshift switch.

92
To view the hours since the error last occurred, press
and hold the upshift switch. The hours will be displayed
for up to two seconds.
NOTE: Hours are counted whenever the engine is
running.

93
To view the number of times the error has occurred (i.e.
how many times the fault has been detected, ongoing
errors will be stored everytime the keyswitch is turned
on), continue to hold the upshift switch after the hours
have been displayed.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
To return to the top of the list press both the upshift and
downshift buttons together.

95
When there are no errors to display or the end of the
last has been reached, the display will show “ _ _ “.

96
HC CLEAR STORED ERROR CODES
This function clears all of the error codes stored in the
memory.

97
With HC selected the process is automatic.
This display changes from “HC” to “EE” to “HH”,
indicating that the stored errors have now been
cleared.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HD DISPLAY LIVE ERROR CODES
The tractor will operate normally in this mode but any
detected errors will be displayed.

99
HE QUICK FILL ADJUSTMENT.
Allows the amount of time to fill the clutch pack to be
adjusted.
This can be carried out with the engine running.

100
‘‘A” appears in the display followed by the quick fill
calibration figure.

101
Adjust the quick fill time using the upshift/downshift
buttons.
Change clutch by pressing the range button.

102

55- 34
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
By selecting forward, the delay in engaging drive can
be checked.

103
HF MANUAL CLUTCH CALIBRATION
ADJUSTMENT
Allows the clutch bite to be manually adjusted. This can
be carried out with the engine running.

104
‘‘A” appears followed by the clutch calibration figure
‘‘H1”.

105
Adjust the calibration figure using the upshift or
downshift buttons.

106

55- 35
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Change the clutch to be adjusted using the range
button.
By selecting forward or releasing the clutch, the clutch
engagement bite point can be checked.
The display will show % clutch pedal position.

107
HJ CLUTCH PRESSURE TEST MODE
This test mode is for use in pressure testing the
transmission clutches, A, B, C, D and E.
It enables each clutch to be energised independently
and allows operation of the clutch pedal to control the
pressure.
Refer to the pressure testing section of the
transmission for details of full operating instructions.

108
HL SYNCHRONISER SHIFT/POSITION MODE
Checks operation of the two synchronisers.
This mode is also used when pressure testing the
synchroniser actuating circuit.
The engine must be running with the transmission in
neutral and clutch pedal released.
Press and hold the downshift button to display the ’Mid’
position as a % of potentiometer movement (approx.
25%).
Press the upshift button for Reverse (75%).
Press both together for Neutral (50%).

109
An LED will flash to indicate which gear is selected for
each check.
If the clutch pedal is then depressed, a similar check
can be carried out for the Low/High synchroniser.
High = approx. 25%
Neutral = approx. 50%
Low = approx. 75%
NOTE: Before changing between synchronisers,
ensure that the synchroniser being tested is shifted
back to neutral, otherwise the shift rail interlock will
prevent the other synchroniser from moving.

110

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Dual Command Transmission ’H’ Routines
The “H” Routine consists of the following menu codes:

HH Transmission Service Menu

H1 Clutch calibration
H2 View clutch calibration
H3 EDC valve calibration values
H4 Software revision level
H5 Switch test
H6 Low clutch quick fill adjust
H7 High clutch quick fill adjust
H8 Non volatile memory reset
H9 Voltmeter
HA Clutch pedal position view (%)
HB Display stored error codes
HC Clear stored error codes
HD Display live error codes
HE Fly shift manual adjust
HF Synchroniser Potentiometer check

111

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H1 CLUTCH AND SYNCHRONISER
CALIBRATION
This mode is used to calibrate the Hi and Lo clutch
packs.

112
NOTE: The clutches should be adjusted when the
transmission oil is at a temperature of 20°C (68°F) or
over.
Park the tractor on level ground, away from obstacles
(in case of unexpected tractor movement).
Apply handbrake, switch off all electrical equipment
and air conditioning if fitted. Stop the engine and place
remote levers in neutral and lower hydraulic equipment
to the ground.
Place all the shift levers in neutral. Block the wheels,
front and rear.
Either, (i) Install tool No. 295041 or VLC 4FT.950 into
the diagnostic plug and select H1 by depressing the
diagnostic switch once or (ii) press and hold both the
Hi and Lo buttons and start the engine.
‘‘CAL‘ will appear in the transmission display, (release
Hi and Lo buttons).
Set engine speed to 1200 ERPM ±100.
Select forward, first gear, high range (C) and release
the clutch.
The transmission is now ready for calibration.

113
Press and hold upshift button to calibrate clutch Hi.
If the start up procedure was incorrect a ‘‘U” code will
appear. See ‘Error Codes’.

114

55- 38
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
After a few seconds the displayed Hi is replaced by a
number which increases during calibration.
Hold the upshift button until the engine speed
decreases by 50 RPM and the number stops
increasing.

