17740958-Mccormick CX Series Cx50 Cx60 Cx70 Cx80 Cx90 Cx100 Tractors Dealer Shop Service Repair Manual - Download
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Table of Contents
CX Series Tractors
Service Manual SM 8-10602
Volume 1 Contains Tabs 1 to 6
Volume 2 Contains Tabs 7 to 10
Section Pub. No.
1 GENERAL
Safety, General Information and Standard Torque Specifications ......... ..... . 1001 SM 8-10080
General Specifications and Torques ......... .................................... .............. 1002 SM 8-10090
2 ENGINE
NOTE: For the Engine Service and Overhaul procedures refer to your Engine
Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder
Engines).
3 FUEL SYSTEM
Fuel Tank Removal and Servicing .... ....... ...... ............. ............ .. .. .......... ....... 3005 SM 8-10130
NOTE: For the Fuel System Service and Overhaul procedures refer to your Engine
Service Manual SM 8-10010 (3 Cylinder Engines) or SM 8-10040 (for 4 Cylinder
Engines).
4 ELECTRICAL
Electrical Schematics .. .... ........................................................................... .4001 SM 8-10140
Instrument Cluster Programming ................................................................ .4002 SM 8-10500
Battery Servicing and Testing .. .................. .. .............. .......... ......... .............. .4004 SM 8-10160
5 STEERING
Steering Column and Steering Hand Pump ................ ... ..... .. ... .. ... ... ... ... ..... 5001 SM 8-10171
2 Wheel Drive Steering Cytinder. ... ...... ..... .... ............. ... ........ ................. .... ..5003 SM 8-10180
2 Wheel Drive Front Axle ...... ....... ............ ..... .. ... ............. ....... ............... ... .... 5004 SM 8-10190
6 TRANSMISSION
Engine Clutch, Master Cylinder and Slave Cylinder ...... ... .. ................. .. .... ..6002 SM 8-10220
Powershift and Forward/Reverse Transmission Servicing ..... ....... ... .... .. .... 6003 SM 8-10230
Creep Transmission Servicing .... ......... ..... ... ............... ...... .. ................... ...... 6004 SM 8-10240
8 Speed Transmission Servicing ............... ........ ................ ..... .................. ... 6005 SM 8-10250
Synchronizer Speed Transmission Servicing ................ ..... .................. ....... 6006 SM 8-10260
Range Transmission Servicing (2 Wheel Drive Tractors) .. .. ........................ 6007 SM 8-10270
Range Transmission Servicing (MFD Tractors) ... ......... ........ ........ .. ............. 6008 SM 8-10280
3 Speed Powershift Transmission Servicing (XtraShift) .... ....... ..... ........... .. 6009 SM 8-12200
Differential and Differential Lock .............. .. ............................................. ..... 6012 SM 8-10290
MFD Clutch, Transfer Gearbox, Drive Shaft and Parking Brake .................6017 SM 8-10301
Rear Axles and Planetaries .......... ................................. .. ............ ...... ... .. ..... 6018 SM 8-10310
Non Shiftable PTO
(XtraShift Prior to Pin JJE0200493)
(Synchronizer Prior to Pin JJE0902626) ....................... .. .... ..... ........... .. .. 6019 SM 8-10320
Non Shiftable PTO
(XtraShift Pin JJE0200494 and After)
(Synchronizer Pin JJE0902627 and After) .... .... .. ........ .. ......... .... ............. 6019 SM 8-14030
Shiftable PTO
(XtraShift Prior to Pin JJE0200493)
(Synchronizer Prior to Pin JJE0902626) .................. ..... ..................... .. ... 6020 SM 8-10330
Shiftable PTO
(XtraShift Pin JJE0200494 and After)
(Synchronizer Pin JJE0902627 and After) ............. ......... .... .................... 6020 SM 8-14020
MFD Axle ....... ....................... .... ............... .. ................................................. 6021 SM 8-10341
Front PTO ...... ................... ... .. .... ............ .. ... .................. .... ................. ...... ... 6025 SM 8-10580
~ 8M 8-10612
© 2004 McCormick Tractors International Limited .
Printed in England
McCORMICK October 2004
Table of Contents
7 BRAKES
Service Brakes ........ ......... ... ................ .. ......................... ..................... .. ..... 7001 SM 8-10360
Parking Brake (2 Wheel Drive Tractors) .... ............ ............ ...... ........ ...... .. ... 7002 SM 8-10370
Hydraulic Trailer Brake ...... .............. ...... ...... .. .. .... .......... .............. ...... ......... 7004 SM 8-10380
8 HYDRAULICS
Hydraulic Troubleshooting and Schematic ...... .. ............ .. .......... .. ........ ....... 8001 SM 8-10400
Filter Manifold and Main Hydraulic Pump .. .. .. .. .. .. .. ........ .... .... .. .. ........ .. ....... 8002 SM 8-10410
Steering Hydraulic Pump (Engine Driven) .................. .. .............................. 8003 SM 8-10420
Regulator Valve .. ... ........... ... ........... ... .. ..... .. ....... ............. .......... .... ... ......... .. 8004 SM 8-10430
Unloading Valve ... .. ................ .. ....... ........ ..... .... .. ........................... ..... .... ..... 8006 SM 8-10440
Remote Valves ................. ..... ................ ..... .. ... .. .......... ........ ... ....... .. ......... .. 8007 SM 8-10450
Hitch Valve and EDC Manifold ....................................... .... ................. ........ 8009 SM 8-10460
Hydraulic Lift Housing Servicing ........... .. ......... ........... .... ....... .... ...... .. ......... 8010 SM 8-10470
Front Hitch ......................... ... .. ............... ........... ... .......... .. ...... ....... ....... ..... .. 8011 SM 8-10480
9 CHASSIS AND MOUNTED EQUIPMENT
Pedal, Lever and Switch Adjustments .. ....... ........ ................... .... ... .. .. .. .... .. . 9001 SM 8-10491
Cab Mountings ... ... .. ....... .. ... .. ... ......... .. .......... .... .... ..... .... ... .... .. ................. .. 9008 SM 8-10540
10CONTROLLER SYSTEMS
Hitch Controller Calibration , Error Codes,
Troubleshooting and Schematics
(Tractors Not Equipped with Ride Control) ................. .. ........... .... ... ..... 10002 SM 8-10550
Hitch/MFD/Differential Lock Controller Calibration , Error Codes,
Troubleshooting and Schematics
(Tractors Equipped with Ride Control) ....... ......................................... 10002 SM 8-10560
Calibration , Error Codes Troubleshooting and Schematics ......... ..... ........ 10006 SM 8-12101
Programming the PTO/FNR Controller
and Hitch/MFD/Differential Lock Controller .. .. .... .. .... .... ................ .... .... 10010 SM 8-10570
8M 8-10612 Issued 10-2004
Section
1001
SAFETY, GENERAL INFORMATION
AND STANDARD TORQUE SPECIFICATIONS
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10080 March 2001
2 SECT/ON 1001
TABLE OF CONTENTS
SAFETY ....................... .................... ........ .... ............ ............... .. ............ .............................. ........... .. ...... ...... .. .......... 3
GENERAL INFORMATION
Cleaning .......................................................................................................................... .. ............ .............. ...... ... 5
Inspection .. ..... ............ .............. ............... ......................... ... .............. .... ........... .... .. .......... ................ .............. ...... 5
Bearings ... ..................... .... ....... ..... .... ... ............. .. .... .. ............................. .............. ...... .... ..... ......... ...... ....... ... ........ 5
Needle Bearings ...... ... ....... .. ... ... .. ..... ..... .............. ... .... ...... ....... ......... .. .......... .. .. .. ........................ ..... .......... ....... ... 5
Gears ........ .... ..................................................................... ............... ... .. .............. ........... ... ...... .... .. .. ... .......... ....... 5
Oil Seals, O-Rings And Gaskets ... ...... .. ..... ........ .. ... ............................................ ............ ... .... ..... ................ ... ... ... 5
Shafts ... ......... ...... .. .. .. ..... ...... ................ ... ... .. ........... ......... .... .......... ....... .......... ..... ....... .... .... ....... ................. .. .... ... 5
Service Parts ............... ........... ................ ............ .. .... ........ ............... .... ........... ... .... ......... .............. ........................ 5
Lubrication ............... ... ............ .... ........... ... .. .............. ............... ........... .... ........................ ............ ... ........... ........... 5
STANDARD TORQUE DATA FOR NUTS AND BOLTS
Chart 1 (Plain Nuts/Bolts) ........ .. ........... .................. .......................... ... ........................................................... ..... 6
Chart 2 (Phosphate Coated Nuts/Bolts) ... ................ .......... ............................. ............................ .. .. .. .... ...... .. ....... 6
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ................................. .. .. ................ .. ............................................... 7
8M 8-10080 Issued 03-2001
SECTION 1001 3
SAFETY
This symbol means A TTENT/ON! BECOME ALERT! YOUR SAFETY
A IS INVOL VED. The message that follows the symbol contains
important information about safety. Carefully read the message.
Make sure you fully understand the causes of possible injury or
death.
To prevent injury always follow the Warn ing,
Caution and Danger notes in this section and WARNING: Before starting engine, study
throughout the manual. Operator's Manual safety messages.
Read all safety signs on machine. Clear
Put a warning tag as shown below on the key for the the area of other persons. Learn and
key switch when carrying out servicing or repairs to
the tractor. Warning tags (publication number 2-1000)
are available from your McCormick dealer.
*'
practice safe use of controls before
operating.
~ It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service, and to
I H:A""~ "
VUlIII,tIlol'IMN'OIr
observe pertinent laws and regulations.
Operator's and Service Manuals may be
obtained from you McCormick dealer.
DO NOT OPERATE WARNING: If you wear clothing that is too
NE PAS UTILISER loose or do not use the correct safety
NICHT BETREIBEN equipment for your job, you can be
NO UTILIZAR
A injured. Always wear clothing that will not
~ catch on objects. Extra safety equipment
• that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector
clothing.
~
2·1000 McCORMICK
WARNING: When working in the area of
1,\
A WARNING: Read the operators manual to
familiarize yourself with the correct
control functions.
the fan belt with the engine running, avoid
l.llloose clothing if possible, and use
extreme caution.
*'
WARNING: Operate the machine and
equipment controls from the seat
~ position only. Any other method could
WARNING: When doing checks and tests
*-
on the equipment hydraulics, follow the
~ procedures as they are written. DO NOT
result in serious injury. change the procedure.
*' WARNING: This is one a man machine, no
~ riders aI/owed.
WARNING: When putting the hydraulic
A cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
1,\ WARNING: Use insulated gloves or
l.ll mittens when working with hot parts.
SM 8-10080 Iss ued 03-2001
4 SECT/ON 1001
CAUTION: Lower all attachments to the CAUTION: When servlcmg or repairing
J,\
ground or use stands to safely support the machine. Keep the shop floor and
~ the attachments before you do any J,\ operator's compartment and steps free of
maintenance or service. £ll oil, water, grease, tools, etc. Use oi/
absorbing material and or shop cloths as
required. Use safe practices at all times.
CAUTION: Pin sized and smaller streams
of hydraulic oil under pressure can
penetrate the skin and result in serious CAUTION: Some components of this
infection. If hydraulic oil under pressure J,\ machine are very heavy. Use suitable
does penetrate the skin, seek medical L:..l. lihing equipment or additional help as
J,\ treatment immediately. Maintain all hoses instructed in this Service Manual.
~ and tubes in good condition. Make sure
all connections are tight. Make a
replacement of any tube or hose that is DANGER: Engine exhaust fumes can
damaged or thought to be damaged. DO cause death. If it is necessary to start the
NOT use your hand to check for leaks, J,\ engine in a closed place, remove the
use a piece of cardboard or wood. £ll exhaust fumes from the area with an
exhaust pipe extension. Open the doors
and get outside air into the area.
CAUTION: When removing hardened pins
such as a pivot pin, or a hardened shah,
A use a soh ~ead (brass or bronze) hammer
or use a drtver made from brass or bronze
DANGER: When the battery electrolyte is
frozen, the battery can explode if (1), you
and a steel head hammer. try to charge the battery, or (2), you try to
J,\ jump start and run the engine. To prevent
L:..l. that battery electrolyte from freezing, try
CAUTION: When using a hammer to to keep the battery at full charge. If you do
remove and install pivot pins or separate not follow these instructions, you or
parts using compressed air or using a
A •
grinder, wear eye protection that
completely encloses the eyes (approved
others in the area can be injured.
goggles or other approved eye DANGER: Batteries contain acid and
protectors). explosive gas. Explosions can result from
CAUTION: Use suitable floor (service)
*"
L:..l.
sparks, flames or wrong
connections. To connect the jumper
cable
cables correctly to the battery of this
J,\ jacks or chain hoist to raise wheels or machine see the Operator's Manual.
~ tracks off the floor. Always block machine Fai/ure to follow these instructions can
in place with suitable safety stands. cause serious injury or death.
SM 8-10080 Issued 03-2001
SECTION 1001 5
GENERAL INFORMATION
Cleaning Gears
Clean all metal parts except bearings, in mineral Check all gears for wear and damage. Replace
spirits or by steam cleaning . Do not use caustic gears that have wear or damage.
soda for steam cleaning . After cleaning dry and put
oil on all parts. Clean oil passages with compressed Oil Seals, O-Rings And Gaskets
air. Clean bearings in kerosene, dry the bearings
completely and put oil on the bearings. Always install new oil seals , o-rings and gaskets.
Put petroleum jelly on seals and o-rings .
Inspection
Shafts
Check all parts when the parts are disassembled .
Replace all parts that have wear or damage. Small Check all shafts that have wear or damage. Check
scoring or grooves can be removed with a hone or the bearing and oil seal surfaces of the shafts for
crocus cloth . Complete visual inspection for damage.
indications of wear, pitting and the replacement of
parts necessary will prevent early failures. Service Parts
Always install genuine McCormick service parts,
Bearings when ordering refer to the Parts Catalog for the
Check bearings for easy action. If bearings have a correct part number of the genuine McCormick
loose fit or rough action replace the bearing. Wash replacement items. Failures due to the use of other
bearings with a good solvent or kerosene and than genuine McCormick replacement parts are not
permit to air dry. DO NOT DRY BEARINGS WITH covered by warranty.
COMPRESSED AIR.
Lubrication
Needle Bearings Only use the oils and lubricants specified in the
Before you press needle bearings in a bore always Operators or Service Manual. Failures due to the
remove any metal protrusions in the bore or edge of use of non specified oils and lubricants are not
the bore. Before you press bearings into position covered by warranty.
put petroleum jelly on the inside and outside
diameter of the bearings.
SM 8-10080 Issued 03-2001
6 SECTION 1001
STANDARD TORQUE DATA FOR NUTS AND BOLTS
NOTE: A "click type" torque wrench is recommended for the bolt torques listed below.
Chart 1 (Plain Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9
SIZE MIN MAX MIN MAX
(mm) Ib ft Nm Ib ft Nm Ib ft Nm Ib ft Nm
M4 3.0 4.0 3.4 4.5 4.3 5 .8 4 .8 6.5
M5 4 .8 6 .5 5.5 7.5 7.0 9 .5 7 .8 10.5
M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0
M8 20 .0 27 .0 22.5 31 .0 28.7 39.0 32 .3 44.0
M10 40.0 54.0 45 .0 61.0 56.0 77.0 64.0 87.0
M12 69 .0 94.0 78 .0 106 .0 100 .0 134 .0 110 .0 151 .0
M14 110 .0 150.0 125 .0 170 .0 160.0 215.0 180.0 240.0
M16 175.0 235.0 190.0 260.0 245.0 335 .0 275.0 375.0
M20 345 .0 470.0 390.0 530.0 480.0 650 .0 540.0 730.0
M22 475.0 640.0 530.0 720 .0 655 .0 890.0 735 .0 1000.0
M24 600 .0 810 .0 675.0 915.0 830.0 1125 .0 930.0 1265.0
M30 1190 .0 1615.0 1340 .0 1815 .0 1645.0 2235.0 1855 .0 2515 .0
M36 2080 .0 2825.0 2340 .0 3175 .0 2875 .0 3900 .0 3235 .0 4390.0
Chart 2 (Phosphate Coated Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9
SIZE MIN MAX MIN MAX
(mm) Ib ft Nm Ib ft Nm Ib ft Nm Ib ft Nm
M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4 .9
M5 3.6 4 .9 4.1 5.6 5.2 7 .1 5.9 8.0
M6 6.2 8.3 6.9 9.4 8.9 12 .0 10.0 13 .5
M8 15 .0 20.3 16.9 23 .3 21.5 29.2 24 .2 32.8
M10 30 .0 41.0 34.0 46 .0 42.0 58.0 48 .0 65.0
M12 52.0 71.0 59.0 80 .0 75.0 101.0 83.0 113.0
M14 83.0 113.0 94 .0 126 .0 120.0 161.0 135 .0 180 .0
M16 131 .0 176.0 143.0 195 .0 185. 0 251.0 205.0 280.0
M20 259 .0 353 .0 293.0 400.0 360.0 490.0 405.0 550 .0
M22 355 .0 480.0 400.0 540.0 490.0 665.0 550.0 750.0
M24 450 .0 608.0 506 .0 686 .0 625.0 845 .0 700.0 950.0
M30 893.0 1211.0 1005.0 1361 .0 1235.0 1675.0 1390 .0 1885.0
M36 1560 .0 2119.0 1755.0 2381.0 2156.0 2925.0 2425. 0 3295.0
8M 8-10080 Issued 03-2001
SECTION 1001 7
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9
SIZE MIN MAX MIN MAX
(mm) Ib ft Nm Ib ft Nm Ib ft Nm Ib ft Nm
M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6
M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0
M6 7.0 9.5 7.8 10.6 10.0 13.6 11 .3 15.3
M8 17.0 23.1 19.1 25.9 24.4 33 .1 27 .4 37 .2
M10 34 .0 46 .0 38.3 52 .0 48.0 65 .0 54 .0 74 .0
M12 59 .0 80.0 66.0 90.0 85.0 114.0 94 .0 128.0
M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205 .0
M16 149.0 200 .0 161.0 220.0 208 .0 285.0 235.0 320 .0
M20 293 .0 400.0 330.0 450.0 408 .0 555 .0 460 .0 620 .0
M22 400 .0 545.0 450.0 615.0 555.0 755.0 625.0 850 .0
M24 510.0 690.0 575.0 780.0 705.0 955.0 790 .0 1075.0
M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0
M36 1770.0 2400 .0 1990.0 2700.0 2445 .0 3315 .0 2750.0 3730 .0
SM 8-10080 Issued 03-2001
Section
1002
GENERAL SPECIFICATIONS
AND TORQUES
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10090 March 2001
2 SECTION 1002
TABLE OF CONTENTS
GENERAL SPECIFICATIONS
Capacities ... ............... ... .......... ...... .. ......... ... ......... ... ... ........ ... ............ .... .......... ... .......... ...... ... ....... .. .... ......... ... ....... 3
Electrical Specifications .. ... ..... .. ............. .. .......... ......... ........ ..... ................... ...... .............. .. ......... .. ..... ............ ........ 3
Steering Specifications ..... .. ..... ....... .. ............... .... .. ............. ....... ........ .. .. ... ... ....... ... ..... .......... .. .... .. .... .... .. ... ......... ... 3
Transmission Specifications ... ... ... ........ ... ..... ..... .... .............. .. ............................. .. ......... ... .. .. .............. ............ ... .... 3
Brake Specifications ................. .... ........ .... .............. ........... ... ............ ..... ........... ... ......... .. ..... ......... .... ............... ...... 5
Hydraulic Specifications .... .. ... .. .. ......... ..... ......... .. ... .. ..... ...... ... ...... ..... ....... ... .... .... ... .... ... ... .. ... ..... ..... ........ .... ... ....... 5
Air Conditioning System Specifications .. .. ...... ...... .... ......... ..... .. ... .... ... ....... .. ......... ..... ................... .... .......... ....... .. .. 6
Conversion Table .... ..... ............. .. ......... .... .......................................................... .. ................ .......... .. ... ......... ......... 6
SPECIAL TORQUES
Steering .... .. .... ........ .... .............. ... ....... .. ..... ... ..... ... ..... ......... ...... ......... .... ......... ......... ........ .. ... ........ ... ............ ... ....... 7
Transmission ........... ... ............... ............................ ............... .. ........ ... ... .... ...... ... .. .. .. .... ....... ..... .... .... ............... ....... 7
Brakes .... ...... ... .. ......... .. .. ... ...... ..... .... .. ........ ... .. ..... .... ... .......... .. .. .......... ... .. ... ...... ... .... ... .. ... ..... ..... ........ ..... ......... ... .. 8
Hydraulics .. .............. .... ............................ ............. .. ......... ... ...... ...... .... ............ ..... ....... ....... ......... ........ ..... ..... .... .... 9
Chassis and Mounted Equipment ......... .. ..... .. ..... ... .. ........ ... .. ... ......... .. ............... .. ......... .. ..... ........ .. ....................... 9
SM 8-10090 Issued 0-3-2001
SECTION 1002 3
GENERAL SPECIFICATIONS
Capacities
TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTA) OIL CAPACITY
2WD Tractors ..... ........ .......... .. ... ......... .... ..... .... .... .... .... ....... .... ........ ... ..... ...... ... ........ .. .......... ..... ..... .... ... .. 34 .5 Litres
MFD Tractors ........... .... ..... ....... ........... .. .. ... .. .... ... ....... .... ...... .. .. ..... ....... ... .... ... .. ....... ........ .. .. ... .. ............ .. .. . 37 Litres
Fuel Tank .... ... ................ ..... ... .. .. .. ..... ..... ........ .... ..... .. ..... ......... .. ..... ... .. .. ...................................... .. ........... 155 Litres
Electrical Specifications
Type of System .......... ... ... ................... .. ..... .. ....... ............ ... ................ ...... ... ... .. .............. ... .. . 12 Volt, Negative Ground
Batteries ............... .. .. .. .................... .. ................. ... .. .. ........... One or Two 12 Volt, Low Maintenance Hybrid Batteries
Connected in Parallel
DIN Type 60527 , Top Stud Terminals
BATTERY SAE (COLD CRANKING AMPERE RESERVE
IEC DIN
TYPE CAPACITY) HOURS CAPACITY
644 660 Amps 440 Amps 400 Amps 95 180 mins
664 770 Amps 515 Amps 465 Amps 105 210 mins
648 810 Amps 545 Amps 490 Amps 120 220 mins
Fuel Level Sender Resistance
Empty ........ .. .............. .. ... .. ......... .. ..... ... ......... .. .......... .. .............. .............................. .. .. .. .. ....... .. ...... .. 28 to 34 Ohms
Full ........................ .. ....... .......... .. ... ..... ......................... ... .. .. .. ............. ....... .. ... .. .. ....... .. ................. 240 to 250 Ohms
Steering Specifications
TRACK ADJUSTMENT
2WD Toe-in .......... .......... .... .................. .. ... ..... ...... .......... .. .. .. .. .. ........... 0 to 5 mm
MFD Toe-in ...... .. .. ................. ........ .............. .. ... .. ................. .. .. .. ........... 0 to 2 mm
STEERING PUMP (ENGINE DRIVEN)
CX50 and CX60
Direction of Rotation ....... ... .. .. .. .. .......... .......... ... .. .. ... .. ....... ..... .. .. ... .. .... ... ... .. .. .......... .... ....... ................ . Clockwise
Flow at 2250 engine rpm ...... .. ................. .... ................. ..... ............... .. .. ..... ....................................... 27 .7 Llmin.
Rated Working Pressure .... ....... ............... .. ... .. ..................... ... ................ ... .................. ...... .................. ... 160 bar
CX70 , CX80, CX90 and CX100
Direction of Rotation .... ........ .. .. ... .. ... ..... .. .. ... .. ................ ... .. .. ..... ............ ..... .. .......... .......... ...... Counterclockwise
Flow at 2200 engine rpm .. .... .. .... ............... .. ...... .... ........ .... .. ........... ....... .. .. .. ....... ........ .... .. ..... .... .. .. .. . 30 .3 Llmin .
Rated Working Pressure ...... .. ................ .. ............................................... ... .. .. .............. ... ................... ..... 160 bar
Transmission Specifications
CLUTCH
CX50/60/70 Tractors
Maximum Clutch Plate Thickness ................................ ....... .. ................. ...................... ....... .................. 10.4 mm
Clutch Plate Diameter ....... ...... .................. ..... ...... .. .......... .. .. ................. ..... ..... .. .......... .. ...... ............. ...... 305 mm
Number of Friction Plate Pads ............ .. ....... .. ...... ..... .... .. .. ...... ........ .. .. .. .. .. .. .. .. ........ ..... ...... .............. 5 each side
CX80/90/1 00 Tractors
Maximum Clutch Plate Thickness .. .. ....... .. ..................... ... ..................... ... ........ ...................... .............. 10.4 mm
Clutch Plate Diameter .......... ... ................ .. .................. ....... .. .... .. ............. ......... .. ...... ..... .. ... .............. .... .. 310 mm
Number of Friction Plate Pads ............................................ ........................ ............ ......... .. .............. 7 each side
SM 8-10090 Issued 03-2001
4 SECTION 1002
SPEED TRANSMISSION
Speed Transmission Synchronizer End Play ...... ... ....... ... .. ....... 0.05 to 0.30 mm
RANGE TRANSMISSION
Pinion Bearing End Play (Maximum) .... .... .. .. ...... .. .......... .. ............................ .. .. .... .......... .. .. .. ........ .... ...... 0.076 mm
Synchronizer Running Clearance .. .......... .... ........ .. .... .. .. .. .. ........ ........ .... .. ........ ...... ...... .... .... ...... ... 0.05 to 0.30 mm
Selector Fork Running Clearance .... ... ......... ....... .. ... ... .. ...... .... .............. ... .. ... ..... .. .. ... .. .. ..... .. ....... .......... .... 0.05 mm
REAR AXLE
Planetary Gear/Planetary Gear Carrier Shimming .......... .... ...... .. .. .. .... .. .. .. .. .. .. ...... .. .. .. .... .. .... refer to Section 6018
DIFFERENTIAL
Differential Lock Selector Ring Clearance (Engaged Position) ........ .. .. ...... .. ...... ............ .... ......... 0.025 to 0.90 mm
Ring Gear to Pinion Backlash ... .......... .. ...... ............ .. .... ...... .. .......... .... .. .......... .... .. .... .... .. ... ....... 0.152 to 0.304 mm
Ring Gear to Differential Housing Run-out ............ .... ....... ........ .. .. ... ......... ....... .. ... .. .. ......... ... ..... ... .. .. 0 to 0 .102 mm
Differential Bearing Rolling Pull ................... ......... .. ............. .. ............ .... ........ ...... .. ........ ... .. .. ......... ... .. 2.0 to 6.5 kg
PTO CLUTCH
Standard Clutch
Number of Friction Plates .. .. ............ .. .. ............................. ... ...... ....... ........................ .. .... ............. .. ............ ... .... 5
Number of Steel Separator Plates (2 between each Friction Plate) .......... .. .. ...... ....... ... .... ......... .. .... .... .. .. .. .. .. .. 8
Heavy Duty Clutch
Number of Friction Plates .. ... .......... ... ... ............... .......... ..... ... .. ..... ..... ......... ... .. .. ....... .. .. ... ....... ... .... ........ .. .. ... .... 6
Number of Steel Separator Plates ...... .............. ..... .......... ... ........... ... ............ ..... ......... .... ........... .... .. ..... ... ....... .. 5
MFD CLUTCH
Friction Plate Thickness (New) .. .......... .... ........... ...... ............ .. ........... ..... ......... ... ......................... . 2.25 to 2.35 mm
Friction Plate Thickness (Minimum) ...... ... ........... .... ........... ... .. ... .. .......... .. ........................ .. ......... .............. 2.00 mm
MFD Clutch Torque ........ ...... ................ ...... .. .................. ......... .... ........ .. .. ...... .. .. ........... ... .. ............. . 638 to 792 Nm
Output Shaft Bearing Preload (without oil seals) ............. .... ............. .. .......... .. .. ................. .............. .. .... 20 to 40 N
MFD Drive Shaft Deflection (below the centre line of the shaft)
(measured at Centre Support Bearing) .... ...... .... ..... ...... .......... .... ...... ........... .......... ... .. ...... ..... .. . 0.50 to 0.55 mm
MFD PARKING BRAKE
Front and Rear Brake Pads (New) ....... ...... ....... ............ ........ .... ....... ... .... ........... .. .......... .... ....... 10.70 to 10.90 mm
Front and Rear Brake Pads (Minimum) ...... .... .............. .. ....... ...... ......... .... .. ....... ...... ....... ........... .. .......... . 10.50 mm
Central Brake Pads (New) .. ...... ... .... ........ ........... .... ............ .... ........... ... .... .... ..... ..... ......... .. .......... .4.00 to 4.10 mm
Central Brake Pads (Minimum) ... ...... .. .. .. ... ........... ... .......... ... ............ .. ............................... .. ..................... 3.50 mm
MFD AXLE
Differential
Separator Plate Thickness .. .... ... .. ..... ... ......... .. .. ... .......... ........ ......... .. .......... ... ........... .. ... ....... .. .. ... ........... 1.5 mm
Friction Disc Thickness ............ .................. .... ................. ... .. ......... .... .. ......... .... .......... .. .. ..... .... .... 1.45 to 1.6 mm
Thrust Plate Thickness ........ .. ......... .. .. .. .. ......... .. ... .... .. .. ................. ... .... .. .. ...... .. .. .. ..... ... .. ........ ...... 2.7 to 2.8 mm
Pinion Shaft Bearing Preload ... ........... ... ....... .... ...... ...... .... ... .. ..... .. ....... .. ..... ... .............. .. ............ .. .. 105 to 157 N
Pinion Shaft/Differential Bearing
Total Preload ............................ .... .... .. .. .. .. ... ............. .. .... .. .... ....... .. ...... .... ...... .. .. .. .. 105 to 157 (+ 29.5 to 44 .1) N
Bevel Gear to Pinion Backlash ....... .... ...... .............. .. .......... .. .... .. ....... .. ............. .. ............ .. ............. 0.16 to 0.22 mm
Lubricants
Planetary and Wheel Hub
Type ........ ..................... .. .... ... ..... ...... .. ... ... ... ........ ... ....... .... .. .. .. ...... ........ .. ............ .. ....... ....... SAE 85W-140EP
Capacity, per Hub ........ ....... ... .. .... ... .............. .. ............ .... ......... ... .............. .......................... ........ ..... 0.6 Litres
Differential/Axle Housing
Type ........................................... ........... ... .... .......................... ....... ... .. ............ .. ............ ....... SAE 85W-140EP
Capacity .......... ... .. .. ... .. ........................ ......... ....... .......... ... ....... .. ..... .............. .. .......... ........... ........ ...... .. 6 Litres
Grease ..... .. ....... ..... .. ... .. ... ........... ... .. ... .. ... ... ...... ... .. ..... .. ... ...... .... ... .. ............ ............ Multi-Purpose Lithium Grease
SM 8-10090 Issued 03-2001
SECTION 1002 5
Brake Specifications
2WD PARKING BRAKE
Number of Friction Discs ....... ... .... ............. ..... ... .. ........ ... .. ................. ....... ....... ................. ....... .......... ..... .... .. ......... 3
Number of Stationary Discs ..... .... .................... ... ................ ... ... ................ ....................... ... .. .......... ... ........ ........... 3
Friction Disc (New) ............... ..... ..... ........ .. .... ... .. ... ... .......... ..... ................ ...... ........... .. ....... .................... .... . 2.90 mm
Stationary Disc Thickness (New) .... .............. ........ .............. ... .......... .... ...... .... .......... .... .... .... .. .... ...... .. ....... 1.80 mm
Type ........... .. ............................... ........ ................ .. ..... ... ..... ... .... ............. ... Hydraulically Operated Oil Cooled Disc
Inner Brake Ring Backlash .. ........ ... ........ .'...... ........ ............. .. ............ ... .. ....... .... .. .......... ........... .. 0.127 to 0.635 mm
Brake Piston Test Pressure
Low Pressure Test ........... ..... .................. .. .. ... .............. .... .. .. ... .. ........ ....... .. .. ... 4 Steps of 3.4 bar up to 13.8 bar
High Pressure Test. ............. .. ..... .. ... ......... .. ... .. ..... .. ..... ... .. ..................... .. ......... .... ................ .. .. .... .. .. ..... .27.6 bar
Hydraulic Specifications
CX50/60 CX70/80/90/100
Hydraulic System Type Open
Steering Hydraulic Pump 27 .7 Llmin. 30.3 Llmin.
at 2250 engine rpm at 2200 engine rpm
Transfer Pump 36 Llmin .
Flow to 540/750 PTa 50 .2 Llmin .
Remotes 59.4 Llmin.
540/1000 PTa 51.7 Llmin .
Main Hydraulic 540/750 PTa 50.2 Llmin .
Pump 59.4 Llmin.
540/1000 PTa 51.7 Llmin.
Pump gear 540/750 PTa 23 19
(No. of teeth)
540/1000 PTa 27 23
Pump mounting N/A 5.31 to 5.43 mm
plate thickness
Main Relief Valve Pressure ...... ... .................. ... ................. ... .. .. ............... ..... .................. ..... ................. .... 172.5 bar
Remote Detent Kick-out Pressure ............... ..... ................. ... .. .............. .... .. ... ....................... .. .... 144.7 to 172.3 bar
Steering Relief Valve Pressure ...... ... .. .. ..... ..... .... .......... .. .. ............ .... .... .. ......... ............ .. .. .... ........... .. 141 to 148 bar
Regulated Pressure ..... ... .. ..... .... ..... ........ ... .. .... ...... ............. ..... .. ............... ... ... ... ......... .......... ... .... ... ..... ...... ... 20 bar
Oil Cooler By-pass Pressure ..... ........... .. ...... ... ...... ............. .... ... ............... .... .. .. ..... ... ...... ..... ... ......... .. ...... ... 10.4 bar
Steering Return Flow
CX50/60 at 2250 engine rpm .. .............. ........ ......................... ........... ......... .... .. ..................... ............ 27 .7 Llmin .
CX70/80/90/100 at 2200 engine rpm .. ..... .. ........................ ............ .. ........ .... .................... .. .. .. ..... .. .... 30 .3 Llmin .
Oil Cooler Flow
CX50/60 at 2250 engine rpm .. .. .. ...... ..... ... .. .. .. .............. .. ....... .. ......... .. .. .. ................. .. .. .. .................. . 23.7 Llmin.
CX70/80/90/100 at 2200 engine rpm ...... .. .. .. ......... .. ... .......... .... ....... ......... .. .... .. ........... .... ..... .. ........ .. 26 .3 Llmin.
PTa Control Spool Assembly
Return Spring - Free Length .. ......... ............. ..... ..... .. ........ .... ..... .. ................................ .. .... ........ .... ... ... 79 .63 mm
High Pressure Spring - Free Length .... .......... .. ... .. ... ...... .... ............ ..... ....... ... .. .. ....... .......... ....... .. .. ..... 29 .65 mm
Low Pressure Spring - Free Length ......... .... ... .......... .. ................ ............................... .... .............. .. .. .. 24.42 mm
Hitch Valve
Load Check Spring - Free Length .......... ................. .. ..... .... .. .............. ........ ................ .... ................... ... 29.7 Mm
Secondary Raise Spring - Free Length ....... ....... .. ..... .. ......... ... .... .... .... .. .. ..... ............... .. .. ............ .. .. .. ... 40.4 mm
Hydraulic Oil Test Temperature ..... .. ..... .. .. .......... ..... ..... .......... .. ...... .. .............. ....... ... ...... ... ....... .. ........ .... .... ....49° C
8M 8-10090 Issued 03-2001
6 SECTION 1002
Air Conditioning System Specifications
Refrigerant Type ...... ..... .. ... ... ...... ........ ....... ...... ...... ....... .... .. ... ................ ...... .... . HFC - 134a Per ARI Standard 700
System Capacity ... ......... .. .... .... ..... ... ... ... ........................................................................ ......................... 1.93 kg
Boiling Point at Atmospheric Pressure .....................................................................................................- 26° C
Compressor
Manufacturer ... ...... ................ ... ...... ..... .......... ..... ............... .... ........... ................................... ......... ........ SANDEN
Model ... .... ............ ... ......... ... .. .......... ..... .... ........ .. .. .......... ... ............ .. ....... ..... ...... .......... ..... ....... SD 7H15MD4609
Number of Cylinders ............. ... ........ ......... ........ ...... ..... .. ...... ........... ..... ....................... .. ............... ... ........... ... .... 7
Displacement Per Revolution .............. ..... ..... .................. .. .................................................................. ..... 155 cc
Clutch Voltage .... ......... ........... ......... ... ....... ......... ..... ........................ ....... ....... .......... .. .. ............ ... ....... ....... .... 12V
Clutch Coil Amperage Draw at 12 Volts ...... ........ ........ .. ....................................................... 3.6 to 4.2 Amperes
Front Clutch Plate Air Gap ............................................................................................................ 0.4 to 0.8 mm
Drive Belt Tension (New) .............................................................. ............ .. ............ .... .. ...... .......... . 422 to 516 N
Drive Belt Tension (Used) ........ .......... .... ........ .......... ............ .. ........ ...... .......... .. .......... .. .. ................ 400 to 489 N
Compressor and System Lubrication (Nominal)
Lubricant Type ...... .. .............................. .. .. ........ ............. ... .. .. .................. .. ................... Sanden SP - 20 PAG Oil
Compressor Capacity (New) ......................................................................................................... 270 to 300 ml
Compressor Capacity (Previously Run) ......................................................................................... . 50 to 100 ml
Component Capacity (add to compressor when component has been replaced)
Receiver Dryer .............................................. ..... .......... .... ..... ..... ... ........... ............ .... ... ....... .. ......... 25 to 30 ml
Condenser ......................................................... ........ ..... ......... .... ........................... .... ............ .. ... 45 to 50 ml
Evaporator ..... ..... ... ........ ..... ......... ............... .... .... ... .. .. ............. ... ... ........... ........ .. .......................... . 35 to 40 ml
Hose and Tubes (Total) .... .... .. .......... ................ ............ ........ ........................................................ 45 to 50 ml
High Pressure Switch
Location ................................................................................. Discharge Hose from Compressor to Condenser
Operation ... .. ..... ... .. ....................... ... .. ... ......................... ................ ............... ..... Closed by Excessive Pressure
Cut Out Pressure ....................................... ..... ....... ..... ... ..... ......... ..... .. .. ....... ... .... ...:................... 26.9 to 28 .3 bar
Low Pressure Switch
Location ...... .......... ........ ........ ................................ ........ ...... .......... .... .......... .. Evaporator Outlet in the Cab Roof
Operation ......................... .. .. ... .. .. ........................................................... ..... ....... .. ........ Closed by Low Pressure
Cut Out Pressure ............................................................... ............ ..... ........ .... .......... ...... ........... 0.14 to 0.41 bar
Temperature Control Switch
Location ........ .......... .. ........................................ .. .............. .. ........................... Evaporator Core in the Cab Roof
0 0
Cut Out Temperature (Maximum Cold Setting) ............................................................................ 0.8 to 2.5 C
0 0
Cut In Temperature (Maximum Cold Setting) .. ........ .. ...... ....... .......... .... ........................ .... ........ .... 5.8 to 7.5 C
Coolant
Fluid Type .................................... ........... .............. ................................. 50 percent Ethylene Glycol and Water
CX50 and CX60 Tractors
Capacity ............ .. ... ....... ...... ......... .. ....... .. ....... ...... ......... .... ..... ... ... .. ........... ... ........ .. .... ..................... 13.4 litres
CX70 , Cx80, CX90 and CX100 Tractors
Capacity .......... .... .......... ......... ..... ....... ................. ................................... .. ..... ......... ............. .... ....... 17.5 litres
Conversion Table
Conversion Conversion
mm X 0.03937 =inches N (Newtons) X 0.225 = Ibf
Bar X 14.5038 = PSI NM X 0.738 =lb. ft
Litres X 0.22 = Imperial Gallons NM X 8.85 = lb. in
Litres X 0.264 = U.S Gallons ° C X 1.8 (=32) = ° F
8M 8-10090 Issued 03-2001
SECTION 1002 7
SPECIAL TORQUES
NOTE: To convert NM to lb . ft. see Conversion Table on Page 6.
Steering
Steering Wheel Retaining Nut ... ......... ........................ ... ......... ........ ...... ............ ..... ....... ...................... .. .. . 45 to 51 Nm
Steering Hand Pump Retaining Bolts .... .... ..... ........ ....... .... .... ...... .... ............ .. ....... ......... .......... ..... .. ... .... .. 45 to 51 Nm
Steering Hand Pump End Cover Retaining Bolts ... ............. ... .. .................. ..... .............. ...... ... .. .. ............. 25 to 35 Nm
Steering Relief Valve Plug ...... ........ .... ........... ...... ... ...... ....... ........ .. .. ............ .. ................... .......... ......... .... 40 to 60 Nm
Front Weight Bracket Retaining Bolts ..... ... ........ .. .... .. ... ......... ...... .... .... .... ... .... ...... ... ..... ......... .......... .. .. 481 to 542 Nm
Front Wheel Nuts ...... ....... ..... .... ........... ...... .................. ...... ....... .refer to Operators Manual for correct wheel rim size
Wheel Bearing Nut ... ......... ..... ...... ... .... .............. .... ...... .... ...... ...... .. .. ... refer to Section 5003 for tightening procedure
2WD Front Axle
Tie Rod Lock Nut. ... ................. .... ............... ... ...... ................ ..... .............. ....... .... ............ .... ................. . 34 to 40 Nm
Tie Rod Lock Bolt.. ....... ..... ..... ........ ...... ..... .... ... .... ... ... .... ... ........... ..... ... .... ..... ... .. .... .. .......... ...... .. ...... .. . 81 to 88 Nm
Tie Rod Tube Lock NuL ... .... ... ..... .... ....... .. .... ..... ....... .................. ..... ..... ............. ................ ............ 235 to 250 Nm
Steering Arm Clamp Bolt. .... .... .. ........ .... .......... .... ...... .. ........ .. .. .. ................ ................ .... .... .. ...... .... .. 108 to 122 Nm
Wheel Bearing Nut .... ................ ........ ........ .. .... ...... ................ .... ................ .. .. .................. .. .. .. refer to Section 5003
2WD Steering Cylinder
Cylinder Clevis (with Loctite 270) .... ........ .. ...... .. .. .... ........ .. .. ........................ ..................... .... ........... 110 to 135 Nm
Cylinder Clevis Pin Retaining Bolt.. .. .. ................... ......... ........... ... .... .... .. .. .... ..... .... .. ... ........... ....... .. ..... 27 to 31 Nm
Lower Bearing Carrier Retaining Bolts .. .. ..... .. ..... .... ...... .. .......... ............ .. .... .. .. .. ...... ..... ......... .......... 110 to 122 Nm
Steering Pump (Engine Driven)
Retaining Bolts ...... ................. .. .. ..... .. .......... .. ... .................. ... ...... .. ..... .. ... .. .. ........ ....... .... ....... .............. 41 to 48 Nm
Inlet Tube Retaining Screws ...................... ...... ................ ..... ................. .. .... .... .. ....... .. .... .... ................ 23 to 31 Nm
Front Bolster to Engine Retaining Bolts (with Loctite 271) .... ...... ....... ...... .... ..................... .. .. .. ..... .. ..... 258 to 284 Nm
Front Bolster to Engine Retaining Nuts (with Loctite 271) ............. .... .. .. .. .. .... .. .. .. .. ...... ...................... .. 258 to 284 Nm
Transmission
Flywheel Retaining Bolts ... .. .. ...... .. .. ....... ...... ... .. ....... ....................... ... .. .. .. ...... .......... ................. .......... 116 to 130 Nm
Clutch Retaining Bolts .... .... ........ .. .. ........ .... .. ...... .. .............. ... .. .......... .. .. ..... ............. ...... .......... .. .. .. .... .... .. 20 to 23 Nm
Engine to Speed Transmission Mounting Bolts .. ................... ...... ............. ... .... ................ ...... .............. 122 to 129 Nm
Speed to Range Transmission Retaining Bolts
1/2 inch Bolts (With Loctite 271) ........................................................... .... ............... .. .... .. ............... 101 to 104 N m
5/8 inch Bolts (With Loctite 271) .. .... .. ..... ..... ... ........ .... .... .... .... .. .. .... .. .... .. .......... ...... ........ ... .. ................ 205 to 230 Nm
Main Shaft Retaining Bolts .... ..... .. .. .... ............ ........ .... ........ .. ...... ...... ....... ... .......... ........ ... .. .. .. .... .... .... .. .... 42 to 47 Nm
Selector Fork to Selector Rail Lock Bolt.. ..... ...... ................ .. ........ .... .. .. ....... ...... .................. ...... .. .. ........ 89 to 100 Nm
Selector Fork to Selector Rail Lock Nut... ........ .. ..... .. ............. .. .... .. ................ .. .................. .. .................... 53 to 59 Nm
PTO Bearing Retainer Bolts (with Loctite 271) ...... ................. ...... ...... .. ................................. ...... .. .......... 42 to 47 Nm
Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) .... .... ........ ... .. .......... .. ......... .. .. .. .. ..... .. 42 to 47 Nm
Pinion Shaft Retaining Bolts .......... .... .... ............. .. .. .. ................ .. ...... ....... .... .............. .... ... ......... ....... ..... .. 42 to 47 Nm
Planet Carrier Retaining Bolt ............... .. ............................................ ................ .................. .. .............. 290 to 330 Nm
Rear Axle Mounting Bolt.. .......... ... ............ ........ .. ............ ....... .. .. .. ......... ....... ..... .. .. ............... .... ............ 270 to 305 Nm
Flange Axle - Wheel Nuts ......... .. .... .. ....................................... .. .. ..................................... ... ........ .. ...... 278 to 298 Nm
Bar Axle - Wheel to Hub Bolts ..... .. ... ..... ...... .. ........ ....... ... .... .. .. ........... ..... .... ....... .. ......... .. .. ...... .. .. ........ 183 to 207 Nm
Differential
Ring Gear Dowel Bolts .......... .... ............. .......... .... ............ .. .. .. .................. .. ..... .. .............. .... ............ 156 to 170 N m
Ring Gear Retaining Bolts ... .. .................... .. ... .. ............... .... .. .......................................... .... ............ 156 to 170 Nm
Bearing Carrier Retaining Bolts ........... ................ .. .......... .... .... .. ...... ......... .... .. .. .... ........... ...... .......... 156 to 170 Nm
PTO Clutch Access Cover .. ........ ...... .. ... .. .. .. .. ..... ....... .. ...... ..... ........ ...................... ..... ...... ....... .. .. ....... .. 117 to 133 Nm
PTO Shaft Cover Retaining Bolts ...... .. .......... ...... ......... .. ............... ........ ...................................... .. .. .. ..... . 45 to 50 Nm
PTO Clutch Access Cover Retaining Bolts ....... .. .... .......... ..... ..... ................... ... .. .. ............................... 117 to 133 Nm
PTO Housing
3/8 inch Retaining Bolts ..... ....... ...................................... .. ....... ................ .. ................... .. ... .. .. ............. 45 to 50 Nm
1/2 inch Retaining Bolts ...... .. .. ......... .. ............ .... ............................. .. ........ ..... .... .. ............. .. .. .... ...... 136 to 152 Nm
SM 8-10090 Issued 03-2001
8 SECTION 1002
MFD Transfer Gearbox
Mounting Bolts ........ .. ........... ............ ...... ... .. ........ .......... .. ........ .... ......... ......... .. ................... .............. 117 to 133 N m
Drain Plug ....... ... ....... .. ........ ......... .... .... .. ..... ........ .... .. .. .. .. ...... ..... ........ ... ...... .. .... ... ...... .............. ... ..... ... ..... .... 80 Nm
Front Cover Retaining Bolts ...... ... ...... .......... .. .. .. .......... .... ... ...... .......... ..... ..... .. .. ......... ........ ... ......... .. ..... .. ... .. 23 Nm
Rear Cover Retaining Bolts ........... ................ ... ... ... ... ............ ... .......... .... ....... ...... .... ...... ..... ... .. ..... .............. .. 23 Nm
Brake Pad Guide Pin Plug ......... .. ................ ... ..................... ..... ........... .... .. .. .... ...... ... .......... .... ... ... ...... ....... 150 Nm
Solenoid Cover Retaining Bolts .... ... ...... ..... .. ... ... ... ........ .. ....... ........... ............. ... ........ ............ .......... ... ........ . 12 Nm
Solenoid Valve ... ..... .... ...... .. ... .. ..... ... ........ .. .................. ... .. .. .... .. ........ ..... ........... ..... ....... ......... ...... ... ... ...... ... . 27 Nm
Drive Shaft Coupling Locknut.. .. ...... .. .... ............... .... ......... ...................... ... ....... .... ....... .. ...... ...... ..... .... .. .. 54 to 61 Nm
MFD Axle
Axle Support Housing Retaining Bolts ....... ........... ....... ...... ....... ... ....... .. .. ....... ... ........ .. .... ..... ... ....... .. .. ....... . 200 Nm
Wheel Hub Drain/Filler Plug ........ .... ....... ..... ...... .... ............... ...... ........... ........... ......... .... ...... .... ... ... .... ........ ... 80 Nm
Axle/Differential Housing Drain Plug .................... ................. ... ....... .................... .. ...... .. .... ....... ..... .. ... ....... ... 70 Nm
Axle Dipstick ... ....... ... .. ...... ............ ... ........ .. ........ ..... ....... ... ........ ........... .... ....... ... ....... ..... ........ ... .. .... ..... ........ . 10 Nm
Wheel Hub to Planetary Gear Carrier Countersunk Screws ...... ...... ... .... ... ... ..... .... ... .... ... .. ... ... ....... ... ......... . 25 Nm
Planetary Gear Carrier to Swivel Housing Retaining Bolts ... .. ..... .. ...... ... ... ....... .. ............. ........ ........ .. ...... .. .. 78 Nm
Upper and Lower King Pin Retaining Bolts ......... ... .. ....... ... ...... ............. ............. ........... ........ .... ....... ........ .. 120 Nm
Differential Housing to Axle Retaining Bolts ........ .......... ...... ..................... .. ...... ....... ..... .................. .... ....... . 169 Nm
Bevel Gear Retaining Bolts (with Loctite 270) ... .. ... ..... ..... ...... .. .. ........ .. ........ .. .. ... .... ..... ...... .. .......... ...... ........ 78 Nm
Differential Bearing Cap Retaining Bolts ... .. .. ... ...... .. ..... ... ...... .... .... ... .. ......... ... ....... .... .... ...... ... ..... ...... ..... .. . 266 Nm
Locking Plate Retaining Bolts ........... ....... .. .. ..... .......... ...... .. ... ....... ... .. .... ... .. ... ... ... ... ..... .... .. ....... .. ..... .. ...... .... 12 Nm
Ball Joint Assembly to Steering Cylinder Piston Rod ... ... ......... ........ ....... .......... ....... .. ........... ......... .. ,........ . 300 Nm
Ball Joint Locknut .... ... .. ......... .... ... ... ... .. .. .. .. .... ..... .. ............. .... ..... .. ....... .... ... ..... ...... .......... .............. .. ... ....... 165 Nm
Steering Cylinder Retaining Bolts ............ .... ................. .. ... .... .... ....... ... ... .................. ............ ..................... 120 Nm
Front Wheel Nuts ... ........... .... ....... .... ........... ... .... ........... ....... .. ... ........... ...... .... ... ........... .. ... ... .... .. ..... 300 to 350 Nm
Front Weight Bracket.. ............ ... .. .... .... ..... .. ..... .. ... ............ ....... ... .... ..... .. ... .............. .. ........... ...... ...... 481 to 542 Nm
Wheel Stud ........... .. .......... ...... .. .. ............. .... ... ...... ...... .. .... .... .. .... ........... .................... .. .......... .. ..... .. .. ... ...... ... 70 Nm
Brakes
Parking Brake Cable Bracket Bolts ... .............. .......... ........... .. ....................... .. ........ ......... ....... .. .......... .... 45 to 50 Nm
Parking Brake Support Bolts ........ ...... ............. ............................ ............. ........................ .. ..................... 45 to 50 Nm
Parking Brake Assembly Support Nuts ............................................. ....... ................... .. .. .... ...... .. ........ 156 to 176 Nm
Hydraulic Trailer Brake Valve
End Cap Socket Head Screws ...... .... ... .... ... .. .............. ..... .. .......... ............ ........ .. .... .. .................................... 10 Nm
Bleed Valve .... .... ... .. ................. .. ....... ................................. .. ..... ............................... ................ ... .... .. .... .. .. .. 2.5 Nm
8M 8-10090 Issued 03-2001
SECTION 1002 9
Hydraulics
Filter Manifold Retaining Bolts ........ ................. .... .......... .... .... .. ... .... ................. ......... ..... ........ .. ...... .... ... . 45 to 50 Nm
Hydraulic Filter Retaining Bolt ..... ...... .. ............... ..... ......... ... ......... ......... ..... ..................... ... .............. ... .. 16 to 21 Nm
Main Hydraulic Pump Retaining Bolts .......... ......... ........... .......... ................ .............. ...... ........ ........ ..... .. 24 to 28 Nm
Main Hydraulic Pump Drive Gear Locknut ....... ... ............. ..... ..... ......... ......... ... .................. ... ... ..... ......... 61 to 68 Nm
Main Hydraulic Pump End Plate
Retaining Bolt ...... ......... ... .... ............... ... ............ ....... ... ... .. .... ........ .......... ....... .... .... .. .......... ..... ........ .. .. 27 to 31 Nm
Cap Screw ....... .. ............. ..... ..... ... ............. ..... ....... .......... ........ ... ....................... ........ .... .... .... .. ............ 24 to 27 Nm
Main Relief Valve ...... ... ............. ... ............. ...... ... ..... ........... .. ..... .... ............ .......................... ... .. .............. 34 to 54 Nm
Fitting, PTO Spool Supply ........ ... ... .. .............. ... ...... ............ ..... ..... ............. ... .... .. ..... ....... ... .... ............... 34 to 54 Nm
Elbow, Filter Manifold Inlet ........ ...... .............. ..... ... .... .. ...... ... ...... ........................ ...... ... .... .................. ..... 34 to 54 Nm
Plug , PTO Spool ...... .. ............ .... ... ...... ....... ..... ......... ...... .. .. ........... .. .. .. ...... ..... ... .. .............. .. ... ... ............. 34 to 54 Nm
Hitch Valve Plugs and Cap Screws ........................................................................................... refer to Section 8009
Regulator Valve
Retaining Bolts ...... .............. ..... .. ................. .. ... ...... .. ........ ........... .. .. ....... ..... .... ......... .. ....... .... ............. . 42 to 47 Nm
Solenoid Valve to Regulator Valve ................................................................................. ....... .............. 10 to 15 Nm
Coil to Solenoid Retaining Nut ................................................. ...... .. ... .. ............... ...................... .. ........... 5 to 8 Nm
Regulator Pressure Valve Locknut.. .............. .... ............... ...... ............... .... ......................... .............. ... 34 to 54 Nm
Oil Cooler By-Pass Valve Plug .... .............. ........ ... ... ........................................ .............. ... .. .... ............ . 34 to 54 Nm
Solenoid Valve Plug (8 Speed Transmission) ..................................................................................... 34 to 54 Nm
Differential Lock Solenoid
Coil to Solenoid Retaining Nut .............. .. ....... ........... .. ..... ...... ... .. ..... .... ..... ...... .. .... ......... ...... ................... 5 to 8 Nm
Unloader Valve
Retaining Bolts ......................................... ..... ... ..................... ... ................. ..... ................ ..................... 42 to 47 Nm
Regulator Valve Plug ........... ........ .... ..... .. ....... ..... ................................................................................. 34 to 54 Nm
Remote Valve
Retaining Bolts ...................................................... .... ..... .. ......... .............. .... ... .. ............... ............... ... .. 16 to 20 Nm
Hydraulic Housing
3/8 inch Retaining Bolts ..... ....... ................. .. .. ... ......... .. ...... ... .................. ........ ............... .. ................... 45 to 50 Nm
1/2 inch Retaining Bolts ......... .... ..... .. ...... ........ ................... .... ..................... .. .. .. .............................. 108 to 122 Nm
Front Hitch
Mounting Bolts ......... .... ....... ......................... .. .......... .. ..... ... .............. .... ..... ............... .. ..................... 406 to 490 Nm
Front Cover Bolts ........ .. ... .. ... .... ..... ... ....... ...... .......... ... ............. .. .................. .. .... .. .............. .................... .. .. 257 Nm
Piston Retaining Nut ............ .... ... .... ......... ... .... .. .... ................... ..... ............ ..... ................ ..... ................... ... . 776 Nm
Chassis and Mounted Equipment
Cab Mounting Nuts .... ......... .. .. .......... .. .. ........... ........ ... .. .... ... ......... .. 190 to 244 Nm 140 to 180 Ib ft
Cab Mounting Bolt to Threaded Plate .............. .. ................ ........ ........ 47 to 61 Nm 35 to 45 Ib ft
Air Conditioning System
Fittings With O-Rings THREAD
FITTING TORQUE M10-1.25 5/8-18 3/4-16/18 7/8-14/18 1-14
Steel to Steel Nm - 31 to 36 40 to 46 45 to 52 -
Brass, Copper or
Aluminium to Nm 10 to 14 18 to 23 24 to 30 30 to 37 45 t052
Steel
IMPORTANT: Lubricate all threads and o-rings with mineral oil.
IMPORTANT: When tightening the air conditioner tubes and hoses, always use a second wrench for
support.
8M 8-10090 Issued 03-2001
Section
3005
FUEL TANK REMOVAL AND SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-101 30 March 2001
2 SECTION 3005
TABLE OF CONTENTS
SPECIFICATIONS ...... ............... .... .............. ............ ... .. ............................. ................ ........ .... ........... ....... ........... ...... 3
SPECIAL TOOLS ....... ........ ................ ..... .. .................. .. ........ .... .... .. .......... ......... ........ ....... ............................ .. ... .... .. 3
FUEL TANK
Removal and Installation ......... .... .. ...... ......... ... ... .... .. .... ....... ................................................................................. 4
FUEL LEVEL SENDER
Removal and Installation ........................................................................ .. ......... ........ ....... .. .... ......................... ... .. 6
Fuel Level Sender Testing ... .... ... ...... ..... ............... ......................... ..... ............... ............... .......... ........ ................ . 7
8M 8-10130 Issued 03-2001
SECTION 3005 3
SPECIFICATIONS
Fuel Tank capacity ... .................................................................................................................................... 155 Litres
Fuel Level Sender Resistance
Empty ............ ............................................................. ............................ .......... ............ ................... 28 to 34 Ohms
Full ..... ... .... ....... ............... ..... .. .. ............. ........................ ... ................. ....... .... .......... .. ... ........ ........ 240 to 250 Ohms
SPECIAL TOOLS
1. MULTIMETER KIT MC2616
SM 8-10130 Issued 03-2001
4 SECTION 3005
FUEL TANK
Removal and Installation
NOTE: For Installation follow the Removal procedure in reverse order.
Before removing the Fuel Tank carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation , connect the positive (+)
terminal first.
STEP 2
DP98A148
Disconnect harness connector (5). Put identification
marks on fuel feed hose (6), return hose (7) and
breather hose (8). Release the hose clips and
disconnect the hoses from the fuel sender. Cap the
hoses and tubes.
DP98A146
Place a suitable container under fuel tank drain plug STEP 5
(1). Remove the plug and drain the fuel. When fuel
has drained install and tighten the plug. Remove
retaining nut (2) and disconnect retaining strap (3).
NOTE: The capacity of a full fuel tank is 155
Litres.
STEP 3
DP98A145
Support the left hand cab steps and remove the
retaining bolts. Remove steps (9) .
DP98A149
Remove the cab floor mat, remove the retaining bolts
and remove access plate (4) .
8M 8-10130 Issued 03-2001
SECTION 3005 5
STEP 6 STEP 9
DP98A144 DP98A142
Remove the fuel tank retaining bracket bolts and Support the front fuel tank mounting bracket and
remove retaining bracket (10). remove retaining bolts (13) . Remove bracket (14).
STEP 7 STEP 10
DP98A143 DP98A141
Support the fuel tank on a suitable hydraulic jack and Carefully lower and remove the fuel tank.
carefully pull the fuel tank outwards.
STEP 11
STEP 8 Remove the fuel level sender, refer to Page 7.
NOTE: For Installation, follow the removal
procedure in reverse order. After installation
remove air from fuel system, refer to your
engine service manual.
DP98A147
Remove retaining bolts (11). Remove rear fuel tank
mounting bracket (12).
8M 8-10130 Issued 03-2001
6 SECTION 3005
FUEL LEVEL SENDER
Removal and Installation
NOTE: For Installation follow the Removal procedure in reverse order.
Before removing the Fuel Level Sender carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 12 STEP 15
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation , connect the positive (+)
terminal first.
STEP 13
DP98A140
Note the position of the fuel sender tubes. Remove
retaining screws (6) .
STEP 16
DP98A149
Remove the cab floor mat, remove the retaining bolts
and remove access plate (1).
STEP 14
DD97N021
Remove fuel sender (7) from the tank, remove and
discard gasket (8). Cap the fuel tank sender opening.
NOTE: For Installation, -make sure the fuel level
sender tubes are in the correct position.
DP98A148
Disconnect harness connector (2). Put identification
marks on fuel feed hose (3), return hose (4) and
breather hose (5). Clamp the hoses and release the
hose clips. Disconnect the hoses from the fuel sender.
Cap the tubes and fittings .
8M 8-10130 Issued 03-2001
SECTION 3005 7
Fuel Level Sender Testing
STEP 1
,
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0097N018
Place fuel level sender (7) on a clean work surface. /
Connect multimeter MC2616 between the terminals
of the fuel sender, check resistance of the sender in
/
full (A) and empty (8) positions.
Ol97N010
FLOAT POSITION RESISTANCE
(A) FULL 28 to 34 OHMS
(B) EMPTY 240 to 250 OHMS
SM 8-10130 Issued 03-2001
Section
4001
ELECTRICAL SCHEMATICS
CX Series Tractors
~ © 2003 McCormick Tractors International Limited .