115
Press the down shift button to calibrate the Lo clutch
in the same manner as the Hi clutch.

116
Synchroniser Calibration
To calibrate the synchroniser, at any stage after initial
tractor preparation, press both the Hi and Lo buttons
and hold.
‘‘SOC” appears during calibration.
‘‘END” displays to signify completion.

117
H2 VIEW CLUTCH CALIBRATIONS
Displays the previous clutch calibrations.

118

55- 39
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
The display will show “Lo” clutch calibration number
and then “Hi” clutch calibration number.

119
H3 EDC VALVE CALIBRATION VALUES
Not used for transmission features.

120
H4 SOFTWARE REVISION LEVEL
Displays the software installed into the processor.

121
The display shows five figures consecutively.
CA -- Hi/Lo
01 -- Production software level
00 -- Prototype software level
30/40 -- 30 or 40 kph

122

55- 40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H5 SWITCH TEST
Tests the function of all switches used in the
transmission or EDC system.

123
The display will show “d0”

124
When a switch is operated, its code will be displayed
and an audible tone heard to indicate correct function.
If the code does not appear and the tone sound, the
switch or the wiring to the switch is at fault

125

55- 41
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Switch Code Switch Description
d71 Clutch pedal switch
d74 Downshift switch
d75 Upshift switch
d81 1, 2 or 4 in gear
d82 3 or 4 in gear
d83 Low or medium range in gear
d85 Neutral safety start switch
d91 Transmission pressure switch
d93 Fuse 12 sense
d95 Shuttle lever in forward
d96 Shuttle lever in reverse
d98 Medium or high range in gear

H6 LOW CLUTCH QUICK FILL ADJUSTMENT

Adjusts the time taken for the initial partial fill of the
clutch.
This adjustment can be carried out with the engine
running and a gear selected.

126
The display will show a fill time value.

127

55- 42
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Increase or decrease the figure with the
upshift/downshift buttons with the clutch pedal
depressed.
Slowly release the clutch pedal.
If the figure is too high a small ’bump’ (forward
movement) is felt, decrease the figure until the ’bump’
disappears.

128
H7 HIGH CLUTCH QUICKFILL ADJUSTMENT
A similar calibration can be carried out for the high
clutch. Displays the H (for high) and the clutch fill time
value.

129
H8 NON VOLATILE MEMORY RESET
Used to reset (clear) all calibration figures in the
processor.

130
With H8 selected the procedure is automatic.
The display changes from ‘‘H8” to ‘‘EE” to ‘‘HH”,
indicating the processor is now reset.

131

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H9 VOLT METER
Allows various voltage tests to be carried out on the
inputs and outputs of the processor.

132
There are 37 channels which can be accessed.
To select a channel use the upshift and downshift
buttons.

133
On reaching the desired channel release the
upshift/downshift button and the channel number will
be replaced by a value. Compare the value displayed
with the value shown in the table on the following page.
NOTE: The value is the output voltage from the
processor displayed as a percentage. This cannot be
directly translated into a voltage due to the internal
processes of the module.

134
If the value displayed varies by more than 5% to that
in the table a fault is indicated in either the component
or the wiring relevant to that channel.
NOTE: It is worthwhile checking the connectors of the
affected circuit, including the processor connectors,
prior to replacing any components.

55- 44
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Channel Description Typical Value
0 Clutch pedal position 91% released
26% depressed
1 Transmission oil temperature 75% at 40°C
2 40 degree oil hydraulic oil 96% > 40°C
temperature switch
3 Fuse 12 sense 96%
4 Not applicable to service --
5 5 volt reference 49%
67% Depressed
6 12 volt Vf input 42%
7 12 volt Vd input 3%
8 12 volt Vh input 41%

9 8 volt reference 79%

10 Solenoid for synchro in high, fast 3% off
current sense
11 Solenoid for synchro in reverse, 3% off
fast current sense
12 Low clutch solenoid, fast current 0% Clutch engaged/out of
sense gear
32% Pedal released in
underdrive
13 High clutch solenoid, fast current 0% Clutch engaged/out of
sense gear
32% Pedal released in
direct drive
14 Solenoid for synchro in high, 0% off
current sense 93% max
15 Solenoid for synchro in reverse, 0% off
current sense 93% max
16 Low clutch solenoid current 0% Clutch engaged/out of
sense gear
82% pedal released in
low
17 High clutch solenoid current 0% Clutch engaged/out of
sense gear
82% pedal released in
high
20 Wheel speed sensor DC check 64%
36 Shuttle lever in forward 26% off,
61% on
37 Shuttle lever in reverse 26% off,
61% on

55- 45
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HA CLUTCH PEDAL POSITION VIEW
This mode allows the tractor to be driven while showing
the clutch pedal position or oil temperature.
The clutch pedal position display is a percentage of
travel (0--99) and is indicated by ’C’ in the first display
digit.

135
The clutch pedal safety start/disconnect switch can be
adjusted in this mode. This switch should be set so that
it is heard to “click” when the pedal is being raised,
somewhere between 8--14%.
Incorrect adjustment of this switch will cause error
codes to be displayed when operating the clutch pedal.

136
Oil temperature in °C can be displayed when the clutch
pedal is fully depressed or fully released by pressing
and holding either the upshift or downshift switch. Also,
when the clutch is fully released the display will change
to oil temperature after five seconds.

137
HB DISPLAY STORED ERROR CODES
This mode displays the error codes stored in the
memory of the transmission processor.
Up to 10 error codes can be stored. The display mode
sorts the error codes so that the error codes which
occurred most recently are displayed first.

138

55- 46
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Whilst in this mode the transmission upshift and
downshift switches are used to control the display.

139
To select the next stored error code, press the
downshift switch.

140
To view the hours since the error last occurred, press
and hold the upshift switch. The hours will be displayed
for up to two seconds.
NOTE: Hours are counted whenever the engine is
running.

141
To view the number of times the error has occurred (i.e.
how many times the fault has been detected, ongoing
errors will be stored everytime the keyswitch is turned
on), continue to hold the upshift switch after the hours
have been displayed.

142

55- 47
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
To return to the top of the list press both the upshift and
downshift buttons together.

143
When there are no errors to display or the end of the
last has been reached, the display will show “ _ _ “.

144
HC CLEAR STORED ERROR CODES
This function clears all of the error codes stored in the
memory.

145
With HC selected the process is automatic.
This display changes from “HC” to “EE” to “HH”,
indicating that the stored errors have now been
cleared.

146

55- 48
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
HD DISPLAY LIVE ERROR CODES
The tractor will operate normally in this mode but any
detected errors will be displayed.

147

HE FLYSHIFT MANUAL ADJUST

The flyshift delay after a clutched mechanical gear shift
can be adjusted to suit various operating speeds.

148
The figure that displays is the ground speed over which
the flyshift delay is eliminated;
3, 4, or 8 mph.

149

55- 49
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Change the ground speed by using the upshift or down
shift buttons.

150
HF SYNCHRONIZER POTENTIOMETER
CHECK
Checks the operation of the forward/reverse
synchronizer.
The engine must be running with the transmission in
neutral and the clutch released.

151
The Hi/Lo indicator lamps flash to indicate test mode.
Press and hold the downshift to display reverse
position indicated as a % of potentiometer movement
-- approx. 75 (%).
Press and hold upshift for forward -- approx. 25 (%)

152

55- 50
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Electronic Draft Control Diagnostic Test Routine
1. Connect diagnostic switch special tool No. 295041
or VLC 4FT.950 into the black diagnostic socket.
Use white socket for PC trans.

60--55--009 TI
153
2. Turn key--start switch ‘On’, the display on
instrument panel will show ‘HH’.

Electronic instrument cluster display.

154
Analogue electronic instrument cluster display.

155

55- 51
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
3. Repeatedly depress the button on the diagnostic
switch until the display on the instrument panel
changes to the required menu.
HH Draft Control Service Menu
H1 Lift control valve / valve calibration
H3 Valve calibration review
H4 Software revision level
H5 Switch test
H8 Memory reset
H9 Voltmeter
Hb Retrieve error codes for viewing
Hc Clear stored error codes
Hd View error codes live
156
H1 CALIBRATION OF THE EDC VALVE
This calibration is required if either the EDC valve or
the microprocessor has been replaced or its memory
has been reset using Diagnostic Menu H8.
NOTE: If the microprocessor memory has been reset
using Diagnostic Menu H8 it is also necessary to reset
the processor for the type of hydraulic system installed
on the tractor, ie ‘Open’ or ‘Closed Centre’ Hydraulics.
This procedure is described on Page 54 under valve
calibration review, H3 diagnostic routine and must be
performed before proceeding with the calibration.

157
Perform the calibration with warm hydraulic oil and a
suitable implment or weight mounted on the hydraulic
lift. The weight of the implement should be sufficient to
overcome any friction in the hydraulic lift assembly and
enable the lift arms to lower without binding.
1. Enter H1 mode, using the diagnostic tool.

TIA35205
158
2. Capture the hitch. Lower the lift below mid range
and then raise the lift to the top.
3. Leave the hitch in this position while it does a series
of three raise/lower cycles.

159

55- 52
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
Each time the hitch makes a correction the display
will progressively change from 0 to 1 to 2 to 3 then
En to signify that calibration is complete.