McCORMICK SM 8-10140 March 2003
2 SECTION 4001
TABLE OF CONTENTS
SPECIAL TOOLS .. .. ........... .... ....... ... ..... .. ....... .. ...... ... .... ...... ... .............. ....... .. ........ ............ .......... ........ .......... .... .... .. . 4
CIRCUIT TESTING
General Information ....... .... .. .... ... .... .. .. ... ..... .... .. ......... ........... ..... ..... .. .. ... .. ..... .. ..... ..... .... ..... ... .. ....................... ...... 5
Schematic Symbols ................. .. ............ .. .. ........... ... ........... .... ........ ... .... ........... .............. .... ........... ... ........... ... ..... 6
Schematic Legend .... .. ........... ................ .. .......... .. ............. .. ..... .......... ......... .. ...... ........... .... ........... ............. .. ........ 7
Wire Colour Code ... ....... .... .... .... ... .... .. ... ..... ... ....... .. .. ... ....... .. .. .... .... ... .... ........ ... .. ......... ... ......... ... ... ...... ..... .. ........ . 7
FUSE LOCATION AND IDENTIFICATION
- European Specification Tractors ........ .. ............. .. .......... ... .. .... ..... ... .. ......... .... .. ...... ....... ...... ......... .... .......... .. ....... 8
FUSE LOCATION AND IDENTIFICATION
- American Specification Tractors ............ ..... ...... ........ .. ..... .. .............. ... .......... ... ..... ...... ..... ........... .. ............ ... .... 10
SWITCHES AND CONTROLS
Instrument Panel ..... ................ .... ........... .... ............ ............... ............. ............................... .. .......... ................. .. .. 12
Right Hand Console Controls (Upper and Lower) ............. .... ........ ...... ... ..... ... .... ............ ................. .................. 13
Deluxe Cab Roof Controls - Operator Environment ...... ....... .............. .. .. .......... ... .. .... ... ..... ....... ... ... .. ... ... ...... .... .. 13
European Specification Low Profile Cab Roof Controls
(Operator Environment) ..... ... ............. .. ............. ... ........... ... ............ ......... .. .... .... .......... ... ............ .............. ...... 14
HARNESS LAYOUT AND CHASSIS GROUND LOCATION
Instrument Panel Harness Components - Tractors Without Ride Control ... ... ........... ..... .... .......... ... ... ....... .. ...... 16
Instrument Panel Harness Components - Tractors With Ride Control ........ .. ..... .. ...... .. ... ......... .. ...... .. ... ....... ..... 17
Right Hand Console Harness Components
- Tractors Without Ride Control ........ .............. .. .. .... ...... .. ............ ............... .. .. .. ......... ..... ........... ... ................ .. 18
Right Hand Console Harness Components
- Tractors With Ride Control .............. ..... ............ .......... .. ....... .... ... ............. ..... .. .. ....... ... ...... .......... .. ..... ..... ..... 19
Engine and Hood Harness Components ............ .. ............. .. ............ ................ ........ ...... .............. ............... .. ..... 20
Transmission Harness Components - Tractors Without XtraShift .................... .. ........... ... .. .. ....... .. ... ........... ... ... 21
Transmission Harness Components - Tractors With XtraShift .... .... ....... ....... ..... ... .. .. ............. ......... .. ............ ... . 22
Deluxe Cab and Rear Fender Harness Components .. ...... ................ .................. .. ............ ............ ..... ........ .. ... .. 23
European Specification Low Profile Cab Harness and
Rear Fender Harness Components ... .... ....................................... .............. ............ ........... ........ .................... 24
Platform Harness Rear Fender Harness Components .... ...... ... ....... ..... ............. ....... ..... ......... ...... ...... ........ .... ... 25
STARTER MOTOR, NEUTRAL START, FUEL SHUT-OFF,
COLD START AND CAB POWER RELAy ....... ... ....... .. ... .. ..... .. ... .. ..... .... .... ....... ......... .. ....... ... ....... ..... ........ ..... .. 26
ALTERNATOR AND INSTRUMENT CLUSTER
WARNING LIGHTS AND GAUGES .. ........ ........... ... ....... .. ............................................................ ... .. ...... ...... ..... 32
PARK BRAKE WARNING, FRONT PTO AND
EUROPEAN SPECIFICATION AIR TRAILER BRAKE ............................ .... .... ...... ........ .... .. ........ .... .... ........ ...... 36
TWO-SPEED POWERSHIFT
- Tractors Without XtraShift ...... ........ .. .. ...... ............. ....... .. .................... ................. .. ......... .. ........ ... .............. ....... 41
ROTARY BEACON LIGHT, IMPLEMENT INTERFACE CONNECTOR
AND 3 PIN AUXILIARY POWER CONNECTORS .......................... .. ............... ........ ................... ... ........ .. .. ....... 45
HORN, CIGAR LIGHTER, EUROPEAN SPECIFICATION SWITCHED
FENDER AUXILIARY POWER CONNECTOR, AMERICAN SPECIFICATION
7 POLE SOCKET AUXILIARY POWER AND ELECTRIC AIR SEAT ... .. .............. .... ............... .... ... .. ..... .......... . 49
RADIO AND INTERIOR LIGHT .... .. ....... .. .. .... .......... ... ......... ................... ........................... ... ............ ............... ....... 52
8M 8-10140 Issued 0 3-2003
SECTION 4001 3
BLOWER MOTOR AND AIR CONDITIONING
- DELUXE CAB TRACTORS ............ .... ....... ... ... ................... ....... ..... .... ..... .. ....................................................... 56
BLOWER MOTOR AND AIR CONDITIONING
- LOW PROFILE CAB TRACTORS ............... ...... ... .......... ..... .. .................. .. .................. ...... ............. .. .. .... .. .. ..... 60
FRONT AND READ WINDSCREEN WIPER/WASHER ... ........ ........ .. ... ......... ........................................................ 64
DIFFERENTIAL LOCK, MFD AND
EUROPEAN SPECIFICATION BRAKE LIGHTS ............................................................................................... 69
EUROPEAN SPECIFICATION POSITION LIGHTS
AND TURN SIGNAL LIGHTS .. .. ......... .......... .... .............. .... ...... ......... ........ ......... .... ............................................ 74
EUROPEAN SPECIFICATION HEADLIGHTS AND REAR FOG LIGHTS ......... .. .................................... .............. 80
AMERICAN SPECIFICATION WARNING AND TURN SIGNAL LIGHTS ....... .... .... .............. .................... ............. 85
AMERICAN SPECIFICATION HEADLIGHTS, POSITION LIGHTS
AND RIGHT HAND CONSOLE LIGHT .............. .... ............... ..... ...................... ................. ..... ............ ...... .......... 91
WORK LIGHTS ..... ... ................................................................. ... ............. .... ...... ...... ............. .... ........... ...... ..... ....... 95
MAIN CONNECTORS ................. .. ......... ... ........ .................. .. ........... .......... .. ..... .. ....... ...... ... .... ................... .. ........ 101
SM 8-10140 Issued 03-2003
4 SECTION 4001
SPECIAL TOOLS
DD98H120 DD97E383
MC2616 MULTIMETER KIT includes: MC31000A HARNESS REPAIR KIT
MC2616-1 MULTIMETER ONLY
MC2616-2 TEST LEADS
MC2616·3 TEMPERATURE PROBE
DI97K101
MC2530 and MC2531 CAB ROOF TILT TOOLS
DD99A051 (REFER TO SECTION 9006)
MC2656 TEST PROBE KIT
SM 8-10140 Issued 03-2003
SECTION 4001 5
CIRCUIT TESTING
General Information
A... WARNING: Never operate the engine in a closed building. Proper
~ ventilation is required under all circumstances.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with the parking
brake engaged and the engine OFF
IMPORTANT: Put blocks in front of and behind the rear wheels.
IMPORTANT: The battery must be at full charge and all connections must be clean and tight before testing. Only
use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage to the switches may occur.
IMPORTANT: Use MC2656 test probe kit when making electrical checks at connectors to avoid the risk of shorting
between the connector pins or terminals.
NOTE: When measuring resistance values, always measure the resistance of the multimeter leads
before testing components. Subtract the resistance of the multimeter leads from the component
resistance to obtain a true resistance value.
NOTE: When testing diodes and diode modules use the multimeter diode test function.
NOTE: All components, wires and connectors disconnected during any electrical checks must be
connected when the checks are completed.
SM 8-10140 Issued 03-2003
6 SECTION 4001
Schematic Symbols
ACTUATORS
T LEVER
T HAND
--l
FOOT
-=C
TEMPERATURE
6 y
~ --Kl-
LIQUID LEVEL FLOAT PRESSURE COIL DIODE
...
CONTACTS
-+~ ~ @ 0
MOMENTARY
MAINTAINED
VARIABLE RESISTOR RESISTOR MAGNETIC
HOUSINGS
®
VACUUM SWITCH
0
PRESSURE SWITCH
@
TEMPERATURE SWITCH
@ Q9
MOTOR LIGHT
SWITCH CONTACT CONFIGURATION
~
/0 /0 ?o ~
o 0
S.P.S.T. S.PD.T. D.P.S.T. D.PD.T.
(SINGLE POLE SINGLE (SINGLE POLE DOUBLE (DOUBLE POLE SINGLE (DOUBLE POLE DOUBLE
THROW) THROW} THROW} THROW}
MISCELLANEOUS SYMBOLS
0'uJ cJO
FUSE CIRCUIT BREAKER
NOTE: Schematic symbols shown with tractor parked and power OFF.
SM 8-10140 Issued 03-2003
SECTION 4001 7
Schematic Legend
- - - - - - 123 Y 1.0 - - - - - - CIRCUIT TAG IF REQUIRED
CIRCUIT NUMB' 1 ~RE
COLOUR
SIZE mm 2
CONNECTOR TERMINAL
~~(I
CONNECTOR TYPE ()()
INDICATES INLINE CONNECTION WITH
TERMINALS
--------~()~--------- INDICATES CIRCUIT CONNECTION TO
BATTERY POWER OR SWITCHED POWER STUD
--------~Ir-------- INDICATES CIRCUIT SPLICE CONNECTION
INDICATES CIRCUIT CROSSING NOT
CONNECTED
INDICATES CHASSIS GROUND CONNECTIONS
Wire Colour Code
R .... ......... ................................... ......... ...................... RED
T ....................................... ......................... .. .............. TAN
W .......................................................................... WHITE
Y ........................................................................ YELLOW
B .......................................................................... BLACK
G ............................................................................. GRAY
0 ....................................................................... ORANGE
P .............................................................................. PINK
V ....... .... .......................... ........ .......... . VIOLET (PURPLE)
BR .... ............................... ...... .............. ........ ....... BROWN
DB ................................................................. DARK BLUE
DG ............. ....................... .. ................. ..... DARK GREEN
LB ............................................................... LIGHT BLUE
LG.. ....... ........ .... ............ ..... ....... ... ....... ..... LIGHT GREEN
SM 8-10140 Issued 03-2003
8 SECTION 4001
FUSE LOCATION AND IDENTIFICATION
- European Specification Tractors
00998073 0097J176
To gain access to the fuses remove the instrument Instrument panel fuse location. For fuse and mini
panel left hand side cover. circuit breaker identification and amp ratings, see
below.
Dl98M144
NOTE: Locations 19, 20 and 32 are mini circuit breakers, which will reset automatically.
Fuse No Circuit Amps
1 HORN 15
2 REAR WORK LIGHTS 25
3 FRONT WORK LIGHTS 25
4 IMPLEMENT INTERFACE CONNECTOR BATIERY POWER 10
5 IMPLEMENT INTERFACE CONNECTOR SWITCHED POWER 10
6 LEFT HAND POSITION LIGHTS 10
7 RIGHT HAND POSITION LIGHTS 10
8 LOADER CONTROL - IF EQUIPPED 15
9 NOT USED - .........
SM 8-10140 Issued 03-2003
SECTION 4001 9
Fuse No Circuit Amps
10 NOT USED -- - - -
11 REAR FOG LIGHT 10
12 LEFT HAND GRILLE HEADLIGHT - HIGH BEAM 10
13 RIGHT HAND GRILLE HEADLIGHT- HIGH BEAM 10
14 NOT USED ---- ...
15 LEFT HAND CAB ROOF HEADLIGHT - LOW BEAM 15
16 NOT USED ...............
17 INSTRUMENT CLUSTER BATTERY POWER 5
18 HAZARD WARNING LIGHT SWITCH 15
19 LEFT HAND GRILLE HEADLIGHT - LOW BEAM - CIRCUIT BREAKER 10
20 RIGHT HAND GRILLE HEADLIGHT - LOW BEAM - CIRCUIT BREAKER 10
21 TURN SIGNAL LIGHTS 15
22 ROTARY BEACON LIGHT 15
23 NOT USED - ............
24 BRAKE LIGHTS 20
25 INSTRUMENT CLUSTER SWITCHED POWER 7_5
26 MFD, DIFF LOCK 30
27 SEAT 15
28 TRANSMISSION CONTROLLER SWITCHED POWER ( •• ) 15
29 REAR FENDER AUXILLIARY POWER CONNECTOR 30
30 INTERIOR LIGHT, RADIO CLOCK BATTERY POWER 7.5
31 REAR WINDSCREEN WIPER/WASHER 15
32 FRONT WINDSCREEN WIPERIWASHER -CIRCUIT BREAKER 15
33 ELECTRONIC HITCH 7.5
34 2 SPEED POWERSHIFT ( •• ) 20
35 PARK BRAKE ALARM 5
36 FRONT PTO, RIDE CONTROL - IF EQUIPPED 10
37 COLD START 20
38 FUEL SHUT-OFF 10
39 CIGAR LIGHTER 10
40 ACCESSORY, INSTRUMENT CLUSTER, RADIO 7.5
41 RIGHT HAND CONSOLE AUXILLIARY CONNECTOR (BATTERY B+) 30
42 FRONT CONSOLE AUXILIARY CONNECTOR - BATTERY B+ 30
43 RIGHT HAND CONSOLE AUXILIARY CONNECTOR - SWITCHED B+ 30
44 FRONT CONSOLE AUXILIARY CONNECTOR - SWITCHED B+ 30
(00) Tractors With XtraShift Only.
SM 8-10140 Issued 03-2003
10 SECTION 4001
FUSE LOCATION AND IDENTIFICATION
- American Specification Tractors
00998073 DD97J175
To gain access to the fuses remove the instrument Instrument panel fuse location. For fuse and mini
panel left hand side cover. circuit breaker identification and amp ratings, see
below.
0198M144
NOTE: Locations 9, 10 and 32 are mini circuit breakers, which will reset automatically.
Fuse No Circuit Amps
1 HORN 15
2 REAR WORK LIGHTS 25
3 FRONT WORK LIGHTS 25
4 IMPLEMENT INTERFACE CONNECTOR BATTERY POWER 10
5 IMPLEMENT INTERFACE CONNECTOR SWITCHED POWER 10
6 NOT USED - ...... _...
7 NOT USED - - ... _...
8 LOADER CONTROL - IF EQUIPPED 15
9 LEFT HAND HEADLIGHT - LOW BEAM - CIRCUIT BREAKER 10
SM 8-10140 Issued 03-2003
SECTION 4001 11
Fuse No Circuit Amps
10 RIGHT HAND HEADLIGHT - LOW BEAM - CIRCUIT BREAKER 10
11 NOT USED -----
12 LEFT HAND HEADLIGHT - HIGH BEAM 10
13 RIGHT HAND HEADLIGHT - HIGH BEAM 10
14 NOTUSED - ........ . . ....
15 NOT USED - ~ ---
16 NOT USED - ----
17 INSTRUMENT CLUSTER BATIERY POWER 5
18 TURN SIGNAL LIGHTS 15
19 WARNING LIGHTS 5
20 FLASHER RELAY 15
21 NOT USED - .... -- ....
22 NOT USED -- .... .... -
23 TAIL LIGHTS 5
24 NOT USED ... - -- -
25 INSTRUMENT CLUSTER SWITCHED POWER 7.5
26 MFD, DIFF LOCK 30
27 SEAT 15
28 TRANSMISSION CONTROLLER SWITCHED POWER (00) 15
29 7 PIN TRAILER CONNECTOR BATTERY POWER 30
30 INTERIOR LIGHT. RADIO CLOCK BATTERY POWER 7.5
31 REAR WINDSCREEN WIPER/WASHER 15
32 FRONT WINDSCREEN WIPERIWASHER - CIRCUIT BREAKER 15
33 ELECTRONIC HITCH 7.5
34 POWERSHIFT (00) 20
35 PARK BRAKE ALARM 5
36 FRONT PTO, RIDE CONTROL - IF EQUIPPED 10
37 COLD START 20
38 FUEL SHUT-OFF 10
39 CIGAR LIGHTER 10
40 ACCESSORY, INSTRUMENT CLUSTER, RADIO 7.5
41 RIGHT HAND CONSOLE AUXILIARY CONNECTOR - BATTERY B+ 30
42 FRONT CONSOLE AUXILIARY CONNECTOR - BATTERY B+ 30
43 RIGHT HAND CONSOLE AUXILIARY CONNECTOR - SWITCHED B+ 30
44 FRONT CONSOLE AUXILIARY CONNECTOR - SWITCHED B+ 30
(00) Tractors With XtraShift Only.
SM 8-10140 Issued 03-2003
12 SECTION 4001
SWITCHES AND CONTROLS
Instrument Panel
DD998074
1. KEY SWITCH 7. CAB HEADLIGHT SWITCH - IF EQUIPPED (*)
2 . LIGHT SWITCH 8 . WORK LIGHT SWITCH
3 . COLD START SWITCH 9 . HAZARD WARNING LIGHT SWITCH
4 . STALK SWITCH - TURNIDIP/HORN
5 . FORWARDINEUTRAL/REVERSE LEVER (ee) (*) European Specification Tractors Only
6. INSTRUMENT CLUSTER (ee) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
SECTION 4001 13
Right Hand Console Controls (Upper and Lower)
DP97J169
1. FRONT PTO SWITCH - IF EQUIPPED 9. MFD SWITCH - IF EQUIPPED
2. ROTATING BEACON SWITCH - IF EQUIPPED 10. HITCH POSITION CONTROL
3. REAR FOG LIGHT SWITCH (*) 11. HITCH DRAFT CONTROL
4. RIDE CONTROL SWITCH - IF EQUIPPED 12. HITCH CONTROLS - REFER TO SECTION 10006
5. DECLUTCH SWITCH ( .. ) 13. 3 POLE AUXILIARY POWER CONNECTOR
6. POWERSHIFT SWITCH
7. HITCH UP-DOWN SWITCH (*) European Specification Tractors Only
8. DIFF LOCK SWITCH (.. ) Tractors With XtraShift Only
Deluxe Cab Roof Controls - Operator Environment
DD95M222
1. WINDSHIELD WIPERIWASHER SWITCH 3. HEATER BLOWER SWITCH
2. TEMPERATURE CONTROL 4. AIR CONDITIONER TEMPERATURE
CONTROL SWITCH
SM 8-10140 Issued 03-2003
14 SECTION 4001
European Specification Low Profile Cab Roof Controls
(Operator Environment)
Heater Controls· Tractors Not Equipped Windscreen Wiper Control
With Air Conditioning -~~~~
DP97K051
DP97J173
1. WINDSCREEN WIPER SWITCH
1. TEMPERATURE CONTROL 2. RADIO
2. BLOWER MOTOR SWITCH
Heater and Air Conditioning Controls
DD99J036
1. TEMPERATURE CONTROL POTENTIOMETER
2. AIR CONDITIONING SWITCH
3. BLOWER MOTOR SWITCH
SM 8-10140 Issued 03-2003
SECTION 4001 15
This Page Has Been Left Blank
8M 8-10140 Issued 03-2003
16 SECTION 4001
HARNESS LAYOUT AND CHASSIS GROUND LOCATION
I I
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~
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-------- --- - - --~,
J _ ... __ __ ..L ... _ _ .,JJ
... -... " . ,, M103B064
1. CONNECTOR 1 - TO CAB HARNESS 19. KEY SWITCH
2. POWERSHIFT CLUTCH PEDAL POSITION 20 . RS232 CONNECTOR ( •• )
POTENTIOMETER ( •• ) 21. FORWARD/NEUTRAL/REVERSE RESISTOR PACK ( •• )
3. POWERSHIFT CLUTCH PEDAL 22. CAB POWER RELAY
POSITION SWITCH (.) 23. HEADLIGHT DIPPER RELAY
4. ROTARY LIGHT SWITCH 24. FLASHER RELAY
5. FUSE BLOCK 25. BLOWER MOTOR CIRCUIT BREAKER
6. COLD START SWITCH 26 . LEFT HAND BRAKE PEDAL SWITCH
7. INSTRUMENT CLUSTER CONNECTOR C2 27 . RIGHT HAND BRAKE PEDAL SWITCH
8. SWITCHED POWER STUD 28 . 3 PIN ACCESSORY POWER CONNECTOR
9. REAR WORK LIGHT RELAY 29. UNSWITCHED POWER STUD - BATTERY POWER
10. FRONT WORK LIGHT RELAY 30 . CONNECTOR 71 - SELF CANCELLING TURN SIGNAL
11. ACCESSORY POWER RELAY 31. CONNECTOR 32 - STALK SWITCH
12. BRAKE POWER RELAY
13. BRAKE EITHER RELAY G1. CHASSIS GROUND CONNECTION G1
14. BRAKE BOTH RELAY
15. INSTRUMENT CLUSTER CONNECTOR C1
16. HAZARD WARNING SWITCH (*) (*) European Specification Tractors Only
17. WORK LIGHT SWITCH (.) Tractors Without XtraShift Only
18. UPPER/LOWER HEADLIGHT SWITCH H ( .. ) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
SECTION 4001 17
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- ... - _ _ _ _ ... _
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, ----____ 11
- - - - - - - - __ ,1/
- -- ---
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, -- - - - - ... - - ... - -. ,,
\~ /'
, - ... - - -:::: -::..-..... -.,
I
_____ - J.. - '- _ ..J' , MJ03B065
... _... I,
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1. CONNECTOR 1 -TO CAB HARNESS 18 . FORWARDINEUTRALIREVERSE RESISTOR PACK (00)
2. POWERSHIFT CLUTCH PEDAL POSITION 19 . CAB POWER RELAY
POTENTIOMETER (.. ) 20 . HEADLIGHT DIPPER RELAY
3. POWERSHIFT CLUTCH PEDAL POSITION SWITCH (0) 21 . FLASHER RELAY
4. ROTARY LIGHT SWITCH 22 . BLOWER MOTOR CIRCUIT BREAKER
5. FUSE BLOCK 23 . LEFT HAND BRAKE PEDAL SWITCH
6. COLD START SWITCH 24 . RIGHT HAND BRAKE PEDAL SWITCH
7. INSTRUMENT CLUSTER CONNECTOR C2 25 . 3 PIN ACCESSORY POWER CONNECTOR
8 . SWITCHED POWER STUD 26 . UNSWITCHED POWER STUD - BATTERY POWER
9 . REAR WORK LIGHT RELAY 27 . CONNECTOR 71 - SELF CANCELLING TURN SIGNAL
10. FRONT WORK LIGHT RELAY 28 . CONNECTOR 32 - STALK SWITCH
11. ACCESSORY POWER RELAY
12. INSTRUMENT CLUSTER CONNECTOR C1 G1.CHASSIS GROUND CONNECTION G1
13. HAZARD WARNING SWITCH (*)
14. WORK LIGHT SWITCH
15. UPPERILOWER HEADLIGHT SWITCH (*) (*) European Specification Tractors Only
16. KEY SWITCH (0) Tractors Without XtraShift Only
17. RS232 CONNECTOR(OO) (00) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
18 SECTION 4001
Right Hand Console Harness Components
- Tractors Without Ride Control
I
I
,
I
MI03B062
19 . POWERSHIFT RESISTOR (00)
1. CONNECTOR #26 - 20 . CONNECTOR #40 - TO TRANSMISSION HARNESS
TO INSTRUMENT PANEL HARNESS 21 . CONNECTOR #52 - TO REAR FENDER HARNESS
2. CONNECTOR #27 - 22. HITCH CONTROL MODULE
TO INSTRUMENT PANEL HARNESS) 23. AUDIBLE ALARM
3. CONNECTOR #28 - 24. SEAT SWITCH CONNECTOR
TO INSTRUMENT PANEL HARNESS (00) 25. OPERATOR PRESENT SWITCH CONNECTOR (00)
4. CONNECTOR #29 - 26. SHIFTABLE PTO SWITCH - IF EQUIPPED
TO INSTRUMENT PANEL HARNESS 27. AUXILIARY POWER CONNECTOR
5. FRONT PTO RELAY - IF EQUIPPED 28. CIGAR LIGHTER
6. MFD RELAY (0) 29. HITCH CONTROLS - REFER TO SECTION 10002
7. AUDIBLE ALARM RELAY (0) OR MFD RELAY (00) 30. TRANSMISSION CONTROLLER (00)
8. DIFFERENTIAL LOCK RELAY 31 . LOAD CONTROL POTENTIOMETER
9. HITCH ENABLE RELAY 32. POSITION CONTROL POTENTIOMETER
10. AUDIBLE ALARM DIODE (0) 33 . MFD SWITCH - IF EQUIPPED
11 . POWERSHIFT SPEED SELECTOR SWITCH 34. DIFF LOCK SWITCH
12 . DECLUTCH SWITCH (00) 35. HITCH ENABLE SWITCH
13 . REAR FOG LIGHT SWITCH - IF EQUIPPED (*)
14. ROTARY BEACON LIGHT SWITCH - IF EQUIPPED G2 . CHASSIS GROUND CONNECTOR
15. FRONT PTO SWITCH -IF EQUIPPED
16. MFD BLOCKING DIODE PACK (*) European Specification Tractors Only
17. POWERSHIFT RELAY (0) (0) Tractors Without XtraShift Only
18 . POWERSHIFT RELAY (0) (00) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
SECTION 4001 19
.~
------"
..... - - ....
19. POWERSHIFT RESISTOR (00)
20. CONNECTOR #40 - TO TRANSMISSION HARNESS
1. CONNECTOR #26 - 21. CONNECTOR #52 - TO REAR FENDER HARNESS
TO INSTRUMENT PANEL HARNESS 22 . HITCH CONTROL MODULE
2. CONNECTOR #27 - 23. AUDIBLE ALARM
TO INSTRUMENT PANEL HARNESS) 24 . SEAT SWITCH CONNECTOR
3. CONNECTOR #28- 25 . OPERATOR PRESENT SWITCH CONNECTOR (00)
TO INSTRUMENT PANEL HARNESS (00) 26. SHIFTABLE PTO SWITCH - IF EQUIPPED
4. CONNECTOR #29 - 27. AUXILIARY POWER CONNECTOR
TO INSTRUMENT PANEL HARNESS 28. CIGAR LIGHTER
5. FRONT PTO RELAY - IF EQUIPPED 29 . HITCH CONTROLS - REFER TO SECTION 10002
6. LEFT BRAKE RELAY 30 . TRANSMISSION CONTROLLER (00)
7. RIGHT BRAKE RELAY 31 . LOAD CONTROL POTENTIOMETER
8. MFD RELAY 32. POSITION CONTROL POTENTIOMETER
9. AUDIBLE ALARM RELAY (0) 33. SLIP CONTROL SWITCH (IF EQUIPPED
10. AUDIBLE ALARM DIODE (0) 34. MFD SWITCH - IF EQUIPPED
11. POWERSHIFT SPEED SELECTOR SWITCH 35 . DIFF LOCK SWITCH
12. DECLUTCH SWITCH (00) 36. HITCH ENABLE SWITCH
13. RIDE CONTROL SWITCH
14. REAR FOG LIGHT SWITCH - IF EQUIPPED (0) G2. CHASSIS GROUND CONNECTOR
15. ROTARY BEACON LIGHT SWITCH - IF EQUIPPED
16. FRONT PTO SWITCH - IF EQUIPPED (0) European Specification Tractors Only
17. POWERSHIFT RELAY (0) (0) Tractors Without XtraShift Only
18. POWERSHIFT RELAY (0) (00) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
20 SECT/ON 4001
Engine and Hood Harness Components
,
I
~::...
-,,'1 '-~) ,
I I
,i
,-,,; (" ~
17
18
MI038067
1. UNSWITCHED POWER STUD 15. FUEL AUTO ADVANCE TEMPERATURE SWITCH
2. CONNECTOR 10 - TO INSTRUMENT PANEL HARNESS 16. ETHER START SOLENOID IF EQUIPPED
3. STARTER RELAY 17. STARTER MOTOR AND STARTER SOLENOID
4. RADAR CONNECTOR 18. OIL PRESSURE SWITCH
5. CONNECTOR 67 - ENGINE HARNESS TO HOOD HARNESS 19 . FUEL AUTO ADVANCE COIL
6. AIR CONDITIONING COMPRESSOR CLUTCH CONNECTOR 20. FUEL SHUT OFF SOLENOID
7. AIR CONDITIONING COMPRESSOR CLUTCH SUPPRESSION DIODE 21 . FLYWHEEL SPEED SENSOR (00)
MI038068
8. COOLANT LEVEL SENDER 22. HORN
9. AIR CONDITIONING HIGH PRESSURE SWITCH - RED 23 . LEFT HAND HEADLIGHT
10. COOLANT TEMPERATURE SENDER 24 . RIGHT HAND HEADLIGHT
11 . THERMOSTART
12. ALTERNATOR G6. CHASSIS GROUND CONNECTION G6
13. CLEAN GROUND CONNECTION - BATTERY NEGATIVE TERMINAL
14. AIR FILTER RESTRICTION SWITCH (00) Tractors With XtraShift Only
SM 8-10140 Issued 03-2003
SECTION 4001 21
Transmission Harness Components - Tractors Without XtraShift
--- --- ,,
,,
,
, ,
,,
,
- ..=.:-- --
,
\
1. CONNECTOR 40 - TO RIGHT HAND CONSOLE HARNESS ....... ~ --
2. HITCH LOAD PIN CONNECTOR
3. HITCH LOWER SOLENOID
4. HITCH RAISE SOLENOID
5. PARK BRAKE SWITCH CONNECTOR
6. DIFFERENTIAL LOCK SOLENOID , .-
7. PTO NEUTRAL START SWITCH ' - -"
8. DIFFERENTIAL LOCK WARNING LIGHT SWITCH
9. 3RD/4TH SHIFT RAIL NEUTRAL START SWITCH
10.
11 .
1ST/2ND SHIFT RAIL NEUTRAL START SWITCH
fUEL LEVEL SENDER
- -....-" .-
12. POWERSHIFT FORWARD/REVERS POSITION SWITCH I,.,
I _
13. CONNECTOR 11 - TO ENGINE HARNESS \
\ ,., /
/
14.
15.
CLEAN GROUND - BATTERY NEGATIVE TERMINAL
LOADER CONTROL CONNECTOR
..... ,J I
-,'
,,-.. ....\
_--
...."" "" ::: '"
.........
16. POWERSHIFT SOLENOID
17. AIR TRAILER BRAKE PRESSURE SWITCH CONNECTOR
18. MFD SOLENOID
19. WHEEL SPEED SENSOR
20 . HITCH POSITION POTENTIOMETER CONNECTOR
MI038048
G3 . CHASSIS GROUND CONNECTION G3
SM 8-10140 Issued 03-2003
22 SECTION 4001
Transmission Harness Components - Tractors With XtraShift
®"'-----
, \
~
- rrr---- :.....:.-,, '
,, , """
" ....J) ,
................~"- .
r; i : - - -
I
, 1
_ _ ---
- ~.... " "-
1. CONNECTOR 40 - TO RIGHT HAND CONSOLE HARNESS
2. HITCH LOAD PIN CONNECTOR
3. HITCH LOWER SOLENOID
, 4. HITCH RAISE SOLENOID
,. , , -' .? ,
't'- .. ~
5. PARK BRAKE SWITCH CONNECTOR
i M ,, 6. DIFFERENTIAL LOCK SOLENOID
I ,'
7. HIGH/LOW RANGE SWITCH
I I ~I <,I
8. PTO NEUTRAL START SWITCH
9. DIFFERENTIAL LOCK WARNING LIGHT SWITCH
I, ,
10. 3RD/4TH SHIFT RAIL NEUTRAL START SWITCH
11 . 1ST/2ND SHIFT RAIL NEUTRAL START SWITCH
}
I
12 . FUEL LEVEL SENDER
(~/ 13. CONNECTOR 11 - TO ENGINE HARNESS
14. FLYWHEEL SENSOR CONNECTOR
, ......... ,
I
, ,/
15. CLEAN GROUND - BATTERY NEGATIVE TERMINAL
16. FORWARD SOLENOID
, I ,
,.. ~ t) ~
17. REVERSE SOLENOID
(J.. ..,
.,'
I
18. POWERSHIFT SOLENOID 2
19. POWERSHIFT SOLENOID 1
-, 20.
21.
POWERSHIFT SOLENOID 3
CLUTCH SENSOR
22 . CLUTCH SENSOR
23. LOADER CONTROL CONNECTOR
) 24 .
25 .
26 .
27 .
AIR TRAILER BRAKE PRESSURE SWITCH CONNECTOR
WHEEL SPEED SENSOR
MFD SOLENOID
HITCH POSITION POTENTIOMETER CONNECTOR
G3 . CHASSIS GROUND CONNECTION G3
MI03BOn
SM 8-10140 Issued 03-2003
SECTION 4001 23
Deluxe Cab and Rear Fender Harness Components
AMERICAN SPECIFICATION
EUROPEAN SPECIFICATION
DI97K125
1 ,
11 '07
" ~
1
1
1
1
1
I
1 I
1 I
:~
II~
I G4 I
I 1
I
D197K102
1. CIRCUIT BREAKER 26. RIGHT HAND REAR WORK LIGHT
2. CONNECTOR 1 - TO INSTRUMENT PANEL HARNESS 27. RIGHT HAND NUMBER PLATE LIGHT (*)
3. RIGHT HAND RADIO SPEAKER 28. LEFT HAND NUMBER PLATE LIGHT (*)
4. RADIO CONNECTOR 29. LEFT HAND REAR WORK LIGHT
5. REAR WINDSCREEN WIPER 30. LEFT HAND REAR TURN LIGHT (**)
6. BEACON LIGHT CONNECTOR 31. LEFT HAND TURN FRONT LIGHT (**)
7. INTERIOR LIGHT DOOR SWITCH 32. LEFT HAND FRONT WORK LIGHT
8. LEFT HAND RADIO SPEAKER 33 . RIGHT HAND FRONT WORK LIGHT
9. CONNECTOR 2 - CAB HARNESS TO CAB ROOF HARNESS 34. RIGHT HAND FRONT TURN LIGHT (**)
10. INTERIOR LIGHT 35. LEFT HAND CAB HEADLIGHT (*)
11. WINDSCREEN WIPER SWITCH 36. RIGHT HAND CAB HEADLIGHT (*)
12. BLOWER SWITCH 37. CONNECTOR 52 - TO RIGHT HAND CONSOLE HARNESS
13. AIR CONDITIONING TEMPERATURE CONTROL SWITCH 38. RIGHT HAND REAR LIGHT CLUSTER
14. AIR CONDITIONING LOCKOUT INDICATOR LIGHT 39. RIGHT HAND HITCH REMOTE SWITCHES
15. LEFT HAND ELECTRIC MIRROR CONNECTOR 40. FENDER AUXILIARY POWER CONNECTOR (*)
16. LEFT HAND BLOWER MOTOR 41.7 POLE TRAILER CONNECTOR
17. BLOWER MOTOR RESISTOR 42. IMPLEMENT SWITCH CONNECTOR
18. FRONT WINDSCREEN WIPER MOTOR 43. NUMBER PLATE LIGHT (*)
19. AIR CONDITIONING LOCKOUT RELAY 44 . LEFT HAND HITCH REMOTE SWITCHES
20. RIGHT HAND BLOWER MOTOR 45 . LEFT HAND REAR LIGHT CLUSTER
21. RIGHT HAND ELECTRIC MIRROR CONNECTOR 46 . FRONT WINDSCREEN WASHER MOTOR
22. RIGHT HAND CONSOLE LIGHT 47 . REAR WINDSCREEN WASHER MOTOR
23. LEFT HAND FRONT LIGHT CLUSTER
24 . RIGHT HAND FRONT LIGHT CLUSTER (*) G4 . CHASSIS GROUND CONNECTION G4
, 25 . RIGHT HAND REAR TURN LIGHT (**) G5. CHASSIS GROUND CONNECTION G5
I MI02H035
,
......... _ -; (*) European Specification Tractors Only
(**) American Specification Tractors Only
SM 8-10140 Issued 03-2003
24 SECTION 4001
European Specification Low Profile Cab and Rear Fender Harness Components
TRACTORS WITH
AIR CONDITIONING
1. CIRCUIT BREAKER
2. CONNECTOR 1 - TO INSTRUMENT PANEL HARNESS
3. RIGHT HAND REAR WORK LIGHT
4. CONNECTOR 52 - TO RIGHT HAND CONSOLE HARNESS
5. RIGHT HAND REAR LIGHT CLUSTER
6. RIGHT HAND HITCH REMOTE SWITCHES
7. FENDER AUXILIARY POWER CONNECTOR (
8. 7 POLE TRAILER CONNECTOR
9. IMPLEMENT SWITCH CONNECTOR
10. BLOWER MOTOR RESISTOR (TRACTORS WITHOUT AIR CONDITIONING)
11 . FENDER NUMBER PLATE LIGHT
12. LEFT HAND HITCH REMOTE SWITCHES
13. LEFT HAND REAR LIGHT CLUSTER
14. LEFT HAND REAR WORK LIGHT
15. LEFT HAND UPPER NUMBER PLATE LIGHT
16. BEACON LIGHT CONNECTOR
17. LEFT HAND RADIO SPEAKER
18. INTERIOR LIGHT DOOR SWITCH
19. BLOWER SWITCH - TRACTORS WITHOUT AIR CONDITIONING
20. BLOWER MOTOR - TRACTORS WITHOUT AIR CONDITIONING
21 . FRONT WINDSCREEN WASHER MOTOR
22. REAR WINDSCREEN WASHER MOTOR
23 . RIGHT HAND UPPER NUMBER PLATE LIGHT
24. REAR WINDSCREEN WIPER CONNECTOR
25. RIGHT HAND RADIO SPEAKER
26. RADIO CONNECTOR
27 . WINDSCREEN WIPER SWITCH
28 . LEFT HAND FRONT LIGHT CLUSTER
29 . LEFT HAND CAB HEADLIGHT
30. LEFT HAND FRONT WORK LIGHT
31. FRONT WINDSCREEN WIPER MOTOR CONNECTOR
32. RIGHT HAND CAB HEADLIGHT
33. RIGHT HAND FRONT LIGHT CLUSTER
34. RIGHT HAND FRONT WORK LIGHT
35 . BLOWER MOTOR - TRACTORS WITH AIR CONDITIONING
36. BLOWER MOTOR RESISTOR - TRACTORS WITH AIR CONDITIONING
37 . AIR CONDITIONING LOW PRESSURE SWITCH - GREEN
38 . AIR CONDITIONING RELAY
39 . WATER CONTROL VALVE MOTOR
40 . AIR CONDITIONING CONTROLLER
~~
41 . AIR CONDITIONING TEMPERATURE SENSOR
42. AIR CONDITIONING TEMPERATURE CONTROL POTENTIOMETER
43 . AIR CONDITIONING SWITCH
44. BLOWER MOTOR SWITCH - TRACTORS WITH AIR CONDITIONING
@-~~
G4. CHASSIS GROUND CONNECTION G4
G5. CHASSIS GROUND CONNECTION G5
tJsV~(~~1f-
~ \.\~
37~ .
TRACTORS WITH
AIR CONDITIONING
SM 8-10140 Issued 03-2003
SECT/ON 4001 25
Platform Harness Rear Fender Harness Components
~
>- ~~
. . ..
..................
"
".
"
" '.
..
.
,
i ""
"~- . :::.....
MI02H036
EUROPEAN SPECIFICATION
1. CONNECTOR 1 - TO INSTRUMENT PANEL HARNESS 11 . NUMBER PLATE LIGHT
2. RIGHT HAND FRONT WORK LIGHT 12. LEFT HAND HITCH REMOTE SWITCHES
3. RIGHT HAND FRONT LIGHT CLUSTER 13. LEFT HAND REAR LIGHT CLUSTER
4. CONNECTOR 52 - TO RIGHT HAND CONSOLE HARNESS 14. LEFT HAND REAR WORK LIGHT
5. RIGHT HAND REAR LIGHT CLUSTER 15. RIGHT HAND FRONT LIGHT CLUSTER
6. RIGHT HAND HITCH REMOTE SWITCHES 16. RIGHT HAND FRONT WORK LIGHT
7. RIGHT HAND REAR WORK LIGHT 17. LEFT HAND UPPER FENDER LIGHT CLUSTER
8. FENDER AUXILIARY POWER CONNECTOR 18. RIGHT HAND UPPER FENDER LIGHT CLUSTER
9. 7 POLE TRAILER CONNECTOR
10. IMPLEMENT SWITCH CONNECTOR G5. FENDER CHASSIS GROUND CONNECTION
SM 8-10140 Issued 03-2003
26 SECTION 4001
STARTER MOTOR, NEUTRAL START, FUEL SHUT-OFF,
COLD START AND CAB POWER RELAY
CIRCUIT GENERAL INFORMATION
Starter Circuit - Tractors Without XtraShift ......................................................................................................... 27
Starter Circuit - Tractors With XtraShift ........... .......... .... ................. .. ....... ............. .... ... ................. .............. ...... .. 27
Fuel Shut Off and Auto Advance Circuit General Information ......... .. ..... ............. .............................. ... ... ..... ..... 28
Cold Start Circuits ......... ... ... ............ .. ....................... ......... ... .......... ... .... .............. ...................... .................... ..... 28
Ether Start (if Equipped) .......... .... .. .. ................................................................ ..... ..................... ............... .. ... 28
Thermostart ........... .... .. ........... ........ .. .. .................. ..................... .... ....................... ........................................ . 28
Accessory Power Relay .. .................. .......... ................. ...................... .... .. ............. ...... ... ............. .. ...... ... ........... . 28
Cab Power Relay .. ..... ............................ ................ ................ ........ .. .... .............. .......... ...................................... 28
SCHEMATIC CIRCUIT - Tractors Without XtraShift .... ...... .............. ..... ... .. ............................................................ 29
SCHEMATIC CIRCUIT - Tractors With XtraShift ......... ... ...... ........ .... .......... .................. .......... .. ........ .................... . 31
SM 8-10140 Issued 03-2003
SECTION 4001 27
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
NOTE: For tractors equipped with master disconnect switches, when the switch is in the OFF position
all battery power is disconnected to the tractor except for power for the instrument cluster clock, interior
light and radio.
Starter Circuit - Tractors Without XtraShift
NOTE: Refer to the Schematic on Page 29.
The starter solenoid will only operate when the transmission speed selector lever is in neutral and the PTO is
disengaged.
With the key switch in the START position, battery power at terminal 1 flows to terminal 2 then to the PTO neutral
switch. With the PTO disengaged power flows through the PTO neutral switch to the starer relay terminal 86 .
Power flows through the relay windings to terminal 85, through the 1st/2nd and 3rd/4th neutral switches
(selector lever in neutral) to ground at G3, energising the starter relay.
With the starter relay energised, battery power at terminal 30 is connected to terminal 87 and flows to the starter
solenoid at terminal S energising the solenoid.
With the starter solenoid energized, battery power flows from the battery to the starter motor (through an
optional jumper stud or battery master disconnect switch) and to ground internally through the motor, operating
the motor.
Starter Circuit - Tractors With XtraShift
NOTE: Refer to the Schematic on Page 31 .
The starter solenoid will only operate when the transmission speed selector and Forward/Neutral/Reverse
levers are in neutral and the PTO is disengaged.
With the key switch in the START position, battery power at terminal 1 flows to terminal 2 then to the Forward/
Neutral/Reverse switch at terminal 4. With the Forward/Neutral/Reverse switch in the neutral position , power
flows through the switch from terminal 4 to terminal 5 and to the PTO neutral switch . With the PTO disengaged
power flows through this PTO neutral switch to the starter relay at terminal 86 . Power flows through the relay
windings to terminal 85 through the 1st/2nd and 3rd/4th neutral switches (selector levers in neutral) to ground
at G3, energising the starter relay.
With the starter relay energised, battery power at terminal 30 is connected to terminal 87 and flows to the starter
solenoid at terminal S energising the solenoid .
With the starter solenoid energized, battery power flows from the battery to the starter motor (through an
optional jumper stud or battery master disconnect switch) and to ground internally through the motor, operating
the motor.
8M 8-10140 Issued 03-2003
28 SECTION 4001
Fuel Shut Off and Auto Advance Circuit General Information
Battery power is available at the key switch terminal 1. When the key switch is in the ON position power flows
from the key switch at terminal 5 through fuse 38 to the fuel shut off solenoid terminal A. Power then flows
through the solenoid to terminal B and to ground at G6 energizing the solenoid.
Power also flows from terminal 5 of the key switch through fuse 38 to the auto fuel advance temperature switch .
When the engine coolant temperature is approximately 50 °C (122°F) power will flow through the switch to the
auto fuel advance solenoid which will melt the wax inside the coil gradually reducing excess fuel delivery to
normal operation after approximately 3 minutes.
If the engine coolant temperature is below 40°C power will not flow through the switch to the auto fuel advance
unit, this will allow excess fuel delivery.
Cold Start Circuits
Early American specification tractors are equipped with either Thermostart or Ether Start, European
specification tractors and later American specification tractors are equipped with Thermostart only.
With the key switch in the ON or START position battery power at terminal 1 is connected to terminal 5 and
flows through fuse 37 to the cold start switch terminal 1. When the switch held ON power flows through the
switch to terminal 5 and to the ether start solenoid or the thermostart unit.
Ether Start (if Equipped)
When the switch is held ON power flows from terminal 1 of the switch to the ether start solenoid terminal A.
Power then flows through the solenoid to terminal B then to ground at G6 energising the solenoid. This allows
a small amount of ether fluid to enter the engine air intake.
Thermostart
When the switch is held ON power flows from terminal 1 of the switch through the Thermostart Unit to ground
operating the thermostart heater element. The element will increase the temperature of the air flowing into the
engine.
Accessory Power Relay
With the key switch in the ON or ACCESSORY position battery power at terminal 1 of the key switch flows
through the switch to terminal 6. Power then flows to the accessory power relay terminal 1 (86) , through the
relay windings to terminal 2 (85) and to ground at G1 energising the relay.
Cab Power Relay
With the key switch in the ON position, battery power at terminal 1 of the key switch flows through the switch to
terminal 3. Power then flows to the cab power relay terminal 86 , through the relay windings to terminal 85 and
then to the accessory power relay terminal 3 (30). With the accessory power relay energized (see above) power
flows through the accessory power relay to terminal 5 (87) and to ground at G1 energising the cab power relay.
With the cab power relay energised battery power at terminal 30 flows through the relay to terminal 87 and is
available at the switched power stud and supplies most fuses .
When the key switch is moved to the START position the accessory relay is de-energized. This will prevent
power flow to ground from the cab power relay, which becomes deenergized.
SM 8-10140 Issued 03- 2003
SECTION 4001 29
SCHEMATIC CIRCUIT - Tractors Without XtraShift
BATTERIES UNSWITCHED POWER STARTER MOTOR FUEL SHUT OFF AND NEUTRAL START KEY SWITCH AND COLD START CAB POWER RELAY AND SWITCHED POWER
-------------------~rr----------------- BATTERYPOWERB+ _ _ _ _ _ _ _ _ _ _ _~(}------------
w-
UNSWITCHED BATTERY POWERB+
POWER STUD
624W75 - - -- - - 624W.75 624W.75 - - - - - - - - - 624W75 SWITCHED
POWER
~ ~D
~
~
, - - -132R25 - -- -- - - - - ---132R2..5
132R.75 - - - - -- - - - -- - - - -+ - -----,
PTO NEUTRAL
TO FUS E 30 3RD/4TH RAIL FUSE
(TRACTORS NOT EOUIPP ED START SWITCH N/O FUSE
NEUTRAL START (WITH 3.9 OHM RESISTOR) #J810A #3720A
WITH MASTE R DI SCONNECT SWITCHN/O SEE NOTE 1 131R.75 - - ------, 0
SWITCH ONLY) ....
(WITH 3.9 OHM RESISTOR) '" s!
ci ...
cr
~131R.75 J
SEE NOTE 1
0
'"~ :!.
~
0
~
START
21 C!
0
STARTER
....
'"
5:
N
N
~
~
If'l
~ ~
I,() COLD
START
SWITCH
"
."
;!
'" KEY SIMTCH ~ ~ '"
RELAY
1ST/2ND RAIL
NEUTRAL START
~L 6;:~:55-------
I~ 622W.75 J
SWITCH N/O 606Wl0 606Wl0 - + - +----'
'"a: (WITH 3.9 OHM RESISTOR) 641W3 • u-_ __ _ _ _ _ __ _ -;_r-
o
'<li"
aJ
SEE NOTE 1
CAB POWER
,y
:
(\,j N
RELAY
~ ~
~24BR 75j-- - - --(i624BR.75
RUN POSITION
~
L,,,,,,
ONLY
~ u
C R.S2 _ _ _.,
_ - - R·S2 - -...... R-S2
TO AUDIBLE
ALARM ~ 279BR.75
'----- 131R.75 - _ _ ---,
RELAY ~
, - - - - - - 606Wl 0
606Wl0
, -- - - - 6 24BR.75- - - - - - J 841W15
BATTERY
FUEL
FUEL
842Wl .0 ADVANCE
SHUTOFF ACCESSORY
TE MP (**) POWER RELAY
SWITCH SOLENOID
STARTER (SEE TABLE)
(CLOSES ON THERMO ETHER
SOLENOID START
AND STARTER ASCENDING SOLENOID
I'UEL TEMP) (IF EOUIPPED) (IF EQUIPPED)
MOTOR
ADVANCE
CO IL
TO FUSE 30
(TRAC TORS EOUIPPED
IMTH MASTER DISCONNECT
SIMTCH ONLY) L - - -- -- - - - - - - t - - -SIMTCHEDACCESSORYPOWER - - -
--4-~~----- CHASSI SGROUND---~""'~----------------~~---------------------4~---~------------~""""r---------------~~~""'""'~------------~----------------~.------------ CHASSISGROUND _______~----------~""""------------
L-_ _ _ _ _ __ CLEAN GROUND G3 G6 G6 Gl_ _ _ _ _ _ _ __ _ _ __ __
CLEAN GROUND _ _ _ _---"
MI03A035
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur. RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
REFERENCE
(**) American Specification Tractors Only.
1 86
2 85
3 30
4 87A
5 87
SM 8-10140 Issued 03-2003
30 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 31
SCHEMATIC CIRCUIT - Tractors With XtraShift
BATIERIES UNSWITCHED POWER STARTER MOTOR FUEL SHUT OFF AND NEUTRAL START KEY SWITCH AND COLD START CAB POWER RELAY AND SWITCHED POWER
UNSWITCHED BATTERY POWER 8+ -----------------------------------~r~------------------------------ BATTERYPOWERB+ ____________________~~-------------------
POWER STUD
624W75 - - - -- - 624W.75 ~ 624W.75 624W75 ~ SWITCHED
~ P~~R
35 34 :e
40 ~ N , . . - - - 132R2.5 - - - - - - - - - - - - 1 3 2 R 2 S
~8 ~
Q PTO NEUTRAL
START SWITCH NIO
~ g;
..,
I32R7S - -- - - - - - - - - - - - - + - - - ----,
a: (WITH 311 OHM RESISTOR) ~;!2
;: .
~ .... m
SEE NOTE I
~ ~
TO FUSE 30 I 3RD/4TH RAIL ci N... <0", FUSE FUSE
(TRACTORS NOT EQUIPPED <:J-------l NEUTRAL START
m
I
WITH MASTER DISCONNECT
SWITCH ONLY)
SWITCH N/O
(WITH 3 9 OHM RESISTOR)
I '"....
s:
1/.3810A #3720A
....
oil
ci
0
d
a::
...
~131R 75 J
SEE NOTE 1 N
N 0 ~
Ix~
;!:
"'
n~
3:
r:e ~
625W75
622W75 - - - - - - - - ,
START
o
~
0
;b
a:
m ~ ~\I 4
5 "'T"':-1 321 o 0
r----
T7T1 2 <D
g ci
~
~
R 62 ;".... FORWARDINEUTRAl
• 9l m !REVERSE ~ U') ~ COLO '";!
STARTER
SHUTTLE ~ :i $ START
SWITCH
~ ~
I
KEY SWITCH
~
SWITCH <'>
N
RELAY
130R2.5
' - - - - - - 622W 75 - - -- - - 622W.75
J
~
t
~ (:FU;iG~~::)
NEUTRAL START
SWITCH N/O m ir606Wl .0
oil (WITH 3.9 OHM RESISTOR) ~ ....
'a::"
m
SEE NOTE 1 ci
III
TO FORWARD/NEUTRAU
REVERSE DIODE PACK CABP0WER
;(j ;(j "!
REFER TO SECTION RELAY
~ ~
~24BR.
W-V 75------66248R
10006
BATTERY 75 i ~
RUN POSITION
ONLY
A-
MASTER DISCONNECT
N
<D
SIMTCH
(IF EQUIPPED)
rio ....
oil
ci
ro~~~ N L -- _ _ 131R.75 _ _ _-,
. - - - - R·62 - _......
ALARM
RELAY
~~
2798R.75
.---_ _ _ _ _4_°-624BR,75 son.75 - - - -- - - - - - - - 507T.75 - - - - - '
, - - - - 606W1 .0 - - -- - - -- - - - 606WI .O
~~FI~g~~~:CE~~~ <}-921R 75 ~ .--- - 64iW2.0 1 - - - - - - - l
BATTERY 10006 ci 606W1 .0
64 1Wl .5
TO TRANSMISSION
CONTROLER
~" 5 > ACCESSORY
FUEL POWER RELAY
STARTER REFER JO~g6ECT IO N 29 FUEL (SEE TABLE)
ADVANCE
SOLENOID SHUTOFF
TEMP (**)
AND STARTER SOLENOID
::~~:E1
SWITCH
MOTOR THERMO ETHER
(CLOSES ON
ASCENDING START SOLENOID
TEMP) (IF EOUIPPED) (IF EQUIPPED)
A T
COIL
TO FUSE 30
[TRACTORS EOUIPPED
WITH MASTER DISCONNECT
SWITCH ONLY) 642Wl .0 ' - - - - - -- - - -- - f - -SWITCHEDACCESSORY POWER - - -
---+--00004..,.-------- CHASSIS GROUND ----~~""'----------00004..,.--------------_1....
G3
-----------------'------------.."."".""_----+------------"""'":".",,.,,'""------------.. . .------..-------------------- G6
CHASSIS GROUND -------+----------~'"".",,-----------
G1
L - - - - -- -- CLEAN GROUND CLEAN GROUND - - -- - - - - -- - - - - - - - - -
MI03B018
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur. RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
REFERENCE
(**) American Specification Tractors Only_
1 86
2 85
3 30
4 87A
5 87
8M 8-10140 Issued 03-2003
32 SECTION 4001
ALTERNATOR AND INSTRUMENT CLUSTER
WARNING LIGHTS AND GAUGES
CIRCUIT GENERAL INFORMATION
Instrument Cluster Circuit .............................. ..................................................................................................... 33
Alternator Charging Circuit .... ................................................................................ .. ............. .............................. 33
SCHEMATIC CIRCUIT ................................................................................................. ............ .. ............................ 34
8M 8-10140 Issued 03-2003
SECTION 4001 33
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
Instrument Cluster Circuit
Battery power flows through fuse 17 to the instrument cluster at connector C 1 pin A-9 to display the clock.
Accessory power flows through fuse 40 to the instrument cluster at connector C 1 pin B-3 to display the hour
meter reading and read or reset the distance travelled and area worked.
Keyed power flows through fuse 25 to the instrument cluster at connector C1 pin A-2.
The instrument cluster is clean grounded through connector C2 pin A-8 directly to the battery negative terminal.
In addition the instrument cluster has a separate chassis ground through connector C1 pin A-7 for the turn
signal warning lamps.
The instrument cluster receives power from the implement switches in addition to Signals from the ground speed
sensor and radar for the area worked , distance travelled , true ground speed and wheel slip functions to operate.
Power flows through each warning light to its relevant switch . When the switches are open the ground circuit is
not complete and the warning lamp will not illuminate. When the switch is closed the ground circuit is complete
and the warning lamp will illuminate.
Power flows through both the engine coolant and the fuel level gauges to their relevant sender units (variable
resistors). The resistance of the sender will vary according to the coolant temperature or the fuel level , this will
restrict the current flow which will register on the relevant gauge.
Alternator Charging Circuit
Keyed power flows through fuse 25 to the instrument cluster at connector C1 pin A-2, then through the
alternator warning light to connector C2 pin A-7 and to the alternator at terminal D+ . Power flows through the
alternator internal regulator circuit and rotor windings to ground illuminating the alternator warning lamp. When
the engine is started this supply energises the alternator rotor winding to initiate charging.
When the alternator output voltage is higher than battery voltage power flows from the alternator at terminal 8+
to the battery. In addition power flows back to the instrument cluster from the alternator D+ terminal to connector
C2 pin A-7 and alternator warning lamp. When there is power at both sides of the alternator warning lamp it will
not illuminate.
The alternator terminal W is connected to the instrument cluster terminal C2 pin A-4 and provides the engine
RPM signal. This signal is alternating current and its frequency increases according to engine RPM.
8M 8-10140 Issued 03-2003
34 SECTION 4001
SCHEMATIC CIRCUIT
INSTRUMENT CLUSTER, WARNING LIGHTS AND GAUGES
----------------------------------------------- BATTERYpOWERB+ --------------------------------------------------~~---------------------------------------------------------------------------- BATTERYPOWERB+ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
S'MTCHED POWER -------------------------------------+--------------------------------------------~~ ~-------------- ~TCHEDPOWER --------------------------------
PIN NO. FUSE
INSTRUMENT CLUSTER 17(7.5A)
(#) 140R 2.0 _ _ _ _...J
~
FUSE
BATTERY POWER FOR CLOCK Cl·A·9 202R.75 - 202R .75 - - - - - - -- - - - -_ _ _ __ _ _ _ __ _ 176R.75 25 (7.5A)
~TCH ED POWER B+ CI·A-2 200Rl0 - - - - - -- -- - - - - - - -- -- - - - - - -- - - - -- - - - - - - + - - 200Rl .0 ----<f\..9-- 148R2.5
ENGINE RPM SIG (ALT TERM WI C2·A-4 216Y 75 -------------------------------------t-- 216Y75----------~r_---------------------------~16Y 75 -----
ALTERNATOR EXCITE C2-A-7 121Yl.0 - - - - -- - - -- - - - -- - - - - - -- - -- -- - - -- - - - - - - t -- -12I Yl0 21Yl .0 - - - -
COOLANT TEMP GAUGE CI-B·4 235Y 75 - - - - -- - - - - - - - - - - - - - - -- - -- - - - - -- - - -- - - +- - - 235Y75 235Y 75 - - - -
AIR FILTER RESTRICTION C2·A-6 266Y 75 - - - - -- - - -- -- -- - - - - - - -- - -- - - - - - - - -- -- - +- - - '266Y 75 266Y.75 _____
LOW ENGINE 0 1L PRESSURE C2-A-ll 255Y 75 - - - - - -- -- - - - -- -- - - - - - -- - - - - - - -- -- -- -- t - - 255Y75 255Y75 - - - - -
COOLANT LEVEL CI·g·S 231Y 75 - -- -- - - -- - -- - - - - - - -- _ _ _ __ _ __ _ _ _ _ __ __ -+_ _ 231Y.75 231Y.75 - - - - -
CLEAN GROUND C2·A·8 200BRMll .0 - -- -- - - - - - - -- - - - -200SRNVI 0 - - - - - - - -:200BRIW1 5 - - -- - - + - - -:2ooBRIWI .5 2OOBRIW1 5 -
MFD CI·A·11 542lB,75 --[> FROM MFD RELAY (*** REFER TO SECTION 10002) FUSE 30 (7.5A)
DIFFLOCK CI-A-6 735lB.75 --[> FROM DIFF LOCK (*"* REFER TO SECTION 10002) ~ 143R 75 143R 7S - - - - - - - - - -- - - ; -- - - - - - - -- - -- - - - - - - -- - - - - - - - 1 43R.75 - - -
WHEEL SPEED SIGNAL C2-A·5 215Y 75 --[> FROM IM-iEEL SPEED SENSOR REFER TO SECTI ON I 0002 ~ FUSE 36 (lOA)
~L.c>
POWERSHIFT (XTRASHIFT ONLY) C2·B-9 930T 75 , - - - - - - 5 5 0 R l .0
FROM TRANSMISSI ON CONTROLLER TO HITCH
POWERSHIFT (XTRASHIFT ONL YJ C2-B-IO 931T.75
CONTROLLER
REVERSE INDICATOR LIGHT (XT RASHIFT ONLY) C2·9·8 507T 75 _--{> REFER TO SECTION 10002 TO INTERIOR LIGHT AND
REFER TO SECTION
} RADIO CLOCK
NEUTRAL INDICATOR LI GHT (XTRASHIFT ONLY) C2·A·3 575R.75 --C> FUSE 33 (75A) 10002
HITCH IMPLEMENT UP 1 DOWN SWITCH C2·9·4 509lB.75 - - - - - - - - - - -- - - - - - - -- -- - - -- -- - -- - - - - 509LB.75- + -- -i 1 - - + - - -509LB.75-- - - , 1
TO HITCH
>- 10 CONTROLLER
RADAR GROUND C2·A·2 280BR 75 R REFER TO SECTION
280BR 75. A BRlLG 75
A 10002
RADAR POWER OUTPUT L+12VJ Cl·A·3 280R 75 - -- - - - - - - - 280R75 280R 75 C LG/R.75 - "l
D
RADAR PRESENT C2·B-2 282Y.75 -----i~---- 282Y75 282Y 75 [) LGIY 75---11771 A
;r, SLIP
RADAR SIGNAL C2·A·l0 281Y 75 - . .- - - : r Y l - - - - - - 281Y 75 281Y 75 B LG/75 R HITCH ~
SLIP
> ' - - ---282Y 75 - - - { > (""*) TO HITCH CONTROLLER
UPIDOWN
CONTROL
) ~TCH
' - - - + -- - --281Y.75 --c> REFER TO SECTION 10002 SVv1TCH
» 282Y75-C>
FRONTPTO
HARNESS
) '--- - - -- 28 1Y 75 -c>
TO IMPLEMENT INTERFACE CONNECTOR
L -__--II- 5OOR1 0
>-: - -- ----,AFS BRIW1 _0--C>
CONNECTOR
>- - -- - - t - - - -.....I -- - 567R,75 (....J
1000/540 PTO RPM S'MTCH CI·9-10 296Y.75 (*)/276Y 75 (....)- - - - -------------- TO WHEEL SPEED
(*) POSITION LIGHT WARNINGI (....) TURN SIGNAL Cl·B·12 ------I> (") LIGHT SWITCH "6", (....) FLASHER TERM 6
215Rl ,0 --[::>
SENSOR
BACKLIGHTING (ANALOG) C2-B-l 726P 75-----[::> FROM HEADLAMP DIPPING RELAY TERM 56 REFER TO
SECTION 10002
HIGH BEAM C2-A-9 723P 75 ----t:> (") FROM UPPER 1LOWER HEADLAMP SWITCH, (.. ") FROM HEADLAMP FUSE 12
)-; 240Y.75 (" ....) ---{:> TO HITCH CONTROLLER REFER TO SECTION 10002 (...... )
TRAILED IMPL UP 1 DOWN SWITCH C2·B-3 S63LB,75 - - - - - - -- -- - 563LB.75 563LB 75/240Y 75 (.... ") - -- - - -- - - - - - - - - - - -- - - ---
Co ) AIR TRAILER BRAKE GAUGE CI·B-1 240Y75 (") - - - - - -- -- - - 240Y 75 (*) 240Y 75 (") ------~
31 240Y 75 (.. ) - - - - 240Y 75 (")
FUEL GAUGE CI·B-11 233Y 75 - - - - - -- - - - -233Y 75'--~-'JI 6 233Y 75 - -- -- - - 2 233Y]5 -;r,
PARK BRAKE
: g
Cl-B·S 269Y75--C> FROM PARK BRAKE SWITCH 27 40 i1_ 10
LOWER & FRONT WORK LIGHTS CI·B·7 784V75-{:> FROM WCRK LIGHT RELAY '".... ...~ TO FENDER
HITCH REMOTE
TURN SIGNAL INDICATOR Cl·A·1O -(> (*) FLASHER TERM "C", (.... ) FLASHER TERM 3 (*) bV ~ (0 tn
""':. ( S'MTCHES
~~~
Il) ~
REFER TO
(* ) 1ST TRAILER CI·A·5 769P.75 - - C > FROM FLASHER TERM C2 ....