160
NOTE: When the tractor is installed with both an
analoge electronic instrument cluster and HI/Lo
transmission the display does not progressively
change from 0 to 1 to 2 and then 3 but changes from
H1 and then constantly shows the word cal.
Under these circumstances it is necessary to observe
the hydraulic lift arms performing the three raise and
lower movements to determine when the calibration
procedure is completed. It should be understood that
the lift arm movement during these raise/lower cycles
are very small and carefull observation is required.

161
4. Key off the tractor to store the calibrations.

162
NOTE: Steps 2 & 3 can be performed several times to
provide a better average of the valve thresholds. The
thresholds (the current required to start the EDC valve
raise and lower solenoids to operate) may be viewed
in mode H3 and are displayed in amps x 100, i.e, 0.530
amps will be displayed as 53. The raise threshold is
displayed first followed by the lower.
It is recommended that the after the EDC valve has
been calibrated the threshold values are reviewed as
explained on the following page and compared to the
typical values shown.

TIA35205
163

55- 53
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
H3 Valve Calibration Review
(Analogue Electronic Instrument Cluster Shown)
1. Enter the diagnostic routine and depress the
button on the diagnostic switch ‘three times’ until
the display on the instrument panel changes to
‘H3’.
2. After approximately 4 seconds the display will
change to show the EDC valve solenoid raise and
lower thresholds.

164
The threshold values will differ for each tractor with
a nominal value of approximately 50.

165
1. After displaying each valve threshhold value, the
display will then show the amount of Assist rams
installed. This is adjustable by operating the
raise/lower/work switch between work and raise
positions to increment the number of rams fitted.
The display will cycle as follows:
r1... r2... r3... r0
Cycle until the display shows the number of assist
rams installed on the tractor.
If it is necessary to replace the EDC
microprocessor always perform this operation
before calibrating the hydraulics.
166
H5 -- Switch Diagnostic Mode
(Electronic Instrument Cluster Shown)
The switch diagnostic mode allows a simple method of
checking the continuity of switches on the electronic
draft control hydraulic system.

167

55- 54
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
The switches on the EDC hydraulic system which can
be checked using H5 diagnostic mode are:--
In cab fast raise/work switch
External lift/lower fender switches

To use diagnostic routine H5 proceed as follows:-

1. Enter the diagnostic routine and depress the
button on the diagnostic switch ’five times’ until the
display on the instrument panel changes to ’H5’.

168
2. After a maximum period of four seconds the
display will again change to ’d0’. This is the switch
diagnostic mode.
3. Depressing either the in cab fast raise/work switch
(2) or external fender switches will cause the
numbers on the display to change as follows
indicating that the switch being tested is operating
correctly.

169
Switch Code Switch Description
d1 Fender switch operating correctly
in lower position
d2 Fender switch operating correctly
in raise position
d3 In cab fast raise/work switch
operating correctly from raise
to work.
d4 In cab fast raise/work switch
operating correctly from work
to raise.
d5 In cab fast raise/work switch
operating correctly from work
to fast dig.
170
H8 -- MEMORY RESET
To reset the memory proceed as follows:--
1. Enter the diagnostic routine and depress the
button on the diagnostic switch ’eight’ times until
the instrument panel changes to H8.

171

55- 55
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
2. Wait for approximately four seconds for the
microprocessor to select the memory erase
routine. The instrument panel display will change
from ’H8’ to ’EE’ and back to ’HH’ indicating
memory in processor has been reset.

172
3. Turn keystart switch ’Off’, wait two seconds and
then turn keystart switch ’On’. The display will
change to code 24 indicating that the hydraulic lift
requires calibration.

173
H9 -- Vehicle Sensor and Voltage Tests
This mode allows service personnel to verify the
operation of various potentiometers and voltage
supplies on the electronic draft control and
transmission.
To use diagnostic routine H9 proceed as follows:--
1. Enter the diagnostic routine and depress the
button on the diagnostic switch ’nine times’ until the
display on the instrument panel changes to ’H9’.

174
2. After approximately four seconds the display will
change to ’0’.

175

55- 56
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
3. If the tractor is installed with a Hi/Lo transmission
this number will then change automatically to
approximately 91 which represents the value of
correct operation of the clutch pedal potentiometer
when the pedal is released. If the tractor is installed
with a semi powershift transmission the display will
remain at zero and the clutch pedal value will be
displayed in the transmission gear display on the
operator control console.

176
4. By repeatedly depressing the in cab fast raise/work
switch (2) the channel number can be increased or
decreased until the desired channel has been
selected. If the tractor is installed with the Hi/Lo
transmission the channel number can also be
selected by depressing both transmission upshift
and downshift switches.

177
5. In Figure 178, Channel 31 has been selected
which checks operation of the height limit control
potentiometer.

178
6. The channel number selected will then change and
on turning the height limit control from minimum to
maximum should display values of approximately
14 to 84.
7. The values displayed must be compared with the
typical value in the H9 Channel chart, and if
different by greater than 10% indicates that there
is a concern in either the potentiometer or circuit
being tested.