II)
AIR SECTION 10002
(*) 2ND TRAILER CI·A- 1 770P 7 5 - - - { > FROM FLASHER TERM C3 ci
(II PRESSURE
~
o SENDER
TURN SIGNAL COMMON Cl·A·7 720 BR.75 (") 1750 BR75("") - - - - -- - -- - - -- -- -- -- - - -- ,
'"
." '"
.... Il) TRAILED ....
ACCESSORY B... I CI·B-3 1 > Z r - 201R.75 gi g'i
E~
H IMPLEMENT
~
CD SVv1TCH 0
FUS g C 563LB.75 :;;
---------------------<~ TO RADIO
- -- - - - - -SWTCHED ACCESSORY POWER
,MIIIIJ/} CHASSIS GROUND ----------~~""r---------------~----------------------~------------""""~------~t-------------------------------~t_--~""~~------------ CHASSISGROUND ---------------4~
~ 1
ClEANGROUND --------------------------------G-l--------------------~-----------------------__G~3~______________________________G~2~_____________________ CLEANGROUNO ---------------~
G~2_
MI03A036
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur.
(") European Specification Tractors Only
("") American Specification Tractors Only
(""") Tractors With Ride Control Only
(*" ....) Tractors Without Ride Control Only
(#) Early Production Tractors Only.
8M 8-10140 Issued 03·2003
SECT/ON 4001 35
INSTRUMENT CLUSTER, WARNING LIGHTS AND GAUGES
-------------------------------------BATTERYPOWERB+ ~
------------------------------------- SWITCHEDPOWER------------------------~~~~
--
10
- - 216Y.75 ---------------H~ K 216Y 75
--121Yl0 p 121Yl0
--235Y .75 L 235Y.75 .
---266Y75 N 266Y.75 .
---255Y75 M 255Y.75 (t)
- - - 231Y 75 ---------------ti~ 231Y.75 .
--200BRIW.75 -------------+.1>71 E 200BRIW1,5 -
---- 143R .75---------&~ 0
16
: =.0J R 1
BATIERY POWER B+ FROM
UNSWITCHED POWER STUD
(ENGINE SIDE) <JI------ 162R1.0
OR MASTER
DISCONNECT SWITCH
, . - - - -----c200BRIW1 .5 - -
'"~
o
N
'"
~
'"g
N
AIR FILTR
RESTRICTION
SWITCH
ALTERNATOR
ENGINE OIL
III PRESSURE
~ ~
SWITCH
"'t-
Il:
8'"
N
II:
'"~
"'"'"'"
N II)
~
"''"
M
CHASSIS GROUND
'"
G6
CLEAN GROUND
MIOlA037
8M 8-10140 Issued 03-2003
36 SECTION 4001
PARK BRAKE WARNING, FRONT PTO AND
EUROPEAN SPECIFICATION AIR TRAILER BRAKE
CIRCUIT GENERAL INFORMATION
Park Brake Circuit
(Tractors Without XtraShift) .... ............. ......... ....... ............ ... .... .. ... ..... ............ ... ............ .. .. .............................. 37
Air Trailer Brake Solenoid Circuit. ...................................................................................................................... 37
Front PTO Circuit ................................................................... ................. ......... ..... ......................... ... ................. 38
SCHEMATIC CiRCUiT ........................................................................................................................................... 39
SM 8-10140 Issued 03-2003
SECTION 4001 37
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
Park Brake Circuit
(Tractors Without XtraShift)
Keyed power flows through fuse 25 to terminal C1 -A-2 of the instrument cluster (refer to "Instrument Cluster
Circuit" on page 33) . Power flows through the instrument cluster park brake warning light to terminal C1-8-5
and then to the park brake switch . With the park brake switch open (park brake disengaged) the ground circuit
is disconnected and the warning lamp will not illuminate. When the switch is closed (park brake engaged) the
circuit is connected to ground and the warning lamp will illuminate.
Keyed power flows through fuse 35 to the audible alarm relay terminals 1 (86) and 3 (30). Power flows through
the relay windings to terminal 2 (85), through the 1st/2nd and 3rd/4th neutral switches (selector lever in neutral)
to ground at G3, energising the audible alarm relay.
With the relay energised the power at terminal 3 (30) is connected to terminal 5 disconnecting the power to the
audible alarm.
If 1st, 2nd, 3rd or 4th speed is selected the relevant switch will open disconnecting the ground circuit for the
relay, de-energizing relay.
With the audible alarm relay de-energized power at terminal 3 (30) is now connected to terminal 4 (87a). Power
then flows to the park brake audible alarm terminal A , through the audible alarm to terminal 8 and to the park
brake switch.
With the park brake disengaged the switch is open and the ground circuit for the alarm is disconnected.
With the park brake engaged the switch is closed and the alarm is now connected to ground sounding the alarm
warning the operator that a gear has been selected with the park brake engaged .
Air Trailer Brake Solenoid Circuit
Switched power flows through fuse 29 and the in-line fuse to the air trailer brake relay terminals 86 and 30 .
With the park brake engaged power flows from terminal 86 through the relay windings to terminal 85, through
the park brake switch to ground, energizing the relay. With the relay energized there is no power flowing through
the relay from terminal 30 to terminals 87a and to the air trailer brake solenoid.
With the park brake disengaged power will not flow from terminal 86 through the relay windings to terminal 85,
and the relay will be de-energized. With the relay de-energized power flows through the relay from terminal 30
to terminals 87a and to the air trailer brake solenoid to ground, energizing the solenoid.
SM 8-10140 Issued 03-2003
38 SECTION 4001
Front PTO Circuit
NOTE: The front PTa is engaged using an electro magnetic clutch for tractors with Kitchin front PTa or
a hydraulic solenoid valve for tractors with Hydrac front PTa.
To energize the front PTa move the switch to the ENGAGE position then to the ON position. If the engine is
switched OFF then restarted with the front PTa switch in the ON position, the PTa will remain disengaged (for
safety reasons) until the switch is moved to the ENGAGE position.
Switched power flows through fuse 36 to the front PTa switch terminals 1 and 6.
With the switch in the OFF position there is no power through the switch.
With the switch in the ON or ENGAGE position, the power at terminal 6 flows through the switch to the front
PTa relay terminal 3 (30).
With the switch in the ENGAGE position , the power at terminal 1 flows through the switch to terminal 3, then to
the internal warning lamp at terminal 9, to the front PTa clutch and to the front PTa relay at terminals 5 (87)
and 1 (86) . Power flows through the relay windings to terminal 2 (85) then to ground at G2, energizing the relay.
When the relay is energized the power at terminal 3 (30) is connected to terminal 5 (87) then terminal 1 (86) to
provide an additional supply to the relay windings . When the front PTa switch is released to the ON position
this additional supply to the relay terminal 1 (86) from terminal 5 (87) maintains the relay energized and supplies
the switch internal lamp and the front PTa clutch/solenoid .
When switch is turned OFF the clutch disengages the clutch windings can induce a high voltage spike to flow
backward into the circuit to find a path to ground . This high voltage spike can damage switches, relays and
electronic components in the circuit. To prevent damage to the circuit the diode is designed to allow power to
flow through the diode directly to ground if the voltage in the circuit rises above a specified level. This will allow
any high voltage spike induced by the clutch to flow to ground directly through the diode.
SM 8-10140 Issued 03-2003
SECTION 4001 39
SCHEMATIC CIRCUIT
PARK BRAKE WARNING LIGHT AND AUDIBLE ALARM EUROPEAN SPECIFICATION AIR TRAILER BRAKE OPTIONAL FRONT PTO
(TRACTORS WITHOUT XTRASHIFT)
------------BATTERYPOV'i1ERB+-----------------------------------------------------------------------------------------------------------------------------------------------------BATTERYPOWERB+ - - - - - - - - - - - - - - - - - - - - - - - - - - - -____
SII'I1TCHED POWER 9. SII'I1TCHED POWER----<t=
1 146R2.0
r - (#) R1 o-
FUSE FUSE
.-----1 A
B
3RD & 4TH RAIL AUDiBlE
29 FUSE
35
(5A)
FUSE
29
~
;;:
E
~
j '" IN-LINE
FUSE
TO 540/1000 SHIFTABLE PTO
SPEED SELECTOR SII'I1TCH
36
(lOA)
33
(7.5A)
50RI 0 _ _ _---tm~C
~~---5lf'>oR1 .0
ALARM (3OA) (lOA)
NEUTRAL SWITCH N/C
(WITH 3 9 OHM RESISTOR)
SEE NOTE
(SEE TABLE) 530R1 0 (IF EQUIPPED) ~
r------5~51lBl .0 ~ SS1lB1 .0 ----'1
<>
N q ~
rr ;r iii
1:2 ';:!
'"
It)
279R 7~
.
~ PARK BRAKE
AUDIBLE
q
;;: '---5S1LB1 0-----,
B · ALARM m
~
i 531T 75 (IF EQUIPPED) - - - - I ~
AIR TRAILER
BRAKE RaAY
1ST & 2ND RAIL ~Y75 1 IF EQUIPPED
U>
H 10
~
NEUTRAL SII'I1TCH N/C
(WITH 3 9 OHM RESISTOR)
DIODE
'rr"
m
~
m FRONT q
SEE NOTE 0 0
PTO iii
~
It>
'"
Ii")
SWTCH ;:'
;: '"
:a
..... ~
~
279BR.75~279BR 75 ;;: I q
~ [ m
<>
oJ
a: 551LB1 0 --+- ----,
INSTRUMENT CLUSTER
...on
~
F '0
":
>- C')
'"'"'
t- (#) R1 0 -
q
;r
N
FUNCT ION PIN NO. '"
N SWTCHED
AIR TRAILER
'"'"
FENDER 0
..... AUXILIARY ~ q BRAKE SOLENOID ~
cr: Yl0
;;:
J
Pi'\RKBRAKE C1 · B·S TRACTORS B+ OFF
m POWER ~ C;; m
~ II'I1THAIR
CO"~OR R"~
30 TRAILER
BRAKE
'"
'"
1 ~
ONLY FRONT
~
PTO
FROM STARTER RaAY
C> RELAY TERM. 85
L R 1 0 - - R10 (SEE TABLE)
Y 1 0 - - - - - - - - -- - -- - - ----Y10 q
~
- (#) B10- - - - - - -- - - - - - - - - - - -(#) B1.0· e:! FRONT
:ll PTO
CLUTCHI
SOL ENOID
--~~-------------- CHASSISGROUND ----------~""'~~----------~----------------------------------~""'~~----- CHASSISGROUND ------------~~------------~----------------------~""'""------------~~---------------------------
G3 G2 G3
-~~--------~CLEANGROUND CLEANGROUND~--------------~~-----------------------------------------
MI02Kl02
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur. RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
(*) European Specification Tractors Only REFERENCE
1 86
(***) Tractors With Ride Control Only
2 85
(#) Early Production Tractors Only 3 30
4 87A
5 87
8M 8-10140 Issued 03-2003
40 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 41
TWO-SPEED POWERSHIFT
- Tractors Without XtraShift
CIRCUIT GENERAL INFORMATION
Two-Speed Powershift Circuit ............................................................................................................................ 42
Powershift Operation ..........................................................................................................................................42
High Speed Selected ....................................................................................... ...................................................42
Low Speed Selected ...........................................................................................................................................42
SCHEMATIC CIRCUIT .............. ......... ............ .. ... ................ .................................... ....... ....................................... . 43
SM 8-10140 Issued 03-2003
42 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
Two-Speed Powershift Circuit
Powershift Operation
High-speed powershift can only be selected in FORWARD. If reverse and high-speed powershift is selected the
powershift transmission will change too or remain in low speed.
Low-speed powershift can be selected in forward or reverse.
High Speed Selected
Battery power flows through fuse 34 to terminal 3 (30) of powershift relay 5 and to the two-speed powershift
switch. Power also flows to the clutch pedal position switch terminal 1.
With high speed selected, power flows through the two-speed powershift switch to terminal 1 (86) of the
powershift relay 6, through the relay windings to terminal 2 (85) and to ground at G2, energising the relay.
With the clutch pedal UP and FORWARD selected, power flows through the clutch pedal position switch and
the forward position switch to terminal 1 (86) of the powershift relay 5 through the relay windings to terminal 2
(85) and to ground at G2, energising the relay.
With both powershift relay's energised power at terminal 3 (30) of relay '5' flows through both relay's to terminal
5 of relay '6' and to the powershift solenoid. Power flows through the solenoid to ground at G3 , energising the
solenoid and engaging High-speed powershift.
NOTE: If the clutch pedal is moved down or reverse is selected the power through the clutch position
switch or forward position switch to terminal 1 (85) of the powershift relay 5 is disconnected and the
relay de-energised. With powershift relay 5 de-energised power flowing from terminal 3 (30) powershift
relay 5 to the powershift solenoid, through both relays is disconnected. the transmission will change to
Low-speed powershift.
Low Speed Selected
If low speed is selected the two-speed powershift switch opens and the power to terminal 1 (86) of powershift
relay 6 is disconnected, de-energising the relay. With powershift relay 6 de-energized power to the powershift
solenoid is also disconnected, de-energising the solenoid, engaging Low-speed powershift .
8M 8-10140 Issued 03-2003
SECT/ON 4001 43
SCHEMATIC CIRCUIT
TWO-SPEED POWERSHIFT
70lB 75 - - -- - -570lB 75
i550R.75
I
1
TWO-SPEED
POWERSHIFT
r
, ~ SWITCH
0:: SHOWN IN
~ LOWSPEEO
r--+-- - 563T1 0 - ---,
POWERSHIFT
POWERSHIFT
RELAY 6
RElAY 5
(SEE TABLE)
(SEETA8LE)
>=
N
FORWARD <0
POSITION SWITCH '"
,,""-
SHOWN IN TRANSMISSION
FORWARD
iil on
,... ...
SEE NOTE 1 t;; ~
<0
POWERSHIFT
SOLENOID
'"
8+ ENGAGED
HIGH SPEED
2 "",,<,,",,,, 0",
1---~562T75 _ _
J
_ _....J
~ CLUTCH PEDAL POSITION
0:: SWITCH
10 ~
0
;;:; SWITCH SHOWN WITH
~ 10 CLUTCH PEDAL IN THE
UP POSITION
(WITH 3 9 OHM RESISTOR)
1
G3
I11III)1111 1
G2
SEE NOTE 1
CHASSIS GROUND
CLEAN GROUND
IIIWIIIII
MI03135
NOTE 1: Only use a HIGH IMPEDANCE
RELAY TERMINAL RELAY TERMINAL
multimeter to test the switches and circuits. Do
BLOCK REFERENCE REFERENCE
not use a test lamp or damage to the switches
may occur. 1 86
2 85
(*) European Specification Tractors Only
3 30
(**) American Specification Tractors Only 4 87A
5 87
8M 8-10140 Issued 03-2003
44 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECT/ON 4001 45
ROTARY BEACON LIGHT, IMPLEMENT INTERFACE CONNECTOR
AND 3 PIN AUXILIARY POWER CONNECTORS
CIRCUIT GENERAL INFORMATION
Rotary Beacon ............................................. ....................................................................................................... 46
Implement Interface Connector Circuit ............................................................................... ........ .......... .............. 46
Front and Rear 3 Pin Auxiliary Power Connector Circuit ............................................... ......... .... ... ... ............. ..... 46
Schematic Circuit ... ........ ................ ................. .. ........................................................................................... ........... 47
8M 8-10140 Issued 03-2003
46 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
Rotary Beacon
Switched power flows through fuse 22 to the rotary beacon switch. With the switch ON power flows through the
switch to the internal warning lamp, trailer rotary beacon connector terminal A and to the rotary beacon light
unit. Power flows through the warning light, beacon light and beacon motor to ground illuminating the lamps
and operating the rotary beacon motor.
Implement Interface Connector Circuit
The Implement interface connector allows the implement systems to be connected to the tractor electrical
system to power the unit and enable the unit to monitor wheel speed and ground speed.
Front and Rear 3 Pin Auxiliary Power Connector Circuit
Battery power flows through fuse 42 to the front 3 pin auxiliary connector pin 2 (15/30 American specification)
and through fuse 41 to the rear 3 pin auxiliary connector pin 2 (15/30 American specification).
Switched Power flows through fuse 44 to the front 3 pin auxiliary connector pin 1 (82 American specification)
and through fuse 43 to the rear 3 pin auxiliary connector pin 1 (82 American specification).
Pin 3 (31 American specification) on both front and rear 3 pin auxiliary connectors are connected to chassis
ground at G1 for the front connector and G2 for the rear connector.
8M 8-10140 Issued 03-2003
SECTION 4001 47
SCHEMATIC CIRCUIT
ROTARY BEACON LIGHT IMPLEMENT INTERFACE CONNECTOR 3 PIN AUXILIARY CONNECTORS
--------------------------------------------------------------------------------~()
""f "
BATTERYPOW£RB+
-----------------------------------------&MTCHEDPOWER------------------------------------4]r----------------------------------~+------------------------49
~ ~
775Rl0
I
q
~~1_----------775Pl O~149Rl.5
q
I FUSE ~:1 0 "moo ~
0::
<D
a:
to
(15A) 4
(lOA)
5
(lOA)
35
(SA)
I:: j:::
q FUSE ( ;BU=" FUSE FUSE FUSE
cr ~
~, ~
41 44 43
(I) ~~ (30A) (30A) (30A)
... a: (I)
IMPLEMENT INTERFACE CONNECTOR ~
I ... ..;
(1)"-
UNSV\i1TCHED POWER B+
KEY SV\i1TCH SENSING 2
AFS R1 0 - -- - - - - - - - - ' .
AFS R1 0 -----l
I I 135R2.5
i
AFS Rl 0
BR 75 SV\i1TCHED POWER B+ 7 AFS Rl 0 AFS Rl 0 '" 0
CLEAN GROUND 3
~ ~
~ ~
CHASSIS GROUND
RADAR SIGNAL
8
5
AFSBR10 AFSBR1 .0 l
281Y75 - - - - - - - - - - - - - - - - - - ,
T "'N '"N
'" a::
ROTARY
BEACON RADAR PRESENT 6 282Y 75 - - - - - - - - - - - - - - - - , ~ ~
q
SV\i1TCH WHEEL SPEED SIGNAL 4 215Y.75 ~ q
"-
<D
j::: 64
'-- ~ ~
~ ~
I ~ ~
N « TO INSTRUMENT
CLUSTER
q TERMC2-A·8
"'....ci a: FROM WHEEL SPEED SENSOR ~2 1 5Y 75 _____ _ _~ ~ ~
~ REFER TOSECTION 10002 ~
N
;r:
"''"~
~
.".
~
...on II>
~
~
L 776P10 - - - - - , ~ ex; C) II)
TO INSTRUMENT ~ N NN
CLUSTER TERM C2-A.5 <:]--215Y 75 - - - - ' a::
.".
M M
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II)
~
ii
FROM RADAR <:}-282Y 75
~
C)
(*")
C)
N AUXILIARY
POWER
TO INSTRUMENT CLUSTER TERM C2-B-2 <:]-282Y 75 CONNECTOR
i
l-SV\i1TCHED
q 2 - UNSV\i1TCHED
ROTARY FROM RADAR <:}-281Y75
0:: BEACON -[ 3-GROUND
~
'" N
TO INSTRUMENT CLUSTER TERM C2-A-l0 <:}-281Y 75 II! q
(*)
[ffij___--.I q ~
'"~
a:
'"
:!!
;;;
0
'"!!?
N-
co,!-
AUXILIARY
POWER
N
a:
~
;:;
ii: ~ CONNECTOR
~ "' ~ (.) ii 38 38
~ ~
~ 81 - SVIi1TCHED
a: ROTARY ti!
CD q• al
CAB CHASSIS (I)
u..
~
0
0 15/30 - UNSV\i1TCHED
m BEACON M CD GROUND ~ N FRONT 31- GROUND REAR
(7 POLE ~ &j
@/82~~~~:.:3
M
TRAILER ~ I
1
- - - - - - - -- - - --
CONNECTOR)
CLEAN GROUND
I'- ~ 826BR1 .0C.)
--------~~----~»"tI"""J""";;---CHASSISGROUND --~~--------~I-----------------------------------~~--------------------------------------------------------------------~~----~--------~._------------- CHASSISGROUND ----~""""~--~------
Gl G5 G4 G4 G2 Gl
CLEAN GROUND
G2
----------==-=----
MI03B015
(*) European Specification Tractors Only.
(**) American Specification Tractors Only.
(.) Deluxe Cab Tractors Only.
(••) European Specification Low Profile Cab Tractors Only.
8M 8-10140 Issued 03-2003
48 SECTION 4001
This Page Has Been Left Blank
8M 8-10140 Issued 03-2003
SECTION 4001 49
HORN, CIGAR LIGHTER, EUROPEAN SPECIFICATION SWITCHED
FENDER AUXILIARY POWER CONNECTOR, AMERICAN SPECIFICATION
7 POLE SOCKET AUXILIARY POWER AND ELECTRIC AIR SEAT
CIRCUIT GENERAL INFORMATION
Horn Circuit. ... .. .. .... ..... ...... ... .... ... ........... .. ........... ...... .. ... .. ... ...... .............. ....... .......... .... ..... ... ............. .... ... .. ..... .... 50
Cigar Lighter Circuit ..... .. .... ..... .... .......... ... ... .. .. .... .......... ... ....................... ............. .... ....... ........ ... ...... .. .............. ... 50
Switched Fender Auxiliary Power Connector
- European Specification .... ... ..................... .. .................. ............................ ................. .. ................... .... .......... 50
7 Pole Socket Auxiliary Power
- American Specification Tractors ...... ... ......... .................... .... .......... .. ... ............. ..... ......... ................... ... .. ...... 50
Electric Air Seat Circuit ...... ... .. .. .. ........... .......... ...... .......... ..... ............. .... ..... .... ... ..... .. ............. ................... ....... ... 50
SCHEMATIC CIRCUIT ...... ... .......... ... ...... ..... .... ......... .. ........ .. .. .. .. ..... ..... ........ ....... ..... ....... ..... .. ... ..... ............... ..... ... 51
8M 8-10140 Issued 03-2003
50 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
Horn Circuit
Battery power flows from fuse 1 to the horn (+) terminal, through the horn windings to terminal (-) and to the
stalk switch terminal 31B. With the horn switch pressed ON (spring release to OFF) power flows through the
switch to terminal 31 then to ground at G1 activating the horn.
Cigar Lighter Circuit
Battery power flows through fuse 39 to the cigar lighter unit. When the cigar element is pushed IN power flows
through the cigar lighter element to ground at G2 heating the element. When the element reaches the required
temperature the element will partially eject and disconnect the power supply to the element.
Switched Fender Auxiliary Power Connector
- European Specification
Switched power flows through fuse 29 to the switched fender auxiliary connector.
7 Pole Socket Auxiliary Power
- American Specification Tractors
Switched power flows through fuse 29 to the 7 pole socket pins 4 and 7.
Electric Air Seat Circuit
Switched power flows through fuse 27 to the seat switch terminal A. With the switch pressed ON (spring release
to OFF) power flows through the switch to the electric seat motor and through the motor to terminal B. Power
then flows to ground at G2 energising the motor.
SM 8-10140 Issued 03-2003
SECTION 4001 51
SCHEMATIC CIRCUIT
HORN CIGAR LIGHTER 7 POLE SOCKET AUXILIARY POWER (**)
FENDER AUXILIARY POWER AND SEAT
F 1
8ATIERY POWER (8+)
1 1
----------------------------------------------------------------------;---------
------SWTC HEDPO~R:--------~----------------~
N
~
<0 a: .,'"
a:
co :;: ;!
L",,,"
FUSE FUSE
29 FUSE
39 27
FUSE 1 (30A)
(lOA) elSA)
(15A)
'"""'"l
890R1.0 - - - - - - - - - - - - - - - - - - - 0
____________-11> FROM FUSE 20 (* " ) N
a: ~
~
762R 75 FROM FUSE 21 (*) '"~ <0
FROM FUSE 18 (**) ~
~
810Rl ~
FROM FLASHER RELAY (*) g
co
71 FROM FLASHER RELAY (**)
TURN SIGNAL SELF } FROM HAZARD SWITCH (* ) ' - - - - - -810RI o------1-H
CANCELLING MODULE
(IF EQUIPPED)
14"8'1 a
11 '8'1,0
15'8'1,0 11 H'l- - - - '
q
,...-------------1 2'8'10 H t---------c> FROM HEADLIGHT DIPPER RELAY TERM'S' cr: ELECTRIC AIR
o
, . . . - - - - - - -'13'8'10 9 IE-(-f--------.., Ol
<0
SEAT AND NJO
SWTCH
,...--------'
L------------890BR1 ,O - - - - - - -- - - ,
o
STALK SWITCH N
a:
-l "~
TURN HORN. DIP
CIGAR ~
' 2'O
LIGHTER
q q 0 I 4 e**l
7 POLE
'"a:
~
cr:
en
HORN ~
<Xl
<>
~
0
m
t t33R2,O
,
7
TRAILER
...
<0
M 0> '"
SOCKET
890BR1'O~'" (* )
SWTCHED
1 - - - --890R 1 0 8 FENDER
7 AUXILIARY
POWER
CONNECTOR
- -...----,:""'om:'1"'"---- CHASSIS GROUND - - - - - -- ... ---------""""lom:om:"'"--- - - - - - - -..- - CHASSIS GROUND -~...---""""lom:om:"'"---...---
__-...:G:..;l_____________________ CLEAN GROUND G1 G2 CLEAN GROUND ____..o...;;.______________________G_2_____
MI03BOO6
(*) European Specification Tractors Only.
(**) American Specification Tractors Only,
SM 8-10140 Issued 03-2003
52 SECTION 4001
RADIO AND INTERIOR LIGHT
CIRCUIT GENERAL INFORMATION
Radio Circuit ......................................................................................... ................... ... .. ............ ..... .. ................... 53
Interior Light Circuit. ..... ........ ....................... ....................... ............... ..... ............................................................. 53
RADIO ADAPTOR HARNESSES SCHEMATIC ........ .. .......... .... ........ ........... .. ............... .. ...................... ................. 54
SCHEMATIC CIRCUIT .......... ... ................. .. ..... ................... .. ......................................... ........................................ 55
SM 8-10140 Issued 03-2003
SECTION 4001 53
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
Radio Circuit
NOTE: If the cab harness radio connector does not connect directly into the radio equipped on the
tractor, adaptor harnesses are available to enable connections to be made different radios .
Power from the key switch (ACC and ON positions only) flows through fuse 40 (general radio supply) to the cab
harness radio connector (connector 72) terminal 7, (terminal 0 for type 1 adaptor harness or terminal 2 for type
2 adaptor harnesses) .
Battery power flows through fuse 30 (supply for radio memory and clock) to the cab harness radio connector
(connector 72) terminal 4, (terminal K for type 1 adaptor harness or terminal 3 for type 2 adaptor harnesses).
The radio is connected to ground at G4 (through the cab splice 11 for deluxe cab tractors) from the cab harness
radio connector (connector 72) terminal 8, (terminal I for type 1 adaptor harness or terminal 1 for type 2 adaptor
harnesses).
The radio speaker ground terminals are connected to the radio through cab harness radio connector (connector
73) terminals 4 and 6, (terminals Land M for type 1 adaptor harness or terminals 5 and 10 for type 2 adaptor
harnesses) .
The radio speaker signal terminals are connected to the radio through cab harness radio connector (connector
73) terminals 4 and 6, (terminals E and F for type 1 adaptor harness or terminals 6 and 9 for type 2 adaptor
harnesses).
Interior Light Circuit
Battery power flows through fuse 30 to the interior lamp unit terminal B. Power flows through the lamp to the
internal switch.
With the switch in the OFF position there is no circuit to ground at G4 (through cab splice 11 for deluxe cab
tractors) and the lamp will not illuminate.
With the switch moved to ON power flows through the switch to terminal A to ground at G4 (through cab splice
11 for deluxe cab tractors) illuminating the lamp.
With the switch moved to AUTO power flows through the switch to terminal C and to the door switch. With the
door open the switch contacts will close allowing power to flow through the switch to ground and the lamp will
illuminate.
8M 8-10140 Issued 03-2003
54 SECTION 4001
RADIO ADAPTOR HARNESSES SCHEMATIC
Type 1 Adaptor Harness
CONNECT TO CONNECTOR 72 7.
I
>
2
8
'Ti
SWITCHED POWER '2 ~ R _8 7
RADIO CLOCK
:;:3 ~ R.8
::;:1 ~
=~
GROUND B _8 8
OPEN 4 5
::;:
LH REAR SPEAKER SIGNAL
=
8
""~ LB _S
LB _8
LH FRONT SPEAKER SIGNAL .!.. u
LH SPEAKER COMMON 10 "
- '-'
0 _8
RH REAR SPEAKER SIGNAL "'1
_ ""u DB ,e
RH FRONT SPEAKER SIGNAL 6- "'-' DB B
RH SPEAKER COMMON "5 <;"<; Y _8 LB _S
....:.. U
0 _8 6
OB .8 3
Y _8
CONNECT TO CONNECTOR 73
Type 2 Adaptor Harness
CONNECT TO CONNECTOR 72 74
76
DIMMER
.£ <.L G-O,S - - - - - - - - - - - - \
- - - - - - - - - -- -1
:::~ ""~
SWITCHED POWER 0 R-O_S
RADIO CLOCK R-0_8 - - - - - - -- -- - -1
~
"'I '-!. B-0 _8 - - - ---------1
=
RADIO GROUND
J
~
--B "
OPEN
RH REAR SPEAKER SIGNAL DB-O_
RH REAR SPEAKER GROUND =
l! ""
<.L
<.L
Y-O
LH REAR SPEAKER SIGNAL
-A ""<.L
LB-O_
LH REAR SPEAKER GROUND "G""
-'-'
0-0
LH FRONT SPEAKER SIGNAL "E<;"<; LB-O_
-<-<
LH FRONT SPEAKER GROUND 'L<;"<; 0-0_
f- "-'
RH FRONT SPEAKER SIGNAL ~ """
f-'-'
DB-O_8 - - - - ,
RH FRONT SPEAKER GROUND f;;j""" Y-O
CONNECT TO CONNECTOR 73
8M 8-10140 Issued 03-2003
SECTION 4001 55
SCHEMATIC CIRCUIT
RADIO INTERIOR LIGHT
----------------------- BATTE RY PoWERB+ ----------------------~~-C)-()----------------------------------------------------------------------------------------------------------------------------------------------- BATTERYPOWERB+ --------------__
- - - - -- - - - - - SWITCHED POWER SWITCHED POWER - - -- - - - -
BATTERY POWER B. FROM
[ 176~~::~~TO FUSE 17 (LATER TRACTORS Or-lLY)
...-- - -- - - - - - - - - --131R.75-- -- - - - - - i -- +--i- - - - - - -131 R 75 - - - - - - , UNSWITCHED POWER STUD (ENGINE SI DE) <::)t--- - - - 162R1 0 ~ 143R1 0
OR MASTER DISCONNECT SWITCH ~
FROM FUSE 19
(*)
TO REAR POSITION
LIGHTS
FUSE !:
B71RO 8 (.)
87100.8 (•• )
--------I-.1 co
FUSE
30
(7.SA)
L-_.r-_ TO FLASHER RELAY TERM '1'
l708Pl .0 (*)
40
(I.SA)
-
'"a:ci !. I
... '" !. [
:3 '"0a: !.• +
784BR08( .)~
870BRO'8( •• ~ I _~
ri
~
B ~
, - - - - 728Pl 0 (**) TO CLUSTER
20 1R.7S --c> TERM.# 1-B-3 ...,...co
III <Xl
0 0 LEFT HAND - "'0:
I---C> TO FUSE 23 706P1 5 (*) a:
,..-----. A SPEAKER ;;
'"
,...
1
0 ci ;:;
13 - a:
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~
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~ ..... II:
....co
1 - - - - - -- - - -- - - n 9 Ii
OR2.S
9 III '"cia:
'"«
-'
z
~
I--{::> TO WORKLI GHT ROCKER
SWITCH TERM 'C'
, . . - - - - - - - - - 726P1.0 (" '*) - - - - ---+--1---'
L------~870RO . 81 ----...,
- - - - - i k -- - -726PO.8
~ ...
M
...'"o
'"
71RO.8 (. )
-i -§
!.
!.
co
""
W
l- , . - - , - - TO HEADLIGHT RELAY TERM '2'
•!!. 726P10(.
RIGHT HAND
SPEAKER
....
I
C
f
It)
o
I-
~
en
II!
0:
co
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a.
<0
726P1 .0 (. )
~
(**)
>-
w ....
0
TO RIGHT HAND
ROTARY CONSOLE LIGHT
'"o
:2 LIGHT SWITCH
r-- - - - - - - - 7 3 SR1.S; - - -- --'
a: . . . - - -- - - -- 720R2.Si- -- - - - - ' 726PO.8
L1.
a: TO RIGHT HAND a:
w FRONT POSITION . -- - l i 70RO,6 ;::
~
<0
LIGHT o<r
!l.
(*) TO NUMBER 871 RO.8 (.) CD
>-
a: PLATE LIGHT
N
....co
ROTARY 871008( •• )
o RH
en LIGHT !.
o SWITCH
FUSE
o 7 (lOA) ANTENNA «!
w
o
o
lECD
«
ow
706P \ 5 (*)
~ INTERIOR
I CAB CHASSIS LIGHT ASSEMBLY
TO LEFT HAND POSITION LIGHTS
r=' GROUND
~ '--4---{> TO CLUSTER SPLICE 11
en TERM.C1-B-12
0 0
«-' -'
...J
z «Z
Z
« z::l
Z
::l
0
II:
<:)
iii
<:)
iii
(!)
iii
0
II:
!:
I---{::> TO HEADLIGHT RELAY TERM '2' <:) (!) 716BR.8
a: a: II:
cr:
ffi « II:w ""w
w w
w
'"w w!l.'" '"W« ;Ii!l. .1ia.'" ;Ii'"
«
a. en a. (/) (/) a.
•
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!:
0
en II: (/)
cr: l- I/)
!. co M
« « z >- ii:ell DOOR
~
II: II: 0
<: w « w 0 z ~ II: SWITCH
w w a: a: 0 CD
II:
II:
I II:
:i
LL a: II: ...co
0 v
,...
<Xl NlC
I
II:
a: l:
...J
I
...J
L1.
I
-'
LL
I
a:
.......
CD
-131R 7
PHILLIPS ENTERTAINMENT RADIO
------------------~»~»~»~»~a~)-------------------- CHASSIS GROUND ----------------------~~""~------------------------------------------------~""""~-----------------------~~--------------
G4
__~~-----,,~""~
G4 G4
CHASSIS GROUND ----__~----------~-----
G4
- - - - -- - - - -- - - - - -- - -- - - - CLEAN GROUND CLEAN GROUND ----=...:.....-- - ------
MI03BOOI
(*) European Specification Tractors Only.
(**) American Specification Tractors Only.
(.) Deluxe Cab Tractors Only.
( ••) European Specification Low Profile Cab Tractors Only.
8M 8-10140 Issued 03-2003
56 SECTION 4001
BLOWER MOTOR AND AIR CONDITIONING
- DELUXE CAB TRACTORS
CIRCUIT GENERAL INFORMATION
Heater Blower Circuit - Deluxe Cab Tractors ............ ..... ............ .. ............ .. .............. ........................................... 57
Low Speed Selected ...... ...................................... ...... .... ........................................................... .. ....................... .57
Medium Speed Selected ............... ........... .. ............... .... ........................................... ............. .............. ................ 57
High Speed Selected ....... .. .......... .. ............ ... ............. ... ............................ .......................................................... 57
Air Conditioning Circuit - Deluxe Cab Tractors ................. .......... .. ........... .. ............................................. ............ 57
SCHEMATIC CIRCUIT ........ ... ........... .. ........................... ... .......... ... .............. .............................................. ............ 59
8M 8-10140 Issued 03-2003
SECT/ON 4001 57
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
Heater Blower Circuit - Deluxe Cab Tractors
Switched power flows through a 40 amp circuit breaker to the fan speed switch terminal E (B) . When the switch
is OFF there is no power through the switch .
Low Speed Selected
With the switch in the low speed position power flows from terminal A (L) of the switch , through two resistors
on the resistor board to terminal A of both blower motors , through the motors to terminal B. Power then flows
from terminal B of the blower motors to ground at G4 (through cab splice 13), operating the motors at low speed.
Medium Speed Selected
With the switch in the medium speed position power flows from terminal B (M) of the switch , through one resistor
on the resistor board to terminal A of both blower motors, through the motors to terminal B. Power then flows
from terminal B of the blower motors to ground at G4 (through cab splice 13) , operating the motors at medium
speed.
High Speed Selected
With the switch in the high speed position power flows from terminal C (H) of the switch to terminal A of both
blower motors , through the motors to terminal B. Power then flows from terminal B of the blower motors to
ground at G4 (through cab splice 13), operating the motors at high speed.
Air Conditioning Circuit - Deluxe Cab Tractors
The air conditioning system will only operate when the blower motor switch is ON and the air conditioning
thermostatic switch is ON.
Switched power flows through a 40 amp circuit breaker to the fan speed switch terminal E (B) (refer to heater
blower circuit) . With the heater blower switch in the L, M or H speed position power flows from terminal F (C)
to the air conditioning temperature control switch. With this switch in the ON position , power flows through the
switch to terminals A on both the high and low pressure switches. Power also flows to the air conditioning
lockout relay terminal 3 (30), through the relay to terminal 4 (87a). The power will then flow to ground through
the easiest path of compressor clutch windings, engaging the clutch. The compressor clutch diode prevents the
current flowing directly to ground .
If the low or high pressure switches or are closed , power flows through the closed switch from terminals A to B
then to the lockout relay terminal 1 (86). Power then flows through the relay windings to terminal 2 (85) and to
ground at G4 (through cab splice 12), energising the relay.
When the relay is energised the power now flows from terminal 3 (30) to terminal 5 (87) of the relay,
disconnecting power to the compressor clutch from terminal 4 (87a) and the compressor clutch will disengage.
When the clutch disengages the clutch windings can induce a high voltage spike to flow backward into the
circuit to find a path to ground.
Continued .....
8M 8-10140 Issued 03-2003
58 SECTION 4001
This high voltage spike can damage switches, relays and electronic components in the circuit. To prevent
damage to the circuit the compressor clutch diode is designed to allow power to flow through the diode directly
to ground if the voltage in the circuit rises above a specified level. This will allow any high voltage spike induced
by the compressor clutch to flow to ground directly through the diode.
Power flows from terminal 5 (87) of the relay to the air conditioning warning lamp, through the lamp to ground
at G4 (through splice 12) illuminating the lamp. Power at terminal 5 (87) is also looped to the relay terminal 1
(86), maintaining the relay in the energised state, even if the closed pressure switch is opened. The temperature
control switch will need to be switched OFF then ON to reset the circuit.
SM 8-10140 Issued 03-2003
SECTION 4001 59
SCHEMATIC CIRCUIT
BLOWER MOTORS AIR CONDITIONING
----------------BATTERYpOwERB+ ----------------------------------------------------------------------------------------BATTERYPOW
ERB+
------------------S~TCHEDPOWER-------------------------------------------------------------------------------------------S~TCHED POWER----------J
----~
RESISTOR _______________________________________________________ 820R4.5 --------<OO------820R4.0
.-r=..:...r.>*-------- 822LG2.0 CIRCUIT BREAKER
40A
~="-B,*--- 823LB.2.0
--:!!..!.!.!.4l,*-8260 2.0 --
fil ]' _ 180002.0
::'i
d-
AIR CONDITIONING <Xl
TEMPERATURE ?l
CONTROL g
SWITCH
_
80002.0
.---- -+ - - - - -- 82604.5
~
A 8020.8 1-----110:20.8 -----------------:8020 8 80208-----,
.---------i C 8040.6 , - - - - -.80202.0
co 10
o
L,
804o.8 1 1
AIR CONDIONING
LOW PRESSURE
SWITCH
(5 '" "l (GREEN)
<C
o 0 CLOSES BELOW
'"
~ .~O
<Xl
AIR CONDITIONING .• __O_.4_B_A_R_I_6_P_SI)
LOCKOUT
RELAY
(SEE TABLE)
dd AIR CONDITIONING
v v LOCKOUT
g g INDICATOR
BLOWER
MOTORS
<0
o
N
o (e ! --
750BR8
'7 50BR8 _________+-_______________
L
804
__0_
.8
~
-: ~
LIGHT
I
750 8
CAB CHASSIS CAB CHASSIS 80302.0~6030 1.5 ~B030 1.5
GROUND
~ ~
GROUND
~I
SPLICE 13 SPLICE 12
' - - - - - 826BR4.5
80J01 .5 - - - - - - - - - . . . .
11 COMPRESSOR
CLUTCH
DIODE
AIR CONDITIONING
COMPRESSOR
CLUTCH
830BR 1 0
}j;;;;;;';; ----------~~~~--------_4~----------~CHASSISGROUND---------------L--~~""r---------------~----
G4 G6
----------------------------~--------------<CLEANGROUND ----------------------------------------------
MI03B070
RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
REFERENCE
1 86
2 85
3 30
4 87A
5 87
8M 8-10140 Issued 03-2003
60 SECTION 4001
LOWER MOTOR AND AIR CONDITIONING
- LOW PROFILE CAB TRACTORS
CIRCUIT GENERAL INFORMATION
Heater Blower Circuit - Low Profile Cab Tractors ......... .. .......................................... .... ................. .. ................... 61
Low Speed Selected ... .. .... ............ ........ ...... ........ .. ....... ............. ...................... ............. ..................... .. ........... 61
Medium Speed Selected ....................................... ........ ..... ....... ... ........ ... ....... .. ..................... ... .................. .... 61
High Speed Selected ........... .. ........ .. .......... ....... .. ............ .. .. ..... ... .. .. ... .. ..... ....... .............. ......... ... ....... ....... .... .. .61
Air Conditioning and Temperature Control Circuit
- Low Profile Cab Tractors ............. .. .......... ......... .... .......... .. ................... .. ............................... ........................ 61
SCHEMATIC CIRCUIT .... ............................................. .. .................................. .............................. .... .................. .. 63
8M 8-10140 Issued 03-2003
SECTION 4001 61
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
The heater and air conditioning blower motor has three speeds, which are controlled by the operator switch and
a resistor board.
Heater Blower Circuit - Low Profile Cab Tractors
Switched power flows through a 40 amp circuit breaker to the fan speed switch terminal 5 (B). When the switch
is OFF there is no power through the switch.
Low Speed Selected
With the switch in the low speed position power flows from terminal 3 (L) of the switch, through two resistors on
the resistor board to terminal A of the blower motor, through the motor to terminal B. Power then flows from
terminal B of the blower motor to ground at G4 , operating the motor at low speed.
Medium Speed Selected
With the switch in the medium speed position power flows from terminal 1 (M) of the switch , through one resistor
on the resistor board to terminal A of the blower motor, through the motor to terminal B. Power then flows from
terminal B of the blower motor to ground at G4 , operating the motors at medium speed .
High Speed Selected
With the switch in the high speed position power flows from terminal 2 (H) of the switch to terminal A of the blower
motor, through the motor to terminal B. Power then flows from terminal B of the blower motor to ground at G4,
operating the motor at high speed .
Air Conditioning and Temperature Control Circuit
- Low Profile Cab Tractors
The air conditioning system will only operate when the blower motor switch is ON and the air conditioning switch
is ON.
Switched power flows through a 40 amp circuit breaker to the fan speed switch terminal 2 (B) (refer to heater
blower circuit), switched power also flows to terminal M1-A (Grey connector) of the air conditioning controller.
With the heater blower switch in the L, Mar H speed position power flows from terminal 6 (C) to terminals 2 and
3 of the air conditioning relay, power also flows to terminal 6 of the air conditioning switch.
With the air conditioning switch in the OFF position and the temperature control switch set for heat the controller
will activate the water control valve motor to allow hot water to flow through the heater radiator. When the
required temperature is reached a signal will be sent to the controller from the temperature sensor. The
controller will then maintain the water control valve in the required position.
With the air conditioning switch in the ON position and the temperature control switch set for cooling the
controller will activate the water control valve motor to close the valve stopping the flow of hot water through
the heater radiator. Power will flow from terminal 2 of the air conditioning relay through the windings to terminal
1. Power then flows to the air conditioning controller terminal M2-A (Black connector) through the controller to
terminal M1-F (Grey connector) then to ground at G4 , energizing the air conditioning relay.
continued ....
SM 8-10140 Issued 03-2003
62 SECTION 4001
With the air conditioning relay energized power flows from terminal 3 to terminal 5 of the relay, power will then
flow to ground through the easiest path of the compressor clutch windings, engaging the clutch. The
compressor clutch diode prevents the current flowing directly to ground. When the required temperature is
reached a signal will be sent to the controller from the temperature sensor. The controller will then switch OFF
the air conditioning relay ground circuit, deenergizing both the relay and the compressor clutch. When the clutch
disengages the clutch windings can induce a high voltage spike to flow backward into the circuit to find a path
to ground. This high voltage spike can damage switches, relays and electronic components in the circuit. To
prevent damage to the circuit the compressor clutch diode is designed to allow power to flow through the diode
directly to ground if the voltage in the circuit rises above a specified level. This will allow any high voltage spike
induced by the compressor clutch to flow to ground directly through the diode.
With the air conditioning system operating normally the low and high pressure switches are closed, power flows
through the closed switch from terminals A to B then to ground at G4, the air conditioning controller will detect
the pressure switch state (switch closed) and allow the system to operate.
If either the low or high pressure switch opens the controller will immediately de-energize both the air
conditioning relay and clutch. When the controller detects a pressure switch open state, the controller will re-
engage the clutch if the switch closes or 10 seconds has elapsed since the switch opened. If after 10 seconds
the switch remains open the controller will disengage the clutch. The controller will try to re-engage the clutch
for period of 60 seconds. If after 60 seconds the pressure switch remains open or the pressure switch opens
then closes, four times for the low pressure switch or twice for the high pressure switch, the controller disengage
the clutch and will flash the air conditioning warning light in the air conditioning switch.
If a low pressure failure is detected by the controller the warning light will flash 5 times per second, if the
controller detects a high pressure failure the warning light will flash 2 times per second
SM 8-10140 Issued 03-2003
SECTION 4001 63
SCHEMATIC CIRCUIT
LOW PROFILE CAB BLOWER MOTOR LOW PROFILE CAB AIR CONDITIONING
_________________ BATTERY POWER B+ ----------------------------- - - -- - - - - -- -- -- - - -- - - - - - - - - - - - - -- - - - - - - - - -- - - - - - - - - - - - - - - - - - BATTERY POWER Bt BATTERYPOWERBt
----------------~S~TCHEDPO~R S~TCHEDPO~R:----------------------------------------------------------------SWITCHEDPO~R:------____________________________
CIRCUIT BREAKER CIRCUIT BREAKER
40A 40A PIN NO. AIR CONDITIONING CONTROLLER
1820R3.0 -------------OO>------820R4 0 - - - - - - - ' 820R40~e20R30~07R3F'05R' 0 05Rl0- k: M1·A SWITCHED POWER Bt
827BR30~B3 .0 Bl0 020Bl.0 - - B M2-C AIR CONDITIONING WARNING LIGHT
C! l llYl0-
00Y1 .0 -
k'
k'
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M2-A
AIR CONDITIONING SWITCH INPUT
AIR CONDITIONING RELAY OUTPUT
~¢j~\
.------------ 03.0 ---------------, o
'"0:: ~ ~ ~
R
~ 09DG1 .0-- M1-C AIR CONDITIONING HIGH PRESSURE SWITCH
- - - -- - - - - - 1 0 0 R 3 0 04Pl0- ~ M2-E WATER CONTROL VALVE Bt
03DB1 .0 - - ~ M2-D WATER CONTROL VALVE CONTROL
BLOWER SWITCH
~
iI
(FAN SPEED) 08DG1 .0 - Ml-B TEMPERATURE SENSOR
BLOWER SWITCH
(FAN SPEED) 110Pl0- e-< M1-D TEMPERATURE CONTROL POTENTIOMETER
A" M2-B
C! AIR CONDITIONING LOW PRESSURE SWITCH
""",..~"G '~"nO"""n'''AnOO
~ ~'''''~
Ml-F CHASSIS GROUND
§ !' .!! i t g±•I
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131Rl .0 CO!
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- 111Y1.0
101DGI a --------------------- -- - - -- --101OG1 _0 I
C!
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§
.---+--100Yl 0 - - - -- - - -100Y1 .0 108DG10
<> AIR CONDIONING
iii LOW PRESSURE
S~TCH
(GREEN)
AIR TEMPERATURE OPENS BELOW
CONDITIONING SENSOR
RELAY
o 4 BAR(6 PSI)
o (SEE TABLE)
'"
o
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<> 11603.0 __________________-----l!
o'"
126LB1 .0 - - - - - - - -
80301 .5 - - - - - 8 0 3 0 1 5----4~ F 80301 5 = ( f B 0 3 0 1 .0
.------~ A 1----80201 0 0 80201 .0
BLO~ C 0401 .0 E 80401 0
BLO~R MOTOR I
..,~
MOTOR 80301 .5 -----------,
TEMPERATURE
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8 COMPRESSOR I L8()4010~ WATER CONTROL CONTROL
~ CLUTCH L...=80201_0~80201 0 VALVE
MOTOR
POTENTIOMETER
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L -___ _ _ _ _ BR3.0 ____...J '" HIGH PRESSURE SWITCH iii <> <>
C! 0 C!
830BRI.O (RED) ; co co iii iii gj
OPENS ABOVE 27.5 BAR
-------t~----------------)"»"z~»~»~»")~CHASSISGROUND------~--~~------. .------~~~~------~------------~~""~-L--------~HASSISGROUND----~------~~"~~Z~
~
--------------------------------~CLEANGROUND
~
~~ "/~----------------
(400 PSI)
1
..
G4
CLEANGROUND--------------------------------~~---------------------~~--~----~CLEAN GROUND
--------------~""~~
fIIIIIll/lI ..!G4----~~---
!
G4
CHASSIS GROUND !
G4
~
G4
!
G4
MI03B071
RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
REFERENCE
1 86
2 85
3 30
4 87A
5 87
SM 8-10140 Issued 03-2003
64 SECTION 4001
FRONT AND READ WINDSCREEN WIPERIWASHER
CIRCUIT GENERAL INFORMATION
Front Windscreen Wiper/Washer Circuit ............................................................................................................ 65
Intermittent Speed (if equipped) ................... ............................................................... ....................................... 65
Low Speed ...................................................................... ....................................................................................65
High Speed ..... .................... ...................... ........................... .... ..... ... .. ... ....................... ...................... ................. 65
Park Position ...................... ... .......................... ....................................................................................................65
Windscreen Washer ............................... ... ................ ... .... ......................................... .. ....................................... 65
Rear Windscreen Wiper/Washer Circuit .. ........................................................................................................... 66
Wiper ON .................................................. ..................... .....................................................................................66
Park Position .......................................................................................................................................................66
Windscreen Washer ...........................................................................................................................................66
SCHEMATIC CIRCUIT .......... .. ......... ......................................................... ............................................................. 67
SM 8-10140 Issued 03-2003
SECT/ON 4001 65
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
Front Windscreen Wiper/Washer Circuit
Switched power flows through a circuit breaker located in fuse socket 32 to the front wiper/washer switch
terminal E and to the wiper motor at terminal C for deluxe cab tractors or terminal 0 for low profile cab tractors.
Intermittent Speed (if equipped)
The intermittent speed position is the range between the OFF and low speed positions. When the switch is near
the OFF position there will be a long interval between each sweep of the wiper. When the switch is near the low
speed position there will be only a short interval between each sweep of the wiper.
With the switch in the intermittent position power at terminal E flows to the internal electronic timer of the switch.
The timer will open and close an internal switch (not shown) intermittently according to the exact position of the
wiper switch.
With the internal switch closed power flows through the wiper switch to terminal B and to the wiper motor at
terminal B for deluxe cab tractors or terminal 0 for low profile cab tractors. Power flows through the wiper motor
to ground at 84 (through cab splice 11 for deluxe cab tractors) operating the motor at low speed.
Low Speed
With the switch in LOW speed position power at terminal E flows through the switch to terminal B and to the
wiper motor at terminal B for deluxe cab tractors or terminal A for low profile cab tractors. Power flows through
the motor to ground at G4 (through cab splice 11 for deluxe cab tractors) operating the motor at low speed.
High Speed
With the switch in HIGH speed position power at terminal E flows through the switch to terminal A and to the
wiper motor at terminal A for deluxe cab tractors. Power flows through the motor to ground at G4 (through cab
splice 11) operating the motor at high speed.
NOTE: Low profile cab tractors are not equipped with two speed wiper motors. When the switch is in
position (III) power at terminal E flows through the switch to terminal A and to terminal B of the switch
operating the motor at low speed, (see above).
Park Position
Power at the motor terminal C for deluxe cab tractors or terminal 0 for low profile cab tractors flows to an internal
switch which is open when the wiper mechanism is in the PARK position but closed when the wiper mechanism
is not in the park position. With the switch closed power flows through the switch to terminal 0 for deluxe cab
tractors or terminal B for low profile cab tractors of the wiper motor. Power then flows to the wiper switch terminal
F. With the switch in OFF power flows through the switch to terminal B and to the motor. Power flows through
the motor to ground at G4 (through cab splice 11 for deluxe cab tractors) operating the motor at low speed.
When the wiper mechanism reaches park position the motor internal switch will open. This will disconnect the
power supply at terminal C for deluxe cab tractors or terminal B for low profile cab tractors causing the motor
to stop immediately.
Windscreen Washer
With the washer switch pressed ON (spring return to OFF) power available at the wiper/washer switch terminal
E flows through the switch to terminal C then to the washer motor. Power flows through the motor to ground at
G5 and the motor operates .
SM 8-10140 Issued 03-2003
66 SECTION 4001
Rear Windscreen WiperlWasher Circuit
Switched power flows through fuse 31 to the rear wiper/washer switch terminal 3 and to the rear wiper motor
through terminal B of the wiper motor assembly connector.
Wiper ON
With the rear wiper switch in the ON pOSition power at terminal 3 of the switch flows through the switch to
terminal 4 to the wiper motor. Power flows through the motor to terminal C of the rear wiper assembly connector
and to ground at G4 (through cab splice 11) operating the motor.
Park Position
Power at the motor from terminal B of the rear wiper assembly connector flows to an internal switch in the motor
which is open when the wiper mechanism is in the PARK position but closed in all other position. With the
internal motor switch closed power flows through the switch to terminal 1 of the wiper motor switch. With the
wiper switch OFF power flows through the switch to terminal 4 then to the motor. Power flows through the motor
to terminal C of the rear wiper assembly connector and to ground at G4 (through cab splice 11) operating the
motor.
When the wiper mechanism reaches park pOSition the motor internal switch will open. This will disconnect the
power supply from the switch connector terminal 3. The current flowing in the circuit is disconnected causing
the motor to stop immediately.
Windscreen Washer
With the washer switch pressed ON (spring return to OFF) power available at the wiper/washer switch terminal
3 flows through the switch to terminal 2 then to the washer motor. Power flows through the motor to ground at
G5 and the motor operates
SM 8-10140 Issued 03-2003
SECTION 4001 67
SCHEMATIC CIRCUIT
DELUXE CAB FRONT WINDSCREEN WIPER FRONT AND REAR WINDSCREEN WASHER LOW PROFILE CAB FRONT WINDSCREEN WIPER REAR WINDSCREEN WIPER
- - - - - - - - - - - - - BATIERY POWER B+ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BATIERY POWER B+
l-- - -- - -- - -
i
SWITCHED POWER SWITCHED POWER - - - -- - - - - - - -- - - - - - - -- - -- -- - - - - - -- - -- -- - -- - - - - -- - -- - -- -- - - - - -- -
FUSE
31
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ii
r l - ~840R1 5
O OI--- - - --830Rl .5 -~ 830R2.0 (-) --~~--- 900R.75 (.)
111_ ~ 830Rl 0 ( - - ) - - - - - - - - - - - - -- --
--C>
- - - - -- - - - -- --
TO MIRROR CONTROL SWITCH (IF EQUIPPED)
840R l .5 -------------------------------;840Rl .5 ~------840Rl0
- - - - - 830Rl 0 (--) ~
- -- - ---,
CIRCUIT
BREAKER
15AAT FUSE
LOCATION
32
, - - - - - - - - - - 830Rl 0 (_) 900R.75 (-)
(- )
--C> TO MIRROR HEATER SWITCH (IF EQUIPPED)
8320.75(_.)
(--)
FRONT
:I
WIPERIWASHER
FRONT
SWITCH
WlPERIWASHER
(-) SWITCH
FRONT r
WIPER MOTOR
(TWO SPEED)
(--)
REAR WIPER
SWITCH AND MOTOR
,..-- - - - - - - -- -V.8 - - - -- - - - -----,
FRONT WIPER MOTOR ASSEMBLY
83302.0 (_) - 1 - - - ,
83202.0 C- ) OFF
REAR
WIPER MOTOR
SINGLE SPEED . . - - --DG.8 -------.:~~:t-,
STANDARD ~C3+-Y8 r----R8-------~-U
WIPER SWITCH
STANDARD
WIPER SWITCH
POSITIONS
SHOWN .-
POSITIONS
SHOWN ,
!.
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!:
OFF cr
m
a'"~ °
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o
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C! 0 LOW o HIGH
m
°~ - 0 HIGH '"
CD
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m
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CIO ~3S0"0( •• } - - _ __ __ _ _ _ __ 83501 .0 ( __ ) _+-__...J
<0
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L '--- - + - - -000.8 _ _ _.....J ' - - - -1--- - -R.8 - - - - - - - J
L 784BR2.0 1_) ---HlH---, L 8350101 - ) B
1
83501'0: ! J
29 ' - -- -----,
830BR1 .0 ( __ )
.......- - - -R8 - - - - - - - - ' .......- - - -R8 - - - r - - - R.8
CAB CHASSIS
GROUND
SPLICE 11 83501 .0 ~83501 .0 ~-----------IB R8 ----------------------------- 1
~ 1
_I
!:
"l
!: cr
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cO
a:
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WASHER
REAR
WASHER
M 52
~ !.
.- a 0.
MOTOR MOTOR
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...
N
OJ
f29l9 f1l
' -- - -840BR 1.0 - - - - - 8 4 0 B R 1.0 '-----84501.0 - - - - - - + -- - - - -- -- + - - - - - - -- - - - - 8 45010 ~t-.
B ---84501 0 ----8TI---84501 .0 -+--li---J
' - - - - - +- 784BR10(.) -------------------------------------~--------+-------- 784BR1 .0e- ) - - - - - - - - - - - - - - - - - - - 7 8 4 B R l 0 (.)
--------~""~~-~~-----~. .-------~""~~--~HASSI SGROUN D -----------------------~-~""""~---e~----------~""""-----CHASSIS GROUND------------~""~~~~----------
-------------G~4~-----~G~5_ _ _ _ _ __ _ _ _ _ __ -4ClEANGROUND G4 G4 CLEANGROUND --------------~G~4~---------
MI02K080
(.) Deluxe Cab Tractors Only.
( ••) European Specification Low Profile Cab Tractors Only.