MM11
179

55- 57
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11
8. If the values are away from specification it is likely
that the potentiometer is defective. Checks on the
harnesses should however be made before
replacing the potentiometer.

180

Channel Channel Description Typical Value

Dual & Range Power
Command Command

5 -- +5V Reference 49
6 -- +12V Supply (VF) 42
8 -- +12V Supply (VH) 42
18 35 EDC Raise Return 0--66
19 36 EDC Lower Return 0--66
20 -- Ground Speed DC Check 64
28 27 lift arm Position Pot 15 Lift lowered,
79 Lift raised
29 28 Lift control lever Pot. 25 Fully lowered
74 Fully raised
30 29 Drop Rate Pot. 84 Fully clockwise
14 Fully counter clockwise
31 30 Height Limit Pot. 84 Fully clockwise
14 Fully counter clockwise
32 31 Draft Sensitivity Pot. 84 Fully clockwise
14 Fully counter clockwise
33 32 Slip Limit Pot. 84 Fully clockwise
14 Fully counter clockwise
34 33 Right Draft Pin 48 When implement is not used
35 34 Left Draft Pin 48 When implement is not used
38 37 Draft Load Wheel 9=0
82=10
43 -- Wheel Speed 0=0mph/kmh, 100=30mph/48kmh

55- 58
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 12 -- Electrical Harnesses

CONTENTS

Section Description Page

55- 1
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
HARNESSES

1
There are four main electrical wiring harnesses used on TM series tractors
1. LT Lighting Harnes 4. CM Chassis Main (Transmission) Har-
2. FM Front Main (Engine) Harness ness
3. RM Rear Main (Cab) Harness

55- 2
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
MAIN CONNECTORS

2
The location of the main Harness to Harness connectors is shown above.
1. CM to LT Harness connector 3. CM to RM Harness connector
2. CM to FM Harness connector

55- 3
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
WIRE COLOUR
Each wire entering a connector on a harness has a co-
lour.
Below is a list of the colours used and their identifiying
letter.

B Black (Ground) LG Light |Green

N Brown (12v Unfused) U Blue (Headlamps)
TN Light Brown TQ Turquoise (Prossesor
Signal)
S Slate
L Lilac (12v Fused Battery
R Red (General Lighting)
Feed
O Orange K Pink
Y Yellow W White (12v Unfused Key
G Green (12v Fused Key ON)
On)

WIRE CODE
The following pages show in detail each wiring har-
ness, the general location of the connectorson on that
harness, followed by a more detailed location. Also
each connector is detailed with pinouts and the wire
code relating to each wire.

3
The wire codes can be read as follows.
First digits indicate the Wiring harness.
Second set indicate the circuit and spur.
Third set indicate wire colour where the first letter is the
base colour, the second is a tracer colour and the third
is the colour of any rings.

55- 4
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

NOTES

55- 5
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
LIGHTING HARNESS

55- 6
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
LIGHTING HARNESS
1. C056 Headlamp Harness Main Connector 4. C059 Right Hand Headlamp
(Page 55--8, Fig 6) (Page 55--8, Fig 7)
2. C057 Horn 5. C060 Left Hand Headlamp
(Page 55--8, Fig 7) (Page 55--8, Fig 7)
3. C058 Right Hand Worklamp 6. C061 Left Hand Work Lamp
(Page 55--8, Fig 7) (Page 55--8, Fig 7)

55- 7
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
LIGHTING HARNESS

6 8

7 9

55- 8
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

NOTES

55- 9
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
FRONT MAIN (ENGINE) HARNESS

55- 10
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
FRONT MAIN (ENGINE) HARNESS
1. C001 Front Main Harness connector 11. C012 Engine Coolant Temperature Sender
(Page 55--12 Fig. 11) (Page 55--13 Fig. 18 )
2. C003 Engine Oil Pressure Sender 12. C013 Alternator Connector
(Page 55--12 Fig. 12 ) (Page 55--13 Fig. 19 )
3. C004 Engine Oil Pressure Switch 13. C014 Steering Angle Sensor
(Page 55--12 Fig. 12 ) (Page 55--13 Fig. 19 )
4. C005 Start Relay 14. C015 Fuel Shutoff Solenoid
(Page 55--12 Fig. 13 ) (Page 55--13 Fig. 19 )
5. C006 Start Solenoid 15. C016 Fuel Pump Connector
(Page 55--12 Fig. 13 ) (Page 55--13 Fig. 23 )
6. C007 Brake Resevoir Fluid Level Switch 16. C017 Water in Fuel Sensor
(Page 55--13 Fig. 17 ) (Page 55--13 Fig. 23 )
7. C008 Engine Coolant Level Switch 17. C018 Thermostart Device
(Page 55--13 Fig. 17 ) (Page 55--12 Fig. 13 )
8. C009 Air Cleaner Vacuum Switch 18. C253 Front Suspension Potentiometer
(Page 55--13 Fig. 18 ) (Page )
9. C010 Air conditioning Compressor Connector 19. C254 Front Hitch/PTO Connector
(Page 55--13 Fig. 18 ) (Page 55--12 Fig. 13 )
10. C011 Air Conditioning De--Icing Stat
(Page 55--13 Fig. 18 )