8M 8-10140 Issued 03-2003
68 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECT/ON 4001 69
DIFFERENTIAL LOCK, MFD AND
EUROPEAN SPECIFICATION BRAKE LIGHTS
CIRCUIT GENERAL INFORMATION
MFD Circuit ....... .... ................... ... ................... ... ........................................................................ ................ .. ........ 70
MFD Switch OFF and One or Both Brakes OFF .................... .................... .. .................... .... .............................. 70
MFD Switch OFF and Both Brakes Applied .................................. ............................................................ ...... .... 70
MFD Switch ON ...................... .. ....................................................................... ................. ..... ................. ... ......... 70
MFD Switch AUTO ................. ................................................ ... .................. .... ................... ... ............................. 71
Differential Lock Circuit. ............... .. .. ... ............. ............................................. .. .......................... .. ...... .. .... .... ........ 71
Differential Lock Operation ................. .................................. .. ........... ..... ..... ....................................................... 71
Differential Lock ON .................................................................. ..................... ................... .. ... ....... .... ... ........... .... 71
Differential Lock Warning Lamp ....................................................................................... .. ..... ............................ 72
European Specification Brake Light Circuit .... ... ................... .......... ........... ........ .. ................... .... ........................ 72
SCHEMATIC CIRCUIT ..... .... ... ..... .. ............... ................. ............... .... ... .. ............ .. .... ....... .. ... .... .. .. .. ... .. ......... ... .... ... 73
SM 8-10140 Issued 03-2003
70 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
MFD Circuit
NOTE: To disengage the MFD clutch the MFD solenoid MUST be energised, if battery power is lost to
the MFD solenoid the MFD clutch will engage.
The MFD switch has three positions OFF, ON and AUTO.
OFF ........... The MFD is OFF except when both brakes are applied (four wheel braking).
ON .............. The MFD is permanently ON
AUTO ......... The MFD is ON except when one brake is applied.
MFD Switch OFF and One or Both Brakes OFF
Switched power flows through fuse 26 to terminal 3 (30) of brake relay No.4 and to the LH brake pedal switch.
Power also flows to the RH brake pedal switch, terminal 4 of the differential lock switch, terminals 5 and 3 of
the MFD switch and to terminal 3 (30) of the MFD relay.
With the MFD switch OFF power at terminal 3 (30) of the MFD relay flows through the relay to terminal 4 (87a)
and to the MFD solenoid, through the solenoid to ground energising the solenoid and disengaging the MFD
clutch.
MFD Switch OFF and Both Brakes Applied
When both brake pedals are applied power flows through the LH brake switch to terminal 1 (86) of the brake
relay No.4 through the relay windings to terminal 2 (85) and to ground at G1 energising the relay. Power also
flows through the RH brake switch to terminal 1 (86) of the brake relay No.6 through the relay to terminal 2 (85)
and to ground at G1 energising the relay.
With both relay's No's 4 and 6 energised power at terminal 3 (30) of relay No.4 flows through the relay to
terminal 5 (87) and to terminal 3 (30) of relay No.6. Power flows from terminal 3 (30) of relay No.6 to terminal
5 (87) through a diode in the MFD blocking diode pack to terminal 1 (86) of the MFD relay. Power flows through
the relay windings to terminal 2 (85) and to ground energising the MFD relay.
With the MFD relay energised power flows from terminal 3 (30) to terminal 5 (87) of the relay and to the
instrument cluster MFD warning light at terminal C1-A-11. With the power now disconnected to the MFD relay
terminal 4 (87a) and to the MFD solenoid the solenoid will de-energise engaging the MFD clutch for four wheel
braking.
MFD Switch ON
With the MFD switch ON power at terminal 3 of the switch flows through the switch to terminal 1. Power then
flows to terminal 1 (86) of the MFD relay through the relay windings to terminal 2 (85) and to ground at G2,
energising the MFD relay.
With the MFD relay energised power flows from terminal 3 (30) to terminal 5 (87) of the relay. Power then flows
to the instrument cluster MFD warning light at terminal C1-A-11. With the power now disconnected to the MFD
relay terminal 4 (87a) and the MFD solenoid, the solenoid will de-energise, engaging the MFD clutch.
SM 8-10140 Issued 03-2003
SECT/ON 4001 71
MFD Switch AUTO
With the switch in the AUTO position power at terminal 3 (30) of brake relay No.4 flows through brake relay's
No's 4 and 5, from terminals 3 (30) to 4 (87a) on each relay, through a diode in the MFD blocking diode pack
to the MFD switch terminal 8. Power flows through the switch to terminal 6 and to the MFD relay terminal 1 (86)
through the relay windings to ground at G2, energising the MFD relay.
With the MFD relay energised power flows from terminal 3 (30) to terminal 5 (87) of the MFD relay and to the
instrument cluster MFD warning light at terminal C1-A-11. With the power now disconnected to the MFD relay
terminal 4 (87a) and the MFD solenoid, the solenoid will de-energise, engaging the MFD clutch.
If the LH brake is applied, power at the LH brake switch flows to terminal 1 (86) the brake relay No.4 and through
the relay windings to terminal 2 (85) to ground at G1 energising the relay. With relay No.4 energised the power
at terminal 3 (30) is now disconnected from terminal 4 (87a) and to the MFD relay terminal 1 (86).
With the MFD relay de-energised the power at terminal 3 (30) of the relay flows through the relay to terminal 4
(87a) and to the MFD solenoid, through the solenoid to ground energising the solenoid, disengaging the MFD
clutch .
If the RH brake is applied, power at the RH brake switch flows to terminal 1 (86) the brake relay No.5 and
through the relay windings to terminal 2 (85) to ground at G1, energising the relay. With relay No.5 energised
power at terminal 3 (30) is now disconnected from terminal 4 (87a) and the MFD relay terminal 1 (86).
With the MFD relay de-energised the power at terminal 3 (30) of the relay flows through the relay to terminal 4
(87a) and to the MFD solenoid, through the solenoid to ground energising the solenoid , disengaging the MFD
clutch .
Differential Lock Circuit
Differential Lock Operation
To engage the differential lock the differential lock switch must first be moved to the engage (momentary)
position then released to the ON position, the switch will spring return automatically to the ON position.
When differential lock is engaged (ON), if one or both brake pedals are applied the differential lock will
disengaged. The differential lock switch will need to be moved to the engage position to re-engage the
differential lock.
To disengage the differential lock move the switch to the OFF position.
Differential Lock ON
Keyed power flows through fuse 26 to the differential lock switch terminal 4. With both brake pedals released
power at terminal 3 (30) of brake relay No.4 flows through relay No.4 to terminal 4 (87a) to terminal 3 (30) of
relay's No's 5. Power then flows to the differential lock switch terminal 1.
With differential lock switch in the ENGAGE position, power flows from terminals 1 to 5 of the differential lock
switch and to terminal 3 (30) of the differential lock relay. Power also flows from terminals 4 to 2 of the differential
lock switch and to terminal 1 (86) of the differential lock relay, though the relay winding to terminal 2 (85) and
to ground at G2 energising the relay.
With the differential lock relay energised power at terminal 3 (30) flows through the relay to terminal 5 (87) and
to the differential lock solenoid. Power flows through the solenoid to ground at G3 energising the solenoid,
engaging the differential lock. Power also flows from terminal 5 (87) to terminal 1 (86) of the relay (maintaining
the relay in the energised state when the switch is released to the ON position).
SM 8-10140 Issued 03-2003
72 SECTION 4001
When the switch is released to the ON position power still flows through the differential lock switch from
terminals 1 to 5 and to terminal 3 (30) of the relay through the relay to terminal 5 (87). Power from terminals 4
to 2 of the differential lock switch now becomes disconnected. Power from terminal 5 (87) still flows to terminal
1 (86) of the relay maintaining the relay in the energised state. The relay will only de-energise when the power
to terminal 3 (30) of the relay is disconnected.
Differential Lock Warning Lamp
When the differential lock is engaged the contacts of the differential lock warning light switch close. With the
switch contacts closed power at the switch terminal A flows through the switch to terminal B and to the
Instrument cluster terminal C1-A-6 to illuminate the differential lock warning light.
European Specification Brake Light Circuit
The brake lights will only operate when both brake pedals are applied.
Switched power flows through fuse 26 to terminal 3 (30) of brake relay No.4 and to the LH brake pedal switch .
Power also flows to the RH brake pedal switch, terminal 4 of the differential lock switch, terminals 5 and 3 of
the MFD switch and to terminal 3 (30) of the MFD relay.
When both brake pedals are applied power flows through the LH brake switch to terminal 1 (86) to brake relay
No.4. Power also flows through the RH brake switch to terminal 1 (86) of the brake relay No.6. Power flows
through both relay No.4 and 6 windings to terminals 2 (85) and to ground at G1 energising the relays.
With both brake relay's No's 4 and 6 energised power at terminal 3 (30) of relay NO.4 flows through the relay to
terminal 5 (87) then to terminal 3 (30) of relay No.6, through relay No.6 to terminal 5 and then to fuse 24 . Power
flows from fuse 24 to terminal 6 of the 7-pin trailer socket and to both brake lights. Power flows through both
lights to ground at G5 illuminating the lights.
SM 8-10140 Issued 03-2003
SECTION 4001 73
SCHEMATIC CIRCUIT
MFD EUROPEAN SPECIFICATION BRAKE LIGHTS BRAKE PEDAL SWITCHES AND BRAKE RELAYS DIFF LOCK
_______________________ BATTERYPO~B ~ ------------------------------------------------------------------------BATTERYPOWERB+ ----------------------------------------------------------------__________---------- BATTERYPOWERB~ -------------------- _____
- - - - - -- - - -- - SWITCHED POWER SWITCHED POWER SWITCHED POWER - - - - -- - - - -- --
B+ FROM HITCH ENABLE RELAY
TERM 5 REFER TO SECTION 10002
<:J--- 511Rl 0 - ------------
, - - - - - - - - - - - - - - -- - - - 7 3 5 L B . 7 5 - - - - - - - -- - - -- - - - - - - - - - 7 3 5 L B.75 ---------------~
l
540Rl .0 - - - t - - - -- - - - - - - - - - - -- -- - i I - - - - - - - -- - - - - -- - - - - 540Rl .0 - - - - - - - - - - - -- - - - - -- - - - - - -----540R l 0
540Rl0 ~ ~ _ ~540Rl . 540Rl0 -----------540Rl0~540R1 ,0
~ 530R I ,O---_-I---------------530R10l ~ ~ 539~«LB75
540Rl'Ol~I 148R2,S---Q
75
530R,7,s - . . /
FUSE 26 530R .
LL- Z ~
[ (30A)
~ 0 ~ ° ~wOO r'-+-'--Lf-'--.L.f-"-''+''-1
o lH BRAKE RH BRAKE ~
0
a::
on
SWITCH NIC SWITCH NIC ~ ~ ~ O? DIFF LOCK.
~ ~ (~I~~g~~ :e ~ (~~~~~g~M ~ ~ 6 SWITCH
a:i SEE NOTE 1 Ii Oi SEE NOTE I '" '----r-II-r--.-i-T--.-t-r'
541la,75 I '"....~ ."
g
.
,g. ,."
540Rl'O ~
540Rl0-----t---~
541LB .7S - - - - - - - - ,
DIFFLOCK
MFD
INSTRUMENT CLUSTER PIN NO.
Cl-A-6
C1-A-11
I
..JJ r 538LBI .O-+-------'
I""·"
30 S31lB,75 53 1lB.75
'--- 530Rl .0
i 537LB1,O
-S42lB.75 542lB.75 - ~
a;...J on .--L-I---1...L-,
r--
0
m ...'"
BRAKE
RELAY
'"
M
It>
BRAKE
RELAY
a:i
...J ...J
BRAKE
RELAY
ai
i'l
DIFFLOCK
RELAY
~ ~ o.
~"",J [~~:
(POWER) (EITHER) (BOTH)
MFD iIi
" "' - -' ' 4r'~ .,.J
No.4 No,S No6 ...J
BLOCKING
DIODE
(SEETASLE) (SEE TABLE) (SEE TABLE) "on
V
MFD
RElAY BR,75 BR.7S
(SEE TABLE) on
r-- BR.75 BR.75 o
'"
...J
N 537LB1 ,O , - - - - - BR.75
r
~
~
l :ri
702Pl 0 - - - - - - - - - - - - - - ,
~ (~)(*)
~
700 Pl ,OC*)
'--I1---542LB 75 702P1 0 (*) l i702Pl
t
26
....
Ii)
iIi _ _ _ RH (*)
a:
~~"'"
,,_ ~ ~ BRAKE FUSE DIFFERENTIAL
q 0 ~ LIGHT 24 (20A)
0:
N
a:N 0:
N [
LOCK WARNING
LIGHT SWITCH
000
r-- r-- ... N/O
~543LB1 0r
~
~
702P1 ,O (*) (WITH 3_9 OHM
RESISTOR)
SEE NOTE 1
a:
MFD SOLENOID
B+ OFF '"2
II>
°iIi
...
~ '"
...J
a::
702Pl ,O (* ) ---t--702Pl 0 (*) 702Pl 0 (*) ~ DIFF LOCK
'" SOLENOID
545LB75 - - - t - - - - - - -- - - - - - - - - - - I - - - - - - - - r - --
544LB10 - - - - - - r - - -- - -- - - - -- - - - - - r - - - - - -- t - - - -
: 5 - - t - - - - -- - - - t - - - - - - - - -- 545LB .75-- - - t - -- - - - - - - - -545lB,7
-4---------------~I_--------------- 544LB10 -----+-------------------- 544LB1 .0 I TO HITCH
SOLENOIDS
532BR 1.0
--------CHASSISGROUND----------~------------------------------~~~""~----. .---------------i~----------------~----------------~~~~------~~-------------------------- CHASSIS GROUND
-----CLEANGROUND _ __ __ ~G_2~ _ _ _ _ _ __ _ __ _ _ _ _ _ _ _ _ _ _ _ _~~_ _ ______~~______________~G~5~_______________________G_5__________________________ G2 G3
CLEAN GROUND
MI02GOG9
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits, Do not use a test
lamp or damage to the switches may occur. RELAY TERMINAL RELAY TERMINAL
BLOCK REFERENCE
REFERENCE
(*) European Specification Tractors Only.
1 86
2 85
3 30
4 87A
5 87
8M 8-10140 Issued 03-2003
74 SECTION 4001
EUROPEAN SPECIFICATION POSITION LIGHTS
AND TURN SIGNAL LIGHTS
CIRCUIT GENERAL INFORMATION
Position Light Circuits ....... .. .. .. ............... .. .................... ....................... .. .. ................. ... ........ ................ ................ 75
Turn Signal and Hazard Warning Light Circuits ............................. .............. .. ........... .. ....... ......... ........................ 75
Turn Signal .... .. .. ....... .. ....... ....... .......... .......... ............. ....... ................. ........ .. ..... .. ... ....... ....... .. ......... ... ... .......... .... 75
Cluster Turn Signal Warning Light ........ .. ........................................... .. ................................ .. ....... .. ... ................. 75
Hazard Warning Light ..... ....................... ... .................. ... .... ................ .. .. .. ......................................... .................. 76
SCHEMATIC CIRCUIT
- European Specification Deluxe Cab Tractors ................ ........................................ ....... ............... ....... .......... .. .. 77
SCHEMATIC CIRCUIT
- European Specification Low Profile Cab and Platform Tractors ...... ................................................................. 79
8M 8-10140 Issued 03-2003
SECTION 4001 75
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
NOTE: Refer to the Schematic on Page 77 for Deluxe cab tractors, or Page 79 for Low Profile cab and
platform tractors.
Position Light Circuits
Battery power is connected to the rotary light switch terminal 4. With the switch in position 1 or 2 power flows through
the switch to terminal 6 then to fuses 6 and 7. Power also flows to the instrument cluster terminal C1-B-12 through
the position warning light to terminal C1-A-7 and then to ground at G1 , illuminating the warning light.
Power flows from fuse 6 to the left hand front position light terminal A and through the light to terminal C. Power
then flows to ground at G4 (through the cab splice 11 for deluxe cab tractors), illuminating the light. Power also
flows from fuse 6 to the 7 pin trailer socket terminal 7, fender number plate light terminal A (if equipped) and
left hand rear position light terminal 2. Power flows through the left hand rear position light to terminal 1 and
number plate light to terminal B, power then flows to ground at G5 illuminating the lights.
Power flows from fuse 7 to the right hand front position light terminal A and through the light to terminal C. Power
then flows to ground at G4 (through the cab splice 11 for deluxe cab tractors), illuminating the light. Power also
from fuse 7 to the 7 pin trailer socket terminal 5 and right hand rear position light terminal 2. Power flows through
the right hand rear position light to terminal 1 to ground at G5 illuminating the light. For deluxe cab tractor power
also flows from fuse 7 to the right hand console light terminal A, through the light to terminal A and to ground
at G4 (through the cab splice 11 for deluxe cab tractors), illuminating the light.
Turn Signal and Hazard Warning Light Circuits
Turn Signal
Switched power flows through fuse 21 to the hazard switch terminal 8. With the switch OFF power flows through
the switch to terminal 6 then to the flasher relay terminal 49, through the relay to terminal 49A then to the self
cancelling module (if equipped) through the module to the stalk switch at terminal 49A.
With the stalk switch in right turn position , power flows through the switch to terminal L through the self
cancelling module (if equipped) to the right hand front turn signal light terminal B, through the light to terminal
C and to ground at G4 (through cab splice 11 for deluxe cab tractors), illuminating the light. Power also flows
to the right hand rear turn signal light terminal 4 and the 7 pin trailer socket terminal 4, power then flows through
the right hand rear turn signal light to terminal 1 and to ground at G5, illuminating the light.
With the stalk switch in left turn position, power flows through the switch to terminal R through the self cancelling
module (if equipped) to the left hand front turn Signal light terminal B, through the light to terminal C and to
ground at G4 (through cab splice 11 for deluxe cab tractors), illuminating the light. Power also flows to the left
hand rear turn signal light terminal 4 and the 7 pin trailer socket terminal 1, power then flows through the left
hand rear turn signal light to terminal 1 and to ground at G5 , illuminating the light.
Cluster Turn Signal Warning Light
When the stalk is moved to the right or left position, power flows from the flasher relay terminal C to the
instrument cluster terminal C 1-A-1 0, through the turn signal warning light to terminal C1-A-7 to ground at G1 ,
illuminating the light.
SM 8-10140 Issued 03-2003
76 SECTION 4001
Hazard Warning Light
Battery power flows through fuse 18 to the hazard switch terminal 2. With the switch ON power flows through
the switch to terminal 6 then to the flasher relay terminal 49 and through the relay to terminal 49A. Power flows
from terminal 49a to the hazard switch terminal 5, through the switch to terminals 1 and 3 and through the
internal warning light to terminal 10 and to chassis ground at G1.
The power at terminal 1 flows to the 7 pin trailer socket terminal 4 and through the right hand front and rear
lights to chassis ground illuminating the lights (See Turn Signal Above).
The power at terminal 3 flows to the 7 pin trailer socket terminal 1 and through the left hand front and rear lights
to chassis ground illuminating the lights (See Turn Signa on Page 75) .
SM 8-10140 Issued 03-2003
SECTION 4001 77
SCHEMATIC CIRCUIT
- European Specification Deluxe Cab Tractors
EUROPEAN SPECIFICATION DELUXE CAB POSITION LIGHTS, NUMBER PLATE LIGHTS AND RIGHT HAND CONSOLE LIGHT EUROPEAN SPECIFICATION DELUXE CAB TURN SIGNAL LIGHTS
__________________________________ BATTERY POWER 6+
r<' BATTERY POWER 8+ ------~
- - - - - - - - - - - - - - - - - SWITCHED POWER SWITCHEDPOWER-----------~--~
706P1.5 - - - - -- -- - 706Pl .5 706Pl .5
I
~ ~
LlGHTS ~
71
FRONT 762R.75 762R.75 - - - - - - ,
LEFT
POSITION RIGHT
III I
A C B 15 A C 8 15
I
L . - - - - - -·762R 7 5 1 762RnTURN SIGNAL SELF
RIGHT HAND LEFT HAND
CAN(7FE~~~~~~~ULE TO HEADLIGHT
=IE
FUSE FUSE q aR.7S - - - , 2 7638R
RELAY TERM '2'
q
7 (lDA)
FENDER
G( IM)
il.
<D
'" ct:
-
0::
g ill •
~
I 14'S'1.0 - 14'6'1.0 10 763Pl .0
~ fll
•
NUM8ER co-
I
o 0 o 0 Ir 11'8'1,0 - 11'6'10 7 756Pl .0 - - - - - , q
o
PLATE
LIGHT "!
Ii:
-
~
~ III 15'8'1,0 - 15'B'1 0 ~; 757Pl0 ~ ~
co :e a.
"'" ,~"rc., r~
q <D
....
III o ON
~
:e
707Pl .0 .... 706P.75 - - - - - - - 706P 75
L " ' - - S P 1'-S-..,j FROM
HEADLIGHT
DIPPING RELAY I r - -167Pl 5 - - - - - -- - - - -767Pl 5 - - - - I
:ea.
rrn- 7D7Pl .D 7846Rl .0 l STALK SWITCH
TURN/HORN/DIP
,------------16'S'1.0 _____...J
TO HORN TERM'S'
:8
....
757Pl 0 - - - -- - - - - - - 7 5 7 P l 0 - - - , /
---+-,/
HAZARD SWITCH
!~ 7 56Pl .0 - - - - - - -- - - - 756Pl .0
il.
:;
....
o
ii
m
ie
INSTRUMENT CLUSTER
POSITION LIGHT
PINNO
1>-: 1--706P 75 J r - - 1--754Pl 0 - - - - - - - - - - - - 7 6 4 P l O-- HH
~
Cl·B-12
, - - - - - -757Pl .0 - - - - - '
TURN SIGNAL Cl-A-l0
I , - - - - - - -756P1 ,0 - - - ----'
"G~~"
1ST TRAILER Cl-A-5
7D7Pl .0 J 7 POLE
SOCKET a.
TO RADIO
DIMMER
2ND TRAILER Cl-A-l
n '" 1I q ~
! >-
TURN INDICATOR GROUND Cl-A-7
a: a: a:
707Pl~O ~ ~~
~
30 '" ;b
~ q 720SR 7~5i J:e . . --------+__
FRONT CAS
J 1 - - - - -'170P 75 . 756P1 ,0 TURN SIGNAL ": q
f
:~:pR OC
III ~ ~ LIGHTS :0 oc
'-------757P l .0 ---~.
...
'"no 0a.- . 708Pl .0 '"
0 1 - - - - - -769P 75
~ fg ~ ~
1 2
:========-___
r ~I
Q'J
'"~ '"g 21
I-""+"'t--.[L "
1 - - - - -768P.75
763Pl.0 763Pl .0
12 32
RIGHT ~------·764P1.0 - - -- - - - - - - -·764P1 .0
HAND e
CONSOLE
RIGHT LEFT ! - - -----·767Pl 5 - - - - -- - - - - -767P1 ,5 --------'
LIGHT
;~;~:~---+---757P'.0 ~
CAB NUM8ER q q q 757P1 .0 (756P1 .0 ***)
PLATE LIGHTS ....
OC OC OC
m
'"
ti
756Pl 0 (757Pl .0 ***)
~
III III
m
CAB CHASSIS
"....'" ".... ...."
(0 (0
o
ELECTRIC 766Pl.0~
....
'" FLASHER
,----------t---766Pl.0~ 784BR1 .0 - - @
GROUND oc 0: LEfT HAND RIGHT HAND ....
'"
LEFT
HAND REAR
POSITION
RIGHT
HAND REAR
POSITION ~---- 7848Rl0---~~---~
SPLICE 11 III
M
Ie
III
<:>
....
N
REAR TURN
SIGNAL
REAR TURN
SIGNAL
765P1 . 0~
. - -- - - - - - - - 7 6 5 P l .0 ~ 7 POLE
C~<:,~~~~IS
uN.UUNU
I
o
ri
0 LIGHT LIGHT SPLICE 11
LIGHT LIGHT
OC q TRAILER
m
"" 1338R2. 5 ~ SOCKET
'"....0 OC
III
765P1 .0 -----1-------------.
~
"'"....
G5 G5 G5
------------------..--------..--..------..
CHASSIS GROUND
__________________~~
G4 ______~~~~
G1 G1 ____~
--------------------~t_~t_----------~""""------------ ------------------------~~~~----~.---------~H~SSISGROUND--------------~t-----~--
Gl ______________________G~·~
..
1 __G~5____________________________~G~5~__________________________________~G~5~______~CLEANGROUND----------------=G4~__~G~l~
CLEAN GROUND
MI03B007
(***) Tractors With Ride Control Only.
8M 8-10140 Issued 03-2003
78 SECTION 4001
This Page Has Been Left Blank
8M 8-10140 Issued 03-2003
SECTION 4001 79
SCHEMATIC CIRCUIT
- European Specification Low Profile Cab and Platform Tractors
EUROPEAN SPECIFICATION LOW PROFILE CAB AND PLATFORM POSITION LIGHTS, NUMBER PLATE LIGHT EUROPEAN SPECIFICATION LOW PROFILE CAB AND PLATFORM TURN SIGNAL LIGHTS
7O6 p1 . 5 --------------------------------------------------------------------------------------~706P l , 5---------------------------------------------------
~RIGHT
r----------------------------------762R75--------------------------------------------------------------~--~--_r----------------·762R.75 ------~
~
706Pl .5
ROTARY
LIGHT
n0:: Of!
1r
N
0::
0
;!
&
en
;!
~
FRONT
~~~~7-5---~:~~:~~~~~~~A~;g~E SWITCH
'"
\I)
..... FUSE FUSE
RIGHT HAND LEFT HAND LEFT POSITION TO HEADLIGHT 18 21
FU SE FUSE LIGHTS RELAY TERM '2' (1 SA) (15A)
(IF EO UIPPED)
7 (IDA) 6 (IDA)
FENDER
NUMBER
PLATE C!
A C 8 15
~ .--------+~14 14'8'1.0
11'8'10
15'8' 1 0
-
-
-
14'8 '1 .0 =0 J 3763Pl .0
11 '8 '1.0
15'8'1 .0
7
11
56Pl ,O - - - - - ,
757PU -------,
C!
I 0:
"l
II
M
Of!
0:
N
LIGHT 0: a.
a? 2 2 I a.~ ~ '"
..... '"....
"':/l
a: . . . o ON
....
'"....
706P 75 - - - -------- 706P.75
L "a'-p-l .5
- ---,I FROM
HEADLIGHT
DIPPING RELAY
I ~ S7P1 5 --- -- - - - - - - - - - - - - - - - -7S7P 1.5 - - ---I
~ 707Pl .0
J,~
o
II
'".....o
(
726P 75 --[:> TO RADI O
..
)
.....
"'
a:
'".....a
STALK SWITCH
TU RN/HORN/DIP
r -- - - - - -- -- - 16'8'1 .0 ______...I
TO HORN TERM 'S'
"'.....a:
8.....
7S7 P10 - -- - - - - - ------------757P l .0 - ----.,.
756P 1.0 - - - - - - - - - - - - - - - - -- -756P1.0
HAZARD SWITCH
....
'" '".....
0:
<II
~
'"
a:
.....
0
.....
0:
.....
a
.....
DIMMER
INSTRUMENT CLUSTER
POSITION LIGHT
PINNO
Cl-8-12 >:i - 706P75 J ..-- 1---764Pl .0 - -- -------------------·764P l .0 - --+-+i
~
r----~757Pl .0 ----'
TURN SIGNAL Cl-A-l0
I , . . . - - - -756Pl.0 - - -----'
1ST TRAILER Cl-A-5
7 POLE 2ND TRAILER Cl-A-l
I 1
707Pl ,OJ SOCKET
'a:"
~
TURN INDICATOR GROUND Cl -A-7 >- l 11)~m;;:
q
0::
C!
n.
707P1 .0 - - - - - - -- - - -- ---ilKi 30 :5 . . . '" "
720BR7~
5 1
FRONT
5 ~ JIe Ie TURN SIGNAL
LIGHTS
70BP1.0 ~
1-------·770P 75 . II>
.....
C! 0..
~ 1 - - - - -769P 75 - -- -f -- - 756P_75 - _ r -- + - -756P.75
'"
o
....
0
..... '"0::
III
'a:" 1 - - - - - -768P.75 --- -- - - - - - - - - - '
8 0'"
.... 12 32 763Pl.0 - - - - - - - - - - - - - - - - - - - - -763Pl .0
~---764Pl 0 ------------- -- - -- -764Pl .0
1--- - -787P1 .5 --------- - - - - - - - - - - -·767Pl 5 - - - - - '
'".....0:
<II
ELECTRIC 766P l .0 ~
0
FLASHER
r---------~~--766P l 0 ~
LEFT RIGHT
0:
<II
LEFT HAND RIGHT HAND \I)
.....
REAR TURN REAR TURN ai
HAND REAR
POSITION
HAND REAR :z..... SIGNAL SIGNAL
765Pl .0 ~ ..---I---l
\I) POSITION LIGHT LIGHT r--------765P l .0 ~ 7 POLE
.....
a:
LIGHT
0
0: "''"0:: LIGHT
0
;r It')
..... ~ TRAILER
\I)
"':
\I)
.....
<II <II III <II e; a: 133BR25~ SOCKET a. a.
\I)
0 0'"
.... '"
'"
VI
0
..... <>
.... '"....
0 '"o.... '"R
765P1 0----~r_------------~
r """"",
G5
!r
G5 G5
CHASSIS GROUND - -. .- - - -- - - - - - - - - - - - - -. .------~t---~t-~t-----~----------------------~--~----------~""""~----------~~------------------------~""""~~-------------CHASS I SGRO U NO --~~--. .~~~~----~--
CLEAN GROUND
__~~ G5 ________________~~ G4 ______~G4____~
Gl __~
G 1____~G~1____________________~G~'~~G
~5~__________________________~G
~5~________________________________~G~5____________~CLEAN G R O UND ----G~4~~G~4~/G~1_G~4~G~4~/G~1__~G~1~
MIO.3BOO8
(***) Tractors With Ride Control Only.
( ••) Low Profile Cab Tractors Only.
8M 8-10140 Issued 03-2003
80 SECTION 4001
EUROPEAN SPECIFICATION HEADLIGHTS AND REAR FOG LIGHTS
CIRCUIT GENERAL INFORMATION
Headlights Circuit. ............................................................................................................................................... 81
Headlight Power Supply .....................................................................................................................................81
Upper/Lower Headlight Switch ..... .. ............... ............................. ........................................................................81
Upper/Lower Switch OFF ................................................................................................... ............................ 81
Upper/Lower Switch ON .................................................................................................... ............................. 81
Dipper Relay Operation ............................................................... ............................. ............................ .............. 82
Rear Fog Lights Circuit ....................................................................................................................................... 82
SCHEMATIC CIRCUIT
- European Specification Tractors ........................................................................... ... ........... .... ......... .............. .. 83
8M 8-10140 Issued 03-2003
SECT/ON 4001 81
CIRCUIT GENERAL INFORMATION
Headlights Circuit
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
NOTE: On tractors not equipped with cab mounted headlights, two jumper leads are installed into the
upper/lower headlight switch connector instead of the switch.
Headlight Power Supply
Battery power is connected to the rotary light switch at terminal 1. When the switch is moved to position 2, power
flows through the switch to terminal 5 then to dipping relay terminal 56 and to the instrument cluster terminal
C2-B-1 to provide cluster backlighting (analog clusters only).
Depending on the operation of the dipper relay, power at terminal 56 will either be connected to terminal 56a
and flow to the upper/lower headlight switch at terminal 6 or the power at terminal 56 will be connected to
terminal 56B and flow to the upper/lower switch at terminal 5.
Upper/Lower Headlight Switch
Upper/Lower Switch OFF
With the upper/lower switch OFF (grille position) and main beam selected, power available at terminal 6 is
connected to terminal 8 and flows to the instrument cluster terminal C2-A-9 to illuminate the main beam warning
light and through fuses 12 and 13 to the grille mounted high beam headlights.
With the upper/lower switch OFF and dipped beam selected, power available at terminal 5 is connected to
terminal 7 and flows through circuit breakers 19 and 20 to the grille mounted low beam headlights through the
lights to ground at G7 illuminating the lights.
Upper/Lower Switch ON
With the upper/lower switch ON (cab position) and main beam selected , power available at terminal 6 is
connected to terminal 2 and flows through fuse 15 to all the cab mounted high and low beam headlights and to
ground at G4 (through cab splice 11 for deluxe cab tractors) illuminating the lights. The power available at the
upper/lower switch terminal 2 is also connected to the internal light and flows through the light to ground at G1,
illuminating the light.
With the upper/lower switch ON (cab position) and dipped beam selected, power available at terminal 5 is
connected to terminal 1 and flows through fuse 15 to all the cab mounted high and low beam headlights and to
ground at G4 (through cab splice 11 for deluxe cab tractors) illuminating the lights. The power available at the
upper/lower switch terminal 1 is also connected to the internal light and flows through the light to ground at G1,
illuminating the light.
SM 8-10140 Issued 03-2003
82 SECTION 4001
Dipper Relay Operation
An additional battery power supply is connected to the headlight dipper relay at terminal 30. This supply flows
through the relay to terminal S then to the stalk switch at terminal 560. When the dipper switch is moved to ON
(spring return to OFF) power flows from terminal 560 to 31 then to ground, energising the relay. With the
headlight dipper relay energised the supply at terminal 30 is connected to terminal 56A to provide the headlight
flash function.
Each time the relay is energised the contact at terminal 56 will move its position i.e. from terminals 56A to 56B,
then when the relay is energised again from terminals 56B to 56A. When the relay is deenergized the contact
is mechanically held in its new position until the next time the relay is energised . This means that each time the
dipper switch is moved to ON (spring return to OFF) the headlights will alternate from low beam to high beam .
Rear Fog Lights Circuit
The rear fog light will only function when the rotary headlight switch is at position 2, dipped beam is selected
and the upper/lower switch is OFF (grille) position.
Battery power is connected to the rotary light switch terminal 1. With the switch in position 2 power flows through
the switch to terminal 5 then to the headlight relay terminal 1 (86). Power flows through the relay windings to
terminal 2 (85) then to ground at G1, energizing the relay.
With the relay energized battery power at terminal 3 (30) flows through the relay to terminal 5 (87) then to the
headlight dipping relay terminal 56 .
With dipped beam selected power flows through the relay to terminal 56B then to the upper/lower headlight
switch terminal 5. With this switch OFF (grille position) power flows through the switch to terminal 7 then to
through fuse 11 to the fog light switch terminal 5. With the switch ON power flows through the switch to terminal
1 and to the rear fog light (if equipped) through the light to ground at G5 illuminating the light. Power also flows
to the 7 pin trailer socket terminal 2 and the rear fog light switch internal warning lamp, through the lamp to
ground at G1 illuminating the lamp.
SM 8-10140 Issued 03-2003
SECTION 4001 83
SCHEMATIC CIRCUIT
- European Specification Tractors
EUROPEAN REAR FOG LIGHT EUROPEAN GRILLE HEADLIGHTS EUROPEAN CAB MOUNTED HEADLIGHTS
n
~--------------SATTERYPOWERB+ ------------------------------------------------------------------------------------------------------------------------------------------ SATTERYPO~RB+ - - - - - - - - - - - - - - - - - - - -
- - - - - - -- - --+-+--- - ----- SWITCHED POWER cr SWITCHED POWER - - - - - - - - - - -
;0:: L-727R15 r------------------726P75 - - - -- -- - - - - - - - - -- - - - -- - - ,
726PU - - - - - -- - - ----+-----, . . . - - - - - - - 7 3 9 Pl ,5 - -- -- - - - - . '"
~ ~ JUMPER LEADS :;:
~ SEE NOTE 4 T PIN NO INSTRUMENT CLUSTER
C2· S·1 SACK LIGHTING (ANALOG)
TO LEFT HAND C2·A·9 HIGH BEAM
POSITION LIGHT
FUSE 6 HEADLIGHT 31
'--
DIPPING
RELAY
i------------72BP1 .5 - - - - - - - - - - --'
FROM FLASHER RELAY
l
TERM '49A'
UPPER !LOWER
HEADLIGHT R . 7 S - - - - - - - - - -- -- SR75
TERM '3~ FROM HAZARD 739Pl .5 SWITCH
- t - - -- - - - i -- - - - - 7 4 4 P 2.0·
TERM ' ~ SWITCH
L-------736Pl .5 - - - - - '
,-----------762R 75 - - - C > FROM FUSE 21 Q.
'--- +-- - - -745P 75
740P1.5 - -- -- - - - - 7 4 0 P l .5
. . . - - - - - 7 27BR.7'S-- -- -----' T
i - - - -762Rt--------.
785Pl.5 - - - - - - - - -
1-- - -7828Rt-------.
FUSE CIRCUIT
11 FUS E. FUSE
BREAKER 13 1:;
14'B'1 .0 14'B'1.0 (IDA) (lOA) AT FUSE (10A) (15A)
II'S'I .0 11'S'I ,O LOCATION 19 HIGH 0
LOW N
15'S'1.0 15'B'l .0 Q.
BB 737P15
738Pl .5
'"
;!
12'8'1,0 - - - - - - - - 1 8 1E*t----------'
740Pl ,5
REAR 741Pl.5
----Cffi
fROM HORN FOG
LIGHT - - . 746P1 .0 ,•• )
16'S'I .0 - - - - - - '
;r
al
SWITCH '"n: .-!. 746Pl .0 ,.)
:5! ;! 0
STALK SWITCH
0:
TURNIHORNIDIP
T <D
;~:;;:~i·,211 !
~---------736SR1 . 01_------------------' ;:!:
I 735SR2 0 (•• ) - ,...--II--t--- 735SR2 .0 (.) --~-:---'
w X
~ - '''''''., '~)..
;=:'~. .-
~:;hl H i ;H
F
!.
j. ~ "" """'~,
s 6 "G",","'
~ ~ t.;~ i Q9 • ~ "'::E:~ "'. '"'"'' ~~~ ~
." 0
I
cO
~ n::
i al co
..,on
....~
-L
1~ ~ L~FT HAN~ ~~HT HANH~ ;P~~CUEN~
....
li2 LAMP SOCKET "" POSITION HEADLIGHT POSITION HEADLIGHT
GRILLE HEADLIGHT GRilLE HEADLIGHT LO 874BR13.0 ,.) LO
-----4~--~i-------~""""~----
Gl Gl
-----~~---------
1111111111 CHASSISGROUND - -. .------------------~----------------------_4~--
G5
CLEANGROUND--~~------------~~-----------~-~~----
G5 ..----~~~~----------------______-4~-4~----------------------------~--------------------
G6 G4 G4
_ ______ __ _ _ _ _ _ _ _~~~~_ _ _ _ _ _ _ _ _ _ _ _ _ _~~___
..G4--------~~~~- CHASSISGROUND _ _ _ _ _ _ _~~_ _ _ _ _ _____ CLEAN GROUND -~~
Gl ___
MI02J010
NOTE 4: For tractors not equipped with cab headlights jumper leads are installed between the
terminals of the switch terminal block as shown.
(.) Deluxe Cab Tractors Only,
( ••) Low Profile Cab Tractors Only.
SM 8·10140 Issued 03·2003
84 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 85
AMERICAN SPECIFICATION WARNING AND TURN SIGNAL LIGHTS
CIRCUIT GENERAL INFORMATION
Turn Signal and Warning Light Circuits ............. ... ....... ........................................ .. .,...... .. .............................. .. .. . 86
Warning Light Circuits ...... .. ... ...................................... .. .. ............................ ......... ........... .............................. ...... 86
Turn Signal Light Circuits .. ............. .. ........................ ........ .... .. ................... .. ..... .. ... .......... .............................. ...... 86
Right Turn ............ .... ... ................ .................. .... .. ........... .. ........................ .... .. .... ........ ..... ... .......................... ... 86
Left Turn ......... ...... ..... .. .. ....... ...... .. ................... .. ... .... .. ................................... ....... .. ..... .... ........................... .. .. 86
SCHEMATIC CIRCUIT
- American Specification Deluxe Cab Tractors ........ ........ .. .... .... ...... ........ ...... ............ ............ ............ ........ ...... ... 87
SCHEMATIC CIRCUIT
- American Specification Platform Tractors ................ .. .. ...................... .. ........ .... .. .. ........................................ .... 89
SM 8-101 40 Issued 03-2003
86 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
NOTE: Refer to the Schematic on Page 87 for deluxe cab tractors or Page 89 for low profile cab and
platform tractors.
Turn Signal and Warning Light Circuits
Warning Light Circuits
Battery power flows through fuse 19 to the rotary light switch terminal 4. With the light switch at positions 2 or
3, power flows through the switch to terminal 6 then to the flasher relay terminal 1. Power then flows from
terminal 4 to ground at G1 activating the relay.
With the flasher relay is activated, battery power flows through fuse 20 to the flasher relay terminal 2 then
through the relay to terminals 7, 5, 3, 6 and 4.
From terminal 7 power flows to the 7 pin trailer socket terminal 5 and to the right hand rear fender light. Power
also flows to the right hand front and rear cab mounted lights (cab tractors only) or to the right hand upper
fender light (platform tractors only).
From terminal 5 power flows to the 7 pin trailer socket terminal 3 and to the left hand rear fender light. Power
also flows to the left hand front and rear cab mounted lights (cab tractors only) or to the left hand upper fender
light (platform tractors only).
From terminal 3, power flows to the instrument cluster terminal C1-A-10 then to the right hand warning light.
From terminal 6, power flows to the instrument cluster terminal C1-B-12 then to the left hand warning light.
Power flows through the lights to ground illuminating the lights (flashing).
Turn Signal Light Circuits
Battery power flows through fuse 18 and the self cancelling module (if equipped) to the stalk switch terminal
49A and through fuse 20 to the flasher relay terminal 2 and the self cancelling module (if equipped).
Right Turn
With the stalk switch in right turn position, power flows through the switch to terminal L then through the self
cancelling module (if equipped) to the flasher relay terminal 5, to the 7 pin trailer socket terminal 3 and to the
left hand rear fender light. Power also flows to the left hand front and rear cab mounted lights (cab tractors only)
or to the left hand upper fender light (platform tractors only). Power flows through the lights to ground
illuminating the lights (ON constant). Power at the flasher relay terminal 5 signals the relay which directs power
available at terminal 2 through the relay to terminal 7 then to the right hand rear fender light. Power also flows
to the right hand front and rear cab mounted lights (cab tractors only) or to the right hand upper fender light
(platform tractors only). Power flows through the lights to ground illuminating the lights (flashing).
Left Turn
With the stalk switch in left turn position, power flows through the switch to terminal R then through the self
cancelling module (if equipped) to the flasher relay terminal 7, to the 7 pin trailer socket terminal 5 and to the
right hand rear fender light. Power also flows to the right hand front and rear cab mounted lights (cab tractors
only) or to the right hand upper fender light (platform tractors only). Power flows through the lights to ground
illuminating the lights (ON constant). Power at the flasher relay terminal 7 signals the relay which directs power
available at terminal 2 through the relay to terminal 5 then to the left hand rear fender light. Power also flows to
the left hand front and rear cab mounted lights (cab tractors only) or to the left hand upper fender light (platform
tractors only). Power flows through the lights to ground illuminating the lights (flashing)
8M 8-10140 Issued 03-2003
SECTION 4001 87
SCHEMATIC CIRCUIT
- American Specification Deluxe Cab Tractors
AMERICAN SPECIFICATION DELUXE CAB TURN SIGNAL WARNING LIGHTS
----{" ,"}---------- --o""------- BATIERY POWER B+ BATIERY POWER B+ - - - - - - - - - - - - - - - - - - - - - - - - - BATIERY POWER B+ - - - - - - - -_ _ _ _ _ _ _ __
- - ,+-- - - - - - - - - - - + - - -- - --SWITCHED P O W E R : - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 S W l T C H E D P O W E R SWITCHEDPOWER:------ -----------
i 726R.75,-- - - - - - + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -.726R.75 nSR..75
,I....
-, ~751Rl ..5 '" 751Rl.S
i 1
I~ ! I ~7~PlrO---------------~--~~ ro3~~l i~
'
"'
H1BRJ 5 - -- - - -- ---------------------------H1BRJ5
'U
~
~
~
;;; JNSTRUMENT CLUSTER PIN NO
2
1
BR.7S
75
~:~~~;:, ,~:~:i:--3-0---' ~ "'::~~:~~g,""
e n · ,",""G"'"m
no.,. G"U'rD_ _ _ _ _ _ _ _ ... :::: LEFTTHAND
FRONT CAB
TURN LIGHT
RIGHT HAND
FRONT CAB
TURN liGHT
~ ~ ~ ~
nOR2,5
.--- -- - -750Pl .0 - - - - - - + - - - - - - - - - 7 5 0 P l.0 - - ----, ~ ~
........ ~
S'15'l ,O B'IS·1 .0
FLASHER
1+-:11-----8·12'1.0 - - - - - - - - I
RELAY
o WARNING LIGHT
~!------S' 13'1 0- -------t
--t----":::':"~
LEFT INDICATOR
1+-:11-- - --8'16'1 0 - - - - - - I
RIGHT INDICATOR 7SOSR.75
0 STALK SWITCH
BATTERY POWER B+ 726R,75 C! TURN/HORN/DIP
ir <Ii
750Pl .0 - - - - ' CD
RIGHT TURN LIGHTS 756Pl ,O
'"'"<> '"
'"....
LEFT TURN LIGHTS 757Pl ,O
706Rl .5 -----t>- TO POSITION LIGHT
FUSE 23
TO DIPPI NG RELAY
TERM'S'
I 763BR10 7~::;~5E56P'75
4 756P 75 56P .75
TO HORN <::J r ...a:
."
a:
r - 7 50BRT5-+--'750BR, 75
~
..... en
781 P2 0 -------"'-- TO ROCKER SWITCH
757Pl0 1 3 = 7 5 6 P l 0 756Pl .0 756Pl .0
t
------...-- TERM '6' 757Pl .0
756Pl .0 - - - - - - - -'756Pl .0 J 757Pl 0 ------~757Pl . 0 - - - -. ---757Pl .0 _ _-+_ _ _ _...J
1
756Pl .0 - -- - ---756Pl .0 <> o ~
TO RH CONSOLE LAMP
a::CD a:: a::
CD CD
TO HEADLIGHT RELAY TERM '2' <> 0
~
Lf) Lf)
....~t--
LEFT HAND
C! RIGHT HAND
REAR CAB
ir 757Pl .0 (756Pl ,O U") ~757Pl 'O
TURN LIGHT T~~RL~~T
'"...'"<> 756Pl .0 (757Pl .0 ***) A 56Pl.0
26 52 CAB CHASSIS
GROUND
'"&! 7 POLE
SPLICE 11 0
a::
m 1RAJLER LEFT HAND RIGHT HAND CD
~ SOCKET REAR FENDER REAR FENDER <>
TURN LIGHT TURN LIGHT '"t--
--~)~»~»7,»~»~»~-------------~CHASSISGROUND------~---~---~~""~---CHASSISGROUND --~""""~~.------------------~~~~--~""~~--~t----------------~~~~----_1t_--~~--
- - - - - - - - - - - - - - - - -- - -4CLEANGROUND Gl Gl CLEANG ROUND--------------------------~--------------------------_ _ _ _ _ _ _ _ _ _~_ _ _~_ _
G5 G5 Gl G4 Gl
MI03B010
(***) Tractors With Ride Control.
8M 8-10140 Issued 03-2003
88 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 89
SCHEMATIC CIRCUIT
- American Specification Platform Tractors
AMERICAN SPECIFICATION PLATFORM TURN SIGNAL WARNING LIGHTS
-~---(y)----------------------<"J-------------- 8ATTERY POWE R8 + -------------------------------------------------------------------------BATTERY powERB+ ----------------------------------------__________ BATTERYPOWER8+ --------------____________________
----4-----------------------~---------------S~TCHEDPOWER:---------------------------------------------------------------------------S~TC H EDPOWER S~CHEDPOWER:-----------------------------------
,i_,
;
N
~
~726R 75
r-
., 1
751 Rl ,5 ____...J~~
~
. -------------i----7S-3-P-I-0---------------------------------------751Rl.S - - - - ------, 763Pl .0 l
726R.7S----------------------- -- - - - -- -- - - - -726 R. 75 i
J
~ c m : :;7S - - - - - - - -- -- - - - -- - -- - -- - - - - - - - - - - -- - - - - - - - - -- - 75 1BR 75
:i ci ~R'7S
. " ~ ~~:~~I~:~ ~;~!,~b~ ~E~ ~ ~ ~ ~ ~ ~:
INSTRUMENT CLUSTER PIN NO,
RIGHT TUR N Cl ·A·IO
1"",", . LEFT TURN
TU RN SIG NAL GROUND
Cl ·B· 12
C l ·A·7
7508R,75
::s
::s
30
L-
I 1 R"
It)
a:
720R2.5
,----------750Pl .0 - - - - - - - - - - +---------------- 750P I,O----------, ...
III
' 15' 1,0 '15'1 .0 ------------------- --1
FLASHER
RELAY
~1__---_e' 12'1 0 ----------------i
WARNING LIGHT
~lI_------_e' 13' 1 .0 ------------------------t
LEFT INDICATOR ...ci
0 ------------ - -------i
...'" ~1__---_e' 16'1
RIGHT INDICATOR
...
N
STALK SWITCH
BATTERY POWER B+ C! TURN/HORN/DIP
a: m
750Pl .0 ---------' CD
RIGHT TURN LIGHTS 1o-------- - 756Pl 0 --- - -- - - '"
0
0'>
M
...
<0
0--------------------------------------------------"'''''1
I
LEFT TURN LIGHTS J.----+- - -757Pl 0 - - - - - - - - ---------'
7638R l
706R1 5 - - - - t > TO POSITION LIGHT TO DIPPING RELAY
FUSE 23 TERM 'S'
4
~1
;:::::
C!
TOHORN ~~--------~ 0:
'"16....
757Pl 'O ~
78 1P2 0 ------"""-- TO ROCKER SWITCH
, ---....- TERM '6' , -------------- - - - - - -756P 75 - - - - - - - - ---------------------------- ---7 56P.75 -----------,
r - - - - 756P1,O J
~ C! ~ 1
.--- - - - - - 7 5 7P.75 757P.75 - - - - - - - + - - 7 5 7 P.75
~ ~,... ,...~ ,...~
. . - - - - - - -757P.75 757P.75
TO RH CONSOLE LAMP ,....
'"'"':
~'I ~
.--+--+- - - - - - - -756P 75 - - - - -
TO HEADLIGHT RELAY TERM '2'
757Pl ,O (756Pl 0 ***) ~757Pl 0 757P.75~ 5 7 POLE
756P1,O (757Pl ,0 ....* ) A 756P1.0 - - - ' l . - - - -756P 75 0 3 TRAILER C! C!
~ 0 1 SOCKET a: a: '"a: ~
'"....'" '"'"....0 '" ri
aJ
1l'"CDi ~
0
LEFT HAND RIGHT HAND LEFT HAND ~ RIGHT HAND
..."'
REAR FENDER REAR FENDER UPPER FENDER UPPER FENDER ....
M
M TURN LIGHT TURN LIGHT TURN LIGHT TURN LIGHT
----~H~H~;~»~»"»~---------------------------CHASSISGROUND------------. .~----~------~""""~-----CHASSISGROUND-----~IIII~IIII""II/~------------------. .------------------------~""""~--~~--~
G1 Gl
/ /I/IIII//F
r
. .--------------------II"""I~II~,II"""I-----4~-------------1~--..--_e~--
G5 G5 G5 G5 G5 Gl Gl
----------------------~CLEANGROUND C lEANGROU N D --------------~~----------------~~-~=----------------=~------~-~~~~--
MI03B069
(***) Tractors With Ride Control Only.
SM 8-10140 Issued 0 3-2003
90 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECT/ON 4001 91
AMERICAN SPECIFICATION HEADLIGHTS, POSITION LIGHTS
AND RIGHT HAND CONSOLE LIGHT
CIRCUIT GENERAL INFORMATION
Headlight and Rear Position Light Circuits .................................. ....................................................................... 92
Rear Position Light Circuits ... ......... ............ .. ......................................... ..... ..................... ..... .. ............................ 92
Headlight Circuits ........... .. ............ ............................................... ........................................................................92
Dipper Relay Operation .... ........... .... ........... ..... ........ .... ............ ... .,........... .. ............ ....... ....... ... ............ ..... ........ ... 92
SCHEMATIC CIRCUIT
- American Specification Tractors .. .. ......................... .......................................................................................... 93
8M 8-10140 Issued 03-2003
92 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information " on page 5.
Headlight and Rear Position Light Circuits
Rear Position Light Circuits
Battery power is connected to the rotary light switch at terminal 1. When the switch is moved to position 3, power
flows through the switch to terminal 3 then through fuse 23 to the 7 pin socket terminal 6 and to the rear position
lights. Power flows through the lights to ground illuminating the lights.
Headlight Circuits
Battery power is connected to the rotary light switch at terminal 1. When the switch is moved to position 2 or 3,
power flows through the switch to terminal 5 then to the headlight relay terminal 1 (86). For deluxe cab tractors
power also flow to the right hand console light, radio dimmer.
Power flows through the relay winding to terminal 2 (85) then to ground at G1, energizing the relay. With the
relay energized, battery power at terminal 3 (30) flows through the relay to terminal 5 (87) to the headlight
dipping relay terminal 56.
Depending on the operation of the dipper relay, power at terminal 56 will either be connected to terminal HI or
terminal La .
Power when available at terminal HI will flow through fuses 12 and 13 to the grille high beam headlights and
the instrument cluster terminal C2-A-9 to supply the high beam warning light. Power will flow through these
lights to ground illuminating the lights.
Power when available terminal La will flow through circuit breakers 9 and 10 to the grille low beam headlights.
Power will flow through these lights to ground illuminating the lights.
Dipper Relay Operation
An additional battery power supply is connected to the headlight dipper relay at terminal 30. This supply flows
through the relay to terminal S then to the stalk switch at terminal 560. When the dipper switch is moved to ON
(spring return to OFF) power flows from terminal 560 to 31 then to ground energising the relay. With the
headlight dipper relay energised the supply at terminal 30 is connected to terminal 56A to provide the headlight
flash function. The dipping relay will alternate from low beam to high beam every time the stalk switch is moved
to the ON position.
SM 8-10140 Issued 03-2003
SECTION 4001 93
SCHEMATIC CIRCUIT
- American Specification Tractors
AMERICAN SPECIFICATION DELUXE CAB RIGHT HAND CONSOLE LIGHT AMERICAN SPECIFICATION GRILLE HEADLIGHTS AMERICAN SPECIFICATION POSITION LIGHTS
-----------------------c)------------ BATTERYPOWERB+ ------------~T~-------------------------------------------------------------------------------------------------------------------------------------------BATTERYPOWERB+
SWITCHED POWER --------~
t----------------------~E SWITCHED POWER - - - - - - - - - - -
- - - - 4 - -- - - -- - - - - - - -- - - - -- -- - - - - - - - -- - - - - - - - - - - 707Pl0
1-:::=:::;::::;;;:!::$]rT~-_l-753Rl.0 - -- - - -- - - - - - - - - ,
~ 727Rl .S
Cl:
PIN NO INSTRUMENT CLUSTER
o
-c>-
r--------726P775~=====i~ijjC~2~.B~.I~ =t~B~A~C~K~L~IG~H~T~IN~G~(~A~N~A~LO~G~)~==========j
( - - - + -:750Pl .0 TO FLASHER
~l!1: '(~:
1
RELAY
r C2·A-9 HIGH BEAM
Ji . ... ...
31
( ) ( )
t _ - - i - -'706R l 5 - - - -- --------,
OPTIONAL OPTIONAL
HEADLIGHT LEFT HAND RIGHT HAND
DIPPING
753R1. 0 n:~ RELAY 0
UPPER FENDER
POSITION LIGHT
UPPER FENDER
POSITION LIGHT
' - - - -- 706Rl 5 707Pl 0 .... ....n: ii:co
~••
.... ...
0 0
-
781 P2.0 --c> TO WORK LIGHT
ROCKER SWITCH
'---------- - - - - -- - -'7 39Pl .S - - -- -/----------,
726Pl,5 - - - - - - - - - - - - - - 7 26Pl .5 - - - - - - -- - -- - --726Pl ,5
FUSE ••
, I
.-• L _ .-
I
I
726Pl ,o-------n"'" ~ (•• ) TO RADIO DIMMER
13 !.!. !.
•
CIRCUIT l!?
ROTARY BREAKER
(lOA)
HIGH
l!? a:;
0.: m
...0.:
." !.
...."'
(lOA) AT FUSE 0
ei
LIGHT SWITCH
"'.... ....:il :il
.... m
LOCATION 9
LOW) , 0
"'....
~
l;
-. "''' O~
FROM FUSE18 I
""''' 737Pl .0
. - - - - - - - - -'726R.75 - -----lC> FROM FLASHER RELAY /- .J L -l
740P l 0 - - - - - - +- - 740Pl .0
=f~~---
- - 750P 75 ( ••• ) - - .J
••
71 FROM FLASHER _ f 741Pl '0
!.
~
'M"l
(. ) 1 I - - - - R 75 - - - - - , RELAY
10
TO RADIO .-------lE-8 2 BR.75---- - - --.
"'....
ei
W III
DIMMER 0
'=! ....
"'
14'8'1.0 14'8'1 .0 10
.,ii:
....
0
11'8'10 11'8'10 7
(. ) 15'8'1.0 15'B'10 11
RIGHT HAND
CONSOLE '=!
LIGHT 12'8'1.0 a 1H:f-- - - - - -- - -'72 7BR.75 _ _ _-.J n:.... a:co
12 ....0 0
....
32
FROM HORN
....
'" OIl
ei III III
n:'" OIl
n:
.-• .•
~
mM
I
d. OC II
'"....~ 16'B" 0
~ ~ ~ 00
M
m
co ;
7 POLE
TRAILER
~~~MI
SOCKET N
f
STALK SWITCH Cl:
CAB CHASSIS
T\JRNIHORN/DIP ..,
m !. •
~
GROUND "'........
a: "'ei
~
SPLICE 11
;;
0
m 0 ~ o
'" III
0
II)
ll\
'"a:: ~
III LO HI
....
LO HI
Ci
m
~
'"
"'.... ....'"
m i;l LEFT HAND RIGHT HAND LEFT HAND REAR :g :g RIGHT HAND REAR
....~
------~~~------~...----------------_4I. . ----------- ..,.r,,.,,.,""_----------------~... CH:::::I::~~:HDT .l...-..I...__ ~ I_4~. . -
Iltl//I///
_ _ __ _ _ __ __G4 •
_ _ _ _ _ __ _ __ G_1_ _ _ __ _ _ CLEAN GROUND
CHASSIS GROUND _______________________. .__________ -G-R-ll---H-
LE E- AD T ______________. ._ G
-L- I-G-H- _R
G6
_ I_LL
_E__
HEA
.."D
"L"IG"H."T
.,...________________--.....___
1/1///1/1// G5
__
CLEAN GROUND _ ...:G:.:5=---..:
p_O_S_IT_IO_N__
G..:5_ _ _ _ _ _ _ _---=G:.:5=---_
Ll_G_H_T__ ••
MI02J008
(.) Deluxe Cab Tractors Only.
( •••) Platform Tractors Only.
8M 8-10140 Issued 03-2003
94 SECTION 4001
This Page Has Been Left Blank
8M 8-10140 Issued 03-2003
SECTION 4001 95
WORK LIGHTS
CIRCUIT GENERAL INFORMATION
Work Light Circuit .. ... ............... .. .......... ....................................................... .... ...................... .............. ... ........ ..... 96
Work Light Switch - Position 1 ................................................................... ......................................... .. .......... 96
Work Light Switch - Position 2 .. ................... ... .................... ........................................ ........................ .. .......... 96
SCHEMATIC CIRCUIT
- Deluxe Cab Tractors ................. ............................................ ................. .. ... .. ......................................... ... .. ...... 97
SCHEMATIC CIRCUIT
- European Specification Low Profile Cab Tractors and Platform Tractors ...... .... .. .... ...... .... .................. .... .... .... 99
SM 8-10140 Issued 03-2003
96 SECTION 4001
CIRCUIT GENERAL INFORMATION
IMPORTANT: Before carrying out any tests refer to "General Information" on page 5.
NOTE: Refer to the Schematic on Page 97 for deluxe cab tractors or Page 99 for European specification
low profile cab tractors and platform tractors.
Work Light Circuit
The front and rear work lights are controlled by one switch located at the left side of the front console.
Position 1 of the switch operates the work lights at the front lower cab, grille and rear fenders .
Position 2 of the switch operates all the work lights.
On American specification tractors the work lights can only be operated with the rotary light switch in position 3.
Work Light Switch - Position 1
Battery power flows through fuse 2 to the front work light relay terminal 3. On European specification tractor
battery power flows from the front work light relay terminal 3 (30) to the work light switch terminal 6.
On American specification tractors, battery power is available at the rotary light switch terminal 1 and flows
through the switch to terminal 2 (switch at position 3 only) then to the work light switch terminals 6 and 3.
With the work light switch at position 1 power flows through the switch to terminal 2 through fuse 4 to the left
hand and right hand fender work lights. Power also flows to the 7 pole trailer socket terminal 2 (America
specification tractors only). Power flows through the fender work lights to ground illuminating the lights.
Power at the work light switch terminal 2 also flows to the front work light relay terminal 1 (86) and through the
relay windings to ground at G1, energizing the relay.
With the relay energised, battery power at terminal 3 (30) flows through the relay to terminal 5 (87) then to the
instrument cluster terminal C1-B-7, left hand and right hand grille work lights and the left hand and right hand
front lower cab work lights. Power flows through the lights to ground illuminating the lights.
Work Light Switch - Position 2
The work lights operate the same as in position 1 with the additional lights as follows :-
Battery power flows through fuse 3 to the cab work light relay terminal 3 (30). On European specification
tractors, battery power flows from the cab work light relay terminal 3 (30) to the work light switch terminal 6.
On American specification tractors , battery power is available at the rotary light switch terminal 1 and flows
through the switch to terminal 2 (switch at position 3 only) to the work light switch terminals 6 and 3.
With the work light switch at position 2, power flows through the switch to terminal 1 then to the internal switch
light and the cab work light relay terminal 2 (85). Power flows through the relay winding to ground at G1
energising the relay.
With the relay energised , battery power at terminals 3 (30) flows through the relay to terminal 5 (87) then to the
left hand and right hand front and rear cab work lights. Power flows through the lights to ground illuminating the
lights.
SM 8-10140 Issued 03-2003
SECTION 4001 97
SCHEMATIC CIRCUIT
- Del uxe Cab Tractors
REAR FENDER WORK LIGHTS FRONT AND REAR DELUXE CAB WORK LIGHTS FRONT LOWER DELUXE CAB WORK LIGHTS
BAnERypowERB+ --------------------------------------------------------------------------~E~-----------------------------------------------------------------------BATTERY POWERB +
- - - - -- ---+--+----- SWITCHED POWER SWITCHED POWER - -- -- - - - -- -
~1~~-------------------------------~--------7~P~ ~
'"
&!
142R2.S I
o
- - - -- - - - - - - - 781P2.0(*)/784Pl 5(**) FUSE FUSE '"
" a::
FUSC ~~
<{ 791P 7S 2 3 ~
w (2SA) (25A) ~
a::
780P 75 (*) INSTRUMENT CLU STER
19
(SA)
WORK
r780P 75 (* ) -
I I-~ 78 1P2.0 792P2.S
:-( FRONT LOWER WORK LIGHTS
LIGHT
SWITCH
I ~=o 1
I ;;;~ REAR FRONT
L..---C> TO FLASHER RELAY --781P2.0 (* ) - - - - - - - 781P2.0 (* ) - - - ~
I 'I Lr+-Hh-I
WORK LIGHT
RELAY
(SEE TABLE)
WORK LIGHT
RELAY
(SEE TABLE)
-780P.75(*)- - - - - - 780P.75 (* ) - -.-l
I---+-r::> TO POSITION LIGHT ;:-
FU SE 23
781 P 75 (**) "- '+1------ SR.7S - - - - -./ 784V2.0 - - - - -- - - - - -- 784V2.0
<>
~ . - - - - - - - 7 8 4 V 2.0
;;;
""
- - -- - - - -- - - 781P2.0 (**) ~ . . . . . - - - - --194P2.0 - - -- -I-....J
TO RIGHT HAND CONSOLE LIGHT
C! C!
I'---t:::> TO HEADLIGHT RELAY
> >
~ ~
. . . . . - - - - -- - 784Pl0
ROTARY LIGHT C! C!
SWITCH
r---- - - - - - - - - - -- -- - - 791BR.7S
756Pl .0 - - - - - -- - - -- - - - - - - - - - - - - - 758Pl 0 C!o
a::
!O
~
.... .......
cr.
!O
00
-6
..-- -- - - 784Pl 0 ----4I~t------- 784P2 . 0 756Pl .0 - -- -- - - -- -- -- - - - - 756Pl .0
> a:
~1Xl
~
(II~
>
l ,,~--, .... ~ ~ ...
t t
794Pl ' O
~
- - - - 794Pl .0
n: 790BR1.0
ie
~'"
790BR10 21
l ~C!
' A'
®
WB
•
&
~
~ ~
~ ®SW
LEFT HAND
FRONT
LOWER CAB
RIGHT HAND
FRONT
LOWER CAB
W B B W
RIGHT HAND ~ tr
0 0 RCARCAB .... ~
:!!
~
CAB CHASSIS "" LEFT HAND RIGHT HAND Ii
m
CAB CHASSIS
LEFT HAND C! C!
RIGHT HAND GROUND
SPLIC E 12E 750BR1 .0
2 FRONT CAB FRONT CAS
...oco o GROUN D
REAR
FENDER
cr ~
RCAR
FEN DCR 750BR13 .0 750B RI 0 : 750BR1.0 _ _ __ _ _...J
~
Cl:
SPLICE 11
!O
...
(II
..,.
~ 0>
.... 750BR1.0 S 750BR10 - - -- - -- - -' '"
...
<Xl
----~~----~~~~----_4~~---CHASSISGROUND--~--------~~--------------------------------------~""""~------------------------------------------~~--~~~~-----CHASSISGRO UND----------------_4.~-------------------------------
G_' _ __ _ _ _ _ _--=:.:...--=~~CLEAN GROUND
_ _--= G5 G4 Gl CLEAN GROUND _ __ _ _ _ __ --=G...,:4_ _ _ _ _ __ _ _ _ _ _ __ __
MI02JOO6
(*) European Specification Tractors Only.
RELAY TERMINAL RELAY TERMINAL
(**) American Specification Tractors Only. BLOCK REFERENCE
REFERENCE
1 86
2 85
3 30
4 87A
5 87
SM 8·10140 Issued 03-2003
98 SECTION 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 99
SCHEMATIC CIRCUIT
- Low Profile Cab and Platform Tractors
REAR FENDER WORK LIGHTS FRONT AND REAR EUROPEAN LOW PROFILE CAB WORK LIGHTS FRONT LOWER PLATFORM AND EUROPEAN SPECIFICATION LOW PROFILE CAB WORK LIGHTS
BATTERY POWER B+ ------------------------------------------------------------------------~E~----------------------------------------------------------------------- BATIERY POWERB+
- - - - - - -- -+--t------ SWITCHED POWER SWITCHED POWER - - - - - -- - - - -
791P75--------------------------------~--------- 791P75 ~
142R2.5 I
781P2.0(*)f764Pl 5(**) - - -- - - - - -- - - 781P2 O(''j/784P1 5(**) FUSE FUSE :e
~~
79 1P 75 2 3 a:
(25Al (25A) ~
FUSE INSTRUMENT CLUSTER
19
(SA) FRONT LOINER WORK LIGHTS
, 780P.75 (*) -
WORK
LIGHT
I r--- 781P2.0 792P2.5
SWITCH
I£ 1
°
I ~co REAR FRONT
L - _ - { > TO FLASHER RELAY - - 781P20(*)- - - - - - - 781P2.0(*) - - -
IT --.J
WORK LIGHT
RELAY
(SEE TABLE)
WORK LIGHT
RELAY
(SEE TABLE)
-7BOP.75(* ) - -- -- - 780P.75 (* ) - ...J
1-----1--[::> TO POSITION LIGHT ;:-
FU SE 23
781P 75 (**) '!..- L,L-II----- BR.75 - - - -- - " 784V2.0 - -- - - - - - - ---784V2.0
°N ....
'"
a. Ii L - - - -- - 794P2.0 -----~
co
.... '"....0; 794P2 .0 - - - - - -- - - - I - - - - - - - - - - 794P2.0
- - - - - - - - - - - 781P2.0 (**) ~ o
TO RI GHT HAND CONSOLE LIGHT ....~ '"....
Ii
'"<Xl
~I-------'I
o
I'---C:> TO HEADLIGHT RELAY ....
784Pl .0
F .-•
ROTARY LIGHT
SWITCH
2 2 ~
~--------------- 791 BR 75 ---~
.- .-•
!. !.
~
0:
;Z
~ 784P2.0
~ ?34?1 0 - -- -- - -- 7B4Pl O~
~
;; ;;
CO!
.-
t::
!.
"<Xl.... ;Z....
7B4Pl 0 ---~ I o.
RIGHT HAND
o 0 FRONT
CAB LOWERI
PLATFORM
MI02J003
(*) European Specification Tractors Only.
RELAY TERMINAL RELAY TERMINAL
(**) American Specification Tractors Only. BLOCK REFERENCE
REFERENCE
(••) European Specification Low Profile Cab Tractors Only. 1 86
( •••) Platform Tractors Only. 2 85
3 30
4 87A
5 87
SM 8-10140 Issued 03-2003
100 SECT/ON 4001
This Page Has Been Left Blank
SM 8-10140 Issued 03-2003
SECTION 4001 101
MAIN CONNECTORS
Connector 1 Connector 2
Location: Instrument Panel Location: Cab Roof Panel
I ~
I J
- -
- --r - -
"""'=r--r=C - - - l-
477196 478196
INSTRUMENT PANEL TO CAB INNER HARNESS CAB INNER TO CAB OUTER HARNESS
Cavity Wire Circuit
Cavity Wire Circuit
No
No
A 830 R FRONT WIPER MOTOR B+
A 750 BR RH REAR TURN SIGNAL GROUND
B 8350 FRONT WIPER/WASHER
B 790 BR RH REAR WORK LIGHT GROUND
C 871 R INTERIOR LIGHT, RADIO
C 705 BR NO PLATE LIGHT GROUND
D 8020 AlC HIGH PRESSURE SWITCH
D 877 BR RADIO ANTENNA GROUND
E 8040 AlC HIGH PRESSURE SWITCH
E .. .. .. .. . OPEN
F 8030 AlC COMPRESSOR
F ........... OPEN
G 870 R RADIO SWITCHED B+
G 726P NO PLATE LIGHT
H 756 LH TURN SIGNAL
H .... - .. - OPEN
J 757 RH TURN SIGNAL
J 756 P REAR WORK LIGHT
K 784 V LOWER CAB WORK LIGHTS
K 757 P LH TURN SIGNAL
L 776P ROTARY BEACON LIGHT
L 756 P RH TURN SIGNAL
M 794 P FRONT CAB WORK LIGHTS
M 794 P FRONT WORK LIGHTS
N 794 P REAR CAB WORK LIGHTS
N 750 BR LH TURN SIGNAL GROUND
P 726P RH POSITION LIGHT/NO PLATE
P .. - .. -- OPEN
LIGHT
R 707 P LH POSITION LIGHT R 750 BR LH FRONT WORK LIGHT GROUND
840 R REAR WINDSCREEN WIPER B+ S 750 BR RH FRONT WORK LIGHT GROUND
S
T .......... OPEN
T 8450 REAR WINDSCREEN WASHER
U .... - .... OPEN
U -- - -- OPEN
V -- - - - OPEN V 746 P CAB HEADLIGHT H
W - .. - .... OPEN W 735 BR CAB HEADLIGHT GROUND H
X - .. - .. - OPEN X 735 BR CAB HEADLIGHT GROUND H
Y ........ - OPEN
Y .. - .... -- OPEN
Z 746 P CAB HEADLIGHTS (*) ..... - ..
Z ~
OPEN
(*) European Specification Tractors.
SM 8-10140 Issued 03-2003
102 SECTION 4001
Connector 10
Location: Cab Firewall
ENGINE TO INSTRUMENT PANEL HARNESS
(ENGINE HARNESS SIDE)
Cavity Wire Circuit Cavity Wire No Circuit
No R 829 BR/W NOT USED
A 8020 AlC HIGH PRESSURE SWITCH S 890 R HORN FEED
B 624 W B+ FROM STARTER T 890 BR HORN GROUND
C 8040 AlC HIGH PRESSURE SWITCH U 828 BR/W NOT USED
D 162 R UNSWITCHED B+ - CLOCK, RADIO V 738 P RH HEADLIGHT - LOW BEAM
AND INSTRUMENT CLUSTER
W 741 P RH HEADLIGHT - HIGH BEAM
E 200 BR/W INSTRUMENT CLUSTER CLEAN
GROUND (BATTERY - TERMINAL)
AA -- -- ... OPEN
BB 737 P LH HEADLIGHT - LOW BEAM
F 803 0 AlC COMPRESSOR CLUTCH
CC 740 P LH HEADLIGHT - HIGH BEAM
G - - - -- OPEN
DD 606W FUEL SHUT-OFF
H 551 LB FRONT PTO
231 Y COOLANT LEVEL EE 280 BR RADAR GROUND
J
FF 281 Y RADAR SIGNAL
K 216 Y ALTERNATOR 'W' TERMINAL,
ENGINE RPM GG 280 R RADAR B+
L 235 Y ENGINE COOLANT HH 282 Y RADAR PRESENT
TEMPERATURE
1 641 W COLD START
M 255 Y ENGINE OIL PRESSURE SWITCH
2 - - - -... OPEN
N 266 Y AIR FILTER RESTRICTION
3 784 V WORK LIGHTS
SWITCH
P 121 Y ALTERNATOR D+ TERMINAL,
4 ---- ... OPEN
WARNING LIGHT AND EXCITE
SM 8-10140 Issued 03-2003
SECTION 4001 103
Connector 26 Connector 27
Location: Right Hand Console (Tractors Without XtraShift
Location: Right Hand Console
I J
L-
l- t--- - I--
1= 1= 1= 480196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
478196
Cavity Wire Circuit
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
No
Cavity Wire Circuit 1 240Y AIR TRAILER BRAKE PRESSURE
No SWITCH
A 542 LB MFD INDICATOR LIGHT 2 515 R LOADER CONTROLS B+
B 707 P LH TAIUPOSITION LIGHT 3 563 T CLUTCH SWITCH
C 708 P RH TAIUPOSITION LIGHT 4 563 LB IMPLEMENT SWITCH
D 500 R HITCH B+ 5 536 LB LEFT HAND BRAKE RELAY (... )
E 622W PTO NEUTRAL START 6 233 Y FUEL LEVEL SENDER
F 735 LB DIFF LOCK INDICATOR LIGHT 7 215 Y WHEEL SPEED SENSOR
G 784 P REAR FENDER WORK LIGHTS 8 --- ... - OPEN
H 810 R SEAT B+ 9 --- ... - OPEN
J 5301 MFD AND DIFF LOCK B+ 10 ----- OPEN
540 R
11 531 LB RIGHT HAND BRAKE RELAY (... )
K 134 R AUXILIARY POWER CONNECTOR
SWITCHED B+ 12 - -
...... ... OPEN
L 757 PI RH TURN SIGNAL
756 P Connector 27 (Tractors With XtraShift)
M 756 PI LH TURN SIGNAL Location: Right Hand Console
757 P
N 282Y RADAR PRESENT
P 133 R AUXILIARY POWER
FENDER HARNESS
CONNECTOR H OR
7 PIN CONNECTOR H
R 135 R RH CONSOLE AUXILIARY POWER 480196
UNSWITCHED B+
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
S 817 R CIGAR LIGHTER
T 269Y PARK BRAKE WARNING LIGHT Cavity Wire Circuit
U 702 R BRAKE LIGHTS (0) No
1 240Y AIR TRAILER BRAKE PRESSURE
V 281 Y RADAR SIGNAL
SWITCH
W 785 R REAR FOG LIGHTS H 2 515 R LOADER CONTROLS B+
X 622W PTO NEUTRAL START 3 ... -- ... - OPEN
Y 296 Y 1000 RPM PTO SWITCH 4 563 LB IMPLEMENT SWITCH
Z 509 LB HITCH DOWN SWITCH 5 930T POWERSHIFT SPEED INDICATOR
6 233 Y FUEL LEVEL SENDER
(*) European Specification Tractors Only 215 y
7 WHEEL SPEED SENSOR
(**) American Specification Tractors Only 8 931 T POWERSHIFT SPEED INDICATOR
(***) Tractors With Ride Control Only 9 929 Y RS232 TX
10 929 DG RS232 RX
11 929 BR RS232 GROUND
12 ......... ... - OPEN
SM 8-10140 Issued 03-2003
104 SECTION 4001
Connector 28 (Tractors With XtraShift) Connector 29
Location: Right Hand Console Location: Right Hand Console
1&1
IL
qe O D
OD
O D
D
462196
480196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire Circuit
Cavity Wire Circuit No
No A 8350 FRONT WINDSCREEN WASHER
1 923 BR F/N/R SENSOR B 8450 REAR WINDSHIELD WASHER
2 500 R TRANSMISSION CONTROLLER B+ C 550 R FRONT PTO B+
3 500 BR TRANSMISSION CONTROLLER D 551 LB FRONT PTO CLUTCH
GROUND
E -- --- OPEN
4 923 BR F/N/R SWITCH
F 531 LB RIGHT HAND BRAKE RELAY (...)
5 921 R INCHING PEDAL SWITCH
G 776P ROTARY BEACON LIGHT
6 900 Y CAN HIGH - NOT USED
H 775R ROTARY BEACON LIGHT B+
7 900 DG CAN LOW - NOT USED
8 900 BR CAN GROUND - NOT USED
9 924 Y INCHING PEDAL SWITCH
10 575 R REVERSE INDICATOR LIGHT
11 507 T NEUTRAL INDICATOR LIGHT
12 536 LB LEFT HAND BRAKE RELAY (***)
(***) Tractors With Ride Control Only.
SM 8-10140 Issued 03-2003
SECTION 4001 105
Connector 30 Connector 31
Location: Instrument Cluster Location: Instrument Cluster
55 ~
00 · 00
00 00
00 00
00 00
00 00
00 00
00 00
00 DO
00 00
00 DO
00 DO
00 DO
GIl
463196 483198
INSTRUMENT CLUSTER CONNECTOR C1 INSTRUMENT CLUSTER CONNECTOR C2
Cavity Wire Circuit Cavity Wire Circuit
No No
A1 nop 2ND TRAILER TURN SIGNAL A1 ..... - - - OPEN
A2 200 R SWITCHED POWER 8+ A2 280 BR GROUND SPEED RADAR GROUND
A3 280 R GROUND SPEED RADAR 8+ OUT A3 507 T SHIFT TO NEUTRAL LAMP (00)
A4 ----- OPEN A4 216 Y ALTERNATOR 'W' TERMINAL,
A5 769 P 1 ST TRAILER TURN SIGNAL ENGINE RPM
A6 735 L8 DIFF LOCK WARNING LIGHT A5 215 Y WHEEL SPEED SIGNAL
720 BR A6 266 Y AIR FILTER RESTRICTION
TURN SIGNAL GROUND
H A7 121 Y ALTERNATOR D+ TERMINAL,
A7 WARNING LIGHT AND EXCITE
750 BR
TURN SIGNAL GROUND
H A8 200 BRI CLEAN GROUND
W
A8 ----- OPEN
A9 723P HIGH BEAM WARNING LIGHT
A9 202 R UNSWITCHED B+ - CLOCK
A10 281 Y GROUND SPEED RADAR SIGNAL
768
TURN SIGNAL LIGHTS A11 255 Y ENGINE OIL PRESSURE
PH
A10
755 P RIGHT HAND TURN SIGNAL
A12 --- - - OPEN
H WARNING LIGHT B1 726P BACK LIGHTING - ANALOGUE
A11 542 LB MFD B2 282Y GROUND SPEED RADAR PRESENT
A12 .... - - .... OPEN B3 563 LB TRAILED IMPLEMENT SWITCH
B1 240 Y AIR TRAILER BRAKE PRESSURE B4 509 LB HITCH IMPLEMENT SWITCH
- - ...... - 85 ... - ... ... ... OPEN
82 OPEN
B3 201 R ACCESSORY POWER B+ B6 - - ... - - OPEN
B4 235 Y ENGINE COOLANT TEMPERATURE B7 - .. --- OPEN
B5 269 Y PARK BRAKE WARNING LIGHT B8 575 R REVERSE INDICATOR LAMP (00)
B6 - .... - - .... OPEN B9 930 T POWERSHIFT SPEED
B7 784 V LOWER WORK LIGHT WARNING INDICATOR (00)
B8 231Y COOLANT LEVEL B10 931 T POWERSHIFT SPEED
B9 267 Y HYDRAULIC FILTER RESTRICTION INDICATOR (00)
B10 276 Y 1000 PTO WARNING LIGHT B11 ... - ......... OPEN
811 233 Y FUEL LEVEL B12 ........... OPEN
706 P
POSITION LIGHT (00) Tractors With XtraShift Only.
H
B12
754 P LEFT HAND TURN SIGNAL
H WARNING LIGHT
(*) European Specification Tractors.
(**) American Specification Tractors.
SM 8-10140 Issued 03-2003
106 SECTION 4001
Connector 40 -Tractors Without XtraShift
Location: Cab Floor (Right Hand Console)
DI99A036
RIGHT HAND CONSOLE TO TRANSMISSION HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 543 LB MFD SOLENOID B+ 25 ... ... - . . .. OPEN
2 233 Y FUEL LEVEL SENDER 26 ...... - ...... OPEN
3 507 R +8 V POSITION POTENTIOMETER 27 530 T NOT USED
4 507 LB POSITION SIGNAL 28 -
...... ..... OPEN
5 507 BR POSITION POTENTIOMETER LOW 29 .. .. -_ .. OPEN
6 .............. OPEN 30 ........ ... - OPEN
7 500 CLEAN GROUND HITCH 31 240Y AIR TRAILER BRAKE PRESSURE
BR/W CONTROLLER ..............
32 OPEN
8 269Y PARK BRAKE WARNING LIGHT
33 - ......... .. OPEN
9 532 LB DIFF LOCK SOLENOID B+
34 622W PTO NEUTRAL START
10 511 R HITCH SOLENOID B+,
35 624 W PTO NEUTRAL START
DIFF LOCK LIGHT B+
36 563 T FORWARD/REVERSE POSITION
11 513 LB HITCH RAISE SOLENOID RETURN
37 563 T FORWARD/REVERSE POSITION
12 514 R HITCH PIN +8 VOLTS
38 735 LB DIFF LOCK LIGHT
13 . . ... ... ....... OPEN
39 516 T LOADER SOLENOID IN
14 514 BR HITCH PIN LOW
40 515 T LOADER SOLENOID OUT
15 514 LB HITCH PIN SIGNAL
41 279 BR AUDIBLE ALARM
16 -
... ........ OPEN
42 T LOADER SOLENOID
17 512 LB HITCH LOWER SOLENOID
RETURN 43 215 R WHEEL SPEED SENSOR B+
44 ... - ...... . . OPEN
18 215 Y WHEEL SPEED SIGNAL
19 ... ..... -- OPEN 45 ......... ..... OPEN
20 ... ......... ... OPEN 46 ............. OPEN
21 ............ ... OPEN 47 ......... - ... OPEN
22 ... .. . ... ... POWERSHIFT SOLENOID 48 ... - . . ..... OPEN
23 ......... ... ... OPEN
24 . . ............ OPEN
SM 8-10140 Issued 03-2003
SECTION 4001 107
Connector 40 - Tractors With XtraShift
Location: Cab Floor (Right Hand Console)
UI99A036
RIGHT HAND CONSOLE TO TRANSMISSION HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 543 LB MFD SOLENOID B+ 24 914 LB POWERSHIFT SOLENOID RETURN
2 233 Y FUEL LEVEL SENDER 25 915 R FORWARD SOLENOID
3 507 R +8 V POSITION POTENTIOMETER 26 915 Y FORWARD SOLENOID RETURN
4 507 LB POSITION SIGNAL 27 530 T NOT USED
5 507 BR POSITION POTENTIOMETER LOW 28 916 R REVERSE SOLENOID
6 481 Y NOT USED 29 916 Y REVERSE SOLENOID RETURN
7 500 CLEAN GROUND HITCH 30 917 LB CLUTCH SPEED SENSOR B
BR/W CONTROLLER
31 240 Y AIR TRAILER BRAKE PRESSURE
8 269Y PARK BRAKE WARNING LIGHT
32 921 LB CLUTCH SPEED SENSOR A
9 532 LB DIFF LOCK SOLENOID B+ -- .........
33 OPEN
10 511 R HITCH SOLENOID B+,
34 622W PTO NEUTRAL START
DIFF LOCK LIGHT B+
35 624 W PTO NEUTRAL START
11 513 LB HITCH RAISE SOLENOID RETURN
36 - ...... ... ~
OPEN
12 514 R HITCH PIN +8 VOLTS
37 ... _... . . - OPEN
13 -
... ......... OPEN
38 735 LB DIFF LOCK LIGHT
14 514 BR HITCH PIN LOW
39 516 T LOADER SOLENOID IN
15 514 LB HITCH PIN SIGNAL
40 515 T LOADER SOLENOID OUT
16 -- - -- RANGE SWITCH
41 _... ...
...... OPEN
17 512 LB HITCH LOWER SOLENOID
RETURN 42 T LOADER SOLENOID
18 215 Y WHEEL SPEED SIGNAL 43 215 R WHEEL SPEED SENSOR B+
19 597 LB FLYWHEEL SPEED SIGNAL 44 --- ...... OPEN
597 BR POWERSHIFT SOLENOID S1 45 ............ . . OPEN
20
46 ............... OPEN
21 267Y POWERSHIFT SOLENOID S2
- - ...... - 47 ............ . . OPEN
22 OPEN
23 583 T POWERSHIFT SOLENOID S3 48 ... - ...... ... OPEN
SM 8-10140 Issued 03-2003
108 SECTION 4001
Connector 52 Connector 67
Location: Cab Floor Right Hand Console Location: Hood
(
I
71
I
l
J
~
...Y
DI98M095
DI99A035
ENGINE HARNESS TO HOOD HARNESS
RIGHT HAND CONSOLE TO FENDER HARNESS
Cavity Wire Circuit
Cavity Wire Circuit
No
No
1 737 P LH HEADLIGHT - LOW BEAM
(.)
LH TURN SIGNAL 2 738 P RH HEADLIGHT - LOW BEAM
765 P
A 3 740 P LH HEADLIGHT - HIGH BEAM
H LH TURN SIGNAL
756 P 4 741 P RH HEADLIGHT - HIGH BEAM
5 740 BR LH HEADLIGHT - GROUND
H RH TURN SIGNAL
766 P 6 738 BR RH HEADLIGHT - GROUND
B
H 7 890 BR HORN GROUND
RH TURN SIGNAL
757 P 8 890 R HORN FEED
C 563 LB IMPLEMENT DOWN SWITCH 9 784 P GRILLE WORK LIGHTS
D 707 P LH TAIUPOSITION LIGHT 10 784 BR GRILLE WORK LIGHTS - GROUND
E 708 P RH TAl UP OSITION LIGHT 11 .......... OPEN
F 789 V REAR FOG LIGHT (.) 12 -- - ..... OPEN
G 702 P BRAKE LIGHTS
H 528 R HITCH REMOTE SWITCH B+
J 528 LB HITCH RAISE
K 529 LB HITCH LOWER
L 8350 FRONT WINDSCREEN WASHER
M 8450 REAR WINDSCREEN WASHER
N 776 P ROTARY BEACON LIGHT
1 133 R AUXILIARY POWER SWITCHED B+
2 784 P REAR FENDER WORK LIGHTS
(*) European Specification Tractors.
SM 8-10140 Issued 03-2003
SECTION 4001 109
7 Pole Trailer Connector
European Specification American Specification
476196 475196
VIEWED FROM HARNESS SIDE VIEWED FROM HARNESS SIDE
Pin Wire Circuit Pin Wire Circuit
No No
1 765 P LEFT HAND TURN SIGNAL 1 133 BR CHASSIS GROUND
2 785 P REAR FOG LIGHT 2 784 P WORK LIGHT
3 133 BR CHASSIS GROUND 3 756 P LEFT HAND TURN SIGNAL
4 766 P RIGHT HAND TURN SIGNAL 4 133 R SWITCHED AUXILIARY POWER B+
5 708 P RIGHT HAND POSITION LIGHT 5 757 P RIGHT HAND TURN SIGNAL
6 702 P BRAKE LIGHTS 6 708 P TAIL LIGHTS
7 707 P LEFT HAND POSITION LIGHTS 7 133 R SWITCHED AUXILIARY POWER B+
A 776 P ROTARY BEACON LIGHT
SM 8-10140 Issued 03-2003
Section
4002
INSTRUMENT CLUSTER PROGRAMMING
CX Series Tractors
~ © 2003 McCormick Tractors International Limited .
McCORMICK SM 8-10500 June 2003
2 SECTION 4002
TABLE OF CONTENTS
DIGITAL INSTRUMENT CLUSTER
GENERAL INFORMATION ......... .... ................. .................. .......... ..... .... ... ..... ....... .............. ........... ............ ..... .......... 3
PROGRAMMING THE DIGITAL INSTRUMENT CLUSTER
(Programme Menus 1 to 6) ........... ... ........... ... ............ ... ........... ................. .. .. ......... .. ............ ..... ............ .. .......... .... ... 4
Clock Programming (Menu Code 1) ..... ... ............................... ............ ... .... ........ ... ........... ................. .......... ..... .... 4
MPH or km/h Speed Display Option Programming (Menu Code 2) ......... .. ...... .. .... .... ... .... ... ... .... ..... ... .... ...... ....... 5
Ground Speed Tire Radius Programming (Menu Code 3) ... ... ....... .... .............. .... ............ ... ............ .. ... ....... ..... .... 6
Service Interval Programming (Menu Code 4) .................... ............ ..... ... ............ .. ........... ............... .... .......... ....... 9
Area Function Mode Programming (Menu Code 5) ........................... ................................. ....................... .... ...... 9
Old Hours Programming
(Menu Code 6).................... .. ................................................. ....... ..... ............... .. ....... .... .......... ......... ....... ...... 10
PROGRAMMING THE DIGITAL INSTRUMENT CLUSTER
(Programme Menu's 7 to 13) ... ............ ...... ... ............... ..... ..... ......... ....... ... .............................................................. 11
PTO Option Programming (Menu Code 7) ............ .... .................... ........ .......... ...... ........ ...... .......... ...... ........ ...... 12
540 rpm PTO Programming (Menu Code 8) ........................ .............................................................................. 13
750 rpm PTO Programming (Menu Code 9) .... ........ ........ ............................ .... .. ................................................ 13
1000 rpm PTO Programming (Menu Code 10) .... ................ .... ........ ...... ................................ ...... .... .. .......... ...... 14
Engine rpm Programming (Menu Code 11) .......... .... ...... ............... .. ................ .. ............................ .. .................. 15
Axle Ratio (Wheel Speed)
Programming (Menu Code 12) .......... .. ......................................................................... ............. .................... 16
True Ground Speed (Radar) Programming (Menu Code 13) .. ........................................ .. ............ .. .... .. ...... ...... 17
Powershift Speed Display Programming (Menu Code 14) ................ .. ................................ ........ ...... ................ 17
ANALOG INSTRUMENT CLUSTER
GENERAL INFORMATION ....................................... .. ... ......... ....... ....... ....... .... .... .. ............. ... ............. ............. ..... . 19
PROGRAMMING THE ANALOG INSTRUMENT CLUSTER .... .............. .................... .. .. .................... ................... 20
Tachometer Programming .... ....... ......... ..... ..... ................... ..... ......... .. ..... ........................ .. .............. ................... 20
Speedometer Programming .... .................. .. ... ........... ........... ..... .. .. ....... .... ..... ...... .......... ............... .. ...... .............. 21
SM 8-10500 Issued 06-2003
SECTION 4002 3
DIGITAL INSTRUMENT CLUSTER
GENERAL INFORMATION
MR01b004
CX SERIES DE LUX DIGITAL INSTRUMENT CLUSTER
A. ENGINE/PTO RPM SWITCH C. UPPER DIGITAL DISPLAY E. CLOCK/HOURMETER (WITH SPEED DISPLAY)
B. AREA SWITCH D. LOWER DIGITAL DISPLAY F. DISTANCE TRAVELED SWITCH
G. AIR PRESSURE GAUGE (IF EQUIPPED)
The instrument cluster is programmed when leaving the factory. Further programming of the instrument cluster
will be necessary if the rear tyre size has been changed or if a new instrument cluster is to be installed.
Programming the instrument cluster requires a number of predetermined "Constants" being entered into the
instrument cluster memory. These "Constants" vary between the different tractor models, it is important that the
correct procedure is followed for each model so an accurate read-out is displayed by the instrument cluster.
To enable the area function to work accurately, the implement width must be programmed into the cluster. Also
if a more accurate loaded tire radius for the ground speed is required Dynamic Calibration of the cluster should
be carried out. These two functions must be carried out by the operator during field operation, the correct
programming procedure can be found in the Operators manual.
To put the cluster into the programme mode for programme menus 1 to 6 press and hold the Engine/PTO RPM
switch (A), then turn the key switch counter clockwise to the accessory position. When the cluster display
appears the switch can be released . The programming menu number will appear on the top digital display (C)
and the function feature to be programmed will appear and flash on and off.
To continue programming menus 7 to 14, menu 6 must be selected first, then press and hold the Engine RPM
switch (A) until the hourmeter (E) stops flashing the word "old".
Exit the programming mode at any time by turning the key switch to the OFF position. When the key switch is
turned to the on position the cluster will return to its normal operating mode.
IMPORTANT: If accessory or battery power is lost before saving the programmed constant in the cluster
memory, the selected constant will not be stored. When the power is restored the cluster will return to
its normal operating mode and not to the programming mode.
SM 8-10500 Issued 06-2003
4 SECTION 4002
PROGRAMMING THE DIGITAL INSTRUMENT CLUSTER
(Programme Menus 1 to 6)
STEP 1 STEP 3
•• • I~~ " " "~
•
( --
~[¥J~
--
DI97M120
Press and hold the Engine/PTO RPM switch (A) and Press and hold switches (A) and (8) at the same
turn the key counter-clockwise to the accessory time. The menu code will change to --1 and 12 or 24
position. The top digital display should display the will appear on the lower digital display (D), release
menu code 1-- as shown. Release the switch, the the switches. The clock display (E) will become
clock display (E) will begin to flash on and off. blank. To change the display press the switch (A) to
select 12 or press switch (8) to select 24.
NOTE: To change the menu code number press
switch (A) to decrease the number and switch NOTE: Selecting 12 will programme the clock to
(B) to increase the number. for a 12 hour time display and selecting 24 will
programme the clock for a 24 hour time display.
Clock Programming (Menu Code 1)
STEP 4
NOTE: The instrument cluster digital clock can
be programmed to display a 12 hour time
,J ,C!?-.:l 5-
®IrE] .
display or a 24 hour time display. ,.
STEP 2 --
1l
-:r (
. [W L:J LI'~I_
~ [¥J ~-----.®
~~-~
~ ~ DI97 M122
Press and hold switches (A) and (8) at the same
time for 1 second to save the selection. The clock
display (E) will appear. To change the hour display
press switch (A) and to change the minutes press
switch (8).
If the menu code display (C) is not as shown press
switches (A) or (8) until the menu code 1-- is
displayed. The clock display (E) will begin to flash
on and off.
8M 8-10500 Issued 06-2003
SECTION 4002 5
STEP 5 STEP 7
Press and hold switches (A) and (8) at the same Press and hold switches (A) and (8) at the same
time for 1 second to save the selection. The code time . The top digital display will change to --2 as
menu display (C) will display 2-- and the M.P.H. and shown, release the switches. The M.P.H. or km/h
km/h symbols will flash on and off alternately. symbol will be displayed (not flashing). Press switch
(A) to select the km/h option or switch (8) to select
MPH or km/h Speed Display Option the M.P.H. option.
Programming (Menu Code 2) STEP 8
STEP 6
. . ,-
'c:=:J444444'~
D [] ,
-
MPH
,~~~ ~4-~=----.J
When the correct speed display option has been
~ ~ DI97M 123
selected, press and hold switches (A) and (8) at
If the menu code display (C) is not as shown, press the same time for 1 second to save the selection.
switches (A) or (8) until the menu code 2-- is The code menu display (C) will display 3-- and
displayed. The M.P.H. and km/h symbols will flash 'tirE' will appear and flash on and off on the clock
on and off alternately. display (E).
SM 8-10500 Issued 06-2003
6 SECTION 4002
Ground Speed Tire Radius STEP 11
Programming (Menu Code 3)
STEP 9
When the correct tire size constant has been
selected, press and hold switches (A) and (8) at the
same time for 1 second to save the selection. The
code menu display (C) will display 4-- and the hour
If the menu code display (C) is not as shown, press glass symbol will flash on and off.
switches (A) or (8) until the menu code 3-- is
displayed, tirE will appear and flash on and off on
the clock display (E).
STEP 10
,e) ,- E
B
Press and hold switches (A) and (8) at the same
time. The top digital display will change to --3 as
shown, release the switches. The previous
programmed tire radius will appear on the lower
digital display (D), the clock display (E) will stop
flashing. Press switch (A) to decrease the constant
and switch (8) to increase the constant.
NOTE: Use the tables on Page 7 and Page 8
the determine the correct tire radius constant to
be programmed into the cluster.
NOTE: If switch (A) or switch (8) is held down
the numbers will increase or decrease rapidly.
To increase or decrease the number by one
press and release the switch.
SM 8-10500 Issued 06-2003
SECTION 4002 7
Tire Radius Constant Table
Rear Tire Size Constant Rear Tire Size Constant
8.3 - 24 470 16.9 - 24 620
8.3 - 32 570 16.9 - 24 INO 610
8.3 - 36 620 16.9 - 26 645
8.3 - 38 645 16.9 - 28 670
8.3 - 44 720 16.9 - 281NO 660
9.5 - 20 455 16.9 - 30 695
9.5 - 24 495 16.9- 34 745
9.5 - 28 545 16.9 - 34 INO 730
9.5 - 36 645 16.9 - 38 795
9.5 - 38 670 16.9 - 42 845
9.5 - 44 745 17.5 L - 24 INO 580
9.5 - 48 795 18.4 - 24 INO 635
11 .2 - 20 465 18.4 - 26 670
11 .2 - 24 515 18.4 - 26 INO 665
11.2 - 28 565 18.4 - 28 INO 685
11.2-36 665 18.4-30 720
11.2 - 38 690 18.4 - 30 INO 715
12.4-20 490 18.4-34 770
12.4 - 24 540 18.4 - 38 837
12.4-28 590 18.4 R - 42 (R1 TREAD) 883
12.4-32 640 18.4 - 42 (R1 TREAD) 889
12.4-36 690 18.4 R - 42 (R2 TREAD) 903
12.4 - 38 720 18.4 R - 46 (R1 TREAD) 936
12.4-42 796 18.4 - 46 930
12.4 - 46 820 19.5 L - 24 IND 610
12.4 - 54 942 20.8 - 34 805
13.6 - 24 560 20.8 - 38 (R2 TREAD) 873
13.6 - 28 610 20.8 R - 38 (R1 TREAD) 872
13.6 - 36 715 20.4 R - 38 (R1W TREAD) 869
13.6 - 38 740 20.4 R - 38 (R2 TREAD) 885
13.6 - 46 845 20.4 - 42 (R1 TREAD) 918
14.9-24 590 20.4 R - 42 (R1 W TREAD) 919
14.9 - 24 INO 580 20.4 R - 42 (R1 TREAD) 926
14.9 - 26 615 21 L - 241ND 635
14.9-28 640 21 L - 30 720
14.9 - 28 INO 630 21.3 - 26 760
14.9-30 665 21.3 - 261ND 750
14.9-38 765 21.3 - 30 810
14.9R-46 882 21.3 - 34 860
15.5 - 38 745
8M 8-10500 Issued 06-2003
8 SECTION 4002
Rear Tire Size Constant Rear Tire Size Constant
24.5 - 32 848 420/80 R 46 (R1 TREAD) 886
24.5 R - 32 851 460/70 R24 590
28 L - 26 720 480/70 R24 620
30.5 L R32 863 480/70 R26 645
800/60 R32 820 480/70 R28 670
440/65 R24 560 480/70 R30 695
440/65 R28 610 480/70 R34 745
480/65 R24 590 480/70 R38 795
480/65 R28 640 500/70 R34 745
540/65 R24 620 520/70 R26 650
540/65 R26 645 520/70 R30 720
540/65 R28 670 520/70 R34 770
540/65 R30 695 520/70 R38 820
540/65 R34 745 540/70 R34 770
540/65 R38 795 580/70 R26 670
600/65 R28 695 580/70 R38 875
600/65 R34 770 580/70 R42 905
600/65 R38 820 600/70 R30 745
650/65 R38 855 620/70 R26 720
750/65 R26 770 620n O R38 855
800/65 R32 870 620170 R4 2 905
260/70 R16 360 650170 R26 745
260/70 R18 390 650170 R30 795
260/70 R20 415 680/70 R32 820
300/70 R16 375 680170 R34 855
300/70 R18 405 710/70 R 38 (R1W TREAD) 920
300/70 R20 445 340/75 R20 480
300/95 R46 (R1 TREAD) 831 380/75 R26 500
320/70 R20 465 620/75 R26 760
320/70 R24 515 620/75 R30 810
320/70 R28 565 620/75 R34 860
360/70 R20 490 650/75 R32 835
360/70 R24 540 650175 R34 (R1 W TREAD) 881
360/70 R28 590 680/75 R32 870
380/70 R20 510 710/75 R34 905
380/70 R24 560 210/80 R16 345
380/70 R28 610 520/85 R46 (R1 W TREAD) 979
400/70 R24 560
420/70 R24 590 NOTE: If the size of tire installed on the tractor
420/70 R28 640
is not listed, refer to the tire manufactures
specification for the rolling circumference.
420/70 R30 665
Divide the specified rolling circumference by
6.28 to give the correct Ground Speed tire
radius constant.
SM 8-10500 Issued 06-2003
SECTION 4002 9
Service Interval Programming STEP 14
(Menu Code 4)
STEP 12
When the correct service interval has been
selected , press and hold switches (A) and (8) at the
same time for 1 second to save the selection . The
code menu display (C) will display 5-- and the area
If the menu code display (C) is not as shown function symbol will flash on and off.
press switches (A) or (8) until the menu code 4--
is displayed. The hour glass symbol will flash on
and off. Area Function Mode Programming
(Menu Code 5)
STEP 13
NOTE: The instrument cluster can be
programmed for manual area or automatic area
display. In the manual area mode the cluster will
continually calculate the area worked when the
area function is turned on. In the auto area
mode the cluster will only calculate the area
worked when the implement is in the lowered
position (working) and the area function is
turned on.
STEP 15
Press and hold switches (A) and (8) at the same
time. The top digital display (C) will change to --4 as
shown, release the switches. The previous
programmed service interval will appear on the
lower digital display (0) and hour glass symbol will
stop flashing. Press switch (A) to decrease the
service interval constant or switch (8) to increase
the service interval constant until the correct
service interval constant '250' is displayed as
shown.
If the menu code (C) displayed is not as shown
press switches (A) or (8) until the menu code 5-- is
displayed. The area function symbol will flash on
and off.
8M 8-10500 Issued 06-2003
10 SECTION 4002
STEP 16 Old Hours Programming
(Menu Code 6)
~ ~~~~c::::::::::J~~~~~~~ ~
NOTE: The cluster hourmeter display reading
LJ ~ r can not be changed. A new cluster or hourmeter
©lC~~
will always start recording at '0". If a new
cluster or hourmeter is to be installed, the
recorded hours from the old cluster can be
programmed into a separate 'OLd hour display
~[i]O in the new cluster. This function provides the
option to store and display the hours recorded
by a replaced cluster or hourmeter, so an
'i!-~-~ accurate recording of the tractors total hours
~ ~ DI97M130
can be kept.
Press and hold switches (A) and (8) at the same
STEP 18
time. The digital display (C) will change to --5 as
shown, release the switches . The previous area
function constant will appear on the lower digital
display (0). The area function symbol will stop
flashing. Press switch (A) to display the auto area
function mode constant '1' or switch (8) to display
the manual area function mode constant '2'.
STEP 17
If the menu code display (C) is not as shown press
switches (A) or (8) until the menu code 6-- is
displayed. OLd will appear and flash on and off in
the hourmeter display (F) and the hour glass
symbol will also flash on and off.
STEP 19
~~~~c=:::J~~~~~~~ ~
[:J
When the correct area function mode has been
selected, press and hold switches (A) and (8) at the
same time for 1 second to save the selection. The B B.
code menu display (C) will display 6-- . OLd will OLd - - .,
appear and flash on and off in the hourmeter
~~ ~~~'rn
display (F) and the hour glass symbol will also flash
on and off.
\91 1 '~~~
-' -' -' U~'-
~[¥JlL®
'i!-~-~
~ ~ DI97M131
Press and hold switches (A) and (8) at the same
time. The digital display (C) will change to --6 as
shown, release the switches. The old hours will
appear on the lower digital display (0) and
hourmeter (F) and hour glass symbol will stop
flashing . Press switch (A) to decrease the old hour
number or switch (8) to increase the number.
SM 8-10500 Issued 06-2003
SECTION 4002 11
STEP 20
.- -
I
~ l¥J ~ i=--J
®~ ~® ."M'"
When the correct old hours have been selected,
press and hold switches (A) and (8) at the same
time for 1 second to save the selection. The code
menu display (C) will display 1-- and the clock
display will flash on and off.
NOTE: The cluster old hour function is
programmed at "0 " at the factory. When a "0" is
programmed into the cluster the cluster will not
display that function.
PROGRAMMING THE DIGITAL INSTRUMENT CLUSTER
(Programme Menu's 7 to 13)
STEP 21 STEP 22
• • • • c=:::J4 • 4 4 • 4 • ~
f
I --
~ l¥J ~
DI97M120
Press and hold the Engine/PTa RPM switch (A) and If the menu code display (C) is not as shown press
turn the key counter-clockwise to the accessory switches (A) or (8) until the menu code 6-- is
position. The top digital display should display the displayed. OLd will appear and flash on and off in
menu code 1-- as shown. Release the switch, the the hourmeter display (F) and the hour glass
clock display (E) will begin to flash on and off. symbol will also flash on and off.
NOTE: To change the menu code number press
switch (A) to decrease the number and switch
(B) to increase the number.
8M 8-10500 Issued 06-2003
12 SECTION 4002
STEP 23 STEP 25
Dt97M132
Press and hold switch (A) until the hourmeter Press and hold switches (A) and (8) at the same
display (F) becomes blank and the hourglass time until menu code --7 is displayed , release the
symbol stops flashing . Release the switch (A), the switches. The previous programmed PTO option
menu code 7-- and PTO symbol will appear, the constant will appear on the lower digital display (D),
PTO symbol will flash on and off. as shown, and the PTO symbol will stop flashing.
Press switch (A) to decrease the PTO constant or
NOTE: Once menu codes 7 to 13 have been switch (8) to increase the PTO constant until the
access it is possible to program menu codes 1 correct PTO option constant '2' is displayed.
to 13.
NOTE: The PTO option constant '2' is
PTO Option Programming programmed into the cluster for tractors equipped
with manual PTO controls. This allows the cluster
(Menu Code 7) to calculate the PTO speed from the measured
engine rpm . For tractors equipped with shiftable
STEP 24 PTO a switch actuated by the PTO speed selector
lever allows the cluster to calculate 540 PTO speed
or 75011000 PTO speeds.
STEP 26
DI97M132
If the menu code (C) displayed is not as shown
press switches (A) or (8) until the menu code 7-- is
displayed. The PTO symbol will appear and flash on
and off. DI97M135
When the correct PTO option has been selected,
NOTE: If a menu code of 1 to 6 is displayed, press and hold switches (A) and (8) at the same
repeat STEP 23 to access the menu codes 7 to 13. time for 1 second to save the selection. The code
menu display (C) will display 8-- and the PTO and
540 symbols will appear and flash on and off.
SM 8-10500 Issued 06-2003
SECTION 4002 13
540 rpm PTO Programming STEP 29
(Menu Code 8)
STEP 27
DI97M137
When the correct 540 PTO constant has been
selected, press and hold switches (A) and (8) at the
same time for 1 second to save the selection. The
DI97M135
code menu display (C) will display 9-- and the 750
If the menu code (C) displayed is not as shown symbols will appear and flash on and off.
press switches (A) or (8) until the menu code 8-- is
displayed . The PTO and 540 symbols will appear
and flash on and off. 750 rpm PTO Programming
(Menu Code 9)
STEP 28
IMPORTANT: The 750 PTO constant must be
programmed into the cluster even if the tractor
is not equipped with 750 rpm PTO
STEP 30
Press and hold switches (A) and (8) at the same
time until menu code --8 is displayed , release the
switches. The 540 PTO constant will appear on the
lower digital display (D), as shown, and the PTO
symbols will stop flashing. Press switch (A) to DI97M137
decrease the 540 PTO constant or switch (8) to If the menu code displayed is not as shown press
increase the 540 PTO constant, refer to the switches (A) or (8) until the menu code 9-- is
following table for the correct PTO option constant. displayed. The PTO and 750 symbols will appear
and flash on and off.
540 PTO
Model
Constant
Shiftable PTO 69
Dual Shaft PTO 71
SM 8-10500 Issued 06-200 3
14 SECTION 4002
STEP 31 STEP 32
DI97M139
Press and hold switches (A) and (8) at the same When the correct 750 PTa constant has been
time at the same time until menu code --9 is selected, press and hold switches (A) and (8) at the
displayed , release the switches. The 750 PTa same time for 1 second to save the selection. The
constant will appear on the lower digital display (0) , code menu display (C) will display 10- and the PTa
as shown , and the PTa symbols will stop flashing. and 1000 symbols will appear and flash on and off.
Press switch (A) to decrease the 750 PTa constant
or switch (8) to increase the 750 PTa constant, 1000 rpm PTO Programming
refer to the following table for the correct PTa
option constant. (Menu Code 10)
IMPORTANT: The 1000 PTa constant must be
programmed into the cluster even if the tractor
750 PTO
Model is not equipped with 1000 rpm PTa.
Constant
540/750 PTa 95 STEP 33
With 540/1000 PTa 0
NOTE: When an option is not available on the
tractor i.e. 750 rpm PTa (For 54011000 PTa
tractors) a '0' must be programmed into the
cluster for that option menu code . This informs
the cluster that this option is not available and
the cluster will not display any information for
that option .
DI97M139
If the menu code displayed is not as shown press
switches (A) or (8) until the menu code 10- is
displayed. The PTa and 1000 symbols will appear
and flash on and off.
SM 8-10500 Issued 06-2003
SECTION 4002 15
STEP 34 Engine rpm Programming
(Menu Code 11)
STEP 36
~~.~c=J4""'4 ~
D B
~II
, ,
Press and hold switches (A) and (8) at the same time
C I [jJ[i]~
at the same time until menu code -10 is displayed , ~~-~~
release the switches. The 1000 PTO constant will
appear on the lower digital display (D) , as shown , and
~ ~ DI97M1 41
the PTO symbols will stop flashing. Press switch (A) If the menu code (C) displayed is not as shown
to decrease the 1000 PTO constant or switch (8) to press switches (A) or (8) until the menu code 11- is
increase the 1000 PTO constant, refer to the following displayed. The engine rpm symbol will appear and
table for the correct PTO option constant. flash on and off.
STEP 37
1000 PTa
Model
Constant
540/750 PTO 0
540/1000 PTO 128
NOTE: When an option is not available on the
tractor i.e. 1000 rpm PTO (For 5401750 PTO
tractors) a '0' must be programmed into the
cluster for that option menu code . This informs
the cluster that this option is not available and
the cluster will not display any information for
that option.
STEP 35 Press and hold switches (A) and (8) at the same
time until menu code -11 is displayed, release the
switches. The engine rpm constant will appear on
the lower digital display (D) , as shown, and the
engine rpm symbol will stop flashing. Press switch
(A) to decrease or switch (8) to increase the engine
rpm constant, refer to the following table for the
correct engine rpm constant.
Engine
Model
Constant
3 Cylinder Engine 143
4 Cylinder Engine 157
When the correct 1000 PTO constant has been
selected , press and hold switches (A) and (8) at the
same t ime for 1 second to save the selection . The
code menu display (C) will display 11- and the
engine rpm symbol will flash on and off.
8M 8-10500 Issued 06-2003
16 SECTION 4002
STEP 38 STEP 40
When the correct engine rpm constant has been Press and hold switches (A) and (8) at the same
selected , press and hold switches (A) and (8) at the time until the menu code -12 is displayed then
same time for 1 second to save the selection. The release the switches. The axle ratio constant will
code menu display will display 12- and the M.P.H . appear on the lower digital display (0) , as shown,
and km/h symbols will flash on and off alternately. and the M.P.H . and km/h symbols will stop flashing.
Press switch (A) to decrease or switch (8) to
Axle Ratio (Wheel Speed) increase the axle ratio constant until the correct
axle ratio constant '408' is displayed.
Programming (Menu Code 12)
STEP 41
STEP 39
When the correct axle ratio constant has been
If the menu code (C) displayed is not as shown selected , press and hold switches (A) and (8) at the
press switches (A) or (8) until the menu code 12- is same time for 1 second to save the selection. The
displayed. The M.P.H. and km/h symbols will code menu display (C) will display 13- as shown.
appear and flash on and off alternately.
SM 8-10500 Issued 06-2003
SECTION 4002 17
True Ground Speed (Radar) STEP 44
Programming (Menu Code 13)
STEP 42
~ ... ... ..
~ " ~
DI97M120
When the correct radar constant has been selected,
press and hold switches (A) and (8) at the same
time for 1 second to save the selection . The code
menu display (C) will display 1-- as shown and the
If the menu code (C) displayed is not as shown clock display (E) will flash on and off.
press switches (A) or (8) until the menu code 13- is
displayed. The radar symbol will appear and flash
on and off. Powersh itt Speed Display
Programming (Menu Code 14)
STEP 43
STEP 45
Press and hold switches (A) and (8) at the same
time until the menu code -13 is displayed, release If the menu code (C) displayed is not as shown
the switches. The radar constant will be displayed press switches (A) or (8) until the menu code 14- is
on the lower digital display (0) , as shown, and the displayed. The powershift speed display will appear
radar symbol will stop flashing. Press switch (A) to and flash on and off.
decrease or switch (8) to increase the radar
constant until the correct radar constant '415' is
displayed.
SM 8-10500 Issued 06-2003
18 SECTION 4002
STEP 46 STEP 47
Press and hold switches (A) and (8) at the same When the correct powershift constant has been
time until the menu code -14 is displayed, release selected, press and hold switches (A) and (8) at the
the switches. The powershift speed constant will be same time for 1 second to save the selection. The
displayed on the lower digital display (0), as shown, code menu display (C) will display 1-- as shown and
and the powershift speed display will stop flashing . the clock display (E) will flash on and off.
Press switch (A) to decrease or switch (8) to
increase the powershift speed constant, refer to the
following table for the correct powershift constant.
Powershift Speed
Model
Constant
Tractors Without XtraShift 0
Tractors With XtraShift 1
8M 8-10500 Issued 06-2003
SECTION 4002 19
ANALOG INSTRUMENT CLUSTER
GENERAL INFORMATION
-..
,--- .. ,--- .. .- - ...
,?[X]~'~ .).:>J' e " 'A'
-- ' , --'\ ----- .--~ .. - "- ,-:;- ,-- -,,- - .
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DS99J060
The instrument cluster is programmed when leaving the factory. Further programming of the instrument cluster
will be necessary if the rear tyre size has been changed or if a new instrument cluster is to be installed.
Programming the instrument cluster requires a number switches on the rear of the cluster being set in the ON
and OFF positions. There are two sets of switches, the Tach programming switches (a set of two or three
switches) and the speedometer programming switches (a set of eight switches) .
SM 8-10500 Issued 06-2003
20 SECTION 4002
PROGRAMMING THE ANALOG INSTRUMENT CLUSTER
STEP 1 Tachometer Programming
STEP 3
•
MPOlbOO7
Turn the key to the OFF position and remove the key.
Remove the retaining screws and remove the DI 97M1 69
instrument cluster from the instrument panel. Do not Follow STEP 1 and STEP 2 on this page to gain
disconnect the instrument panel from the harness. access to the Tachometer programming switches
(1) . Use the table bellow to set the switches in the
STEP 2 correct position.
1 2 3
TACHOMETER SWITCHES
DP (&M208
(4 CYLINDER SWITCH POSITIONS SHOWN)
Remove the cover from the back of the instrument
cluster.
CALIBRATION SWITCH
TRACTOR POSITIONS
1 2 3
3 Cylinder Engine ON
4 Cylinder Engine ON
8M 8-10500 Issued 06-2003
SECTION 4002 21
Speedometer Programming
STEP 4
DI97M1 69
Follow STEP 1 and STEP 2 on Page 20 to gain
access to the Speedometer programming switches
(2) . Use the following tables to set the switches in the
correct position for the tyre size installed.
1 2 3 4 5 6 7 8
SPEEDOMETER SWITCHES
(EXAMPLE SHOWN IS SWITCH POSITIONS FOR 13.6 R· 36 TIRES)
Switch Positions
Rear Tire Size
1 2 3 4 5 6 7 8
8.3 - 24 ON ON ON
8.3 - 32 ON ON ON ON ON
8.3 - 36 ON ON ON ON ON
8.3 - 38 ON ON ON ON ON
8.3 - 44 ON ON ON ON
9.5 - 20 ON ON ON ON ON
9.5 - 24 ON ON ON ON
9.5 - 28 ON ON ON ON ON ON ON
9.5 - 36 ON ON ON ON ON
9.5 - 38 ON ON ON
9.5 - 44 ON ON
9.5 - 48 ON ON
8M 8-10500 Issued 06-2003
22 SECTION 4002
Switch Positions
Rear Tire Size
1 2 3 4 5 6 7 8
11.2 - 20 ON ON ON ON
11.2 - 24 ON ON ON ON
11.2 - 28 ON ON ON ON ON
11.2 - 36 ON ON ON
11 .2 - 38 ON ON ON ON ON
12.4 - 20 ON ON ON ON
12.4-24 ON ON
12.4 - 28 ON ON ON ON
12.4 - 32 ON ON ON
12.4 - 36 ON ON ON ON ON
12.4-38 ON ON ON ON
12.4-46 ON ON ON ON ON ON
12.4R-46
12.4R-54 ON ON ON
13.6 - 24 ON ON ON ON ON ON
13.6 - 28 ON ON ON ON ON ON
13.6 - 36 ON ON ON ON ON
13.6 - 38 ON ON ON
13.6 - 46 ON ON ON ON
14.9 - 24 ON ON ON ON
14.9 - 24 INO ON ON ON ON ON ON
14.9 - 26 ON ON ON ON ON
14.9 - 28 ON ON ON
14.9 - 281NO ON ON ON ON ON
14.9 - 30 ON ON ON
14.9 - 38 ON ON ON ON
14.9R-46
15.5 - 38 ON ON
16.9 - 24 ON ON ON ON ON
16.9 - 24 INO ON ON ON ON ON ON
16.9 - 26 ON ON ON ON ON
16.9 - 28 ON ON ON
16.9 - 28 INO ON ON ON
16.9 - 30 ON ON ON ON ON
16.9 - 34 ON ON
16.9 - 34 INO ON ON ON ON
16.9 - 38 ON ON
16.9 - 42 ON ON ON ON
17.5 L - 24 INO ON ON ON ON ON ON
SM 8-10500 Issued 06-2003
SECTION 4002 23
Switch Positions
Rear Tire Size
1 2 3 4 5 6 7 8
18.4 - 24 INO ON ON ON ON
18.4 - 26 ON ON ON
18.4 - 26 INO ON ON ON
18.4 - 28 INO ON ON ON ON ON
18.4 - 30 ON ON ON ON
18,4 - 30 INO ON ON ON ON ON
18.4 - 34 ON ON ON
18.4-38 ON ON ON ON ON ON
18.4 - 42 ON ON ON ON
18.4 - R42 R 1W
18.4-R42R2
18.4-46
19.5 L - 24 INO ON ON ON ON ON ON
20.8 - 34 ON ON
20.8 - 38 ON ON ON ON ON
20.8 - 42 ON ON ON ON
21 L- 24 INO ON ON ON ON
21 L- 30 ON ON ON ON
21.3 - 26 ON ON ON
21.3 - 261NO
21.3 - 30
21 .3 - 34
24.5 - 32 ON ON ON ON ON
28 L- 26 ON ON ON ON
30.5 L R 32 ON ON ON ON ON
800/60 R 32
440/65 R 24 ON ON ON ON ON ON
440f65 R 28 ON ON ON ON ON ON
480/65 R 24 ON ON ON ON
480/65 R 28 ON ON ON
540/65 R 24 ON ON ON ON ON
540/65 R 26 ON ON ON ON ON
540/65 R 28 ON ON ON
540/65 R 30
540/65 R 34
540/65 R 38 ON ON
600/65 R 28
600/65 R 34 ON ON ON
600/65 R 38 ON ON ON ON ON ON
8M 8-10500 Issued 06-2003
24 SECTION 4002
Switch Positions
Rear Tire Size
1 2 3 4 5 6 7 8
650/65 R 38 ON ON ON ON ON
750/65 R 26 ON ON ON
800/65 R 23 ON ON ON ON
260170 R 16
260170 R 18
260170 R 20
300170 R 16
300170 R 18
300170 R 20 ON ON ON ON ON
300/95 R 46 ON ON ON ON ON ON
320170 R 20 ON ON ON ON
320170 R 24 ON ON ON ON
320170 R 28 ON ON ON ON ON
340/85 R 46 R2
360170 R 20 ON ON ON ON
360170 R 24 ON ON
360170 R 28 ON ON ON ON
380170 R 20
380170 R 24 ON ON ON ON ON ON
380170 R 28 ON ON ON ON ON ON
400170 R 24
420170 R 24 ON ON ON ON
420170 R 28 ON ON ON
420170 R 30 ON ON ON
420/80 R 46
460/70 R 24
480170 R 24 ON ON ON ON ON
480170 R 26 ON ON ON ON ON
480170 R 28 ON ON ON
480170 R 30 ON ON ON ON ON
480/70 R 34 ON ON
480170 R 38 ON ON
480/80 R 38
500170 R 34
520170 R 26
520170 R 30 ON ON ON ON
520170 R 34 ON ON ON
520170 R 38 ON ON ON ON ON ON
540170 R 34 ON ON ON
580170 R 26
580170 R 38 ON ON ON ON ON
580170 R 42 ON ON ON ON
SM 8-10500 Issued 06-2003
SECTION 4002 25
Switch Positions
Rear Tire Size
1 2 3 4 5 6 7 8
600/70 R 30
620/70 R 26 ON ON ON ON
620/70 R 38
620/70 R 42
650/70 R 26
650/70 R 30
680/70 R 32
680/70 R 34
710/70 R 38 ON ON ON ON
340/75 R 20 ON ON ON ON ON
380/75 R 20 ON ON ON ON
620/75 R 26 ON ON ON
620/75 R 30 ON
620/75 R 34 ON ON ON ON ON
650175 R 32
650175 R 34 ON ON ON ON
680/75 R 32 ON ON ON ON
710/75 R 34 ON ON ON ON
210/80 R 16
942 MM RADIUS ON ON ON
8M 8-10500 Issued 06-2003
Section
4004
BATTERY SERVICING AND TESTING
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10160 March 2001
2 SECTION 4004
TABLE OF CONTENTS
SPECIFICATIONS ...................................................................................................... ............................................. 3
SPECIAL TOOLS .............. ... ................. .................... ............................................................................................... 3
SAFETY PROCEDURES .. .............................. ....................................... .. ................................ ................................ 4
MAINTENANCE
Electrolyte Level.. ........................................................................................................................ ......................... 4
Inspecting and Cleaning the Battery, Cables and Terminals .......... ..................... ... ... ... ............... .. ...................... 4
BATTERY TESTING
Method One - Five Step Battery Test ...................................................... .................................... ......... ............... 5
Method Two - Using Heavy Duty Battery Tester. ............................ ... ............. .. ...... .................. ... ................. ....... 6
CHARGING THE BATTERY ................... ... .................... .. ............................................................... ... ................... ... 8
PREPARING A DRY CHARGED BATTERY FOR USE ............................................ .......................... .................. ... 8
BOOSTER BATTERY CONNECTIONS .. ... ..... .. ................... ............................................ ...................................... .. 9
SM 8-10160 Issued 03-2001
SECTION 4004 3
SPECIFICATIONS
Type of System ...... ....... .. ....... .. .. ... .. ..... ............ .................... ... ..... .............................. ... ....... 12 Volt, Negative Ground
Batteries ................ .. ... ... ........... ..... .................... ... ....................... ... One 12 Volt, Low Maintenance Hybrid Battery or
Two 12 Volt, Low Maintenance Hybrid Batteries Connected in Parallel
DIN Type 60527, Top Stud Terminals
BATTER SAE (COLD CRANKING AMPERE RESERVE
IEC DIN
YTYPE CAPACITY) HOURS CAPACITY
629 1000 Amps 670 Amps 600 Amps 170 320 mins
644 660 Amps 440 Amps 400 Amps 95 180 mins
664 770 Amps 515 Amps 465 Amps 105 210 mins
648 810 Amps 545 Amps 490 Amps 120 220 mins
SPECIAL TOOLS
0098H086 0098H115
MC10930 HEAVY DUTY BATIERY TESTER MC10932 OPTICAL ENGINE COOLANT AND
OR EQUIVALENT BATTERY ELECTROLYTE TESTER
OR EQUIVALANT
DD98H115
MC10931 RECHARGEABLE BATTERY PACK
OR EQUIVALANT
8M 8-10160 Issued 03-2001
4 SECTION 4004
SAFETY PROCEDURES
*'
WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND
~ BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEA TH.