55- 11
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
FRONT MAIN (ENGINE) HARNESS

11 14

12 15

13 16

55- 12
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

17 20

18 21

19 22

23 24

55- 13
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
REAR MAIN (TRANSMISSION) HARNESS

55- 14
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
REAR MAIN (TRANSMISSION) HARNESS
1. C019 Extension Harnesss Connector 1 22. C042 Differential Lock Solenoid
(Page 55--16, Fig 26) (Page 55--18, Fig 36)
2. C020 Extension Harnesss Connector 2 23. C043 Differntial Lock Pressure Switch
(Page 55--16, Fig 26) (Page 55--17, Fig 34)
3. C021 Creeper Engaged Switch 24. C044 Ground Speed PTO Engaged Switch
(Page 55--16, Fig 28) (Page 55--18, Fig 38)
4. C022 Fuel Tank Sender 25. C045 Hydraulic Pump Connector
(Page 55--20, Fig 49) (Page 55--18, Fig 38)
5. C023 Transmission Oil Temperature Sender 26. C047 Left Hand Draft Sensing Pin
(Page 55--17, Fig 34) (Page 55--18, Fig 39)
6. C024 Clutch E Solenoid 27. C048 Right Hand Draft Sensing Pin
(Page 55--17, Fig 30) (Page 55--18, Fig 39)
7. C025 Clutch D Solenoid 28. C049 Diverter Valve Connector
(Page 55--17, Fig 30) (Page 55--19, Fig 42)
8. C026 Clutch C Solenoid 29. C050 Trailer Brake Connector
(Page 55--17, Fig 30) (Page 55--19, Fig 44)
9. C027 Clutch B Solenoid 30. C052 Rockshaft Potentiometer
(Page 55--17, Fig 30) (Page 55--19, Fig 44)
10. C028 Clutch A Solenoid 31. C053 Remote Valve Solenoid
(Page 55--17, Fig 30) (Page 55--20, Fig 48)
11. C031 Medium Range Solenoid 32. C054 PTO Speed Sensor
(Page 55--17, Fig 32) (Page 55--19, Fig 45)
12. C032 Low Range Solenoid 33. C055 Trailer Socket
(Page 55--17, Fig 32) (Page 55--20, Fig 48)
13. C033 PTO Brake Solenoid 34. C217 EDC Raise Solenoid
(Page 55--18, Fig 36) (Page 55--20, Fig 48)
14. C034 Four Wheel Solenoid 35. C218 EDC Lower Solenoid
(Page 55--18, Fig 36) (Page 55--19, Fig 45)
15. C035 Four Wheel Drive Pressure Switch 36. C241 PTO Lubrication Solenoid
(Page 55--17, Fig 34) (Page 55--19, Fig 42)
16. C036 Transmission Oil Pressure Switch 37. C243 High Range Pressure Switch
(Page 55--17, Fig 34) (Page 55--17, Fig 32)
17. C037 Transmission Mid Speed Sensor 38. C244 Medium Range Pressure Switch
(Page 55--16, Fig 28) (Page 55--17, Fig 32)
18. C038 Transmission Ouput Speed Sensor 39. C245 Low Range Pressure Switch
(Page 55--17, Fig 32) (Page 55--17, Fig 32)
19. C039 High Range Solenoid 40. C246 Reverse Range Pressure Switch
(Page 55--17, Fig 32) (Page 55--17, Fig 32)
20. C040 Reverse Range Solenoid 41. C248 Front Axle Suspension Connector
(Page 55--17, Fig 32) (Page 55--19, Fig 42)
21. C041 PTO Solenoid 42. C255 Engine Speed / Torque Sensor
(Page 55--18, Fig 36) (Page 55--20, Fig 49)

55- 15
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
REAR MAIN (TRANSMISSION) HARNESS

28 29

55- 16
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

30 31

34 35

55- 17
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

36 37

38 40

39 41

55- 18
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

44 46

45 47

55- 19
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

48 50

49 51

55- 20
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

NOTES

55- 21
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
CAB MAIN HARNESS - (ALL MODELS)