M171B
WARNING: BATTERY ACID CAUSES A WARNING: Do not charge a frozen battery,
SEVERE BURNS. Batteries contains ili it can explode, causing serious injury. M529
sulphuric acid. Avoid contact with skin, eyes
or clothing. Antidote: EXTERNAL - flush with
water. INTERNAL - drink large quantities of WARNING: Battery explosion and/or
water or milk. Follow with milk of magnesia, damage to electrical components can result
ili
A beaten egg or vegetable oil. Call a physician
immediately. EYES - flush with water for 15 8. •
from improper connection of booster
batteries or charger. Connect positive to
positive and negative to negative. Externally,
• minutes and get prompt medical attention.
BA TTERIES PRODUCE EXPLOSIVE battery acid can cause burns and blindness,
GASES. Keep sparks, flame and cigarettes and taken internally is poison. M146A
away. Ventilate when charging or using in an
enclosed space. Always shield eyes when
WARNING: Always connect the ground
working near batteries. KEEP OUT OF
A cable last and disconnect the ground cable
REACH OF CHILDREN. M144A
ili first so you do not cause a spark at the
• battery. A spark can cause a battery
WARNING: When working around storage explosion and cause injury. M530
A batteries, remember that all of the exposed
ili metal parts are 'live'. Never lay a metal
• object across the terminals because a spark
or short circuit will result. M145A
MAINTENANCE
Electrolyte Level
Check the electrolyte level in each cell every 300 hours of operation . The machine is equipped with either one
(1) or two (2) Low Maintenance batteries.
If electrolyte level is low add distilled water to just cover the top of the separators. DO NOT OVER FILL. Do not
use water which contains minerals. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well.
When distilled water is added at ambient temperatures below OOC (32°F) the batteries must be charged imme-
diately to mix the water and electrolyte or the water will freeze, because the water will stay on top of the elec-
trolyte.
Inspecting and Cleaning the Battery, Cables and Terminals
Inspect the battery at regular intervals for dirt, corrosion and damage. Electrolyte and dirt on the top of the
battery can cause the battery to discharge by providing a passage for the current to flow. Make sure the vents
are installed firmly in position and the battery top is clean and dry. The battery terminals must be kept clean
and tight. Remove all corrosion with a wire brush, then wash with a weak solution of baking soda or ammonia.
Apply petroleum jelly to the terminals to prevent more corrosion. DO NOT apply grease.
8M 8-10160 Issued 03-2001
SECTION 4004 5
BATTERY TESTING
Method One - Five Step Battery Test
Follow STEP 1 to STEP 5 to correctly determine the condition of the battery if Automatic Battery Tester
MC10930 is not available .
NOTE: Batteries may be overcharged or undercharged due to a fault in the tractors electrical system. Always make sure the
electrical system is working correctly.
NOTE: If the Voltmeter Reading in STEP 2 shows a reading of below 10 volts, it may not be possible to successfully recharge
the battery and its further service life is often greatly reduced.
NOTE: Where discoloured electrolyte is observed, this is always due to a service related condition.
STEP 1. VISUAL CHECK
• Make sure cable connections are clean and tight. Clean foreign material from the battery top.
• Inspect the battery case, battery posts and cables for damage.
• Check the electrolyte level, refer to "Electrolyte Level" on page 4
• If you added distilled water to the battery, the battery must be charged for 15 minutes at 15 to 20 amperes to mix
the water with the electrolyte.
STEP 3. HIGH
STEP 2. STEP 5.
RATE STEP 4. HYDROMETER
VOLTMETER BATTERY
DISCHARGE READING (see NOTE 1)
READING CONDITION
TEST
10 to 11.5 volts Below 9 volts REPLACE
(voltage often
rises)
GREEN (ABOVE 1260SG)
WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)
tim]] BATTERY
10 to 11.5 volts Below 9 volts REPLACE
~
(voltage often GREEN (ABOVE 1260SG ) BATTERY
rises) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)
oto 12.6 volts Below 3 volts REPLACE
(voltage normally
zero)
GREEN (ABOVE 1260 SG)
;:~T(:~~~: t~2~:6~:~) M ~ 'Yi\
','" •...
BATTERY
~:~~:(::~~~,E,~::OSSG~} M
6 to 12.4 volts Below 9 volts REPLACE
(voltage steadily BATTERY
falls)
RED (BELOW 1225 SG)
Below 10 volts Below 3 volts RECHARGE
(voltage can be GREEN (ABOVE1260SG}~ BATTERY
WHITE (1225 to 1260 SG)
zero) (see NOTE 2)
RED (BELOW 1225 SG )
Above 11.5 volts 3 to 9 volts RECHARGE
(voltage remains
tIITrn BATTERY
GREEN (ABOVE 1260 SG)
stable) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)
NOTE 1: Record readings from each battery cell. The cell nearest the positive terminal is cell number 1. Using the hydrometer
as a pump check the two end cells for discoloured electrolyte.
NOTE 2: The battery is over discharged and may not recover after recharging.
8M 8-101 60 Issued 03-2001
6 SECTION 4004
Method Two - Using Heavy Duty Battery Tester
TESTING ~
I
n TEST
TEST COMPLETE
RE-TEST AFTER t
CHARGING
DD98H087
1. CONTROL KNOB (SAE CRANK AMPS)
2. TEMPERATURE SWITCH
3. TEST BUTTON
4. CHARGE LEVEL INDICATOR
5. BATTERY CONDITION INDICATOR
6. TEST IN PROGRESS INDICATOR LAMP
7. TEST COMPLETE INDICATOR LAMP
8. RE-TEST AFTER CHARGING INDICATOR LAMP
STEP 1
Connect MC10930 heavy duty battery tester onto the battery. Set the AMPS SAE control knob (1) to the cor-
rect SAE (cold cranking capacity) for the battery installed, refer to "SPECIFICATIONS" on page 3
STEP 2
Make sure the TEMPERATURE switch (2) is in the >O°C (normal) position.
NOTE: In temperatures below DoC (32°F) move the TEMPERATURE switch (2) to the <D oC (cold) position.
STEP 3
Connect the positive (+ RED) cable clamp of the automatic battery tester to the positive (+ RED) cable termi-
nal on the machine battery.
Connect the negative (- BLACK) cable clamp of the automatic battery tester to the positive (- BLACK) cable
terminal on the machine battery.
NOTE: It is not necessary to disconnect and remove the battery from the tractor. If the automatic battery tester is incorrectly
connected it will not work. If the bleeper sounds the battery must be recharged before the test can continue, refer to "CHARGING
THE BATTERY" on page 8.
STEP 4
Press the TEST button (3) and the test will begin automatically. The test will be completed in 40 seconds or
less, to determine the condition of the battery refer to 'Test Results" on page 7.
STEP 5
If the battery charge level is below 20% it is not possible to complete the test without a booster battery, the re-
test after charging indicator lamp (8) will flash and a bleeper will sound. To re-test the battery, using the cables
supplied connect MC 10930 heavy duty battery tester to a booster battery and repeat STEP 4 .
Alternatively connect MC10931 Rechargeable Battery Pack to MC10930 heavy duty battery tester and repeat
STEP 4.
SM 8-10160 Issued 03-2001
SECTION 4004 7
Test Resu Its
BATTERY CHARGE LEVEL
CHARGE LEVEL
DISPLAY READING RESULT
INDICATOR
Flashing Display Result being calculated
Solid Display Result confirmed
5 Bars Illuminated 100% (fully charged)
4 Bars Illuminated 80%
3 Bars Illuminated 60%
2 Bars Illuminated 40%
1 Bar Illuminated 20%
1 Bar Flashing BATTERY FLAT, refer to "CHARGING
THE BATTERY" on page 8
BATTERY CONDITION
CONDITION INDICATOR DISPLAY READING RESULT
Flashing Display Result being calculated
Solid Display Result confirmed and bleeper sounds
3 Green Bars Illuminated Good battery - return to service
2 Green Bars Illuminated Good battery - return to service
1 Green Bar Illuminated Battery performance adequate
(but may need replacing in near
future)
1 Red Bar Illuminated Replace battery - unserviceable
2 Red Bars Illuminated Replace battery - unserviceable
NOTE: Red bars continue to flash at end of test.
SM 8-10160 Issued 03-2001
8 SECTION 4004
CHARGING THE BATTERY
IMPORTANT: If the battery has been in storage check
At.. WARNING: Do not charge a frozen battery, the voltmeter reading, if the reading is above 12.5 volts
ill it can explode, causing serious injury. M529 the battery does not need charging. If the voltmeter
reading is below 12.5 volts follow the charging procedure
IMPORTANT: Before charging the battery check the to recharge the battery.
electrolyte level, refer to "Electrolyte Level" on page 4
STEP 1
Install the battery onto a suitable variable battery charger. Select the correct battery type installed on your
tractor, refer to "SPECIFICATIONS" on page 3. Set the charging rate at 5 to 7 amps for batteries above 90
Ampere Hours (set charging rate of 3 to 4 amps for batteries below 90 Ampere Hours) . Charge the battery for
12 hours.
NOTE: If an automatic battery charger is used, battery charging is complete when the GREEN indicator light is illuminated.
STEP 2
After charging allow the battery to stand for 24 hours before measuring battery voltage, the voltage reading
should be above 12.7 volts.
If the battery is immediately required measure the cells with a hydrometer, the hydrometer reading for each
cell should be a minimum of 1.270 Sg
NOTE: If the voltage reading or hydrometer readings are not correct repeat STEP 2 and recharge the battery. If after a second
charge the battery fails to achieve the correct readings, refer to "BATTERY TESTING" on page 5
PREPARING A DRY CHARGED BATTERY FOR USE
STEP 1
Remove the battery vents and fill each cell with electrolyte to just cover the top of the separators. DO NOT
OVER FILL. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well. Install the battery vents.
STEP 2
Follow the procedure above for CHARGING THE BATTERY.
SM 8-10160 Issued 03-2001
SECTION 4004 9
BOOSTER BATTERY CONNECTIONS
WARNING: Battery explosion and/or WARNING: Always connect the ground
damage to electrical components can result A cable last and disconnect the ground cable
ili
A •
from improper connection of booster
batteries or charger. Connect positive to
positive and negative to negative. Externally,
•
first so you do not cause a spark at the
battery. A spark can cause a battery
explosion and cause injury. M530
battery acid can cause burns and blindness,
and taken internally is poison. M146A
IMPORTANT: When connecting a booster battery to the machine battery make sure the booster battery and the
discharged battery have the same voltage (i.e. 12 VOLTS). Make sure you connect positive to positive and negative to a
good ground on the machine chassis frame. DO NOT connect booster battery cables across the terminals of the starter.
Always follow the procedure in your Operators Manual for Starting the Engine.
STEP 1
Position the machine with the booster battery next to the machine with the discharged battery so the booster
cables can be easily connected. MAKE SURE the machines do not touch.
STEP 2
Check the electrolyte levels and inspect the batteries, "MAINTENANCE" on page 4.
STEP 3
On both machines turn OFF all electrical loads. Connect the positive (+) cable clamp of the booster battery to
the positive (+ RED) cable terminal on the discharged battery. Connect the negative (-) cable clamp of the
booster battery to a good ground on the chassis frame of the machine with the discharged battery.
STEP 4
Start the engine of the machine with the booster battery and run for approximately two minutes.
STEP 5
Follow the procedure in your Operators Manual and start the engine of the machine with the discharged bat-
tery. If the engine will not start after 30 seconds STOP THE PROCEDURE. Wait three minutes to allow the
starter motor to cool.
STEP 6
After starting allow the machine to idle, remove the negative (-) cable clamp from the chassis frame, then
remove the negative (-) cable clamp from the booster battery. Remove the positive (+) cable clamp from the
discharged battery, then remove the positive (+) cable clamp from the booster battery.
....------TO STARTER SWITCH ______
DISCHARGED BATTERY
BOOSTE~
§ BOOSTl CABLES
§/
§ §
TO GROUND
~=~ I ~~~=:.~~
TO GROUND
GROUND
DI98J017
8M 8-10160 Issued 03-2001
Section
5001
STEERING COLUMN
AND STEERING HAND PUMP
CX Series Tractors
~ © 2003 McCormick Tractors International limited.
McCORMlCK 8M 8-10171 June 2003
2 SECTION 5001
TABLE OF CONTENTS
SPECiFiCATIONS ...... ... ..... .... .................................................... ....... .. ................ ...... .... ........ ................. ........ .. ....... . 3
SPECIAL TORQUES .. .. ............... ......... .. ....... .. ......... ................. ........ .. ............... ... ...... .. ...... ........ .... ............... .. ........ 3
SPECIAL TOOLS ....... .. ......................... .. ... ........... ... ....... ... ....... .. ..... ..... ............. ... ...... .... ..... .. ..... .... ............... .. ........ 3
STEERING COLUMN
Removal and Installation .... ................................. .. ......... .................................................. .. .................................. 4
Disassembly and Assembly... ..... ....... ....... ................... .................................................. .... ......... ....... ...... .... ....... . 5
STEERING HAND PUMP
Removal and Installation .................................................................................................................................... 10
Disassembly... .... ....... ..... .. ......... .. ....... ...... ............ ... ...... .... .. ........ .... ...... ... .... ... ............... .. .. ....... ................ ......... 12
Inspection ............................................................................................................... .. .................. ........ .. .............. 14
Assembly .... .. ............ ..... .. .......... .. .... .. ..... ... .. .. ..... .. ........ .......................... .. .............. ... ........ ............... .................. 14
STEERING RELIEF VALVE ADJUSTMENT ..... ..... .. ........ .. .... ... ...... ............... ... .. ........ .... .. .. ............ ...... ................. 18
SM 8-10171 Issued 06-2003
SECTION 5001 3
SPECIFICATIONS
STEERING HAND PUMP
Steering Relief Valve Pressure ........................................................................................ ................. 120 to 130 bar
Pump Displacement .................................................................................. Single 100cc!rev
Steering Column Lower Splined Shaft Lubricant... ..................................................... Multi-Purpose Lithium Grease
SPECIAL TORQU ES
Steering Wheel Retaining Nut .................. .... .... ............................ .................................... ....................... 45 to 54 Nm
Steering Column Retaining Locknut .................. .... ...................................... ............ " ...... ........................ 29 to 32 Nm
Mounting Bracket to Steering Hand Pump
Retaining (Shoulder) Screw ................................... ............. ....... ... .... .................. " ....................... .. ..... 41 to 61 Nm
Steering Hand Pump End Cover Retaining Bolts ................................................................ .......... .......... 25 to 35 Nm
Steering Relief Valve Plug ........... ...................... ................................ ......... ................................ ... ...... " .. 40 to 60 Nm
SPECIAL TOOLS
DD98Hl14 DD97G08A
MC2612 BUSHING INSTALLER MC2552 SEAL INSTALLER
(USE WITH HANDLE MC1924)
SM 8-10171 Issued 06-2003
4 SECTION 5001
STEERING COLUMN
Removal and Installation
NOTE: Items are numbered in the order of Removal, for Installation follow the Removal procedure in
reverse order.
Before removing the Steering Column it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect the battery,
positive (+) terminal first.
STEP 2
Remove the RH and LH instrument panel side
covers.
NOTE: Disconnect the harness from the
auxiliary power socket on the RH side cover.
DR98H152
STEP 3 Remove the steering wheel cap. Remove the
retaining nut (3) and washer (4), remove the
steering wheel.
NOTE: For Installation, tighten the steering wheel
retaining nut (3) to a torque of 45 to 54 Nm.
STEP 5
DR98H151
Remove the cab floor mat and remove the two
retaining screws (1) and remove the steering
column cover (2).
DR98H153
Remove the retaining screws (5). Disconnect the
harness and remove the instrument cluster (6).
8M 8-10170 Issued 06-2001
SECTION 5001 5
STEP 6 Disassembly and Assembly
NOTE: Items are numbered in the order of
Disassembly, for Assembly follow the same
procedure in the reverse order.
STEP 8
DP98B073
Disconnect the FNR switch/turn signal harness
connector (7) and turn signal self cancelling
harness connector (8) (if equipped).
STEP 7
DD98H155
Remove the torx screw (1). Remove the rubber
bellows (2) from the upper cover (3).
STEP 9
DR98H154
Remove the harness from the clip. Remove the four
locknuts (9) and washers (10), remove the steering
column assembly (11).
NOTE: For Installation, tighten the locknuts (9) DD98A292
to a torque of 29 to 32 Nm. Remove the harness (4) from the clip and remove
the lower cover (5) .
NOTE: For Installation, apply Multi Purpose
Lithium grease, or equivalent, to the splines of the
lower shaft of the steering column assembly (11).
8M 8-10170 Issued 06-2001
6 SECTION 5001
NOTE: For tractors equipped with self STEP 12
cancelling turn signal switches it will be
necessary to remove the turn signal switch
assembly top cover retaining screw and top
cover. Loosen the locking allen screw and
remove the self cancelling ring.
STEP 10
DD98A296
Remove the knob (8) from the tilt/telescope lever
and remove the rubber bellows (2) .
STEP 13
DD98A293
Gain access to the Allen screw through cut out (A)
in the side of the FNR switch/turn signal switch
assembly, loosen the Allen screw (6) and raise the
FNR switch/turn signal switch assembly.
NOTE: Use same procedure for synchro shuttle
tractors.
STEP 11
00980264
Put the splined end of the steering column in a soft
jawed vice. Use a lever between the steering
column and vice body, as shown , to remove the
lower splined shaft, seal ring and bushings from the
steering column. Remove the bushings (9).
STEP 14
For steering columns equipped with a seal ring
(10) , remove seal ring (10) and o-ring (11) from the
lower splined shaft (12).
DD98A295
Remove the plate (7) from the rubber bellows (2) ,
thread the harness through the rubber bellows (2)
and remove the turn signal switch assembly from
the steering column.
8M 8-10170 Issued 06-2001
SECTION 5001 7
,,
----10
DJ98G231
NOTE: Refer to STEP 15 to STEP 21 for Installation of bushings (9), seal ring (10) and o-ring (11) .
9. BUSHING (2) 17. BUSHING 2 5. SPRING
10. SEAL RING (IF EQUIPPED) 18. RETAINING RING 26 . RETAINING SCREW
11 . O-RING (IF EQUIPPED) 19. LEVER 27. TOOTH SEGMENT PLATE (3)
12. LOWER SPLINED SHAFT 20. BUSHING 28. PIVOT PIN
13. RETAINING RING 21. LOWER LINK ARM 29 . ARM
14 . FLANGE LOCKNUT 22 . RIVET 30. SPRING
15 . WASHER 23 . WASHER 31. SPRING
16. UPPER LINK ARM 24. LINK
SM 8-10170 Issued 06-2001
8 SECTION 5001
STEP 15 STEP 17
D098H116 0D980266
0198H1 21
For steering columns equipped with a seal ring 0198H078
(10). Install a new seal ring (10) onto lower splined Install one half of bushing (9) onto lower splined
shaft (12) make sure the lip (A) of seal ring (10) is shaft (12), make sure shoulder (8) of lower splined
against shoulder (8) of lower splined shaft (12). shaft (12) and lip (A) of seal ring (10) (if equipped)
Install a new o-ring (11) into the groove (C) in seal locate into the groove in bushing (9)
ring (10).
STEP 18
STEP 16
Lubricate the seal ring (10) and the internal splines
of lower splined shaft (12) with Multi-Purpose
Lithium grease.
00980265
Install the second half of bushing (9) onto lower
splined shaft (12), make sure the tabs and slots in
bushing (9) are aligned.
8M 8-10170 Issued 06-2001
SECTION 5001 9
STEP 19 STEP 20
DD98H117 DD98H118
Install the steering column into a suitable press . I nstall seal installer (F) MC2612 over the lower
Install the lower splined shaft (12) onto the upper splined shaft onto bushing (9). Press bushing (9)
shaft splines. Align tab (E) of the bushing (9) with into position.
the mounting holes as shown .
NOTE: Use handle (G) MC1924 as a spacer if
necessary.
STEP 21
Lubricate the drive splines of lower splined shaft
(12) with Multi-Purpose Lithium grease.
8M 8-10170 Issued 06-2001
10 SECTION 5001
STEERING HAND PUMP
Removal and Installation
NOTE: Items are numbered in the order of Removal, for Installation follow the Removal procedure in
reverse order.
Before removing the Hand Pump it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Raise the hood and remove the left hand side panel.
NOTE: For tractors not equipped with tiltable hoods, remove the hood and side panels.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal first. Remove the Steering Hand Pump.
NOTE: For Installation , connect the battery, NOTE: For Installation , install and support the
positive (+) terminal first. steering hand pump in position.
STEP 2 STEP 5
DP98J11 6 DP98H1 59
Put identification marks on and disconnect and cap Remove the four retaining screws (1) and washers
the hoses from the steering hand pump, remove (2), remove the bracket (3).
and discard the o-rings from the fittings.
NOTE: For Installation, tighten the retaining
STEP 3 screws (1) to a torque of 41 to 61 Nm.
Support the steering hand pump and remove the
Steering Column, refer to Page 4.
NOTE: It is not necessary to remove the
steering wheel.
8M 8-10170 Issued 06-2001
SECTION 5001 11
STEP 6 STEP 7
DP98H160 DP988356
Remove the seal (4). check for wear or damage and Check for wear or damage to the four rubber
replace if necessary. grommets (5) in the bracket (3) and replace if
necessary.
NOTE: For Installation, follow the same
procedure in reverse order. After Installation,
start and run the engine and check the
operation of the steering hand pump. DO NOT
hold the steering wheel during engine start up.
A WARNING: Never operate the engine in a
closed building. Proper ventilation is required
under all circumstances.
SM 8-10170 Issued 06-2001
12 SECTION 5001
Disassembly STEP 4
Remove pin (13) from the spool and sleeve
STEP 1
assembly (8). Remove the spool (14) from sleeve
Put the steering hand pump in a clean soft jaw vice, (15), remove centring springs (16) and (17) from
DO NOT overtighten the vice. Remove the fittings spool (14) .
and discard the o-rings.
STEP 5
STEP 2
Remove and discard seal (18) and dust seal (19).
STEP 6
Remove threaded bushing (20) and ball (21) , valve
pins (22) and balls (23).
IMPORTANT: DO NOT use a magnet to remove
balls (21) and (23).
STEP 7
Remove relief valve assembly (24) , remove and
discard seals.
D DOOF064
Put alignment marks (A) on pump body (26), valve
plate (8) , stator (5) and end cover (3). Remove IMPORTANT: DO NOT remove check valve (25)
retaining bolts (1) , mark the position and remove from pump body (26) .
special bolt (2), remove end cover (3). Remove
spacer (4). stator (5), rotor (6) , drive shaft (7) and
valve plate (8) . Remove and discard o-rings (9),
(10) and (11).
STEP 3
DDOOF065
Turn the spool and sleeve assembly (8) until pin (13)
is parallel to the hydraulic fitting mounting face.
Remove spool and sleeve assembly (8) and thrust
bearing assembly (12) from pump body (26) .
8M 8-10170 Issued 06-2001
SECTION 5001 13
NOTE: Items are numbered in order of Disassembly.
DI99J 103
1.RETAINING BOLT (6) 10.0-RING 19 .DUST SEAL
2.SPECIAL BOLT 11 .0-RING 20.THREADED BUSHING
3.END COVER 12.THRUST BEARING 21.BALL
4.SPACER 13.PIN 22.VALVE PIN (2)
5.STATOR 14.SPOOL 23.BALL (2)
6.ROTOR 15.SLEEVE 24 .RELIEF VALVE ASSEMBLY
7.DRIVE SHAFT 16.0UTER CENTERING SPRING (2) 25.CHECK VALVE
8.VALVE PLATE 17.INNER CENTERING SPRING (2) 26.PUMP BODY
9.0-RING 18.SEAL
SM 8-10170 Issued 06-2001
14 SECTION 5001
Inspection Assembly
STEP 8 NOTE: Refer to Page 17 for component
identification.
Clean and inspect parts for wear or damage.
STEP 11
STEP 9
Lubricate and install new seals onto relief valve
assembly (24). Install relief valve assembly (24)
into the pump body (26).
IMPORTANT: The steering relief valve pressure
must be set after the steering hand pump has
been installed onto the tractor, refer to Page 18.
STEP 12
SM1298
Measure the thickness of rotor (6) and stator (5) . If the
rotor is 0.051 mm (0.002 inch) less than the stator,
replace the steering hand pump.
STEP 10
0097G094
SM1297
Align rotor (6) and stator (5) as shown. Measure gap
(C) between the rotor and stator, if the gap is 0.127
mm (0.005 inch) or more, replace the steering hand
pump.
0000F066
Lubricate a new seal assembly (18) with clean
transmission oil. Using MC2552 seal installer,
install locator (D) onto arbor (E) , install seal
assembly (18) onto locator (D) as shown. Install
sleeve (F) into pump body (26). Fully install arbor
(E) against the shoulder in the pump body (26) .
Remove arbor and sleeve, remove the locator
forwards from the pump body.
8M 8-10170 Issued 06-2001
SECTION 5001 15
STEP 13 STEP 15
OOOOF068 SM1303
Install thrust washer assembly (12) onto spool (14)
in the following order, small thrust washer (A) ,
thrust bearing (8) and large thrust washer (C).
STEP 16
DDOOF069
Install and centralize the outer and inner centring
springs (16) and (17) into the spool (14), in the
positions shown.
NOTE: Make sure the centering springs (16) and
DDOOF065
(17) are installed with the cut outs (H) towards
Carefully install the spool and sleeve assembly (8)
the bottom ofthe spool (14).
into the pump body (26) with pin (13) parallel to the
fitting mounting face as shown . DO NOT turn the
STEP 14 spool and sleeve assembly (8) .
NOTE: Heat from your hands may expand the
spool and sleeve assembly (B), preventing the
assembly being installed, DO NOT use force to
install the spool and sleeve assembly (B) . Allow
the assembly to cool and repeat STEP 16.
STEP 17
Install the balls (23) and pins (22). Install the ball
(21) and install and tighten threaded bushing (20) .
NOTE: DO NOT use a magnet to install balls
DDOOF067 (23) and (21).
Insta II the spool (14) into sleeve (15) . Make sure the
springs (16) and (17) locate in slots of sleeve (15),
install pin (13).
NOTE: Heat from your hands may expand spool
(14) preventing it from being installed. Allow the
spool (14) to cool and repeat STEP 14.
SM 8-10170 Issued 06-2001
16 SECTION 5001
STEP 18 STEP 20
Lubricate and install new o-rings (10) and (9) into
the grooves in stator (5) . Align the marks made in
STEP 2, Page 12 and install stator (5).
STEP 21
Install spacer (4) on top of drive shaft (7).
STEP 22
Install the end cover (3) and install the special bolt
(2) in the position noted in STEP 2, Page 10. Install
the remaining bolts (1) . Tighten the bolts (1) and
special bolt (2) to a torque of 25 to 35 Nm.
DDOOF070
Lubricate and install a new a-ring (11) into the
groove in the pump body (26). Install the valve plate STEP 23
(8) , align the marks made in STEP 2, Page 12. With
Install a new dust seal (19). Install new a-rings onto
pin (13) parallel to the fitting mounting face (G),
the fittings removed in STEP 1, Page 10.
install drive shaft (7). Make sure the pin (13) is
between the slot in drive shaft (7) .
STEP 19
SM1296
Install rotor (11) onto drive shaft (7). When pin (13)
is in the correct position one of the rotor gear teeth
will be aligned with the connector mounting face (G)
as shown.
IMPORTANT: If rotor (11) is installed incorrectly
the steering hand pump will operate as a motor
when installed onto the tractor and the engine is
running . The steering wheel will rotate
continually which may cause damage and
injury.
8M 8-10170 Issued 06-2001
SECTION 5001 17
~.,
~
~
1/ 1
.... y
~~ I
I
I
I
DI99Jl03
1.RETAINING BOLT (6) 1O.0-RING 19.DUST SEAL
2.SPECIAL BOLT 11.0-RING 20.THREADED BUSHING
3.END COVER 12.THRUST BEARING 21.BALL
4.SPACER 13.PIN 22.VALVE PIN (2)
5.STATOR 14.SPOOL 23.BALL (2)
6.ROTOR 15.SLEEVE 24 .RELIEF VALVE ASSEMBLY
7.DRIVE SHAFT 16.0UTER CENTERING SPRING (2) 25.CHECK VALVE
8.VALVE PLATE 17.INNER CENTERING SPRING (2) 26 .PUMP BODY
9.0-RING 18 .SEAL
SM 8-10170 Issued 06-2001
18 SECTION 5001
STEERING RELIEF VALVE ADJUSTMENT
NOTE: To check the Steering Relief Valve pressure, refer to Section 8001.
Before adjusting the steering relief valve it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
STEP 1 STEP 2
Check the Steering Relief Valve pressure, refer to
Section 8001. When the pressure is correct, tighten
the plug (1) to a torque of 40 to 60 Nm.
DD97G063
Remove the plug (1), turn the adjuster screw
clockwise to increase or counterclockwise to
decrease the steering relief valve pressure. Install
and tighten the plug (1).
SM 8-10170 Issued 06-2001
Section
5003
2 WHEEL DRIVE STEERING CYLINDER
C and CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10180 March 2001
2 SECTION 5003
TABLE OF CONTENTS
SPECiFiCATIONS .......................................................................................................... ........... ................................ 3
SPECIAL TORQUES .. ...................................................................................................... ......... .. .............................. 3
STEERING CYLINDER PIVOT BUSHINGS
Removal and Installation ....... ................................................................................................................................4
STEERING CYLINDER
Removal and Installation ....................................................................................................................................... 6
Disassembly and Assembly .................................................................................................................................. 8
Cross Sectional Drawing of the Steering Cylinder .............................................................................................. 10
8M 8-10180 Issued 03-2001
SECTION 5003 3
SPECIFICATIONS
Lubricant .......................... ... ............................................. .. ............................ ........... ... Multi-Purpose Lithium Grease
SPECIAL TORQUES
Steering Cylinder Clevis (with Loctite 270) ........................ ........................................ .. ........................ 110 to 135 Nm
Steering Cylinder Clevis Pin Retaining 801t ............. ........... ..................... ...... .. .............. ............ .............. 27 to 31 Nm
Lower Bearing Carrier Retaining Bolts .... ......................................................................... .... .. ............. 110 to 122 Nm
8M 8-10180 Issued 03-2001
4 SECTION 5003
STEERING CYLINDER PIVOT BUSHINGS
Removal and Installation STEP 3
Remove the lock nuts (6). Use a suitable ball joint
STEP 1 splitting tool and remove the ball joints (7) from the
Park the machine on hard level ground and apply upper bushing bracket (8). Remove the cover
the parking brake. Stop the engine and remove the retaining screws (9), cover (10) and bushing (11).
key.
NOTE: For Installation, use a hydraulic press
and install the new upper bushing (11) into the
STEP 2
upper bushing bracket (8). Make sure hole (B)
Remove the cover retaining bolts (1) and cover (2), is aligned with the grease fitting . Apply a
remove and discard the gasket (3). Remove the continuous bead of Loctite 3951 or Terastat 930
bushing (4) from the lower bushing carrier (5). (e) to the top bushing mounting bracket as
shown.
NOTE: For Installation , use a hydraulic press
and install the new lower bushing (4) into the NOTE: For Installation, follow the same procedure
lower bushing carrier (5). Make sure hole (A) is in reverse order. Lubricate all bushings and grease
aligned with the grease fitting . Install a new fittings with the correct grade of grease, refer to
gasket (3). Specifications on Page 3.
SM 8-10180 Issued 03-2001
SECTlON~5~O~O~3_ _ _ __ _ 5
SM1313
1. BOLT
7. BALL JOINT
UPPER BUSHIN G BRACKET
2 COVER 8. W
. GASKET
~. BUS~:~~
9 SCRE
.
LOWER
LOWER BUS
CARRIER 10. COVEE~ BUSHING
11 . UPP
65.. LOCK NUT
SM 8-10180 Issue d 03-2001
6 SECTION 5003
STEERING CYLINDER
Removal and Installation STEP 4
Remove the lower bushing carrier retaining bolts (6)
STEP 1 and lower bushing carrier (7). Remove the steering
Park the machine on hard level ground and apply cylinder (8).
the parking brake. Stop the engine and remove the
key. NOTE: For Installation, apply Loctite 275 to the
lower bushing carrier retaining bolts (6) and
tighten to a torque of 110 to 122 Nm.
STEP 2
Put a suitable container under the steering cylinder. STEP 5
Put identification marks on and disconnect the
steering hoses (1) and (2). Check the axle pivot bushings (9) for wear or damage,
refer to Section 5004.
STEP 3
NOTE: For Installation follow the same procedure
Bend back the lock tab (4) and remove the clevis pin in reverse order. Lubricate all bushings and grease
plate retaining bolt (3), lock tab (4) and clevis pin (5). fittings with the correct grade of grease, refer to
Specifications on Page 3.
NOTE: For Installation, install a new lock tab (4)
and tighten the clevis pin retaining bolt (3) to a NOTE: After Installation, start the engine and
torque of 27 to 31 Nm. Bend the lock tab (4) operate the steering from full left hand lock to
over the retaining bolt (3) and clevis pin plate full right hand lock to remove air from the
(A). steering system.
A NEVER operate an engine in a closed
building. Proper ventilation is required
under all circumstances.
SM 8-10180 Issued 03-2001
SECTION 5003 7
,,
,,
,,
,,
,,
,,
,,
,,
,
,
SM1313
1. STEERING HOSE 6. BOLT
2. STEERING HOSE 7. LOWER BUSHING CARRIER
3. BOLT 8. STEERING CYLINDER
4. LOCK TAB 9. AXLE PIVOT BUSHING
5. CLEVIS PIN
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
SM 8-10180 Issued 03-2001
8 SECTION 5003
Disassembly and Assembly STEP 9
Remove and discard the o-ring (8) , back-up ring (9) ,
STEP 6
wiper seal (10) and rod seal (11) from the end cap (7).
Secure the lower pivot pin of the steering cylinder in
a soft jaw vice. Remove the fittings (1) and (2), NOTE: For Assembly, lubricate a new rod seal
discard the o-rings. (11) and wiper seal (10) with clean transmission
oil, install the rod seal (11) and wiper seal (10)
NOTE: For Assembly, install the fittings (1) and into the end cap (7). Make sure the lip of the rod
(2) with new o-rings. seal (11) is towards the inner edge of the end
cap (7) and the lip of the wiper seal (10) is
towards the outer edge of the end cap (7) .
STEP 7
Lubricate a new a-ring (8) and back-up ring (9)
Hold the piston rod (12) using a suitable wrench on with clean transmission oil, install the a-ring (8)
the flats (A). Remove the clevis (3) and o-ring (4) and back-up ring (9) as shown.
from the piston rod (12) .
STEP 10
NOTE: For Assembly, apply Loctite 270 to the
piston rod threads. Hold the piston rod (12) Repeat Steps 10 and 11 to remove the other end cap
using a suitable wrench on the flats (A) . Install and seals.
and tighten the clevis (3) to a torque of 110 to
135 Nm. STEP 11
Remove the piston rod (12) from the cylinder body
STEP 8
(13) . Remove and discard the piston seal (14) and 0-
Remove the snap ring (5). Push the end cap (7) into ring (15) from the piston rod (12) .
the cylinder body to gain access to the retaining
ring (6) , remove the retaining ring (6) . Remove the NOTE: For Assembly, lubricate a new a-ring
end cap (7). (15) with clean transmission oil and install into
the piston groove. Warm a new piston seal (14)
in hot water for several minutes, install the
piston seal (14) into the piston groove .
Lubricate the piston with clean transmission oil,
using a soft hammer, with one movement,
install the piston rod (12) into the cylinder body
(13) .
8M 8-10180 Issued 03-2001
_
~~~~~____________~S~E~C~T~/O~N~50~O~3~____________________ 9
5M14038
5M1402
1. FITTING 9. BACK UP RING
2 . FITTING 10 . WIPER SEAL
3 . CLEVIS 11 , RODSEAL
4. O-RING 12 . PISTON ROD
5. SNAP RING ~~ . CYLINDER BODY
--=5M:14~033AA
. PISTON SEAL
_ _ _ __ 6. RETAINING 15. O-RING
NOTE: Items ar 7. END CAP RING
marked nm e numbered .in ord 8 . O-RING
y, Assembly is in th e reverse order of D'Isassembly. Items
ust be replaced er of Disassembl
SM 8-10180 Issued 03-2001
10 SECTION 5003
Cross Sectional Drawing of the Steering Cylinder
I ,
L _ _ ______________________________ _
-- - -----------------------------~
--------------------------------,, r ------- -- ----------------- - -----
I
SM 1404
5. SNAP RING 11. ROD SEAL
6. RETAINING RING 12. PISTON ROD
7. END CAP 13. CYLINDER BODY
8. O-RING 14. PISTON SEAL
9. BACK UP RING 15. O-RING
10. WIPER SEAL
SM 8-10180 Issued 03-2001
Section
5004
2 WHEEL DRIVE FRONT AXLE
e and ex Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10190 March 2001
2 SECTION 5004
TABLE OF CONTENTS
SPECiFiCATIONS .. .... ............. .... ....... ......... ... .. .......... ............ ... .. .... .... .. ..... ... .... .. .. ........ .... ..... .... ... ........... .... .. .... ....... 3
SPECIAL TORQUES ... ............ ...... ........ ............................................. ......... ....... .... ... ....... ........... ... ...... ....... ... .... ....... 3
FRONT AXLE .... ....... ....... ....... .. .. ..... ...... ....... ..... ... ... ....... .. .................. ................... .... ..... .. .................... ... ...... ..... ....... 4
WHEEL BEARING
Removal and Installation ......... ......... .......... .. ..... ........ ......... ......... .... ...... ................ .. ......................... .................... . 4
Disassembly and Assembly .. ..... .... .... .... ... ....... .... ........ ....... .. .. ..... .. .. .... ..... .. ... .. ............. ....... ..... ...... ..... .... ...... ... .... 4
FRONT AXLE
Removal and Installation .................. ................. ......... .. ......................... ........ .................... ......................... .. ....... .. 5
Disassembly and Assembly - Utility Adjustable Straight Axle ... ... .... .. ... ..... ......... ......... ... .... .............. .................. .. 6
Disassembly and Assembly - Row Crop Adjustable Straight Axle ........ ........................... .. ..... .... .............. ... ........ . 7
TIE ROD
Removal and Installation .. .... ... .............. ...... .......... .... ... ......... ....... ......... ................ ... ...... ......... ........... ......... .... .. .... 8
Disassembly and Assembly ....................... ......... ................. ......... .. ...... ............ ...... .. ...... ........... ...... ......... ............ 8
SM 8-10190 Issued 03-2001
SECTION 5004 3
SPECIFICATIONS
TRACK ADJUSTMENT
Toe-in ...................... ....... ..... .................................. .... ... .......................... ................ .... ... ........................... 0 to 5 mm
Lubricant ...................... ... ... ... .. .. ... ................................ ........ .. ......... ............................. Multi-Purpose Lithium Grease
SPECIAL TORQUES
Front Weight Bracket Retaining Bolts .............................. ........................................ .... ........................ 481 to 542 Nm
Front Wheel Nuts .......... ........................................ ............ ......... refer to Operators Manual for correct wheel rim size
Steering Arm Clamp Bolt ............................................... ... ..... ............................. .. .. .......... ................... 108 to 122 Nm
Wheel Bearing Nut ...... ............ .. .......................... ...... ........ .. .. ....................... refer to Page 4 for tightening procedure
Tie Rod
Lock Nut .......... .. .. ........................................... ........ ........ ...... .. ............................... ......... ..................... 34 to 40 Nm
Lock Bolt ...................... ... ......................... .. ............ ... ....... .... ..... ........................ .. ... .. ....... ..................... 81 to 88 N m
Tie Rod Tube Lock Nut ... ...... ................................. ... .... .............. .. .. ................... ..... ......................... 235 to 250 Nm
8M 8-10190 Issued 03-2001
4 SECTION 5004
FRONT AXLE
Before removing the Front Axle or components carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
WHEEL BEARING
Removal and Installation
STEP 1
Loosen the wheel nuts. Use a hydraulic jack under the front axle to raise the machine and remove the front wheel.
Support the machine on a suitable axle stand.
NOTE: For Installation , refer to Page 3 for the correct wheel nut torque.
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
NOTE: For assembly lubricate the bearings and hub with the correct grade of grease, refer to Specifications
on Page 3.
1. HUB CAP 5. OUTER BEARING CONE
2. COTTER PIN 6. WHEEL HUB 10 . INNER BEARING CUP
3. NUT 7. INNER BEARING CONE 11. OUTER BEARING CUP
4. WASHER 8. DUST SEAL 12 . STEERING KNUCKLE
NOTE: After assembly of the Wheel Bearing and Hub use the following procedure to tighten the nut (3).
1. Tighten the nut (3) to a torque of 95 Nm.
2. Loosen the nut (3) and then tighten to a torque of 68 Nm for Adjustable Swept Back Axles or 34 Nm for Adjust-
able Straight Axles.
3. If necessary turn the nut (3) counterclockwise to the nearest hole and Install the cotter pin (2) .
SM 8-10190 Issued 03-2001
SECTION 5004 5
FRONT AXLE
Removal and Installation STEP 4
STEP 1 Remove the retaining bolts and cover plate to gain
access to the front axle pivot pin .
Remove the front weights and bracket, if equipped .
NOTE: For Installation, tighten the weight bracket
retaining bolts to a torque of 481 to 542 Nm.
STEP 2
.)
H09614
Put a hydraulic jack under the front axle. Remove
the two retaining bolts (2) from the axle pivot pin,
remove the pivot pin and carefully lower the axle.
H09610 Put the axle on suitable stands.
Put identification marks on and disconnect and cap
the hoses (1) from the steering cylinder. NOTE: For Installation, before installing the
pivot pin, lubricate the pivot pin with the correct
grade of grease, refer to Specifications on Page 3.
STEP 3
Use a hydraulic jack to raise the tractor high enough NOTE: After Installation of the pivot pin, lubricate
for removal of the front axle. Support the tractor on pivot pin grease fitting with the correct grade of
a wooden block or suitable stand under the engine. grease, refer to Specifications on Page 3.
NOTE: DO NOT support the tractor under the
front axle.
8M 8-10190 Issued 03-2001
6 SECTION 5004
Disassembly and Assembly - Utility Adjustable Straight Axle
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
NOTE: For Assembly, lubricate all bushings and grease fittings with the correct grade of grease, refer to
Specifications on Page 3.
~~\§)
~~~~ -@
__ / ' 0 "OIf----®
C:!1)
if""0,,-
24
,§;
§;~
I " ~
@ ~8 1 ~ 1
.... ~ 111ffi®.;~1~'
23@<
~ - ~~ ~A ~'
,
~ , I- "
Refer to Step 5
for Removal and
Installation
Refer to Section
5003 for Removal
and Installation
SM1324
LH AXLE EXTENSION 9. LOWER BUSHING 16. WOODRUFF KEY AXLE CENTRE
1. NUT 10. NUT (2) 17 . STEERING KNUCKLE 25. AXLE - CENTER SECTION
2. BOLT 11. SHOULDER BOLT (2) 18. THRUST BEARING 26. REAR PIVOT BUSHING
3. STEERING ARM 12. LH AXLE EXTENSION 19 . FELT WASHER 27. FRONT PIVOT BUSHING
4. WOODRUFF KEY 20. UPPER BUSHING 28. STEERING CYLINDER
5. STEERING KNUCKLE RH AXLE EXTENSION 21 . LOWER BUSHING MOUNTING BRACKET
6. THRUST BEARING 13.NUT 22 . NUT (2) BUSHING
7. FELT WASHER 14. BOLT 23. SHOULDER BOLT (2) 29. CLEVIS PIN BUSHING
8. UPPER BUSHING 15 . STEERING ARM 24 . RH AXLE EXTENSION
SM 8-10190 Issued 03-2001
SECTION 5004 7
Disassembly and Assembly - Row Crop Adjustable Straight Axle
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly
NOTE: For Assembly, lubricate all bushings and grease fittings with the correct grade of grease, refer to
Specifications on Page 3.
Refer to Step 5
for Removal and
Installation
Refer to Section
5003 for Removal
and Installation
SM1323
LH AXLE EXTENSION 9. LOWER BUSHING 16. WOODRUFF KEY AXLE CENTRE
1. NUT 10. NUT (3) 17. STEERING KNUCKLE 25 . AXLE - CENTRE SECTION
2. BOLT 11 . SHOULDER BOLT (2) 18. THRUST BEARING 26. REAR PIVOT BUSHING
3. STEERING ARM 12. LH AXLE EXTENSION 19. FELT WASHER 27. FRONT PIVOT BUSHING
4. WOODRUFF KEY 20 . UPPER BUSHING 28. STEERING CYLINDER
5. STEERING KNUCKLE RH AXLE EXTENSION 21. LOWER BUSHING MOUNTING BRACKET
6. THRUST BEARING 13 . NUT 22 . NUT (3) BUSHING
7. FELT WASHER 14 . BOLT 23 . SHOULDER BOLT (2) 29 . CLEVIS PIN BUSHING
8. UPPER BUSHING 15 . STEERING ARM 24 . RH AXLE EXTENSION
SM 8-10190 Issued 03-2001
8 SECTION 5004
TIE ROD
Removal and Installation
STEP 1
H1 0027
Remove the lock nuts (1) and (2) from both ball
joints and remove the tie rod (3) .
NOTE: After Installation, check the toe-in, this
should be 0 to 5 mm.
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
,~,-:~ ?
~ ' ~@r ®
/' .
SM1 342
1. LOCK BOLT 3. BALL JOINT 5 . TAB WASHER 7 . TUBE ASSEMBLY
2 . LOCK NUT 4. BALL JOINT 6. LOCK NUT
NOTE: For Assembly, refer to Page 2 for correct torques for items (1), (2) and (6).
SM 8-10190 Issued 03-2001
Section
6002
ENGINE CLUTCH, MASTER CYLINDER
AND SLAVE CYLINDER
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK 8M 8-10220 March 2001
2 SECTION 6002
TABLE OF CONTENTS
SPECiFiCATIONS ....................... .. ....... ......... .................................... ........................................................................ 3
SPECIAL TORQUES .. ............................................................................................................................................... 3
TOOLS TO BE MADE ........................... .................................................................................................................... 3
CLUTCH MASTER CYLINDER
Removal and Installation ...................................................... ........ .. ............... .. ....... .. ....... .. ..... ... ....... ... .................. 4
CLUTCH SLAVE CYLINDER
Removal and Installation .... ................................................................................................................................... 5
Disassembly and Assembly ........ ..................... ... .................. .. ...................... .. ...................... .... ....... .. ................... 6
REMOVING AIR FROM THE CLUTCH HYDRAULIC SYSTEM .......................................................... .. ................... 7
ENGINE CLUTCH AND FLYWHEEL
Removal .... ... ................................................ .... .... ....... ............ .. ... .... ...... .. ..... ........ ... ........ ..................... ................ 8
Inspection .............................................................................................................................................................. 8
Cross Sectional Drawing of the Friction Plate ........................................................................................................... 9
Cross Sectional Drawing of the Pressure Plate, Friction Plate and Flywheel ........ ................................................. 10
SM 8-10220 Issued 03-2001
SECTION 6002 3
SPECIFICATIONS
CX50, CX60, CX70/75 Tractors
Maximum Clutch Plate Thickness ............................................................................................................. 10.4 mm
Clutch Plate Diameter ............ .......................................................... ......... ..... ................. .. ................... .. .... 305 mm
Number of Friction Plate Pads .. ...... ........ ...... .. .............. ................ .. .............................. ........ .... ........ .. .. 5 each side
CX80/85, CX90/95 and CX100/105 Tractors
Maximum Clutch Plate Thickness ........................................................... ..... ......... ................................... . 10.4 mm
Clutch Plate Diameter .......... .... ........................................................................................ ... ................... .. .. 310 mm
Number of Friction Plate Pads .......... ...... .. .......................... .... ...................... ...... .............. .................... 7 each side
SPECIAL TORQUES
Flywheel Retaining Bolts .......................................... ............ .. .. .... .... ............ .... ...... .... ........ ...... .......... 116 to 130 Nm
Clutch Retaining Bolts .... .... ... ......... .............. .......................... .. ... ...... ... .. ..... .. ..... ..... .. ..... .... ... ............ .. .. .. 20 to 23 Nm
Rear Wheel Nuts
Flange Axle ....... ..... ............................................ ........... ........... ................... ................... ................. 278 to 298 Nm
Bar Axle (5/8 inch) ......................... ................ ...... ... .. ....... .. ..... ..... .. ............... .. .............. .. ................. 183 to 207 Nm
Bar Axle (3/4 inch) .................. ..... ...................... ........... ............ ... .. .................................................. 241 to 264 Nm
TOOLS TO BE MADE
NOTE: For the correct alignment of the clutch a universal clutch alignment tool should be used. If a
universal alignment tool is not available it will be necessary to make an alignment tool to the
dimensions shown below.
I~
®
A. 35mm Diameter 0.150 mm
B.24 mm Diameter E.41 mm
C.19.995 mm Diameter F.25 mm
8M 8-10220 Issued 03-2001
4 SECTION 6002
CLUTCH MASTER CYLINDER
Before servicing the Clutch Master Cylinder it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, follow the same procedure in reverse order.
Removal and Installation STEP 4
STEP 1
Raise or remove the hood .
STEP 2
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, install and tighten the
positive (+) terminal first.
STEP 3
Remove the retaining clip (2) and disconnect the
clevis from the clutch pedal.
NOTE: For Installation, adjust the master
cylinder linkage, refer to Section 9001.
DD97J1 76
Remove the LH instrument panel side cover (1). STEP 5
MD0 1C002
Disconnect and cap the tube (3) and remove the
bolts (4). Remove clutch master cylinder (5) .
SM 8-10220 Issued 03-2001
SECTION 6002 5
CLUTCH SLAVE CYLINDER
Before servicing the Clutch Slave Cylinder it is necessary to carry out the following :
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the front wheels.
o Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, install and tighten the positive (+) terminal first.
Removal and Installation STEP 3 CX70/75, CX80/85, CX90/95 and CX100/105
STEP 1
Raise the rear of the tractor, support the tractor on a
suitable stand or block and remove the RH rear
wheel.
NOTE: For Installation, install and tighten the
rear wheel nuts to the correct torque, refer to
Page 3.
STEP 2 CX50 and CX60
DD97K039
Disconnect and cap the tube (4) from the clutch
slave cylinder (5). Remove the bolts (6) and clutch
slave cylinder (4).
MR01B01 3
Disconnect and cap the tube (4) from the clutch
slave cylinder (5) . Remove the bolts (3) and clutch
slave cylinder (2) .
8M 8-10220 Issued 03-2001
6 SECTION 6002
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
D197M046
1. COVER
2. RETAINING RING
3.PISTON ROD
4.SEAL
5. BODY
NOTE: /tems (3) and (5) are not serviced separately, if worn or damaged the clutch slave cylinder must
be rep/aced .
SM 8-10220 Issued 03-2001
SECTION 6002 7
REMOVING AIR FROM THE CLUTCH HYDRAULIC SYSTEM
Before removing air from the Clutch Hydraulic System it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
STEP 1 STEP 4
Check the clutch pedal adjustment, refer to Section Open the bleed screw and press the clutch pedal
9001 . fully down, hold the clutch pedal in this position .
Tighten the bleed screw and slowly release the
STEP 2 clutch pedal, check the level of oil in the reservoir
and add oil if necessary.
STEP 5
Repeat STEP 4 until the oil flowing through the
plastic hose is free of air.
STEP 6
Check the level of oil in the reservoir and add oil if
necessary.
Check the level of oil in the clutch reservoir (1) and
add oil if necessary.
STEP 3
MR01B012
Install a clear plastic hose onto the bleed screw (2)
on the clutch slave cylinder and put the open end
into a suitable container.
8M 8-10220 Issued 03-2001
8 SECTION 6002
ENGINE CLUTCH AND FLYWHEEL
Removal
Before removing the Engine Clutch and Flywheel carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
o Separate the Engine from Speed Transmission, refer to Section 6001 .
Inspection Flywheel
Friction Plate Inspect the face of the flywheel for grooves and
flatness. Grooves less than 0.64 mm are
The friction plate should be replaced if there is less acceptable and it is not necessary to reface the
than 0.24 mm of friction material above the rivet flywheel. The maximum amount of material to be
heads. If the friction plate has been contaminated removed from the face of the flywheel is 3.2 mm.
with oil or grease it can be cleaned with a suitable
cleaning solvent and used again . Check the flatness of the flywheel using a straight
edge , a flatness error of 0.152 mm or less is
IMPORTANT: Friction plate pads which turned acceptable.
blue in colour do not indicate excessive heat.
Friction plate pads showing signs of flaking or NOTE: Refer to the Engine Service Manual for
cracking between the rivets do not need to be Removal and Installation of the Flywheel.
replaced as this is a normal condition.
Pressu re Plate
The pressure plate must be replaced if there are
any signs of wear or damage.
NOTE: DO NOT reface a pressure plate.
8M 8-10220 Issued 03-2001
SECTION 6002 9
Cross Sectional Drawing of the Friction Plate
CX50/60/70 CX80/90/100
FLYWHEEL SIDE FLYWHEEL SIDE
ffiCC::::::l4-j
D197E349
NOTE: Make sure the friction plate is installed onto the flywheel as shown.
8M 8-10220 Issued 03-2001
10 SECTION 6002
Cross Sectional Drawing of the Pressure Plate, Friction Plate and Flywheel
\ '-----
D197J092
1. PRESSURE PLATE ASSEMBLY
2.FRICTION PLATE
3.FLYWHEEL
SM 8-10220 Issued 03-2001
Section
6003
2 SPEED POWERSHIFT AND SYNCHRO
FORWARD/REVERSE
TRANSMISSION SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10230 March 2001
2 SECTION 6003
TABLE OF CONTENTS
SPECIAL TORQUES ... ......... .. ... ..... ....... ... .. .. ....... .. .......... ................... ..... ............ ....... ..................... .......................... 3
SPECiFiCATIONS ........ ............................................ ... ............ ........ ...... ... ............ .. ............ .... ................................... 3
SPECIAL TOOLS ...................................................... ....... ..................... .. .............. ... ..................................... ... ......... 3
TOOLS TO BE MADE ........ .. ...... .................. ........ ................ ... ......... .. ........ ....... ..... .... ....... .......... ..... .. ....................... 4
POWERSHIFT AND FORWARD/REVERSE TRANSMISSION
Removal .... .. ............................................ .. ........... .. ...................... ... ....... ........ ................ .... .... ..... ... .. .............. ....... 5
FORWARD/REVERSE SELECTOR FORK COVER
Disassembly and Assembly ... ... ....................................................................................... ............ .. ................ ... .. 11
FORWARD/REVERSE IDLER GEAR COVER
Disassembly and Assembly .................................. ............................................ .................................. ................ 12
FORWARD/REVERSE SYNCHRONIZER
Disassembly and Assembly ....................................................... ........... ............ ........................................... .. ..... 13
POWERSHIFT CLUTCH
Disassembly ............. .... ............................... ....... ... .... ........... ............................................................................... 14
Assembly ..... .. ........... .... .............. ............. .. ............ .. .......................................... ................ .. ...... ....................... ... 16
Cross Sectional Drawing of the Powershift Clutch Assembly .................... .. ................................. ...... ....... .... ... .. 23
POWERSHIFT AND FORWARD/REVERSE TRANSMISSION
Installation ................. ................ ...................... .......... ................... .. ......... ... ............ ......... .. ... ......... .. .. ......... .. .. ..... 24
Cross Sectional Drawing of the Powershift and Forward/Reverse Transmission ............ ..................... ............ .. 30
8M 8-10230 Issued 03-2001
SECTION 6003 3
PECIAL TORQUES
Speed Transmission to Range Transmission Retaining Bolts
1/2 inch diameter (with Loctite 271) ........ ...... ............ ... ......... ..... ......... .. .. .. ...... .. ..... ........... ... .... .. ..... 101 to 104 Nm
5/8 inch diameter (with Loctite 271) ........... ... ........... ............... .. ............ ..... .......... .... .......... .. ........... 205 to 230 Nm
Main Shaft Retaining Bolts ....... ......... .. .. ............. .. ........ .. .... ... .. ...... .. ......... ........ ....... ..... .... ..... ... .. .. .... ... ... . 42 to 47 Nm
Selector Fork to Selector Rail Lock Bolt ..... ...... ............ ... ... ............ .............. .............. ... ...... .... ... ........ ... 89 to 100 Nm
Selector Fork to Selector Rail Lock Nut... .... .. ... ........ ... .... ....... ... ..... ......... ... .. .......... .... .......... ... ... .......... .. . 53 to 59 Nm
PTa Bearing Retainer Bolts (with Loctite 271) .......... ........... ... .... ... .. ..... .. ... ........ .. .. .... ...... .. ....... .......... .... 42 to 47 Nm
Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) ............ .. ............ .. ............... .. .......... .. 42 to 47 Nm
SPECIFICATIONS
Input Shaft Spline Lubricant ............ .............. ......................................................... MOLYKOTE D321 R or equivalent
SPECIAL TOOLS
H02503 DD97K036
(A) POWERSHIFT CLUTCH ALIGNMENT TOOL MC 1921A ALIGNMENT STUDS MC1995·7
(B) SPRAG CLUTCH INSTALLER SLEEVE MC 1920 (part of Kit MC1995B)
l'"
DD97G232 DD 97K035
(C) SEAL EXPANDER/PROTECTOR MC 2519·1 REMOVER AND INSTALLER FOR PTO DRIVEN SHAFT MC2559
(D) SPACER RING MC 2519·2
(E) SEAL COMPRESSOR MC2520
SM 8-10230 Issued 03-2001
4 SECTION 6003
TOOLS TO BE MADE
A.
A.
101 .6 MM 30KPH TRACTORS
106.5 MM 40KPH TRACTORS
0.44 .5 MM
E. 25.4 MM
H. 12.7 MM
J.12 .7MM
F t G
SM1150
B. 38 MM F. 6.4 MM
C. 12.7 MM G. 3.2 MM
-j r- 10mm
65mm
150mm
10mm
SM1134
COMPRESSION TOOLS TO BE USED WITH MC1920 AND MC1921A
SM 8-10230 Issued 03-2001
SECTION 6003 5
POWERSHIFT AND FORWARD/REVERSE TRANSMISSION
Before servicing the Powershift and Forward/Reverse Transmission it is necessary to carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Lower the rear three point hitch.
o Stop the engine and remove the key.
o Put blocks in front of and behind the front wheels.
o Put wooden blocks between the front axle bolster and front axle.
o Remove the front tractor weights, if equipped.
o Separate the Tractor between the Engine and Speed Transmission, refer to Section 6001.
NOTE: Before connecting the Engine to the Speed Transmission, lubricate the input shaft splines with
MOLYKOTE 0321 R or equivalent.
o Remove the MFD Transfer Gearbox, if equipped, refer to Section 6017.
o Remove the PTO Clutch, refer to Section 6019. Refer to Section 6020 for Tractors equipped with Shiftable PTO.
NOTE: It is not necessary to remove the Speed Transmission to service the Powershift Clutch or
Forward/Reverse Synchronizer Assembly.
Removal STEP 4
STEP 1
DD97H109
Disconnect the clutch slave cylinder linkage by
DD97J091 removing retaining ring (1), spring (2) and retaining
Remove the RH cab step. ring (3). Remove roll pin (4) and plate (5) from the
cross shaft .
STEP 2
STEP 5
Raise the rear of the tractor, support the RH rear
axle on a suitable axle stand and remove the RH
rear wheel.
STEP 3
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect the battery,
positive (+) terminal first.
Remove the clutch release bearing assembly (6).
Remove roll pins (7) , cross shaft (8) and fork (9).