55- 22
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
CAB MAIN HARNESS - (ALL MODELS)
1. C001 Front Main Harness Connector 31. C092 Console Lamp
(Page 55--25, Fig 54) (Page 55--29, Fig 80)
2. C019 Transmission Harness Connector 32. C093 Left Hand Rear NASO Flasher
(Page 55--25, Fig 55) (Page 55--29, Fig 84)
3. C020 Transmission Harness Connector 33. C094 right Hand Rear NASO Flasher
(Page 55--25, Fig 55) (Page 55--30, Fig 86)
4. C056 Lighting Harness Connector 34. C095 Left Hand Rear Licence Plate / Worklamp
(Page 55--26, Fig 58) (Page 55--29, Fig 84)
5. C062 Right Hand Stop Lamp Switch 35. C096 Right Hand Rear Licence Plate / Worklamp
(Page 55--26, Fig 59) (Page 55--30, Fig 86)
6. C063 Left Hand Stop Lamp Switch 36. C097 Left HAnd Beacon
(Page 55--26, Fig 59) (Page 55--30, Fig 87)
7. C066 Right Hand Side Light 37. C098 Right HAnd Beacon
(Page 55--26, Fig 60) (Page 55--29, Fig 80)
8. C067 Left Hand Side Lamp 38. C099 Interior Lamp
(Page 55--26, Fig 60) (Page 55--30, Fig 87)
9. C068 Radar Connector 39. C106 Radio Connector A
(Page 55--26, Fig 61) (Page 55--30, Fig 91)
10. C069 Starter Solenoid 40. C107 Radio Connector B
(Page 55--26, Fig 61) (Page 55--30, Fig 91)
11. C072 Key Start Switch 41. C108 Clock
(Page 55--27, Fig 66) (Page 55--30, Fig 90)
12. C073 Front Windshield Wiper Switch 42. C109 Rear Wiper Motor
(Page 55--27, Fig 66) (Page 55--31, Fig 94)
13. C074 Turn Switch 43. C110 Right Hand Speaker Connector
(Page 55--27, Fig 67) (Page 55--29, Fig 80)
14. C075 Shuttle lLever Switch 44. C111 Left Hand Speaker Connector
(Page 55--27, Fig 67) (Page 55--30, Fig 87)
15. C076 Clutch Pedal Switch 45. C119 Heater / Air Conditioning Connector
(Page 55--27, Fig 68) (Page 55--30, Fig 91)
16. C077 Clutch Pedal Potentiometer 46. C129 Worklamp Right Hand Fender
(Page 55--27, Fig 68) (Page 55--31, Fig 95)
17. C078 Rear Wiper Switch 47. C130 Worklamp Left Hand Fender
(Page 55--26, Fig 59) (Page 55--31, Fig 98)
18. C079 Instrument Cluster “A” 48. C131 Lower Licence Plate Lamp
(Page 55--28, Fig 72) (Page 55--31, Fig 98)
19. C080 Instrument Cluster “B” 49. C132 Rear Lamp Right Hand Fender
(Page 55--28, Fig 72) (Page 55--31, Fig 99)
20. C081 Instrument Cluster “C” 50. C133 Rear Lamp Left Hand Fender
(Page 55--28, Fig 72) (Page 55--32, Fig 102)
21. C082 Beacon Switch 51. C134 Right Hand External HPL Switch
(Page 55--28, Fig 74) (Page 55--32, Fig 102)
22. C083 Hazard Warning Light Switch 52. C135 Left Hand External HPL Switch
(Page 55--28, Fig 74) (Page 55--31, Fig 99)
23. C084 Left Hand Upper Front Worklamp 53. C136 Hand Brake Switch
(Page 55--28, Fig 75) (Page 55--32, Fig 103)
24. C085 Right Hand Upper Front Worklamp 54. C137 PTO Alarm Seat Switch
(Page 55--29, Fig 78) (Page 55--32, Fig 103)
25. C086 Left Hand Front NASO Flasher 55. C138 Seat Pump
(Page 55--28, Fig 75) (Page 55--32, Fig 103)
26. C087 Right Hand Front NASO Flasher 56. C139 Front Washer Motor
(Page 55--29, Fig 78) (Page 55--32, Fig 104)
27. C088 Front Wiper Motor 57. C140 Rear Waher Motor
(Page 55--28, Fig 75) (Page 55--32, Fig 104)
28. C089 Air Trailer Brake Pressure Guage 58. C144 Air Brake Connector
(Page 55--29, Fig 79) (Page 55--32, Fig 108)
29. C090 Left Hand Door Switch 59. C147 Remote Valve Lockout Switch
(Page 55--29, Fig 79) (Page , Fig )
30. C091 Right Hand Door Switch 60. C148 Diverter Valve
(Page 55--29, Fig 80) (Page , Fig )

55- 23
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
61. C256 Throttle Potentiometer 64. C260 Indicator Flasher Unit
(Page 55--33, Fig 110) (Page 55--33, Fig 111)
62. C257 Left Hand fender PTO Switch 65. C261 Indicator “On” Buzzer Unit
(Page 55--31, Fig 98) (Page 55--28, Fig 74)
63. C258 Right Hand fender PTO Switch 66. C264 Front Omplement Socket
(Page 55--31, Fig 95) (Page 55--33, Fig 111)