8M 8-10230 Issued 03-2001
6 SECTION 6003
STEP 6 STEP 8 CX50 and CX60
DD97J085 MR01B013
Remove the cab floor mat and panel. Disconnect Disconnect and cap tube (16) from the clutch slave
and cap tubes (10) and (11) from regulator valve cylinder (17) . Remove bolts (18) and clutch slave
(12). Disconnect harness (13) from the solenoid. cylinder (17).
Remove the bolts and regulator valve (12). Remove
the bolts and front transmission cover (14), remove STEP 9 CX70175, CX80/85, CX90/95 and CX100/105
and discard the gasket. Remove the powershift
supply tube, remove and discard the o-rings.
STEP 7
MR01B01 2
Disconnect and cap tube (19) from the clutch slave
cylinder (20). Remove bolts (21) and clutch slave
cylinder (20) .
DD97H11 3
Remove the bolts and forward/reverse selector fork STEP 10
cover (15) from the bottom of the transmission
housing, refer to Page 11 for Disassembly and
Assembly.
DD97H107
Remove the bolts and forward/reverse idler gear
cover assembly (22), refer to Page 12 for
Disassembly and Assembly.
8M 8-10230 Issued 03-2001
SECTION 6003 7
STEP 11 STEP 14
DD97H1 14
Remove the retaining bolts and PTO bearing Pull the PTO driven shaft rearward and remove the
retainer (23). PTO driven gear (26) and spacer (27) through the
opening in the bottom of the transmission housing.
STEP 12
STEP 15
DD97H118
Remove external retaining ring (24) .
Remove retaining ring (28) and thrust washer (29)
STEP 13 from the counters haft.
STEP 16
Use the removal tool, (25), MC2559, to remove the
PTO driven shaft from the bearing. Remove the
bearing. Remove thrust bearing (30) from the countershaft.
8M 8-10230 Issued 03-2001
8 SECTION 6003
STEP 17 STEP 18
DD97H116
D197H091
Remove PTO drive shaft (34). Remove and discard oil
seal (35) from PTO drive shaft (34). If it is necessary
to replace bearing (37), remove snap ring (36) and
use a hydraulic press to remove bearing (37) from the
DI97H092 PTO drive shaft (34).
Remove clutch release bearing carrier (31). Remove STEP 19
and discard o-ring (32) and oil seal (33).
Remove two of the bolts (3.8) and install two alignment
studs (A), MC1995B, as shown. Remove the
remaining bolts (38). Install two of the bolts (38), into
the threaded holes (B), these bolts are used as
jacking bolts to move the powershift clutch housing
(39) forward. The powershift clutch housing (39) must
be moved approximately 15 mm forward to provide
clearance for removal of the forward/reverse
synchronizer and gear assembly.
SM 8-10230 Issued 03-2001
SECTION 6003 9
STEP 20 STEP 22
DD97H120
Remove reverse driven gear (40), synchronizer Remove rear thrust bearing (44) and thrust washer
assembly (41) and forward driven gear (42) through (45).
the bottom of the transmission housing, refer to
Page 13 for Synchronizer Disassembly and STEP 23
Assembly.
NOTE: Care must be taken when removing the
synchronizer assembly (41), not to lose the
springs and poppets.
STEP 21
DD97Hl22
Remove retaining ring (46), remove and check lube
ring (47) for wear or damage.
STEP 24
DD97H170
Remove and discard sealing ring (43) from the
forward driven gear (42).
Remove the powershift clutch assembly (39).
NOTE: Refer to Page 14 for Disassembly of the
Powershift Clutch Assembly (39).
8M 8-10230 Issued 03-2001
10 SECTION 6003
STEP 25 STEP 28
H02331
Remove snap ring (48) and clutch disc carrier (49) . Remove rear roller bearing (51) from the powershift
Check the clutch disc carrier splines for wear or drive gear assembly (50) , check for wear or damage
damage and replace if necessary. Check for wear and replace if necessary.
or damage to the needle roller bearings in the
powershift drive gear assembly. STEP 29
NOTE: Refer to STEP 26 to STEP 29 if the
powershift drive gear or needle roller bearings
are to be replaced.
STEP 26
Remove the Mainshaft, Gears and Synchronizers ,
refer to Section 6006.
STEP 27
H02329
Remove needle roller bearings (52) from the
powershift drive gear assembly (50) if worn or
damaged.
OD9-7F062
Remove powershift drive gear assembly (50).
SM 8-10230 Issued 03-2001
SECTION 6003 11
FORWARD/REVERSE SELECTOR FORK COVER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
0--
DI97H089
1. SELECTOR FORK SHIFT FINGER 4. SELECTOR FORK
2. RETAINING RING 5. SELECTOR FORK COVER
3. PIN
NOTE: Remove pins (3) in the directions shown.
SM 8-10230 Issued 03-2001
12 SECTION 6003
FORWARD/REVERSE IDLER GEAR COVER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly
:-~CD
OI97H09O
1. ROLL PIN 5. ROLLER BEARING
2. PIN 6. SPACER
3. GEAR CLUSTER 7. IDLER GEAR COVER
4. WASHER
NOTE: Drive roll pin (1) into pin (2) until pin (2) can be removed.
SM 8-10230 Issued 03-2001
SECTION 6003 13
FORWARD/REVERSE SYNCHRONIZER
Disassembly and Assembly
, 1,
DD97K175
1. REVERSE DRIVEN GEAR 7. SPRING
2. CLUTCH BODY RING 8. SYNCHRONIZER HUB
3. SYNCHRONIZER RING 9. SYNCHRONIZER RING
4. COLLAR 10. CLUTCH BODY RING
5. POPPET 11 . FORWARD DRIVEN GEAR
6. PIN
SM 8-10230 Issued 03-2001
14 SECTION 6003
POWERSHIFT CLUTCH
Disassembly STEP 3
STEP 1
Remove retaining ring (5) and bearing cage (6)
DD97H127
from the shaft.
Put the powershift clutch assembly in a soft jawed
vice. Remove the retaining ring, use a suitable STEP 4
puller and remove the clutch assembly.
STEP 2
DD97H130
Remove and discard the two sealing rings (7).
Remove retaining ring (8), bearing (9) and thrust
DD97H128
washer (10).
STEP 5
DI99A068
Rotate gear assembly (1) to check the operation of
the sprag clutch (4). Remove woodruff key (2) and
gear assembly (1). Remove and discard oil seal (3),
remove the sprag clutch (4).
NOTE: The gear assembly (1) must only rotate
in a clockwise direction as viewed from the
front. If gear assembly (1) rotates in both
directions it must be replaced. Gear assembly
Put clutch assembly (11) onto a hydraulic press and
(1) must be replaced if the bushing is worn or
compress the reduction side clutch plates. Remove
damaged.
retaining ring (12).
8M 8-10230 Issued 03-2001
_ _ _ S_ECTION 6003 _ _ _ 15
STEP 6
(12) ~EFER TO STEP 5
~ ORREMOVAL
/'
~I
/'
/'
/'
/'
/
DI99A052
12 . RETAINING RING 26. STEEL SEPARA
27 . FRICTION TOR PLATE
13 . BAC KING PLATE PLATE
14. FRICTION PLATE 28. BACKING
29 S PLATE
15 . STEEL SEPARA . HIM
16 . FRICTION TOR PLATE
PLATE 30. SCREW (3)
17. STEEL SEPARA 31 . NUT (3)
18. FRICTIO TOR PLATE
N PLATE 32 . PRESSUR E PLATE
19 . BACKING 33 . BELLEVILLE
20 S PLATE 34 . PISTON WASHER (3)
. HIM
21 . RETAINING RING 35 . WASHER (3)
22. BACKING PLATE 36 . O-RING
23 . FRICTION PLATE 37. O- RING
24. STEEL SEPAR 38 . CLUTCH HO USING
25 . FRICTION ATOR PLATE
PLATE
SM 8-10230 Issued 03-2001
16 SECT/ON 6003
Assembly STEP 13
Turn the clutch housing (38) onto its side. Apply
STEP 7
Loctite 271 onto new nuts (31) . Install the nuts (31)
Measure the stack height of the following clutch and tighten the bolts (30) to a torque of 7 to 8 Nm .
components pressure plate (32) , items (19) to (13) Support the bolt heads and use a centre punch to
and the retaining ring removed in STEP 5. Use the stake nuts (31) onto bolts (30). 180 degrees apart.
following chart to select the correct shim pack (20).
STEP 14
Dimension Measured Shim Required
26 .80 to 26.47 mm No shim required Install shim pack (20) calculated in STEP 7. Install
0.35 mm items (19) to (13) .
26.44 to 26.08 mm
26.06 to 25.80 mm 0.60 mm
STEP 15
STEP 8
Lubricate and install new o-rings (36) and (37) onto
piston (34) .
STEP 9
Apply petroleum jelly to washers (35), for location
purposes , and install into the clutch housing.
STEP 10
Carefully install the piston (34) into the clutch
housing (38).
H02506
NOTE: Make sure the holes in piston (34) and Install alignment tool (B) , MC1921A, and sleeve
washers (35) are aligned with the holes in the (A), MC1920, into the gear assembly.
clutch housing (38).
STEP 16
STEP 11
SM11 37
Install the three Belleville washers (33) into housing
(38), as shown.
H02512
STEP 12 Remove sleeve (A), MC1920, and install gear
assembly (1) to align the friction plates.
Install pressure plate (32) . Install new bolts (30)
through pressure plate (32), belleville washers (33) ,
clutch housing (38), washers (35) and piston (34) .
IMPORTANT: Make sure bolts (30) are correctly
seated in pressure plate (32) .
SM 8-10230 Issued 03-2001
___________ SECTION 6003 17
DI99A052
13. BACKING PLATE 31. NUT (3)
14 . FRICTION PLATE ~2. PRESSURE PLATE
15 . STEEL SEPA 3. BELLEVILLE W
16. FRICTION RATOR PLATE 34. PISTON ASHER (3)
1 PLATE
7 . STEEL SEPAR 35. WASHER (3)
18. FRICTION ATOR PLATE
PLATE 36 . O-RING
19. BACKING PLATE 37. O-RING
20. SHIM 38. CLUTCH HOUSING
30. SCREW (3)
SM 8-10230 Issued 03-2001
18 SECTION 6003
STEP 17 STEP 19
Measure clutch components (28) to (21) . Record
this measurement as (8). Use the following
calculation and chart to obtain the correct shim .
A - 8 + 0.88 mm clearance = C
Dimension C Shim Required
Oto 0.38 mm No shim required
0.38 to 0.63 mm 0.35 mm
0.66 to 0.89 mm 0.60 mm
0.91 to 1.14 mm 0.91 mm
H02509
1.16 to 1.39 mm 0.35 + 0.91 mm
Compress the clutch pack, using alignment tool,
MC1921A, and compression tools, refer to Tools to 1.42 to 1.65 mm 0.60 + 0.91 mm
be Made, Page 4. Install retaining ring (12) and 1.67 to 2.03 mm 0.91 + 0.91 mm
remove the special tools.
STEP 18 STEP 20
Install shim pack (29) calculated in STEP 19. Install
Turn the clutch pack over, measure the distance items (28) to (21) .
between the top of the retaining ring groove and
face of the piston (34) . Record this measurement as NOTE: After installing the clutch pack, check
(A) . the clearance between retaining ring (21) and
backing plate (22), this should be between 0.76
and 1.0 mm.
SM 8-10230 Issued 03-2001
SECTION 6003 _____ 19
DI99A052
12.RETAINING RING 26 .STEEL SEP
27 .FRICTION ARATOR PLATE
21.RETAINING RING PLATE
22 .BACKING PLATE 28.BACKING PL ATE
23.FRICTION PLATE 29 .SHIM
24.STEEL SEPARA 34 .PISTON
25 .FRICTION TOR PLATE
PLATE
SM 8-10230 Issued 03-2001
20 SECTION 6003
STEP 21 STEP 23
DD97G227
Install thrust washer (10) and bearing (9) onto the Remove sealing ring installer, MC2519-1, and
shaft. install spacer MC2519-2. Install the sealing ring
installer and repeat STEP 22 to install the second
STEP 22 sealing ring (7).
STEP 24
DD97G226
Install bearing retaining ring (8). Install sealing ring
DD97G228
installer, MC2519-1 , onto the shaft. Lubricate a new
sealing ring (7) with petroleum jelly, slide sealing
ring (7) down the installer and into the bottom
sealing ring groove.
DD97G231
Compress sealing rings (7) by hand and carefully
install sealing ring compressor, MC2520, leave the
compressor in position for 5 minutes. Remove the
compressor and check sealing rings (7) for damage
and replace if necessary.
SM 8-10230 Issued 03-2001
SECTION 6003 21
STEP 25 STEP 27
DD97H133 DD97H134
Lubricate sealing rings (7) with petroleum jelly and Install sleeve (A), MC 1920, onto the shaft. Carefully
install bearing cage (6) onto bearing (9) , care must install gear assembly (1) over sleeve (A) onto the
be taken not to damage sealing rings (7). Install shaft. Remove sleeve (A), MC1920, from the shaft.
retaining ring (5).
NOTE: Make sure gear assembly (1) will rotate
STEP 26 in one direction only, clockwise viewed from the
front.
STEP 28
SM1138
Install sprag clutch (4) into gear assembly (1) .
Install oil seal (3) to a dimension of 1.27 mm.
NOTE: Make sure bearing cap (A) is installed
between the sprag clutch (4) and oil seal (3) .
A04936
Install woodruff key (2) into the shaft. Apply Loctite
609 to the clutch mounting area of the shaft.
8M 8-10230 Issued 03-2001
22 SECTION 6003
STEP 29
DD97H1 36
Install the clutch assembly onto the shaft and install
the retaining ring.
8M 8-10230 Issued 03-2001
SECTION 6003 23
Cross Sectional Drawing of the Powershift Clutch Assembly
~:--+'I-tJ()\
r-~
"'" "i:I [-'+---~-@
E ll I
'; I ~----1@
OI99A053
1. GEAR ASSEMBLY 23 . FRICTION PLATE
3.0ILSEAL 24. STEEL SEPARATOR PLATE
4. SPRAG CLUTCH 25 . FRICTION PLATE
12 . RETAINING RING 26. STEEL SEPARATOR PLATE
13 . BACKING PLATE 27 . FRICTION PLATE
14. FRICTION PLATE 28 . BACKING PLATE
15. STEEL SEPARATOR PLATE 29. SHIM
16. FRICTION PLATE 30 . SCREW (3)
17. STEEL SEPARATOR PLATE 31 .NUT(3)
18. FRICTION PLATE 32. PRESSURE PLATE
19.BACKING PLATE 33 . BELLEVILLE WASHER (3)
20. SHIM 34. PISTON
21. RETAINING RING 35 . WASHER (3)
22 . BACKING PLATE 38 . CLUTCH HOUSING
SM 8-10230 Issued 03-2001
24 SECTION 6003
POWERSHIFT AND FORWARD/REVERSE TRANSMISSION
Installation STEP 4
STEP 1
SM11 33
Install two needle roller bearings (52) into the Install clutch disc carrier (49) and snap ring (48).
powershift drive gear assembly (50) to the
dimensions shown. STEP 5
STEP 2
Install two 3/8 UNC alignment studs (A) into the
DD97F062
speed transmission housing. Apply Loctite 515 onto
Install the powershift drive gear assembly (50). the speed transmission housing, carefully push
Install the rear roller bearing (51). powershift clutch assembly (39) along alignment
studs (A) until the housing is approximately 15 mm
STEP 3 from the speed transmission.
Install the Mainshaft, Gears and Synchronizers, IMPORTANT: The above procedure must be
refer to Section 6006. carried out to allow the forward driven gear,
forward/reverse synchronizer and reverse
driven gear to be installed onto the
countershaft.
8M 8-10230 Issued 03-2001
SECTION 6003 25
STEP 6 STEP 9
DD97H122 DD97K040
Install lube ring (47) and retaining ring (46) . Use a new lube ring (47) to compress sealing ring
(43) .
STEP 7
STEP 10
DD97H12 1
DD97H120
Install the thinnest (2 .25 mm) thrust washer (45)
and thrust bearing (44) onto the countershaft. Install forward driven gear (42), forward/reverse
synchronizer (41) and reverse driven gear (40).
STEP 8
STEP 11
DD97H1 37
DD97H118
Lubricate sealing ring (43) with petroleum jelly and
install by hand onto the forward driven gear (42). Install thrust bearing (30), thinnest (2.25 mm) thrust
washer (29) and retaining ring (28) .
SM 8-10230 Issued 03-2001
26 SECTION 6003
STEP 12 STEP 14
r-..-~'"
---®
/ /
DI97H091
Install oil seal (35) into PTO drive shaft (34) . Make
sure the lip of oil seal (35) is towards the
transmission side of the shaft and against the
shoulder, as shown. If it is necessary to replace
bearing (37) , use a hydraulic press and install
bearing (37) onto PTO drive shaft (34) , install
snap ring (36).
DI97J188 STEP 15
Push reverse driven gear (40), forward/reverse
synchronizer (41) and forward driven gear (42)
towards the rear of the countershaft, measure the
clearance between retaining ring (26) and thrust
washer (27), this must be between 0.03 and 0.60
mm. Replace thrust washer (27) to obtain the
correct clearance.
STEP 13
DD97Hl16
Install PTO drive shaft (34).
STEP 16
Fully install the powershift clutch assembly (39) and
remove alignment studs . Apply Loctite 271 to the
threads of retaining bolts (38), install and tighten the
bolts to a torque of 47 to 53 Nm.
DI97H092
Install oil seal (33) into the clutch release bearing
carrier (31). Make sure the lip of oil seal (33) is
towards the transmission side of the carrier and
against the shoulder, as shown. Install a new a-ring
(32) onto clutch release bearing carrier (31).
SM 8-10230 Issued 03-2001
SECTION 6003 27
STEP 17 STEP 19
DD97H115
Install clutch release bearing carrier (31). Apply Use installation tool (25), MC2559, to install the
Loctite 271 to the threads of the bolts, install and bearing onto the PTO driven shaft.
tighten the bolts to a torque of 45 to 50 Nm.
NOTE: Lock the PTO driven shaft in the rear of
STEP 18 the transmission to prevent moving rearwards.
STEP 20
DD97Hl14
Install PTO driven gear (26) and spacer (27). Install
DD97Hl11
the PTO driven shaft.
Install external retaining ring (24).
NOTE: Make sure spacer (27) is between gear
(26) and bearing.
8M 8-10230 Issued 03-2001
28 SECTION 6003
STEP 21 STEP 23 CX70, CX80, CX90 and CX100
MR01B0 13
Apply Loctite 515 to the face of the PTO bearing Install clutch slave cylinder (20), install and tighten
retainer (23) and Loctite 271 to the threads of the bolts (21) to a torque of 42 to 47 Nm. Remove the
retaining bolts . Install retainer (23) , install and tighten caps, install and tighten tube (19) onto clutch slave
the retaining bolts to a torque of 42 to 47 Nm. cylinder (20).
STEP 22 STEP 24 CX50 and CX60
DD97H107 1ll891B(P(PS
Apply Loctite 515 to the face of the forward/reverse Install clutch slave cylinder (17), install and tighten
idler gear cover assembly (22) and Loctite 271 to the bolts (18) to a torque of 45 to 50 Nm. Remove the
threads of the retaining bolts. Install cover assembly caps, install and tighten tube (16) onto clutch
(22), install and tighten the retaining bolts to a torque master cylinder (17).
of 42 to 47 Nm.
SM 8-10230 Issued 03-2001
SECTION 6003 29
STEP 25 STEP 27
DD97H113 DD97H108
Apply Loctite 515 to the face of the forward/reverse Install fork (9), cross shaft (8), roll pins (7) and
selector fork cover assembly (15) and Loctite 271 to clutch release bearing assembly (6).
the threads of the retaining bolts. Install cover
assembly (15), install and tighten the retaining bolts STEP 28
to a torque of 45 to 50 Nm.
NOTE: Make sure the shift pin on the selector
fork engages in the shift linkage and the
selector fork shift fingers engage in the
synchronizer.
STEP 26
DD97H109
Install the clutch slave cylinder linkage by installing
plate (5) onto cross shaft (8) and install roll pin (4).
Install retaining ring (3), spring (2) and retaining
ring (1) .
NOTE: Make sure the groove in rolf pin (4) faces
away from the grease fitting in cross shaft (8).
Install new o-rings , install the powershift supply tube NOTE: Check the adjustment of the clutch slave
with the retaining clip towards the top. Install the front cylinder linkage, refer to Section 9001 .
transmission front cover (14) and gasket, install and
tighten the retaining bolts to a torque of 42 to 47 Nm. STEP 29
Install new o-rings, install regulator valve (12), install
and tighten the bolts to a torque of 42 to 47 Nm. Raise the rear of the tractor, remove the axle stand
Remove the caps, install and tighten tubes (10) and and install the RH rear wheel, tighten the wheel
(11) onto regulator valve (12). Connect harness (13) nuts to a torque of 278 to 298 Nm.
onto the solenoid. Install the cab floor plate and mat.
STEP 30
Install the RH cab step.
8M 8-10230 Issued 03-2001
30 SECTION 6003
Cross Sectional Drawing of the Powershift and Forward/Reverse
Transmission
1. POWERSHIFT CLUTCH ASSEMBLY 4. REVERSE DRIVEN GEAR
2. FORWARD/REVERSE SYNCHRONIZER 5. MAINSHAFT
3. FORWARD DRIVEN GEAR 6 . COUNTERS HAFT
SM 8-10230 Issued 03-2001
Section
6004
CREEP TRANSMISSION SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10240 March 2001
2 SECTION 6004
TABLE OF CONTENTS
SPECiFiCATIONS .. .... .. ...... .... ..... ............... .... .......... ... ..... ............... ... ........ ............. ........... ....... .............. ... .... ....... .... 3
SPECIAL TORQUES ........ ... ....... ... .... ........... ... ... .... .......... .. ... .... ........... .... ......... ... ... ........... ... .................. ...... ....... ..... 3
SPECIAL TOOLS ....... .... ...................... ....... .. ........... ......... ... ............. ...... ............ .. ..... ....... ... ...... .......... .............. .. ..... 3
TOOLS TO BE MADE ...... ................................................ .. .. .......... .... ................. ..... ................ ... ......... .. ................... 3
CREEP TRANSMISSION ..... .. ... ......... .. ....... .. ........... .. ..... .. ... ....... ..... ...... ...... ...... ... .. ...... .. ......... ........... ... ...... ... ... ...... . 4
Disassembly and Assembly of the Creep Carrier Housing ............ .... .. .. ............ .... .......................... ........ .... .. .... ... 5
Removal and Installation of the Creep Mainshaft and Gears .............. .. ........ ...................................... ........ .. ........ 6
Cross Sectional Drawing of the Creep Carrier Housing ............ .. .............................. .. .. ........ .. ...................... .. ...... 7
Cross Sectional Drawing of the Creep Mainshaft and Gears ........................ .... .......... .. ...................... .... .. ............ 7
RANGE TRANSMISSION
Disassembly .... ....... ............ ... ....... ...................... ... ......... .. ........... ........ ............ ....................... ....... .... .............. ...... 8
HIGH/LOW RANGE SYNCHRONIZER
Disassembly and Assembly .................... ... ............................. .......................... ....................... ....... ... ... ..... .. ....... 10
CREEP SYNCHRONIZER
Disassembly and Assembly ........ ...... .................... .................... ... ...................................... ..... ............................ 11
PINION SHAFT
Inspection and Disassembly ... .. .. ..... ....... ... ..... .... .. .......... ......... .. .. ..... .... ........ .. .......... .... .......... .. ...... ........ .. ..... ..... 12
Pinion Shaft Bearing Preload , Mounting Distance and Assembly ......... .. ............................................................ 12
RANGE TRANSMISSION
Assembly ................... ........................................... .. ....... .... ....... .. ....... ... .. ........ ............ .. ......... ... ........ ... ........ ........ 15
Cross Sectional Drawing of the Creep Transmission .. .......... .. ........ ................ .. .............. ........ ............ .. .......... .... 18
8M 8-10240 Issued 03-2001
SECTION 6004 3
SPECIFICATIONS
Pinion Bearing End Play (Maximum) ................................................................ .................. ... ...................... 0.076 mm
Synchronizer Running Clearance ...................................................................................................... 0.05 to 0.30 mm
Selector Fork Running Clearance .......... ............ ..... ............. ....... .......... .. ..... .. ..................... .......... .............. ... 0.05 mm
SPECIAL TORQUES
Pinion Shaft Retaining Bolts ..................................................... ............................................................... 42 to 47 Nm
SPECIAL TOOLS
H03301
SHIFT RAIL GAUGE,MC2365
TOOLS TO BE MADE
A
A ................... .. ........... ....... ... 98 mm
c D E B .......................................... 10 mm
f
C ......... ................... ... ....... .... 10 mm
D .............................. ...... . 24.80 mm
E .................................... ... ... 17 mm
F ........ ...................... ........... 93 mm)
G .......................................... 83 mm
F
H ............... ..... .... ......... ...... .. . 53 mm
G
J ........................... ........... 16.90 mm
H
_
L
_I ,
M K .................................... (30°) 7 mm
/;1
~cqL-1~==~==~dI
7 ? 7
'\;
I I
),
.
L ......... ..... ... ... ........... .. .... . 24 .80mm
?
- -I M ............... .......... ......... ... 19.10 mm
K 1-- DI98N045
Selector Fork Installation Bullets , refer to Page 16.
SM 8-10240 Issued 03-2001
4 SECTION 6004
CREEP TRANSMISSION
Before Disassembling the Creep Transmission carry out the following:
Park the tractor on hard level ground and apply the parking brake.
Stop the engine and remove the key.
Put blocks in front of and behind the rear wheels.
Remove the Transfer Gearbox, refer to Section 6017.
Remove the Hydraulic Lift Housing, refer to Section 8010.
Separate the Range Transmission from the Speed Transmission.
Remove the Rear Axles, refer to Section 6018.
Remove the Differential, refer to Section 6012.
Remove the PTO Clutch, refer to Sections 6019 or 6020 .
NOTE: For Installation of the Creep Transmission follow the above procedure in reverse order.
STEP 1 STEP 2
DP98M210 DP98M211
Remove the retaining bolts and remove the Creep Remove the Creep Mainshaft and Gears (B), refer
Carrier Housing Assembly (A), refer to Page 5 for to Page 6.
Disassembly and Assembly. Remove and discard
the o-ring from the creep carrier housing.
NOTE: For Installation , clean the surfaces of
the range transmission and creep carrier
housing. Apply Loctite 515 to the mounting
surface of the transmission housing, install a
new o-ring into the creep carrier housing. Install
and tighten the retaining bolts.
8M 8-10240 Issued 03-2001
SECTION 6004 5
Disassembly and Assembly of the Creep Carrier Housing
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
. ,/'
I
/~~--0
c/f) \
if
\
\
DI98M180
1. CREEP CARRIER HOUSING 7. O-RING
2. ROLL PIN 8. NEEDLE ROLLER BEARING
3. SHAFT 9. SPACER
4. THRUST WASHER 10, NEEDLE ROLLER BEARING
5.GEAR (15/27 TEETH) 11 . CUP
6 .THRUST WASHER
SM 8-10240 Issued 03-2001
6 SECTION 6004
Removal and Installation of the Creep Mainshaft and Gears
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
FRONT OF
TRANSMISSION
DI98M178
NOTE: Remove shaft (3) from the range transmission housing in the direction shown.
1. RETAINING RING 11. THRUST WASHER
2. RETAINING RING 12. GEAR (20/37 TEETH)
3. SHAFT 13. THRUST WASHER
4. THRUST WASHER 14. THRUST BEARING
5. GEAR (15/45 TEETH) 15. THRUST WASHER
6. THRUST WASHER 16. NEEDLE ROLLER BEARING
7. NEEDLE ROLLER BEARING 17. NEEDLE ROLLER BEARING
8. NEEDLE ROLLER BEARING 18. SPACER
9. THRUST WASHER 19. O-RING
10. THRUST BEARING
SM 8-10240 Issued 03-2001
SECTION 6004 7
Cross Sectional Drawing of the Creep Carrier Housing
vi (I
/
I ' ,.f I ' .
D198M179
1. CREEP CARRIER HOUSING 8. NEEDLE ROLLER BEARING
5. GEAR (15/27 TEETH) 10. NEEDLE ROLLER BEARING
Cross Sectional Drawing of the Creep Mainshaft and Gears
D198M177
3. SHAFT
5. GEAR (15/45 TEETH)
12. GEAR (20/37 TEETH)
SM 8-10240 Issued 03-2001
8 SECTION 6004
RANGE TRANSMISSION
Disassembly STEP 6
STEP 3
Remove the speed sensor.
STEP 4
DP98M204
Turn selector rail (4) 90 degrees in either direction.
Remove selector rail (4) from the selector forks , in
the direction shown, and remove bushing (5).
Remove the selector forks and check the bushings
for wear or damage and replace if necessary.
~
DP98M202
Remove locknut (1) and roll pin (2). NOTE: Care must be taken when removing
selector rail (4) from the selector forks, the
detent spring and ball are under tension .
STEP 5
STEP 7
DP98M200
Remove the shim rings (3) .
DP98M209
Remove the retaining rings (6) . Slide the speed
pick-up gear (7) along the pinion shaft and remove
the locating ball. Remove the retaining ring (8) from
the creep driven gear.
SM 8-10240 Issued 03-2001
SECTION 6004 9
STEP 8 STEP 11
DP98M209 H02528
Remove retaining ring (9) from the groove and Remove retaining ring (13) from the transmission
move the MFD drive gear (10) along the pinion housing .
shaft.
STEP 12
STEP 9
DD97K062
H02520 Remove retaining ring (14) from the groove, pull the
Remove the pinion shaft bearing housing retaining countershaft (15) forward and remove retaining ring
bolts (11) and plates (12). (14). Remove the countershaft (15), low range
driving gear (16), spacer (17) and constant mesh
STEP 10 driven gear (18).
Make sure all retaining rings are removed from the
grooves and move the pinion shaft towards the rear
of the transmission. While removing the pinion
shaft, remove the high/low range synchronizer, low
range driven gear, creep synchronizer, creep driven
gear, speed pick-up gear and MFD drive gear.
NOTE: Refer to Page 10 for Disassembly and
Assembly of the Synchronizer.
8M 8-10240 Issued 03-2001
10 SECTION 6004
HIGH/LOW RANGE SYNCHRONIZER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
SMl163
NOTE: If synchronizer hub (5) or synchronizer shift collar (9) are worn or damaged the synchronizer
assembly must be replaced.
1. RING 4. SYNCHRONIZER RING 7. DETENT BALL PIN (3)
2. SYNCHRONIZER RING 5. SYNCHRONIZER HUB 8. DETENT SPRING (3)
3. RING 6. SHIFT POPPET (3) 9. SYNCHRONIZER SHIFT COLLAR
SM 8-10240 Issued 03-2001
SECTION 6004 11
CREEP SYNCHRONIZER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
DI98N036
NOTE: If synchronizer hub (3) or synchronizer shift collar (7) are worn or damaged the synchronizer
assembly must be replaced.
1. RING 5. DETENT BALL PIN
2. SYNCHRONIZER RING 6. DETENT SPRING
3. SYNCHRONIZER HUB 7. SYNCHRONIZER SHIFT COLLAR
4. SHIFT POPPET 8. RETAINING RING
SM 8-10240 Issued 03-2001
12 SECTION 6004
PINION SHAFT
Inspection and Disassembly Pinion Shaft Bearing Preload,
Mounting Distance and Assembly
STEP 13
STEP 15
A00726
Use a dial gauge to measure the pinion bearing end A00723
play. This must be less than 0.076 mm , if the Use a hydraulic press to install the bearing
measurement is greater, the bearing assembly assembly (2) onto the pinion shaft. Rotate the
must be replaced. bearing housing until a slight preload is applied .
STEP 14 STEP 16
A00711
A00709
Remove the snap ring and spacer (1). Use a Install the spacer (1) and thinnest snap ring
hydraulic press to remove bearing assembly (2) available.
from the pinion shaft.
NOTE: Snap rings (1) are available in the
following sizes : 1.68, 1. 75, 1.83, 1. 90, 1.98,
2. 06, 2.13, 2.21 , 2.28 and 2.36 mm.
SM 8-10240 Issued 03-2001
SECTION 6004 13
STEP 17 STEP 20
A
AO0711
Use a hydraulic press to apply pressure to the
bearing assembly (2) as shown until the spacer (1)
is tight against the snap ring.
B C
STEP 18
SM1145
The mounting distance (A) from the pinion bearing
mounting face to the centre line of the differential is
approximately 167.64 mm. This distance can vary for
each transmission housing, for accurate installation of
the pinion shaft a number (0) is stamped on the rear
frame, as shown . The number refers to the variation
from distance (A), where distance (A) is smaller a
minus (-) sign will be shown . Add or subtract the
stamped figure to the figure of 167.64 mm.
NOTE: The number (D) on the rear frame will be
stamped in millimeters as shown in the
AO0726 following example with or without a minus (-)
Use a dial gauge to measure the bearing end play. sign: .......... .... .............. ...... .......... 0,22 or ,22.
Use the following to calculate the correct snap ring
to be installed: A + B = C
A-Snap ring installed in STEP 16 .. ........... 1.68 mm
B-Measured bearing end play .. ...... .......... 0.31 mm
C-Snap ring to be installed ...... ...... ........... 1.98 mm
STEP 19
Remove the snap ring installed in STEP 16 and
install the snap ring calculated in STEP 18.
NOTE: A final setting of 0.076 mm end play is
acceptable on the bearing assembly.
8M 8-10240 Issued 03-2001
14 SECTION 6004
STEP 21 STEP 22
MI01B014
Stand the pinion on a flat surface and measure the
A00729
distance (C) between face of the pinion and the
The pinion cone mounting distance (8) is marked on bearing housing mounting face.
the face of the pinion and shows the distance between To calculate the amount of shims to be installed,
the face and the centre line at the differential. The add distance (C) to the pinion cone mounting
distance (8) is approximately 105.16 mm. distance (8) and subtract the result from mounting
distance calculated in STEP 20, refer to example
NOTE: The pinion shaft will be marked with the full below.
number (i.e. 105.16) or marked with one digit before
the decimal point. For pinion shafts marked with NOTE: A tolerance of +/- 0.025mm is allowed.
only one digit before the decimal point then 10 must
be placed before the number when calculating the Example:-
shim pack (i.e 5.16 = 105.16). C+8=X
A±D=Y
Y-X= ammount of shims to be installed in STEP 25.
C+8=X
Dimension C ...................................... 59 .75 mm
+ Dimension 8 .................................... 104.98 mm
= Dimension X .. .............. .. .... .... ...... .. .. 164.73 mm
A±D=Y
Dimension A .......................... .. ...... .. 167.64 mm
± Stamped Number D ...... .. .. ...... .. ......... - 0.22 mm
= Dimension Y .. ........................ .. ...... .. 167.42 mm
IMPORTANT: If stamped dimension 0 is a minus
number it must be subtracted from dimension A.
V-X = amount of shims to be installed in STEP 25.
Dimension Y ........ .. ........ .. ...... .. ...... .. 167.42 mm
- Dimension X .. .. ...... .... .... .. ............ ..... 164.73 mm
= Shims .. .. ................................ .. ...... .. .... 2.69 mm
8M 8-10240 Issued 03-2001
SECTION 6004 15
RANGE TRANSMISSION
Assembly STEP 25
STEP 23
H02630 Install the shims calculated in STEP 22 onto the
pinion bearing housing. Install the pinion shaft and
install the following items in order:
1. MFD Drive Gear
2. Retaining Ring
3. Speed Pick-up Gear
4. Thrust Washer
5. Thrust Bearing
6. Creep Driven Gear
7. Thrust Bearing
8. Creep Synchronizer
9. Low Range Driven Gear
10. High/Low Range Synchronizer
STEP 26
DD97K062
Install the constant mesh driven gear (18), spacer
(17) , low range driving gear (16) and retaining ring
(14). Install the countershaft (15), make sure the
retaining ring (14) is fully seated in the groove.
STEP 24
H02620
Apply Loctite 242 to the threads of bolts (11). Install
the pinion shaft retaining plates (12) and bolts (11),
make sure a spacer is installed with bolt (A).
Tighten the bolts (11) to a torque of 33 to 37 Nm.
Install the countershaft bearing retaining ring (13).
SM 8-10240 Issued 03-2001
16 SECTION 6004
STEP 27 STEP 31
Connect the Range Transmission to the Speed
Transmission, BEFORE carrying out the
synchronizer shimming procedure.
STEP 28
0D98N043
Apply Loctite 271 onto the pinion shaft between the
pick-up gear retaining ring grooves. Install the
locating ball and slide the speed pick-up gear (7)
along the pinion shaft, install the retaining rings (6).
DI98M176
Push items (4) to (10) , refer to STEP 25, and the STEP 32
speed transmission main shaft towards the front of
the transmission. Install the thinnest retaining ring
into the groove (A), make sure it is seated towards
the rear of the groove.
STEP 29
Measure the distance between the retaining ring
and thrust washer (4), add the thickness of the
retaining ring installed in STEP 28 to determine the
thickness of retaining ring to be installed.
STEP 30
DI98N046
Using the measurement calculated in STEP 29 Install the detent balls and springs into the selector
select the correct retaining ring from the table forks.
below to give a running clearance between 0.10 I nstall the selector fork installation bullet (A) into the
and 0.40 mm for the synchronizer assemblies. If the high range selector fork.
measurement is greater than 3.08 mm, repeat Install the selector fork installation bullet (B) into the
STEP 28 and STEP 29. creep selector fork.
MEASUREMENT RETAINING RING NOTE: Refer to Page 3, Tools to be Made, for
CALCULATED (mm) REQUIRED (mm) the dimensions of the Selector Fork Installation
1.910 to 2.100 1.76 Bullets (A) and (B).
2.101 to 2.300 1.95
2.301 to 2.500 2.15
2.501 to 2.700 2.35
2.701 to 2.900 2.55
2.901 to 3.080 2.74
8M 8-10240 Issued 03-2001
SECTION 6004 17
STEP 33 STEP 36
009aM204
Install the bushing (5). Install the selector forks and Using feeler gauges, measure the gap (A) between
installation bullets, install the selector rail (4) the bushing (5) and selector rail (4).
through the selector forks , in the direction shown, at
the same time remove the installation bullets . Install STEP 37
the roll pin (2).
It is necessary to ADD 0.05 mm to the
NOTE: DO NOT install the locknut. measurement obtained in STEP 36 to allow a
running clearance on the selector fork.
STEP 34
STEP 38
Select the correct thickness of shim rings (3) to be
installed between the bushing (5) and selector rail
(4).
NOTE: Calculate the shim rings (3) required to
the nearest 0. 1 mm.
Shim rings (3) are available in the following
sizes: 0.5,0.6, 0.7,0.8, 0.9 and 1.0 mm.
STEP 39
OI9aM 182
Install the shift rail gauge, MC2365, between the
low range driven gear and synchronizer, as shown.
STEP 35
Hold the gears and synchronizers fully forward.
Make sure the selector forks are seated in the
neutral detents.
Remove the shift rail gauge, MC2365. Install the
shim rings (3) selected in STEP 38. Install and
tighten the locknut (1) .
8M 8-1 0240 Issued 03-2001
18 SECTION 6004
STEP 40
SM1425
Apply sealant, Loctite 572, to the threads of the
ground speed sensor (A). Install the sensor (A) into
the transmission housing and turn it clockwise until
the tip lightly touches the speed pick-up gear (8),
then turn it counterclockwise one full turn and
tighten the locknut (C).
Cross Sectional Drawing of the Creep Transmission
1. PINION SHAFT 6. LOW RANGE DRIVEN GEAR
2. MFD DRIVE GEAR 7. HIGH/LOW RANGE SYNCHRONIZER
3. SPEED PICKUP GEAR 8. COUNTERS HAFT
4. CREEP DRIVEN GEAR 9 . LOW RANGE DRIVING GEAR
5. CREEP SYNCHRONIZER 10. CONSTANT MESH DRIVEN GEAR
SM 8-10240 Issued 03-2001
Section
6005
8 SPEED TRANSMISSION SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10250 March 2001
2 SECTION 6005
TABLE OF CONTENTS
SPECIAL TORQUES .... ... ... ...... .... .. .. .......... ................................... .. ....... .... .......... ... ............................................. ..... 3
SPECiFiCATIONS ........ ........ ..... .... ..... .... .......... ............... .......... ..... ... ... ........... ...... ....... ...... ... .... .. ... ... ...... ......... .. ... .. .. 3
SPECIAL TOOLS ......... ...... ............ ......................................... .. ... ......................... ............... .... ..... .. ... .... ................... 3
8 SPEED TRANSMISSION
Removal ................................... ... ............................................ .......... ..... ............. ... ............ ......... ....... ......... .......... 4
FORWARD/REVERSE SELECTOR FORK COVER
Disassembly and Assembly ................................................................................................................................ 11
FORWARD/REVERSE IDLER GEAR COVER
Disassembly and Assembly .... ..... ....... .... ....... ..... .. ............. ..... ....... ......................................... ;...... .. ......... ..... ..... 12
FORWARD/REVERSE SYNCHRONIZER
Disassembly and Assembly .... ........ .... ................................................ .......... ....... .. ..................... ... .. ... .... ...... .. .... 13
8 SPEED TRANSMISSION
Installation .................................................. ........ .. .. ... .. ... .. .... .. ........ .. ........... .... ...... ........ .. .......... ..... .. ................... 14
Cross Sectional Drawing of the 8 Speed Transmission ........ .... ................. ............ ...... ...... ........... .. ............. .... ... 21
SM 8-10250 ~ssued 03-2001
SECTION 6005 3
SPECIAL TORQUES
Speed Transmission to Range Transmission Retaining Bolts
1/2 inch diameter (with Loctite 271) ........................ .. .............. ... .................. .. ...... ..... ... .. .... ............. 101 to 104 Nm
5/8 inch diameter (with Loctite 271) ................................................................................................ 205 to 230 Nm
Main Shaft Retaining Bolts .......... .... ........ ......... .............. ........................... .................... .... ...................... 42 to 47 Nm
Selector Fork to Selector Rail Lock Bolt ........................ .. ............ .... ............................ ............ .. ............ 89 to 100 Nm
Selector Fork to Selector Rail Lock Nut.. ...... ...... .... .......... ...................................... ...... ........................... 53 to 59 Nm
PTO Bearing Retainer Bolts (with Loctite 271) .... ............ ...................................... .. ...... ...... .... .. .............. 42 to 47 Nm
Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) ......................................................... 42 to 47 Nm
SPECIFICATIONS
Input Shaft Spline Lubricant .............................. ............ .. .................. ........ ........ ..... MOLYKOTE D321 R or equivalent
SPECIAL TOOLS
DD97K036 DD97K035
ALIGNMENT STUDS MC1995·7 REMOVER AND INSTALLER FOR PTO DRIVEN SHAFT MC2559
(part of Kit MC1995B)
SM 8-10250 Issued 03-2001
4 SECTION 6005
8 SPEED TRANSMISSION
Before servicing the 8 Speed Transmission it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Put wooden blocks between the front axle bolster and front axle.
• Remove the front tractor weights, if equipped.
• Separate the Tractor between the Engine and Speed Transmission, refer to Section 6001.
NOTE: Before connecting the Engine to the Speed Transmission, lubricate the input shaft splines with
MOLYKOTE D321 R or equivalent.
• Remove the MFD Transfer Gearbox, if equipped, refer to Section 6011.
• Remove the PTO Clutch, refer to Section 6013. Refer to Section 6014 for Tractors equipped with Shiftable PTO.
NOTE: It is not necessary to remove the Speed Transmission to service the Input shaft Assembly or
Forward/Reverse Synchronizer Assembly.
Removal STEP 4
STEP 1
Disconnect the clutch slave cylinder linkage by
DD97J091 removing retaining ring (1), washer (2) and spring
Remove the RH cab step. (3). Remove roll pin (4) and plate (5) from the cross
shaft.
STEP 2
STEP 5
Raise the rear of the tractor, support the RH rear
axle on a suitable axle stand and remove the RH
rear wheel.
STEP 3
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect the battery,
positive (+) terminal first.
Remove the clutch release bearing assembly (6).
Remove roll pins (7), cross shaft (8) and fork (9) .
8M 8-10250 Issued 03-2001
SECTION 6005 5
STEP 6 STEP 8 ex 50 and eX60
MR01B013
Remove the cab floor mat and panel. Disconnect Disconnect and cap tube (15) from the clutch slave
and cap tubes (10) and (11) from regulator valve cylinder (16). Remove bolts (17) and clutch slave
(12). Remove the bolts and regulator valve (12). cylinder (16).
Remove the bolts and front transmission cover (13),
remove and discard the gasket. STEP 9 eX70/75, eX80/85, eX90/95 and eX100/105
STEP 7
MR01B012
Disconnect and cap tube (18) from the clutch slave
DD97H113
cylinder (19). Remove bolts (20) and clutch slave
Remove the bolts and forward/reverse selector fork cylinder (19) .
cover (14) from the bottom of the transmission
housing, refer to Page 11 for Disassembly and STEP 10
Assembly.
0097H107
Remove the bolts and forward/reverse idler gear
cover assembly (21), refer to Page 12 for
Disassembly and Assembly.
8M 8-10250 Issued 03-2001
6 SECTION 6005
STEP 11 STEP 14
DD97H114
Remove the retaining bolts and PTO bearing Pull the PTO driven shaft rearward and remove the
retainer (22). PTO driven gear (25) and spacer (26) through the
opening in the bottom of the transmission housing.
STEP 12
STEP 15
DD97H118
Remove external retaining ring (23).
Remove retaining ring (27) and thrust washer (28)
STEP 13 from the countershaft.
STEP 16
Use the removal tool, (24), MC2559, to remove the
PTO driven shaft from the bearing. Remove DD97H11 9
bearing. Remove thrust bearing (29) from the countershaft.
8M 8-10250 Issued 03-2001
SECTION 6005 7
STEP 17 STEP 18
DD97H115 DD97Hl16
DI97H091
Remove PTO drive shaft (33). Remove and discard oil
seal (34) from PTO drive shaft (33). If it is necessary
to replace bearing (36), remove snap ring (35) and
use a hydraulic press to remove bearing (36) from the
DI97H092 PTO drive shaft (33).
Remove clutch release bearing carrier (30). Remove
and discard o-ring (31) and oil seal (32).
Remove two of the bolts (37) and install two alignment
studs (A), MC1995B, as shown. Remove the
remaining bolts (37). Install two of the bolts (37), into
the threaded holes (8), these bolts are used as
jacking bolts to move the front bearing housing (38)
forward. The front bearing housing (38) must be
moved approximately 15 mm forward to provide
clearance for removal of the forward/reverse
synchronizer and gear assembly.
8M 8-10250 Issued 03-2001
8 SECTION 6005
STEP 20 STEP 22
DD97H120
Remove reverse driven gear (39), synchronizer Remove rear thrust bearing (43) and thrust washer
assembly (40) and forward driven gear (41) through (44).
the bottom of the transmission housing, refer to
Page 13 for Synchronizer Disassembly and STEP 23
Assembly.
NOTE: Care must be taken when removing the
synchronizer assembly (40), not to lose the
springs and poppets.
STEP 21
DD99C082
Remove retaining ring (45), remove and check lube
ring (46) for wear or damage.
STEP 24
DD97H170
Remove and discard sealing ring (42) from the
forward driven gear (41).
Remove the input shaft assembly (38).
SM 8-10250 Issued 03-2001
SECTION 6005 9
STEP 25 STEP 28
DD99C119
Remove retaining ring (47) . and drive gear (48). Check for wear or damage to the needle roller
bearings (54) in the drive gear assembly.
STEP 26
NOTE: Refer to STEP 29 to STEP 32 if the drive
gear or needle roller bearings are to be
replaced .
STEP 29
Remove the Mainshaft, Gears and Synchronizers,
refer to Section 6006 .
STEP 30
Remove retaining ring (49). Remove shaft and
bearing from housing (50) check for wear or
damage and replace if necessary.
STEP 27
DD97F062
Remove drive gear assembly (55).
DD99C 1221
Remove retaining ring (51) . Use a hydraulic press
to remove bearing (52) from the shaft and remove
thrust washer (53).
8M 8-10250 Issued 03-2001
10 SECTION 6005
STEP 31 STEP 32
~
\
H02331 H02329
Remove rear roller bearing (56) from the drive gear Remove needle roller bearings (54) from the drive
assembly (55), check for wear or damage and gear assembly (55) and replace if worn or
replace if necessary. damaged .
8M 8-10250 Issued 03-2001
SECTION 6005 11
FORWARD/REVERSE SELECTOR FORK COVER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
01971-1089
1. SELECTOR FORK SHIFT FINGER 4. SELECTOR FORK
2. RETAINING RING 5 . SELECTOR FORK COVER
3 . PIN
NOTE: Remove pins (3) in the directions shown.
SM 8-10250 Issued 03-2001
12 SECTION 6005
FORWARD/REVERSE IDLER GEAR COVER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly
0197H090
1. ROLL PIN 5. ROLLER BEARING
2. PIN 6. SPACER
3. GEAR CLUSTER 7. IDLER GEAR COVER
4. WASHER
NOTE: Drive roll pin (1) into pin (2) until pin (2) can be removed.
SM 8-10250 Issued 03-2001
SECTION 6005 13
FORWARD/REVERSE SYNCHRONIZER
Disassembly and Assembly
DD97K175
1. REVERSE DRIVEN GEAR 7. SPRING
2. CLUTCH BODY RING 8. SYNCHRONIZER HUB
3 . SYNCHRONIZER RING 9. SYNCHRONIZER RING
4. COLLAR 10 . CLUTCH BODY RING
5. POPPET 11. FORWARD DRIVEN GEAR
6. PIN
SM 8-10250 Issued 03-2001
14 SECTION 6005
8 SPEED TRANSMISSION
Installation STEP 4
STEP 1
SM11 33 DD99C1221
Install two needle roller bearings (54) into the Install thrust washer (53). Use a hydraulic press to
powershift drive gear assembly (55) to the Install bearing (52) onto shaft and Install retaining
dimensions shown. ring (51) .
STEP 5
DD97F062
Install the drive gear assembly (55). Install the rear Install shaft and bearing into the housing (50) and
roller bearing (56). Install retaining ring (49).
STEP 3
Install the Mainshaft, Gears and Synchronizers,
refer to Section 6006 .
8M 8-10250 Issued 03-2001
SECTION 6005 15
STEP 6 STEP 8
DD99C1201 DD97H122
Install drive gear (48) and retaining ring (47). Install lube ring (46) and retaining ring (45).
STEP 7 STEP 9
DD97J006
Install two 3/8 UNC alignment studs (A) into the Install the thinnest (2.25 mm) thrust washer (45)
speed transmission housing. Apply Loctite 515 onto and thrust bearing (44) onto the countershaft.
the speed transmission housing, carefully push
Input shaft assembly (38) along alignment studs (A) STEP 10
until the housing is approximately 15 mm from the
speed transmission.
IMPORTANT: The above procedure must be
carried out to allow the forward driven gear,
forward/reverse synchronizer and reverse
driven gear to be installed onto the
countershaft.
DD97H137
Lubricate sealing ring (42) with petroleum jelly and
install by hand onto the forward driven gear (41) .
8M 8-10250 Issued 03-2001
16 SECTION 6005
STEP 11 STEP 14
DD97K040
Use a new lube ring (46) to compress sealing ring
(42).
STEP 12 DI97J1 B8
Push reverse driven gear (39), forward/reverse
synchronizer (40) and forward driven gear (41)
towards the rear of the countershaft, measure the
clearance between retaining ring (26) and thrust
washer (27), this must be between 0.03 and 0.60
mm. Replace thrust washer (27) to obtain the
correct clearance.
STEP 15
DD97H120
Install forward driven gear (41), forwardlreverse
synchronizer (40) and reverse driven gear (39).
STEP 13
Fully install the Input shaft assembly (38) and
remove alignment studs. Apply Loctite 271 to the
threads of retaining bolts (37) , install and tighten the
bolts to a torque of 47 to 53 Nm.
DD97H11B
Install thrust bearing (29), thinnest (2.25 mm) thrust
washer (28) and retaining ring (27) .
SM 8-10250 Issued 03-2001
SECTION 6005 17
STEP 16 STEP 18
,----,.,~.~ @ ,
DI97H091
Install oil seal (34) into PTa drive shaft (33). Make
sure the lip of oil seal (34) is towards the
transmission side of the shaft and against the
shoulder, as shown . If it is necessary to replace DI97H092
bearing (36), use a hydraulic press and install Install oil seal (32) into the clutch release bearing
bearing (36) onto PTa drive shaft (33), install carrier (30) . Make sure the lip of oil seal (32) is
snap ring (35) . towards the transmission side of the carrier and
against the shoulder, as shown. Install a new o-ring
STEP 17 (31) onto clutch release bearing carrier (30).
STEP 19
DD97H116
Install PTa drive shaft (33).
Install clutch release bearing carrier (30). Apply
Loctite 271 to the threads of the bolts, install and
tighten the bolts to a torque of 45 to 50 Nm.
8M 8-10250 Issued 03-2001
18 SECTION 6005
STEP 22
DD97H114
Install PTO driven gear (25) and spacer (26). Install Install external retaining ring (23).
the PTO driven shaft.
STEP 23
NOTE: Make sure spacer (26) is between gear
(25) and bearing.
STEP 21
Apply Loctite 515 to the face of the PTO bearing
retainer (22) and Loctite 271 to the threads of the
retaining bolts. Install retainer (22), install and tighten
the retaining bolts to a torque of 42 to 47 Nm.
Use installation tool (24), MC2559 , to install the
bearing onto the PTO driven shaft.
NOTE: Lock the PTO driven shaft in the rear of
the transmission to prevent moving rearwards.
8M 8-10250 Issued 03-2001
SECTION 6005 19
STEP 24 STEP 26cX50 and CX60
DD97H107 iIlBIlIsmms
Apply Loctite 515 to the face of the forward/reverse Install clutch master cylinder (16), install and tighten
idler gear cover assembly (21) and Loctite 271 to the bolts (17) to a torque of 45 to 50 Nm. Remove the
threads of the retaining bolts. Install cover assembly caps, install and tighten tube (15) onto clutch
(21), install and tighten the retaining bolts to a torque master cylinder (16).
of 42 to 47 Nm.
STEP 27
STEP 25CX70175, CX80/85, CX90/95 and CX100/105
MR01B012
Apply Loctite 515 to the face of the forward/reverse
Install clutch slave cylinder (19), install and tighten selector fork cover assembly (14) and Loctite 271 to
bolts (20) to a torque of 42 to 47 Nm. Remove the the threads of the retaining bolts. Install cover
caps, install and tighten tube (18) onto clutch slave assembly (14), install and tighten the retaining bolts
cylinder (19). to a torque of 45 to 50 Nm.
NOTE: Make sure the shift pin on the selector
fork engages in the shift linkage and the
selector fork shift fingers engage in the
synchronizer.
SM 8-10250 Issued 03-2001
20 SECTION 6005
STEP 28 STEP 30
DD91l8me9
Install the front transmission front cover (13) and Install the clutch slave cylinder linkage by installing
gasket, install and tighten the retaining bolts to a plate (5) onto cross shaft (8) and install roll pin (4).
torque of 42 to 47 Nm. Install new o-rings, install Install retaining ring (3), spring (2) and retaining
regulator valve (12), install and tighten the bolts to a ring (1).
torque of 42 to 47 Nm. Remove the caps, install and
tighten tubes (10) and (11) onto regulator valve (12). NOTE: Make sure the groove in roll pin (4) faces
Install the cab floor plate and mat. away from the grease fitting in cross shaft (8).
STEP 29 NOTE: Check the adjustment of the clutch slave
cylinder linkage, refer to Section 9001.
STEP 31
Raise the rear of the tractor, remove the axle stand
and install the RH rear wheel, tighten the wheel
nuts to a torque of 278 to 298 Nm.
STEP 32
Install the RH cab step.
DD97H10e
Install fork (9), cross shaft (8), roll pins (7) and
clutch release bearing assembly (6).
SM 8-10250 Issued 03-2001
SECTION 6005 21
Cross Sectional Drawing of the 8 Speed Transmission
1.FORWARD DRIVE GEAR 4.FORWARD/REVERSE SYNCHRONIZER
2.MAINSHAFT 5. REVERSE DRIVEN
3.FORWARD DRIVEN
SM 8-10250 Issued 03-2001
Section
6006
SYNCHRONIZER SPEED
TRANSMISSION SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK 8M 8-10260 March 2001
2 SECTION 6006
TABLE OF CONTENTS
SPECIFICATIONS ..................... ........ ........ ..... ...... ............... ....... ...................... ....... ................................................. 3
SPECIAL TORQUES ........ ......... ..... .. ..... ... .... .. ..... .. ......................................................... .. .................................... .. .. 3
SPECIAL TOOLS ..... .......... ....... ..... ....... ....... .. ..............,........................................... ............................. .. .... ......... .... 3
SPEED TRANSMISSION
SELECTOR FORKS AND RAILS
Removal ....... ... ..... ....... ... .... ........ .... ..... ..... ........ ... ... .... ..... ....... ............. ... ..... ........ ................. .... .. ...... .. ...... ....... ..... 4
Installation ........ ............ .......... .. ................ ..... ..... .. ...... .... .... ..... ........ .... ........... .. ...... ....... ...... ... .... ... .... ...... ......... .... 6
MAIN SHAFT
Removal .. ...... .............. .. ...................... ..... .. ....... .. .... ... ............ ... .. ..... .. .. .. ........... .. .............. .. ....... ................... .... ... 8
Installation ...... ....... ....... ... ............ .............. .. .... ......... .. ..... .. ..... ....... ........ .. ...... ....... ....... ....... ... ... .. ....... .. .. ... ........ .. 12
Cross Sectional Drawing of the Main Shaft .. .. ........ ...... ...................... .. .......... ........ ...... ........ .. .... ..... .. ....... .......... 20
COUNTERSHAFT
Removal ........ .. ...... .. ..... .. ...................... .... ........ ....... .... .... .. ..... ............... .. ... .. ..... .... .. ...... ..... ...... ,..... ... ....... ..... ... .. 21
Installation .... ... ........... ..... .... ............. .... .... ... ............. .. ....................... .......................... ............... .. ..... ....... ... .... ... 22
Cross Sectional Drawing of the Countershaft .. .. ....... .............. .. .... .... .. .... .. ............... .. ... .. ...... ........... .. .......... ...... 23
8M 8-10260 Issued 03-2001
SECTION 6006 3
SPECIFICATIONS
Speed Transmission Synchronizer End Play ... .................. ......... .................. ..................................... 0.05 to 0.30 mm
SPECIAL TORQUES
Speed Transmission to Range Transmission Retaining Bolts
1/2 inch diameter (with Loctite 271) .................................... ............................................................ 101 to 104 Nm
5/8 inch diameter (with Loctite 271) ........... ... ... .. ................. ..... ... .. ......... .... ... .............. ...... .............. 205 to 230 Nm
Main Shaft Retaining Bolts .. ............... ..... ..... ............ ....... ............. .... .... .. ...................... ...... .. .. ...... ... .... .... 42 to 47 Nm
Selector Fork to Selector Rail Lock Bolt ... .... .... ..... .. .. ... ....... ... ................. ..... ............ ..... .......... ..... ... ... ... 89 to 100 Nm
Selector Fork to Selector Rail Lock Nut.. ... ................................. ..... ............... ................ ........ ................. 53 to 59 Nm
PTO Bearing Retainer Bolts (with Loctite 271) .... ................. ...... .. ............ .. ...... ... ............. ......... ............. . 42 to 47 N m
Clutch Release Bearing Carrier Retaining Bolts (with Loctite 271) ......................... ......... ......... ...... .. ..... . 45 to 50 Nm
SPECIAL TOOLS
DD97F1 07 DD97K034
MAINSHAFT SEALING RING EXPANDER/PROTECTOR (A) SEALING RING EXPANDER/PROTECTOR MC2557
MC2366 (8) SEALING RING COMPRESSOR MC2556
DP97F108 DD97K035
MAINSHAFT SEALING RING COMPRESSOR REMOVER AND INSTALLER FOR PTO DRIVEN SHAFT MC2559
MC2367
8M 8-10260 Issued 03-2001
4 SECTION 6006
SPECIAL TOOLS (continued)
DD97K0 37 DD97K038
INSTALLER FOR REAR LUBE RETAINING RING HANDLE MC2555 (FOR USE WITH MC2558)
AND NEEDLE ROLLER BEARING MC2558
SPEED TRANSMISSION
Before servicing the Speed Transmission it will be necessary to carry out the following :
Park the tractor on hard level ground and apply the parking brake.
Lower the rear three point hitch.
Stop the engine and remove the key.
Put blocks in front of and behind the front wheels.
Put wooden blocks between the front axle bolster and front axle.
Remove the front tractor weights, if equipped.
Remove the Speed Transmission.
SELECTOR FORKS AND RAILS
Removal STEP 2
STEP 1
DD97FOSO
Remove the plug (3), spring (4) and 1st/2nd
detent pin and ball (5) from the RH side of the
Remove the neutral start switches (1). Remove the transmission housing.
selector cover (2).
STEP 3
Repeat STEP 2 and remove the 3rd/4th detent pin
from the LH side of the transmission housing .
8M 8-10260 Issued 03-2001
SECTION 6006 5
STEP 4 STEP 6
DD97F049 DD97F251
Loosen the locknut (6) and bolt (7) in the 3rd/4th Remove the selector forks (8) and (13).
selector fork (8) and remove the selector rail (9), use
a magnet to remove the rail interlock pin (10). STEP 7
STEP 5 Check the bushings (16) for wear or damage. If the
bushings require replacing, remove the clip (15)
and remove the bushing (16) .
~
DD97F235 ;\6@.. ...