Right Hand Console Options

A. . . . . . . . . . . . Power Command
(Page 55--34, Fig 116)
B. . . . . . . . . . . . Range Command
C. . . . . . . . . . . . Dual Command
D. . . . . . . . . . . . Shuttle Command

55- 24
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
CAB MAIN HARNESS - (ALL MODELS)

54 56

55- 25
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

58 62

59 63

60 64

61 65

55- 26
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

66 69

67 70

68 71

55- 27
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
1: CM-1034-LG/R 9: CM-1006-N/Y
2: CM-1035-W/N 10: CM-1026-U/W
3: CM-1033-LG/Y 11: CM-1005-B/S
4: CM-649-B/O 13: CM-1022B-N/R
5: CM-50A-G/R 14: CM-1013A-R
6: CM-1003A-G 15: CM-2029-P
7: CM-57CN-B 16: CM-29-G/B
8: CM-39-G/U

1: CM-2016B-Y/G-Y/S 6: CM-31-Y/S
2: CM-2026B-S/R 7: CM-2070-O/U/B
3: CM-2027A-R 8: CM-2080-O/R
4: CM-2028D-G 9: CM-2095B-G/W/B
5: CM-2014-G/K 10: CM-57X-B
11: CM-2095C-G/W/B

1: CM-2012-Y/O
2: CM-7120-Y/B
3: CM-1003C-G
5: CM-7130-B/N
6: CM-3045-Y/U/S
7: CM-2040-LG/G/S
8: CM-3014-R/K
9: CM-44D-LG/N
10: CM-2015A-W/S

74 76

75 77

55- 28
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

78 81

79 82

80 83

84 85

55- 29
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

86 88

87 89

90 92

91 93

55- 30
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

94 96

95 97

98 100

99 101

55- 31
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

102 105

103 106

104 107

108 109

55- 32
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

110 112

111 113

114 115

55- 33
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
POWER COMMAND - RIGHT HAND
CONSOLE

116

55- 34
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12
CAB MAIN HARNESS - POWER COMMAND RIGHT HAND CONSOLE
1. C100 TCM Connector 1 (Black) 15. C123 Limp Home Connector
(Page 55--36, Fig 117) (Page 55--37, Fig 123)
2. C101 TCM Connector 2 (Red) 16. C125 Diagnostic Plug TCM
(Page 55--36, Fig 117) ( 130, 130)
3. C103 Gear Shift Connector 17. C126 Diagnostic Plug GCM
(Page 55--36, Fig 119) (Page 55--38, Fig 130)
4. C104 gear Shift Indicator 18. C127 GCM Connector CN2 (Red)
(55--36, Fig 119) (Page 55--39, Fig 134)
5. C105 EMU Connector 19. C128 GCM Connector CN1 (Black)
(Page55--37, Fig 123) (Page 55--39, Fig 134)
6. C113 Front Hitch Potentiometer 20. C143 Rear Implement Socket
(Page 55--37, Fig 124) ( Page 55--39, Fig 140)
7. C114 PTO Engaged Lamp 21. C145 Rear Accessory Panel
(Page 55--37, Fig 125) (Page 55--39, Fig 140)
8. C115 Front PTO Switch 22. C237 Ground Speed Connector
(Page 55--37, Fig 125) (Page 55--38, Fig 130)
9. C116 Rear PTO Switch 23. C239 TCM Connector 3 (Red)
(Page 55--38, Fig 128) (Page 55--36,Fig 117)
10. C117 Rear PTO Engaged Lamp 24. C240 EDC Control Module
(Page 55--38, Fig 128) (Page 55--39, Fig 136)
11. C118 Rear PTO Brake 25. C242 GCM Connector 3 (Black)
(Page 55--38, Fig 128) (Page 55--39, Fig 134)
12. C120 EDC Control Panel 1 26. C247 Front Suspension Switch
(Page 55--38, Fig 129) (Page 55--39, Fig 137)
13. C121 EDC Control Panel 2 27. C259 PTO Soft Start Switch
(Page 55--38, Fig 129) (Page 55--39, Fig 137)
14. C122 EDC Control Panel 3 28. C262 Auto Transmission Switch
(Pag 55--38, Fig 129) (Page 55--39, Fig 137)

55- 35
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12
CAB MAIN HARNESS - POWER COMMAND RIGHT HAND CONSOLE

117 120

118 121

119 122

55- 36
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

123

124 126

125 127

55- 37
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

128 131

129 132

130

133

55- 38
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

134 137

135 138

136 139

140 141

55- 39
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

142 143

55- 40
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 12

144
Ground Locations

55- 41
SECTION 55 --ELECTRICAL SYSTEM -- CHAPTER 12

NOTES

55- 42

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