Loosen the locknut (11) and bolt ( 12) in the 1stl2nd
selectorfork (13) and remove the selectorrail ( t 4). ~
l \ .:l>
'"
if~~O E) ... 8
~ /r-" -~-
, 3
"
~
D197Gl38
3. PLUG 8. 3RD/4TH SELECTOR FORK 13. 1ST/2ND SELECTOR FORK
4. SPRING 9. 3RD/4TH SELECTOR RAIL 14. 1ST/2ND SELECTOR RAIL
5. DETENT PIN AND BALL 10. INTERLOCK PIN 15. RETAINING CLIP
6. LOCK NUT 11 . LOCK NUT 16. BUSHING
7. BOLT 12. BOLT
SM 8-10260 Issued 03-2001
6 SECTION 6006
Installation STEP 11
STEP 8
If the bushings (16) are to be replaced . Install the
new bushings (16) and clips (15).
STEP 9
Install the 1stl2nd detent pin and ball (5) and spring
(4) . Install and tighten the plug (3) .
STEP 12
Repeat STEP 11 and install the 3rd/4th detent pin.
Put the selector forks (8) and (13) onto the STEP 13
synchronizer assemblies . Install the 1st/2nd
selector rail (14) through the selector forks and into
the front bushing. Looking through the neutral start
switch location make sure the selector rail is in the
neutral position. Install the rail interlock pin (10) .
NOTE: Make sure the flat machined in the rail
(14) is facing outwards.
STEP 10
DD97F049
Put the 1st/2nd synchronizer assembly in the
neutral position. Push the selector fork (8) forward
to remove the free play in the synchronizer
assembly (in the neutral position) and put a mark
(A) on the selector rail. Push the selector fork
rearward to remove the free play in the
synchronizer assembly and put a mark on the
selector rail (8). Position the selector fork (8)
between the two marks (A) and (8) and tighten the
lock bolt (12) onto the selector rail.
Install the 3rd/4th selector rail (9) through the
selector forks and into the front bushing. Looking
through the neutral switch location make sure the
selector rail is in the neutral position.
NOTE: Make sure the flat machined in the rail
(9) is facing outwards.
SM 8-10260 Issued 03-2001
SECTION 6006 7
STEP 14 STEP 16
Check the operation of the synchronizer by
selecting 1st and 2nd gear, the same free play must
be obtained in each position. Tighten the lock bolt
(12) to a torque of 89 to 100 Nm and the lock nut
(11) to a torque of 53 to 59 Nm.
STEP 15
Repeat STEP 13 and STEP 14 for adjustment of the
3rd/4th selector fork .
0097H124
Apply a coat of Loctite 515 to the top of the
transmission housing and install the selector cover
(2). Apply Loctite 271 to the bolts, install and tighten
the bolts to a torque of 50 Nm. Install and tighten
the neutral start switches (1).
0197G138
3. PLUG 8. 3RD/4TH SELECTOR FORK 13 . 1ST/2ND SELECTOR FORK
4. SPRING 9. SELECTOR RAIL 14. SELECTOR RAIL
5. DETENT PIN AND BALL 10. INTERLOCK PIN 15. RETAINING CLIP
6. LOCK NUT 11 . LOCK NUT 16. BUSHING
7. BOLT 12. BOLT
SM 8-10260 Issued 03-2001
8 SECTION 6006
MAIN SHAFT
Removal STEP 4
STEP 1
Remove the Selector Forks and Selector Rails,
refer to Page 4.
STEP 2
0097F095
Carefully slide the main shaft rearwards, remove
the thrust washers (4) and (6), needle thrust
bearings (5) and (7) from between the synchronizer
assemblies. Remove the 2nd speed driven gear (8)
and synchronizer assembly (9) and 1st speed
driven gear (10).
0097F052
Remove the two retaining rings (1) and (2) between STEP 5
2nd and 4th gears on main shaft.
STEP 3
0097K093
Remove the rear retaining ring (A) from the 4th
speed drive gear on the countershaft and slide the
0097F051 gear fully rearwards towards the 2nd speed drive
Remove the four bearing carrier bolts (3) gear.
8M 8-10260 Issued 03-2001
SECTION 6006 9
D197H093
1. RETAINING RING 6 . THRUST WASHER
2. RETAINING RING 7 . THRUST BEARING
3. BOLT 8 . 2ND DRIVEN GEAR
4. THRUST WASHER 9 . SYNCHRONIZER ASSEMBLY
5. THRUST BEARING 10 . 1ST DRIVEN GEAR
SM 8-10260 Issued 03-2001
10 SECTION 6006
STEP 6 STEP 9
DD97F281
Remove the 4th driven gear (11) and synchronizer Remove and discard the sealing rings (19).
assembly (12) from the direct drive gear (13). Remove the snap ring (20).
NOTE: Refer to Section 6003 for removal of the STEP 10
direct drive gear (13).
STEP 7
0D97F274
DD97F252
Remove the thrust washer (14) and thrust bearing
(15) from the main shaft. Remove and discard the
o-ring (16) from the bearing housing (17).
STEP 8
DD97F272
Remove the washer (A) and outer race (8) of the
bearing assembly (21). Remove the internal snap
ring (18). Use a hydraulic press and remove the
bearing inner race (C) from the main shaft (22) .
DD97F253
Remove the internal retaining ring (18). remove the
main shaft and bearing from the housing (17).
8M 8-10260 Issued 03-2001
SECTION 6006 11
STEP 11
0197G206
Remove the o-ring (25) from the transmission
housing.
0 197H093
11 . 4TH DRIVEN GEAR 18. SNAP RING
12. SYNCHRONIZER ASSEMBLY 19. SEALING RINGS
14. THRUST WASHER 20. SNAP RING
15. TH RUST BEARING 21. BEARING ASSEMBLY
16. O-RING 22 . MAIN SHAFT
17. BEARING HOUSING
SM 8-10260 Issued 03-2001
12 SECTION 6006
Installation STEP 14
STEP 12
If a new main shaft is to be installed make sure the
lubrication plug (23) and roll pins (24) are installed
in the main shaft.
STEP 13
DD97F277
Install the snap ring (20), make sure the snap ring
locates correctly into the groove in the main shaft
(22). Install the sealing ring expander/protector,
MC2366 , onto the main shaft . Lubricate a new
sealing ring (19) with petroleum jelly, slide the
sealing ring into the bottom groove.
DD97F272 STEP 15
DD97F279
DD97F274
Install the bearing assembly (21), inner race (C) Remove the sealing ring expander/protector,
onto the main shaft (22) , make sure the bearing MC2366 , and install the spacer. Install the sealing
inner race (C) is fully seated against the shoulder ring expander/protector and repeat STEP 14 to
on the main shaft. Install internal snap ring (18) , install the second sealing ring (19).
bearing outer race (8) and washer (A).
SM 8-10260 Issued 03-2001
SECTION 6006 13
0197H093
18 . SNAP RING 22 . MAIN SHAFT
19. SEALING RINGS 23 . PLUG
20. SNAP RING 24 . ROLL PINS
21 . BEARING ASSEMBLY
SM 8-10260 Issued 03-2001
14 SECTION 6006
STEP 16 STEP 17
DD97F280 DD97F253
Lubricate the sealing rings (19) with petroleum jelly,
carefully install the main shaft and bearing
assembly into the bearing housing (17) . Install the
retaining ring (18) , make sure the retaining ring (18)
locates correctly into the groove in the bearing
housing.
NOTE: Care must be taken not to damage the
sealing rings.
NOTE: Before installing the main shaft into the
transmission it is possible to determine the
retaining ring required to retain the 1st/2nd
DD97F282 driven gear and synchronizer assembly onto the
Compress the sealing rings by hand and carefully main shaft, use the following procedure.
install the sealing ring compressor, MC2367. Leave
the compressor in position for 5 minutes. Remove STEP 18
the compressor and check the sealing rings (19) for
damage. Replace the sealing rings if damaged.
DD97F259
Put the main shaft (22) in an upright position as
shown and install the needle thrust bearing (15) ,
thrust washer (14) and 1st driven gear (10),
synchronizer assembly (9) and 2nd driven gear (8).
8M 8-10260 Issued 03-2001
SECTION 6006 15
DI97G139
8. 2ND DRIVEN GEAR 17. BEARING HOUSING
9. SYNCHRONIZER ASSEMBLY 18. SNAP RING
10. 1ST DRIVEN GEAR 19. SEALING RINGS
14. THRUST WASHER 22. MAIN SHAFT
15. THRUST BEARING
SM 8-10260 Issued 03-2001
16 SECTION 6006
STEP 19 STEP 22
DD97F262 DD97F053
Install the needle thrust bearing (7) and thrust Lubricate and install new o-ring (16) onto the
washer (6). Select and install the thinnest retaining bearing housing (17).
ring (2), lift the 1st/2nd driven gear and
synchronizer assembly, to seat the retaining ring STEP 23
(2) at the top of the groove, lower the assembly
and measure the gap between the retaining ring (2)
and thrust washer (6).
STEP 20
Remove the retaining ring (2). Select and install the
retaining ring (2) required to obtain a distance of
0.05 to 0.30 mm between retaining ring (2) and
thrust washer (6).
STEP 21
Install the 4th driven gear (11) and synchronizer
assembly (12) onto the direct drive gear (13) and
hold in position .
STEP 24
DD97F259
Remove retaining ring (2), thrust washer (6), needle
thrust bearing (7), 2nd driven gear (8),
synchronizer assembly (9) and 1st driven gear
(10) from the main shaft (22).
Keep all parts together for assembly onto the
main shaft.
DD97K093
NOTE: It is not necessary to remove the needle
Push the 4th speed drive gear on the countershaft
thrust washer (14) and thrust bearing (15) forward and install the retaining ring (A), make sure
installed first onto the main shaft.
the retaining ring locates correctly into the groove in
the counters haft.
SM 8-10260 Issued 03-2001
SECTION 6006 ______ 17
STEP 25
[2]
Lubricate and Install
transm;ss . ""G~
Ion housing. a new o-ring (25) into the
0I97H093
2. RETAINING RING 12 . SYN CHRONIZER
14. THRUST ASSEMBLY
6. THRUST WASHE
15 TH WASHER
7. THRUST BEARING
8 R
16 ' 0 RUST BEARING
. 2ND DRIVEN . -RING
9. SYNCHR GEAR 17. BEAR
ONIZER
10. 1ST DRIVEN ASSEMBLY 22 . MAIN ING HOUSING
SHAFT
11 4 GEAR
. TH DRIVE N GEAR
SM 8-10260 Issued 03-2001
18 SECTION 6006
STEP 26 STEP 28
Install the retaining ring (2) determined in STEP 20
and check that the gap is still 0.05 to 0.30 mm
before measuring for the retaining ring (1) for the
4th driven gear and synchronizer assembly.
STEP 29
Select and install the thinnest retaining ring (1)
against the thrust washer (4) .
STEP 30
DD97F052
Partially install the main shaft. Install in the
following order, 1st driven gear (10), synchronizer
assembly (9), 2nd driven gear (8), needle thrust
bearing (7), thrust washer (6), thrust washer (4),
needle thrust bearing (5) , onto the main shaft.
IMPORTANT: Make sure thrust bearing (7) is
between the 2nd driven gear (8) and the thrust
washer (6) and thrust bearing (5) is between the
4th driven gear (11) and the thrust washer (4).
STEP 27
Make sure the 4th driven gear is pushed fully
against the synchronizer assembly. Use a lever to
push the synchronizer assembly and 4th driven
gear rearwards to make sure the retaining ring is
correctly seated in the rear of the groove on the
main shaft.
DD97F051
Fully install the main shaft into the 4th driven gear
and synchronizer assembly, install and tighten the
four bearing carrier bolts (3) to a torque of 42 to 47
Nm.
NOTE: It may be necessary to use the bearing
carrier bolts (3) to fully install the main shaft
into the transmission housing. Care must be
taken to apply even pressure to avoid damage
to the o-rings.
8M 8-10260 Issued 03-2001
SECTION 6006 19
STEP 31 STEP 32
Install the Selector Forks and Selector Rails, refer
to Page 6.
DI97F258
Push the main shaft forward, to eliminate free play
in the main shaft bearing, measure the gap
between the retaining ring (1) and thrust washer (4),
Select and install the retaining ring to obtain a
distance of 0.05 to 0.30 mm between the retaining
ring (1) and thrust washer (4). Remove the retaining
ring (1) installed in STEP 29 and install the correct
retaining ring (1) . Check thatthe gap is still between
0.05 and 0.30 mm.
8M 8-10260 Issued 03-2001
20 SECT/ON 6006
Cross Sectional Drawing of the Main Shaft
Ol97G135
1. RETAINING RING 7. THRUST BEARING 12. SYNCHRONIZER ASSEMBLY
2. RETAINING RING 8. 2ND DRIVEN GEAR 14. THRUST BEARING
3. THRUST WASHER 9. SYNCHRONIZER ASSEMBLY 15. THRUST WASHER
4 . THRUST BEARING 10. 1ST DRIVENGEAR 17. BEARING HOUSING
6. THRUST WASHER 11. 4TH DRIVEN GEAR 21 . BEARING ASSEMBLY
22 . MAIN SHAFT
SM 8-10260 Issued 03-2001
SECTION 6006 21
COUNTERS HAFT
Removal STEP 6
STEP 1
Remove the Mainshaft, Gears and Synchronizers,
refer to Page 8.
STEP 2
Remove the Reverse Driven Gear, Synchronizer
Assembly and Forward Driven Gear, refer to
Section 6003.
STEP 3
DD97K042
Remove and discard the sealing ring from the
countershaft.
STEP 7
Remove the inner snap ring (1) from the groove in
the transmission housing.
STEP 4
, Remove the rear lube retaining ring (2) and needle
bearing (3) from the transmission housing.
DD97K041
Remove the retaining rings from both sides of the
drive gears on the countershaft.
STEP 5
Pull the countershaft rearwards and remove the
constant mesh gear, 4th drive gear, 2nd drive gear
and 1st drive gear.
8M 8-10260 Issued 03-2001
22 SECTION 6006
Installation STEP 10
STEP 8
DD97K044
Compress the sealing rings by hand and carefully
DD97K048 install the sealing ring compressor, MC2556 . Leave
the compressor in position for 5 minutes. Remove
the compressor and check the sealing rings for
damage.
STEP 11
Use the installer (A) , MC2558, and handle (8),
MC2555, to install the rear lube retaining ring. Turn
the installer (A), MC2558, and install the needle
DD97K045
bearing.
Wrap tape around the sealing ring installed in STEP
STEP 9 9. Install the countershaft through the 1st drive
gear, 2nd drive gear, 4th drive gear and constant
drive gear.
STEP 12
Remove the tape and lubricate the sealing ring with
petroleum jelly, fully install the countershaft into the
bearing.
DD97K043
Install the sealing ring expander/protector,
MC2557, onto the countershaft. Lubricate a new
sealing ring with petroleum jelly, slide the sealing
ring into the sealing ring groove.
8M 8-10260 Issued 03-2001
SECTION 6006 23
STEP 13 STEP 14
dd97k041
Install the inner snap ring (1) into the groove in the Install the retaining rings to both sides of the drive
transmission housing. gears on the countershaft.
STEP 15
Install the Forward/Reverse Driven Gear and
Synchronizer Assembly, refer to Section 6003.
Install the Mainshaft, Gears and Synchronizers,
refer to Page 12.
Cross Sectional Drawing of the Countershaft
DD97K093
1. COUNTERSHAFT 5. 1ST SPEED DRIVE GEAR
2. FORWARD DRIVEN GEAR 6. 2ND SPEED DRIVE GEAR
3. SYNCHRONIZER ASSEMBLY 7. 4TH SPEED DRIVE GEAR
4. REVERSE DRIVEN GEAR 8. CONSTANT MESH GEAR
SM 8-10260 Issued 03-2001
Section
6007
RANGE TRANSMISSION SERVICING
2 Wheel Drive Tractors
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK SM 8-10270 March 2001
2 SECTION 6007
TABLE OF CONTENTS
SPECiFiCATIONS ..................................................................................................................................................... 3
SPECIAL TORQUES ................................................................................................................................................. 3
SPECIAL TOOLS ..................................................................................................................... .,............................... 3
TOOLS TO BE MADE .. ............................................................................................................................................. 3
RANGE TRANSMISSION
Disassembly .. ........................................................................................................................................................4
SYNCHRONIZER
Disassembly and Assembly .................................................................................................................................. 7
PINION SHAFT
Inspection and Disassembly ......... .................................... ..... .. ...... ................... .............................. ........... .. ......... 8
Pinion Shaft Bearing Preload, Mounting Distance and Assembly .. ....................................................................... 8
RANGE TRANSMISSION
Assembly ........................................................................................................ .............. ....................................... 11
Cross Sectional Drawing of the Range Transmission ............................................................................................. 15
8M 8-10270 Issued 03-2001
SECTION 6007 3
SPECIFICATIONS
Pinion 8earing End Play (Maximum) ................. ......... ........................... .. ....................... ............................. 0.076 mm
Synchronizer Running Clearance ... ................... ............ ... ...................... .... ... ............. ....................... 0.05 to 0.30 mm
Selector Fork Running Clearance ... ... ........................... ... .......................... .. .............................. .. .......... ........ 0.05 mm
SPECIAL TORQUES
Pinion Shaft Retaining 80lts ............................ ........... ... .. .. ..................... .... .. .............. .......... ....... ...... ...... 42 to 47 Nm
SPECIAL TOOLS
H03304 H03301
SYNCHRONIZER GAUGE, MC2364 SHIFT RAIL GAUGE, MC2365
TOOLS TO BE MADE
A
A ........... ............... ..... .......... .... 98 mm
-- 8 - - 8 .......... .... .......... ..... ............ .... 10 mm
C ... ... ... ............... .... ............ 24.80 mm
t
[,",,-----
I _~--.-C
DI97KOO2
TOOL TO 8E USED WHEN INSTALLING RANGE SELECTOR FORK (refer to Page 13)
SM 8-10270 Issued 03-2001
4 SECT/ON 6007
RANGE TRANSMISSION
Before disassembling the Range Transmission carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the Hydraulic Lift Housing, refer to Section 8010.
• Separate the Range Transmission from the Speed Transmission.
• Remove the Rear Axles, refer to Section 6018.
• Remove the Differential, refer to Section 6012
• Remove the PTO Clutch, refer to Section 6019. Refer to Section 6020 for Tractors equipped with Shiftable PTO.
NOTE: For Installation of the Range Transmission follow the same procedure in reverse order.
Disassembly STEP 3
STEP 1
DR99C193
Remove shim rings (5).
DP99C200
Remove the Speed Sensor (1). Disconnect and STEP 4
remove the lubrication tube (2).
STEP 2
DR99C194
Turn the selector rail (6) 90 degrees in either
direction, remove the selector rail (6) and bushing
DP99C201 (7), in the direction shown, from the selector fork.
Remove locknut (3) and roll pin (4). Remove the selector fork, check the bushings for
wear or damage and replace if necessary.
SM 8-10270 Issued 03-2001
SECTION 6007 5
STEP 5 STEP 7
DR99C195 DP99C202
Remove the speed pick-up gear retaining rings (8) Move the pinion shaft towards the rear of the
and retaining ring (9). Slide the speed pick-up gear transmission, make sure retaining ring (9) is
(10) along the pinion shaft and remove the locating removed from the groove. Remove the gear and
ball. synchronizer assembly and pinion shaft . Refer to
Page 7 for Disassembly and Assembly of the
STEP 6 synchronizer assembly.
STEP 8
Remove the pinion shaft bearing housing retaining
bolts (11) and plates (12) .
Remove retaining ring (13) from the housing.
SM 8-10270 Issued 03-2001
6 SECTION 6007
STEP 9 STEP 11
0097K062
Remove retaining ring (14). pull the countershaft Remove the two retaining screws (22) and remove
forward and remove retaining ring (14) . Remove the the lubrication pump (20) from the housing .
countershaft, low range driving gear (15). spacer
(16) and constant mesh driven gear (17).
STEP 10
H0253A
Remove retaining ring (18) and drive gear (19) from
the lubrication pump (20). Disconnect the
lubrication tube (21) .
SM 8-10270 Issued 03-2001
SECTION 6007 7
SYNCHRONIZER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
NOTE: If items marked (*) are worn or damaged the synchronizer assembly must be replaced.
SM1163
1. RING 4. RING 7. POPPET (3)
2. RING 5. HUB' 8 . SPRING (3)
3. RING 6. PLATE (3) 9.COLLAR·
SM 8-10270 Issued 03-2001
8 SECTION 6007
PINION SHAFT
Inspection and Disassembly Pinion Shaft Bearing Preload,
Mounting Distance and Assembly
STEP 12
STEP 14
H03822
Use a dial gauge to measure the pinion bearing end H03825
play. This must be less than 0.076 mm , if the Using a hydraulic press, install the bearing
measurement is greater, the bearing assembly assembly onto the pinion shaft. Install the parking
must be replaced. brake hub assembly. Rotate the bearing housing
until a slight preload is applied.
STEP 13
STEP 15
Remove retaining ring (23) and parking brake hub
assembly (24) . Remove bearing assembly (25) Install the thinnest retaining ring (23) available.
from the pinion shaft.
NOTE: Retaining rings (23) are available in the
following sizes: 1.68, 1. 75, 1.83, 1.90, 1.98,
2.06, 2. 13, 2.21 , 2. 28 and 2. 36 mm.
8M 8-10270 Issued 03-2001
SECTION 6007 9
STEP 16 STEP 19
A
Use a hydraulic press to apply pressure to bearing
assembly (25), as shown , until the parking brake
hub assembly (24) is tight against the retaining ring
(23). The mounting distance (A) from the pinion bearing
mounting face to the centre line of the differential is
STEP 17 approximately 167.64 mm. This distance can vary for
each transmission housing, for accurate installation of
the pinion shaft a number (D) is stamped on the rear
frame, as shown. The number refers to the variation
from distance (A), where distance (A) is smaller a
minus (-) sign will be shown. Add or subtract the
stamped figure to the figure of 167.64 mm.
NOTE: The number (0) on the rear frame will be
stamped in millimeters as shown in the
following example with or without a minus (-)
sign: ......... ...... .............. ........ ....... 0,22 or ,22.
H03822
Use a dial gauge to measure the bearing end play.
Use the following to calculate the correct retaining
ring (23) to be installed: A + B = C
A - Retaining ring installed in STEP 15 ..... 1.68 mm
B - Measured bearing end play .... ............ 0.31 mm
C - Retaining ring (23) to be installed ...... . 1.99 mm
STEP 18
Remove the retaining ring (23) installed in STEP 15
and install the retaining ring calculated in STEP 17.
NOTE: A final setting of 0.076 mm end play is
acceptable on the bearing assembly.
SM 8-10270 Issued 03-2001
10 SECTION 6007
STEP 20 STEP 21
MI018014
Stand the pinion on a flat surface and measure the
A0072 9
distance (C) between face of the pinion and the
The pinion cone mounting distance (B) is marked on bearing housing mounting face.
the face of the pinion and shows the distance between To calculate the amount of shims to be installed ,
the face and the centre line at the differential. The add distance (C) to the pinion cone mounting
distance (B) is approximately 105.16 mm. distance (B) and subtract the result from mounting
distance calculated in STEP 19, refer to example
The pinion shaft will be marked with the full number below.
(i.e. 105.16) or marked with one digit before the
decimal point. For pinion shafts marked with only NOTE: A tolerance of +/- O.025mm is allowed.
one digit before the decimal point then 10 must be
placed before the number when calculating the shim Example:-
pack (i.e 5.16 =105.16). C+B=X
A±D=Y
Y-X= ammount of shims to be installed in STEP 25.
C+B=X
Dimension C .......... ........... .. .. ............. 59.75 mm
+ Dimension B .......................... .......... 104.98 mm
= Dimension X .. ...... .... .... .. .......... .... .. .. 164.73 mm
A±D=Y
Dimension A ........ ............................ 167.64 mm
± Stamped Number D .. ... ....... ........ .... .. . - 0.22 mm
= Dimension Y ........ ................. ........... 167.42 mm
IMPORTANT: If stamped dimension 0 is a minus
number it must be subtracted from dimension A.
V-X = amount of shims to be installed in STEP 25 .
Dimension Y .................................... 167.42 mm
- Dimension X .. .. .. .. .. .. .... .... .. ...... .. .. .. ... 164.73 mm
= Shims .. .. .............................................. 2.69 mm
SM 8-10270 Issued 03-2001
SECTION 6007 11
RANGE TRANSMISSION
Assembly STEP 23
STEP 22
DD97K062
Install the constant mesh driven gear (17), spacer
A03413 (16), low range driving gear (15) and retaining ring
Install the lubrication pump (20), install and tighten (14). Install the countershaft, make sure retaining
the two retaining screws (22). Install drive gear (19) ring (14) is fully seated in the groove.
and retaining ring (18). Install and tighten the
lubrication tube (21). STEP 24
H02528
Install the countershaft bearing retaining ring (13).
8M 8-10270 Issued 03-2001
12 SECTION 6007
STEP 25 STEP 26
Install the pinion shaft retaining plates (12) and
bolts (11) , make sure a spacer is installed with bolt
(A). Tighten bolts (11) to a torque of 33 to 37 Nm.
STEP 27
Connect the Range Transmission to the Speed
Transmission, BEFORE carrying out the
synchronizer shimming procedure.
STEP 28
DI99A056
Install the shims calculated in STEP 21, Page 10,
onto the pinion bearing housing . Install the pinion
shaft and install the following items in order :
1. Speed Pick-up Gear
2. Splined Washer
3. Spacer
4. Splined Washer
5. Low Range Driven Gear
6. High/Low Range Synchronizer DI99A056
Push items (2) to (6) and the speed transmission
main shaft towards the front of the transmission.
Install the thinnest retaining ring into the groove (A) .
Make sure the retaining ring is seated towards the
rear of the groove in the pinion shaft.
STEP 29
Measure the distance between the retaining ring
and splined washer (2) and add the thickness of the
retaining ring installed in STEP 28 to determine the
thickness of retaining ring to be installed.
SM 8-10270 Issued 03-2001
SECTION 6007 13
STEP 30 STEP 32
Using the measurement calculated in STEP 29
select the correct retaining ring from the table
below to give a running clearance between 0.10
and 0.40 mm for the synchronizer assemblies. If the
measurement is greater than 3.08 mm , repeat
STEP 28 and STEP 29.
MEASUREMENT RETAINING RING
CALCULATED (mm) REQUIRED (mm)
1.910t02 .100 1.76
2.101 to 2.300 1.95 DI97K004
2.301 to 2.500 2.15 Install the detent ball and spring into the high range
2.501 to 2.700 2.35 selector fork, install the selector fork installation
bullet (A).
2.701 to 2.900 2.55
2.901 to 3.080 2.74 NOTE: Refer to Page 3, Tools to be Made, for
dimensions of the Range Selector Fork
STEP 31 I nstallation Bullet (A) .
STEP 33
DR99C 195
Apply Loctite 271 to the pinion shaft between the
DD97K057
speed pick-up gear retaining ring grooves. Install
the locating ball and slide the speed pick-up gear Install bushing (7). Install the selector fork and
(10) along the pinion shaft, install the retaining installation bullet (A), install selector rail (6) through
rings (8). the selector fork, in the direction shown , at the
same time remove installation bullet (A). Install roll
pin (4).
NOTE: DO NOT install the locknut.
8M 8-10270 Issued 03-2001
14 SECTION 6007
STEP 34 STEP 38
Select the correct thickness of shim rings (5) to be
installed between bushing (7) and selector rail (6).
NOTE: Calculate shim rings (5) required to the
nearest 0. 1 mm .
Shim rings (5) are available in the following
sizes:
0.5, 0. 6, 0.7, 0.8, 0.9 and 1.0 mm.
STEP 39
DI 99A057
Install shift rail gauge, MC2365 , between the low
range driven gear and synchronizer, as shown.
STEP 35 DP99C20 1
Hold the gears and synchronizers fully forward. Remove shift rail gauge , MC2365. Install the shims
Make sure the selector forks are seated in the selected in STEP 38. Install and tighten locknut (3).
neutral detents.
STEP 40
STEP 36
'------~~J II I_ron
1
,.
Using feeler gauges, measure gap (8) between
bushing (7) and selector rail (6).
H02424
'\
Apply sealant, Loctite 572, to the threads of the
SM1425
ground speed sensor (1). Install the sensor into the
STEP 37 transmission housing and turn it clockwise until the
tip lightly touches speed pick-up gear (9), then turn
It is necessary to ADD 0.05 mm to the it counterclockwise one full turn and tighten locknut
measurement obtained in STEP 36 to allow a (A).
running clearance on the selector fork .
8M 8-10270 Issued 03-2001
SECTION 6007 15
Cross Sectional Drawing of the Range Transmission
5
~--:-::.=--=~::. -.
~_t)r-I---.
·~-7)-··
i
i r·,
i
;- ~
,
,,.
,-
OD99C200
1. PARKING BRAKE HUB 6. HIGH/LOW SYCHRONIZER
2. PINION SHAFT 7. COUNTERSHAFT
3. SPLINED WASHER 8. LOW RANGE DRIVE GEAR
4 . SPACER 9. CONSTANT MESH DRIVEN GEAR
5. LOW DRIVEN GEAR 10. SPEED TRANSMISSION MAIN SHAFT
SM 8-10270 Issued 03-2001
Section
6008
RANGE TRANSMISSION SERVICING
MFD Tractors
ex Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10280 March 2001
2 SECTION 6008
TABLE OF CONTENTS
SPECiFiCATIONS ..................................................................................................................................................... 3
SPECIAL TORQUES ..... ...................................................... .. ........... ................................... .......... ............................ 3
SPECIAL TOOLS ....... .................... .............................................................. ............................................................. 3
TOOLS TO BE MADE ........ ............................................................ .................................................... ..... .................. 3
RANGE TRANSMISSION
Disassembly .................. ........................................................................................................................................4
SYNCHRONIZER
Disassembly and Assembly .................................................................................................................................. 7
PINION SHAFT
Inspection and Disassembly .................................................................................................................................8
Pinion Shaft Bearing Preload, Mounting Distance and Assembly ......................................................................... 8
RANGE TRANSMISSION
Assembly ............................................................................ ................................................................................. 11
Cross Sectional Drawing of the MFD Range Transmission .................................................. ........... ................... 15
8M 8-10280 Issued 03-2001
SECTION 6008 3
SPECIFICATIONS
Pinion Bearing End Play (Maximum) ... ...................... ......... ..... .......................... ... .... .. ..... ... ................ .. ... 0.076 mm
Synchronizer Running Clearance ... .......... .. ........... ... ... .. ...... ... ...... ........ .. ... .......... ...... ........ ..... ....... 0.05 to 0.30 mm
Selector Fork Running Clearance ... ........................ .. ............. .. ............ ............. ... .. .. .. ................... ..... ....... 0.05 mm
SPECIAL TORQU ES
Pinion Shaft Retaining Bolts ....... .. ... .. ....... .. ...... ..... ... ...... ..... ....... ... ..................................... .. .............. .42 to 47 Nm
SPECIAL TOOLS
H03304 H03301
SYNCHRONIZER GAUGE, MC2364 SHIFT RAIL GAUGE, MC2365
TOOLS TO BE MADE
A
___ B - -
O,,-_-r- C
DI97K002
A .......... .......... ......... ..... .. . 98 mm
B ... ... .. .. ...... .. .... ... .. .......... 10 mm
C ....... .... ............ ..... .... 24.80 mm
TOOL TO BE USED WHEN INSTALLING RANGE SELECTOR FORK (refer to Page 13)
8M 8-10280 Issued 03-2001
4 SECTION 6008
RANGE TRANSMISSION
Before disassembling the Range Transmission carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the MFD Transfer Gearbox, refer to Section 6011.
• Remove the Hydraulic Lift Housing, refer to Section 8010 .
• Separate the Range Transmission from the Speed Transmission.
• Remove the Rear Axles, refer to Section 6018.
• Remove the Differential, refer to Section 6012
• Remove the PTO Clutch, refer to Section 6019. Refer to Section 6020 for Tractors equipped with Shiftable PTO.
NOTE: For Installation of the Range Transmission follow the same procedure in reverse order.
Disassembly STEP 4
STEP 1
Remove the Speed Sensor.
STEP 2
DD97K058
Turn selector rail (4) 90 degrees in either direction,
remove selector rail (4) and bushing (5), in the
direction shown, from the selector fork. Remove the
selector fork, check the bushings for wear or
damage and replace if necessary.
DD97K056
Remove locknut (1) and roll pin (2). STEP 5
STEP 3
DD97K059
Remove the speed pick-up gear retaining rings (6).
DD97K057 Remove retaining rings (7) and (8) from the grooves
Remove shim rings (3). in the pinion shaft.
8M 8-10280 Issued 03-2001
SECTION 6008 5
STEP 6 STEP 8
Move the speed pick-up gear (9) along the pinion Move the plmon shaft towards the rear of the
shaft and remove the locating ball. transmission, make sure retaining rings (7) and (8)
are removed from the grooves. Remove the gear
STEP 7 and synchronizer assemblies and pinion shaft.
Refer to Page 7 for Disassembly and Assembly of
the synchronizer assembly.
STEP 9
Remove the pinion shaft bearing housing retaining
bolts (10) and plates (11) .
H02S28
Remove retaining ring (12) from the housing.
8M 8-10280 Issued 03-2001
6 SECTION 6008
STEP 10 STEP 12
DD97K062 A03413
Remove retaining ring (13) , pull the countershaft Remove the two retaining screws (21) and remove
forward and remove retaining ring (13). Remove the the lubrication pump (19) from the housing.
countershaft, low range driving gear (14) , spacer
(15) and constant mesh driven gear (16).
STEP 11
H02534
Remove retaining ring (17) and drive gear (18) from
the lubrication pump (19). Disconnect the
lubrication tube (20).
8M 8-10280 Issued 03-2001
SECTION 6008 7
SYNCHRONIZER
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
NOTE: If items marked (*) are worn or damaged the synchronizer assembly must be replaced.
S M1163
1. RING 4. RING 7. POPPET (3)
2. RING 5. HUB' 8. SPRING (3)
3. RING 6. PLATE (3) 9. COLLAR'
SM 8-10280 Issued 03-2001
8 SECTION 6008
PINION SHAFT
Inspection and Disassembly Pinion Shaft Bearing Preload,
Mounting Distance and Assembly
STEP 13
STEP 15
A00726
Use a dial gauge to measure the pinion bearing end A00723
play. This must be less than 0.076 mm, if the Use a hydraulic press to install the bearing
measurement is greater, the bearing assembly assembly (23) onto the pinion shaft. Rotate the
must be replaced. bearing housing until a slight preload is applied .
STEP 14 STEP 16
A00709
A00709
Remove the retaining ring and spacer (22) . Use a Install spacer (22) and thinnest retaining ring
hydraulic press to remove bearing assembly (23) available.
from the pinion shaft.
NOTE: Retaining rings (22) are available in the
following sizes: 1.68, 1.75, 1.83, 1.90, 1. 98,
2. 06, 2.13, 2.21 , 2.28 and 2.36 mm.
8M 8-10280 Issued 03-2001
SECTION 6008 9
STEP 17 STEP 20
A
C)
A00709
Use a hydraulic press to apply pressure to bearing
assembly (23) as shown until spacer (22) is tight
against the retaining ring .
The mounting distance (A) from the pinion bearing
STEP 18 mounting face to the centre line of the differential is
approximately 167.64 mm . This distance can vary
for each transmission housing, for accurate
installation of the pinion shaft a number (D) is
stamped on top of the rear frame, as shown. The
number refers to the variation from distance (A),
where distance (A) is smaller a minus (-) sign will be
shown. Add or subtract the stamped figure to the
figure of 167 .64 mm.
NOTE: The number (0) on the rear frame will be
stamped in millimeters as shown in the
following example with or without a minus (-)
sign: ......... .... ........ .............. ........ . 0,22 or ,22.
A00726
Use a dial gauge to measure the bearing end play.
Use the following to calculate the correct retaining
ring to be installed : A + B = C
A - Retaining ring installed in STEP 16 ..... 1.68 mm
B - Measured bearing end play .. .............. 0.31 mm
C - Retaining ring to be installed .............. 1.99 mm
STEP 19
Remove the retaining ring installed in STEP 16 and
install the retaining ring calculated in STEP 18.
NOTE: A final setting of 0.076 mm end play is
acceptable on the bearing assembly.
SM 8-10280 Issued 03-2001
10 SECTION 6008
STEP 21 STEP 22
MI01B014
Stand the pinion on a flat surface and measure the
A00729
distance (C) between face of the pinion and the
The pinion cone mounting distance (8) is marked bearing housing mounting face.
on the face of the pinion and shows the distance To calculate the amount of shims to be installed ,
between the face and the centre line at the add distance (C) to the pinion cone mounting
differential. The distance (8) is approximately distance (8) and subtract the result from mounting
105.16mm. distance calculated in STEP 20 .
NOTE: The pinion shaft will be marked with the full NOTE: A tolerance of +/- 0.025mm is allowed.
number (i.e. 105.16) or marked with one digit before
the decimal point. For pinion shafts marked with Example:-
only one digit before the decimal point then 10 must C+8=X
be placed before the number when calculating the A±D=Y
shim pack (i.e 5.16 = 105.16). Y-X= ammount of shims to be installed in STEP 26.
C+8=X
Dimension C .... ... .. .. .... ... .... ... ...... ... .... 59 .75 mm
+ Dimension 8 .... ...... .. ............. ....... .... 104.98 mm
= Dimension X .. .. ... .... ... ... ..... .. ....... ... .. 164.73 mm
A±D=Y
Dimension A ..... .. .. .. ... ... .... ...... .. .. .. .. . 167.64 mm
± Stamped Number D ........... .. ........ .. .... - 0.22 mm
= Dimension Y .. .... ... ......... ... ........... .. .. 167.42 mm
IMPORTANT: If stamped dimension D is a minus
number it must be subtracted from dimension A.
V-X = amount of shims to be installed in STEP 26.
Dimension Y .... ....... .... ... ........ ........ .. 167.42 mm
- Dimension X ................................. ... . 164.73 mm
= Shims ... .. ........ ....... ... .... ... ... .. ... ......... ... 2.69 mm
SM 8-10280 Issued 03-2001
SECTION 6008 11
RANGE TRANSMISSION
Assembly STEP 24
STEP 23
H02530
DD97K062
Install the constant mesh driven gear (16), spacer
(15), low range driving gear (14) and retaining ring
Install the lubrication pump (19), install and tighten (13). Install the countershaft, make sure retaining
the two retaining screws (21) . Install drive gear (18) ring (13) is fully seated in the groove.
and retaining ring (17) . Install and tighten the
lubrication tube (20). STEP 25
HQ2528
Install the countershaft bearing retaining ring (12).
8M 8-10280 Issued 03-2001
12 SECTION 6008
STEP 26 STEP 27
Install the pinion shaft retaining plates (11) and
bolts (10), make sure a spacer is installed with bolt
(A). Tighten bolts (10) to a torque of 33 to 37 Nm.
STEP 28
Connect the Range Transmission to the Speed
Transmission, BEFORE carrying out the
synchronizer shimming procedure.
STEP 29
Install the shims calculated in STEP 22 onto the
pinion bearing housing . Install the pinion shaft and
install the following items in order:
1. MFD Drive Gear
2. Retaining Ring
3. Speed Pick-up Gear
4. Splined Washer
5. Spacer
6. Splined Washer DI99A056
7. Low Range Driven Gear
Push items (4) to (8), refer to STEP 26, and the
8. High/Low Range Synchronizer
speed transmission main shaft towards the front of
the transmission. Install the thinnest retaining ring
into the groove (A), make sure it is seated towards
the rear of the groove.
STEP 30
Measure the distance between the retaining ring
and splined washer (4), add the thickness of the
retaining ring installed in STEP 29 to determine the
thickness of retaining ring to be installed.
8M 8-10280 Issued 03-2001
SECTION 6008 13
STEP 31 STEP 33
Using the measurement calculated in STEP 30
select the correct retaining ring from the table
below to give a running clearance between 0.10
and 0.40 mm for the synchronizer assemblies. If the
measurement is greater than 3.08 mm , repeat
STEP 29 and STEP 30.
MEASUREMENT RETAINING RING
CALCULATED (mm) REQUIRED (mm)
1 .91 0 to 2.100 1.76
2.101 to 2.300 1.95 DI97K004
2.301 to 2.500 2.15 Install the detent ball and spring into the high range
2.501 to 2.700 2.35 selector fork, install the selector fork installation
bullet (A) .
2.701 to 2.900 2.55
2.901 to 3.080 2.74 NOTE: Refer to Page 3, Tools to be Made, for
dimensions of the Range Selector Fork
STEP 32 Installation Bullet (A).
STEP 34
H024 32
Apply Loctite 271 to the pinion shaft between the
DD97K057
speed pick-up gear retaining ring grooves. Install
the locating ball and slide the speed pick-up gear Install bushing (5). Install the selector fork and
(9) along the pinion shaft, install the retaining rings installation bullet (A), install selector rail (4) through
(6). the selector fork, in the direction shown , at the
same time remove installation bullet (A) . Install roll
pin (2).
NOTE: DO NOT install the locknut.
8M 8-10280 Issu ed 03-2001
14 SECTION 6008
STEP 35 STEP 39
Select the correct thickness of shim rings (3) to be
installed between bushing (5) and selector rail (4).
NOTE: Calculate shim rings (3) required to the
nearest 0.1 mm.
Shim rings (3) are available in the foJ/owing
sizes:
0.5,0.6,0.7,0.8,0.9 and 1.0 mm.
STEP 40
DI99A057
Install shift rail gauge, MC2365, between the low
range driven gear and synchronizer, as shown.
STEP 36 DD97K056
Hold the gears and synchronizers fully forward . Remove shift rail gauge, MC2365. Install the shims
Make sure the selector forks are seated in the selected in STEP 39 . Install and tighten locknut (1) .
neutral detents.
STEP 41
STEP 37
H02424
SM1425
Using feeler gauges, measure gap (8) between
bushing (5) and selector rail (4). Apply sealant, Loctite 572, to the threads of the
ground speed sensor (A). Install the sensor into the
STEP 38 transmission housing and turn it clockwise until the
tip lightly touches speed pick-up gear (8), then turn
It is necessary to ADD 0.05 mm to the it counterclockwise one full turn and tighten locknut
measurement obtained in STEP 37 to allow a (C).
running clearance on the selector fork.
8M 8-10280 Issued 03-2001
SECTION 6008 15
Cross Sectional Drawing of the MFD Range Transmission
SM1169
1 . SELECTOR FORK ASSEMBLY 6 . LOW DRIVEN GEAR
2. MFD DRIVE GEAR 7 . HIGH/LOW SYCHRONIZER
3. PINION SHAFT 8. COUNTERS HAFT
4. SPLINED WASHER 9. LOW RANGE DRIVE GEAR
5. SPACER 10 . CONSTANT MESH DRIVEN GEAR
11 . SPEED TRANSMISSION MAIN SHAFT
SM 8-10280 Issued 03-2001
Section
6009
3 SPEED POWERSHIFT
TRANSMISSION SERVICING
(XtraShift)
CX Series Tractors
~ © 2003 McCormick Tractors International Limited.
McCORMICK 8M 8-12200 June 2003
2 SECTION 6009
TABLE OF CONTENTS
SPECIFICATIONS ... ....... .... .... .................. ....... .......... ...... .......... .. ..... ....... ... ....................... ...................... ............. 3
SPECIAL TORQUES ... ..... ... ........... ........ ... ............................ ..... .. ........ .. .......... .. ........ .. .... ........... ................ ......... 3
SPECIAL TOOLS .......... ....... .. ..................... .......... .. ..................... .......... ............................ ....... ................. ........... 4
TRANSMISSION FRONT COVER
Removal and Installation ....... .. .......... .. ....... ..... ...................... .................... .... ..... ........................................... 5
Shim setting of Powershift Main shaft and Counter shaft covers .. .. ......... .......... .. ......... ... ............................. 8
Powershift Main Shaft
Disassembly and Assembly of Reverse Clutch ....................................... .. ......... .. ......... .. ............................ 10
Powershift Main Shaft
Disassembly and Assembly of 2nd and Forward Clutch ..................................... .. ........ .... ....... ... ................ 12
Cross Sectional Drawing of the Powershift Main Shaft ................ .. .......... .. ........ .... ..................................... 16
Powershift Counter Shaft
Disassembly and Assembly ..................................... ....... .............................................. .... ........................... 18
Cross Sectional Drawing of the Counter shaft ................... .. ..................... ................................................... 22
8M 8-12200 Issued 06-2003
SECTION 6009 3
SPECIFICATIONS
Transmission Oil ... .... ................................ ... ...... .... ... ....................... ... ....... ... ........... ...... ... ... .. ......... ...McCormickHTX
Friction Plate Thickness ............. ..... .. ............... ..... .. ... ............. ... .... 2.45 to 2.60 mm 0.096 to 0.102 inch
Separator Plate Thickness ........ ... ... ................... ... ........ ............ ..... 2.16 to 2.31 mm 0.085 to 0.091 inch
Backing Plate Thickness .... .. ... ... ... ......... ........ ... ........ .. .... ......... ...... 5.58 to 5.71 mm 0.22 to 0.23 inch
Total Thickness ...... ...... ........ .... ...... .............. .......... .... .... .. ...... . 10.8 to 11 .05 mm 0.425 to 0.435 inch
Number of Plates
1st Speed Clutch Pack (Counter Shaft) ........ ...... ................ .... ........ ...... 4 Friction 5 Separator
3rd Speed Clutch Pack (Counter Shaft) .................................... .... .. ..... 4 Friction 5 Separator
2nd Clutch Pack (Main shaft) ............ .. .. .. .............. .. ...... ...... .... ........ ..... 4 Friction 5 Separator
Forward Clutch Pack (Main shaft) .. ...... .. .................... .............. .. .......... 6 Friction 6 Separator
Revers Clutch Pack (Main shaft) ................................ .......................... 6 Friction 6 Separator
SPECIAL TORQUES
Transmission Front Cover Retaining Bolts .......... .. .................... .. .. ....... 45 to 47 Nm 33 to 35 Ib ft
Main Shaft Cover Retaining Bolts .. .... .................. .. .................... ...... .... 45 to 47 Nm 33 to 35 Ib ft
Counter Shaft Cover Retaining Bolts ................ .. .... .. ................ ...... ..... 45 to 47 Nm 33 to 35 Ib ft
Drop shaft Cover Retaining Bolts .... ........ .. .. .......... .. .................. .. ....... .45 to 47 Nm 33 to 35 Ib ft
8M 8-12200 Issued 06-2003
4 SECTION 6009
SPECIAL TOOLS
SEAL EXPANDER/PROTECTOR, MC1999A
DD97K035
FRONT COVER REMOVAL TOOL MC2559B
)S988482
SEAL COMPRESSOR, MC2005·1
MP03G028
SPECIAL COUNTER SHAFT COVER 1016T1
MP03F015
SPRING COMPRESSORS MC1992 AND 1013T1
MP03G029
SPECIAL SHIM SETTING BOLT 1018T1
MP03G027
SHIM SETTING FORK 1017T1
8M 8-12200 Issued 06-2003
SECTION 6009 5
TRANSMISSION FRONT COVER
Removal and Installation
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
Before removing the Transmission Front Cover and servicing the Input and Drop Shafts it will be necessary to
carry out the following :
o Park the tractor on hard level ground and apply the parking brake.
o Lower the rear Three Point Hitch and Front Hitch (if equipped) .
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
o Put suitable containers under the transmission drain plugs and drain the transmission.
o Remove cab. .
o Separate the tractor between the Engine and Speed transmission, refer to Section 6001 .
NOTE: After Installation fill the transmission with clean McCormick HTX the correct level. Connect the battery
(+) terminal first.
STEP 1 IMPORTANT: Before tightening powershift shaft
cover (1) and counter shaft cover (2) refer to
"Shim setting of Powershift Main shaft and
Counter shaft covers" on page 8.
STEP 3
Remove powershift shaft cover (1) counter shaft
cover (2) and drop shaft cover (3).
STEP 2
Remove retaining clip (5) from drop shaft
MP03Dl01
Remove the retaining bolts (4) from the powershift
front cover.
NOTE: for installation, tighten the retaining bolts
for covers (1),(2),(3) and (4) to a torque of 45 to
47Nm (33 to 35 Ib ft) .
SM 8-12200 Issued 06-2003
6 SECTION 6009
STEP 4 STEP 8
Remove speed selector forks, syncros, gears and
main shaft. See section 6006.
STEP 9
Use the removal tool (6) MC2559B to remove the
front cover (7) and bearing from the drop shaft.
STEP 5 DD97F266
Remove the inner snap ring (10) from the groove in
the transmission housing.
STEP 10
Remove spacer (8) and gear (9).
STEP 6
Remove snap ring (11) from 1st speed driving gear
and snap rings (12) from 2nd speed driving gear.
STEP 11
MP03D103
Remove reverse idler.
STEP 7
Remove hydraulic pipes and electrical wires
necessary, to split transmission between speed and MP03D088
range box. Remove lower speed box plate and snap ring (13)
from IPTO driven gear (14).
SM 8-12200 Issued 06-2003
SECTION 6009 7
STEP 12 STEP 15
MP03E001 MP03D102
Remove snap rings (15) from reverse driven gear With IPTO driven gear removed, remove counter
(16) . shaft (19) and powershift shaft (20).
STEP 13
MP03D088
Slide shuttle shaft (17) back until the IPTO driven
gear can be removed.
STEP 14
MP03D102
Remove front part of powershift shaft and IPTO
drive gear (18).
SM 8-12200 Issued 06-2003
8 SECTION 6009
Shim setting of Powershift Main shaft and Counter shaft covers
STEP 1 STEP 3
MP03G033 MP03G030
Tighten powershift cover bolts (4) and drop shaft Place existing shim pack and special counter
cover (3) to a torque of 45 to 47 Nm (33 to 35 Ib ft) . shaft cover tool 1016T1 over counter shaft and
tighten retaining bolts to 45 to 47 Nm (33 to 35
STEP 2 Ib ft) . Screw special bolt 1018T1 in to the end of
the counter shaft. Install a dial gauge on to the
bolt 1018T1. push the counter shaft to the rear
of the transmission and zero the gauge . Using
special tool 1017T1 pull the counter shaft fully
forward and note the end float reading on the
gauge. The correct end float must be 0 .00 to
0.05 .
NOTE: If the end float is not correct, shims must
be added or removed and STEP 3 repeated.
STEP 4
MI03F066
Measure the distance shown in STEP 2 of both the
counter shaft cover and the special counter shaft
cover tool 10 16T1 and note the difference. If the
counter shaft cover is greater then the difference
must be subtracted from the final shim pack. If the
counter shaft cover is smaller then the distance
should be added to the final shim pack.
MP03G034
Remove special tool cover 1016T1 and replace
counter shaft cover (2).
8M 8-12200 Issued 06-2003
SECTION 6009 9
STEP 5
MP03G032
Replace existing shim pack and the powershift
main shaft cover (1) and tighten retaining bolts
to 45 to 47 Nm (33 to 35 Ib ft). Install a dial
gauge on to the powershift main shaft. Push the
shaft to the rear of the transmission and zero
the gauge. Using special tool 1017T1 pull the
counter shaft fully forward and note the end
float reading on the gauge . The correct end
float must be 0.00 to 0 .05. the end float is not
correct, shims must be added or removed and
STEP 5 repeated.
8M 8-12200 Issued 06-2003
10 SECTION 6009
Powershift Main Shaft
Disassembly and Assembly of Reverse Clutch
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
STEP 1 STEP 3
MP03D094
Remove and discard the sealing rings (1) . Use a Install the mainshaft onto a suitable hydraulic press.
suitable bearing puller and remove the bearing Use the spring compressor 1013T1 (A) to
cone (2), spacer (3) thrust washer (4), thrust compress the piston return spring (15). Release the
bearing (5), thrust washer (6), bearing cage (7), snap ring (13) from the groove in the main shaft.
bearing cage (8) and the reverse shuttle gear (9) . Release the pressure from the press and remove
the spring compressor.
NOTE: Lubricate seals before installation . use
seal expander tool MC1999A and seal STEP 4
compressor MC2005-1
Remove the snap ring (13), spring retainer (14) and
IMPORTANT: When replacing Bearing, heat the spring (15).
bearing cone (2) in a bearing oven to a
temperature of 110°C (230°F) . Install the STEP 5
bearing cone (2) onto the main shaft. Make sure
the bearing cone is against the thrust washer Remove the snap ring (16), backing plate (17),
(3). friction plates (18) separator plates (19) and lube
collar (20) .
A WARNING: Always wear heat protective
gloves or mittens when handling heated
parts. NOTE: Check the lube collar, friction plates and
separator plates for wear or damage and
replace as necessary. If new friction plates are
STEP 2 to be installed, make sure the friction plates are
soaked in clean transmission oil before
Remove thrust washer (10), thrust bearing (11), installation .
and thrust washer (12)
STEP 6
Remove the piston (21) from the reverse clutch
housing. Remove and discard the piston sealing ring
(22), o-ring (23), sealing ring (24) , o-ring (25) .
NOTE: Lubricate new a-rings and seals before
installation and make sure a-rings are installed
before the sealing rings.
8M 8-12200 Issued 06-2003
SECTION 6009 11
' I
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MI030 119
NOTE 1: Items are numbered in order of Disassembly, items marked * must be replaced.
8M 8-12200 Issued 06-2003
12 SECTION 6009
Powershift Main Shaft
Disassembly and Assembly of 2nd and Forward Clutch
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
STEP 1 STEP 4
MP03E064 MP03E085
Remove input assembly (1). Use a suitable puller to Install the mainshaft onto a suitable hydraulic press .
remove bearing (2) and gear (3). Use the spring compressor MC1992 (A) to
compress the piston return spring (9) . Release the
STEP 2 snap ring (7) from the groove in the main shaft.
Release the pressure from the press and remove
CheCk bearing cup (4) and needle bearing (5) for the spring compressor.
wear or damage and replace as necessary.
STEP 5
STEP 3
Remove the snap ring (7), spring retainer (8) and
Use a suitable bearing puller and remove the spring (9) .
bearing cone (6)
STEP 6
IMPORTANT: When replacing Bearings, heat
the bearing cone in a bearing oven to a Remove the snap ring (10), backing plate (11),
temperature of 110°C (230°F). Install the friction plates (12) separator plates (13) and lube
bearing cone onto the shaft . Make sure the collar (14) .
bearing cone is fully seated.
WARNING: Always wear heat protective NOTE: Check the lube collar, friction plates and
& gloves or mittens when handling heated
parts.
separator plates for wear or damage and
replace as necessary. If new friction plates are
to be installed, make sure the friction plates are
soaked in clean transmission oil before
installation.
STEP 7
Remove the piston (15) from the reverse clutch
housing. Remove and discard the piston sealing ring
(16), o-ring (17) , sealing ring (18), o-ring (19).
NOTE: Lubricate new o-rings and seals before
installation and make sure o-rings are installed
before the sealing rings.
SM 8-12200 Issued 06-2003
SECTION 6009 _ _ _ _ _ _ 113
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~ '0 MI03D1 17
NOTE: Items are numbered in ord er of 0 Isassembly,
8M 8-12200
" item s marked * must be repl aced.
Issued 06-2003
14 SECTION 6009
STEP 8 STEP 14
Remove clutch cup assembly (20). Remove Remove the piston (41) from the forward clutch
retaining ring (21) from clutch cup (20). Remove housing. Remove and discard the piston sealing ring
o-ring (22) from main shaft. Remove gear (23). (42), o-ring (43), sealing ring (44), o-ring (45).
STEP 9 NOTE: Lubricate new o-rings and seals before
installation and make sure o-rings are installed
Remove thrust washer (24), thrust bearing (25), before the sealing rings.
and thrust washer (26).
STEP 10 NOTE: The 2nd speed clutch pack has 4 friction
and 5 metal separator plates. The forward and
Remove forward shuttle assembly (27), needle reverse clutch packs have 6 friction and 6 metal
roller bearing (28) and needle roller bearing (29). separator plates. If new friction plates are to be
Remove thrust washer (30) , thrust bearing (31), installed, make sure all the friction plates are
and thrust washer (32). soaked in clean transmission oil before
installation.
STEP 11
Install the mainshaft onto a suitable hydraulic press.
Use the spring compressor 1013T1 (A) to
compress the piston return spring (35). Release the
snap ring (33) from the groove in the main shaft.
Release the pressure from the press and remove
the spring compressor.
STEP 12
Remove the snap ring (33), spring retainer (34) and
spring (35).
STEP 13
Remove the snap ring (36), backing plate (37),
friction plates (38) separator plates (39) and lube
collar (40).
NOTE: Check the lube collar, friction plates and
separator plates for wear or damage and
replace as necessary. If new friction plates are
to be installed, make sure the friction plates are
soaked in clean transmission oil before
installation .
SM 8-12200 Issued 06-2003
SECTION 6009 _ _ _ _ _ _ 115
NOTE: Items are
SM 8-12200
r er of 0"Isassembly,I"t ems marked
numbered in 0 d * must be replaced"
Issued 06-2003
16 SECTION 6009
Cross Sectional Drawing of the Powershift Main Shaft
1. REVERSE CLUTCH PACK 3 . 2ND SPEED CLUTCH PACK 5. LOW DRIVEN GEAR
2. FORWARD CLUTCH PACK 4 . FORWARD SHUTTLE ASSEMBLY 6. HIGH DRIVEN GEAR
SM 8-12200 Issued 06-2003
SECTION 6009 17
THIS PAGE HAS BEEN LEFT BLANK
SM 8-12200 Issued 06-2003
18 SECTION 6009
Powershift Counter Shaft
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
STEP 1 STEP 3
Remove and discard the sealing rings (1). Use a
suitable bearing puller and remove the bearing
cone (2).
NOTE: Lubricate seals before installation. use
seal expander tool MC 1999A and seal
compressor MC2005-1
STEP 2
DI96A040
Install the drop shaft onto a suitable hydraulic
press. Use the spring compressor MC1992 (A) to
compress the piston return spring (17). Release the
snap ring (7) from the groove in the input shaft. Re-
lease the pressure from the press and remove the
spring compressor.
STEP 4
MP03E084 Remove the snap ring (7) and piston (8). Remove
Release the snap ring (3) from the groove in the 1st and discard the piston sealing ring (9), o-ring (10),
speed clutch housing (6). Use a suitable puller and sealing ring (11) and o-ring (12).
remove the bearing cone (4), o-ring (5) and clutch
housing (6). NOTE: Lubricate new a-rings and seals before
installation and make sure a-rings are installed
IMPORTANT: When replacing Bearings, heat before the sealing rings.
the bearing cone in a bearing oven to a
temperature of 110°C (230°F). Install the STEP 5
bearing cone onto the shaft. Make sure the
Remove the separator plates (13), friction plates
bearing cone is fully seated.
(14), backing plate (15) and snap ring (3).
A WARNING: Always wear heat protective
gloves or mittens when handling heated
parts.
STEP 6
Remove lube collar (16), spring (17), spring retainer
(18) and snap ring (19).
NOTE: Check the lube collar, friction plates and
separator plates for wear or damage and
replace as necessary. If new friction plates are
to be installed. make sure the friction plates are
soaked in clean transmission oil before
installation .
STEP 7
Remove the thrust washer (20), thrust bearing (21),
thrust washer (22), bearing cage (23), bearing cage
(24) and high gear assembly (25).
8M 8-12200 Issued 06-2003
SECTION 6009 _ _ _ _ _ _ 119
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8M 8-12200 Issued 06-2003
20 SECTION 6009
STEP 8 STEP 12
Remove the thrust washer (26). thrust bearing (27). Remove the snap ring (41), spring retainer (42)
thrust washer (28), thrust bearing (29) and thrust spring (43) and lube collar (44).
washer (30).
STEP 13
STEP 9 Remove the piston (45) from the 3rd speed clutch
Remove low gear assembly (31) Remove bearing housing. Remove and discard the piston sealing ring
cage (32) and bearing cage (33), Remove thrust (46), o-ring (47). sealing ring (48) and o-ring (49).
washer (34), thrust bearing (35) and thrust washer
(36). NOTE: Make sure the o-rings are installed
before the sealing rings.
STEP 10
IMPORTANT: Never use force to correct wrong
Remove the retaining ring (37). backing plate (38)
alignment of the piston.
separator plates (39) and friction plates (40).
NOTE: Check the friction plates and separator
plates for wear or damage and replace as
necessary. If new friction plates are to be
installed, make sure the friction plates are
soaked in clean transmission oil before
installation.
STEP 11
MP03E167
Install the drop shaft onto a suitable hydraulic
press . Use the spring compressor MC1992 (A) to
compress the piston return spring (42). Release the
snap ring (41) from the groove in the input shaft.
Release the pressure from the press and remove
the spring compressor.
8M 8-12200 Issued 06-2003
SECTION 6009 _ _ _ _ _ _ 221
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NOTE: Items are numbered'In order o f DIsassembly
. it aced.
8M 8-12200 must be rep I
Issued 06-2003
22 SECTION 6009
Cross Sectional Drawing of the Counter shaft
e-~
e-. . . .
1. SEALING RING 3. 3RD SPEED CLUTCH PACK 5. HIGH GEAR
2. 1ST SPEED CLUTCH PACK 4 . LOW GEAR
NOTE: The 1nd and 3rd speed clutch packs have 4 friction and 5 metal separator plates.
SM 8-12200 Issued 06-2003
Section
6012
DIFFERENTIAL AND
DIFFERENTIAL LOCK
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10290 March 2001
2 SECTION 6012
TABLE OF CONTENTS
SPECiFiCATIONS ..... .... ....... ....... .. ... .... ... ........................ ... ..... ........ ... .................... .. .... .... ............... ............... .. ......... 3
SPECIAL TORQUES ... ................ ........................... ................. .. .............. ... .................... .. ..... ...... ... ............... ... .... .. ... 3
DIFFERENTIAL
Removal ........ ........................... .... ... ......... ... ............ ..................... ................................... .................... ............... ... 4
Disassembly ........... ........ ................... .. ..... .......... ..... .... .. .... .. ....... .... ...... ............................... .. .... .... .......... ... ......... .. 6
Assembly .......................................... ............................................ .. ....... .............................................. .............. .... 7
Positioning the Ring Gear onto the Differential Housing ............................. .... .. .............. .................... ...... ............ 8
Cross Sectional Drawing of the DifferentiaL ....... .. ........................ .... ..................................................................... 9
Setting the Differential Bearing Preload ................................ ........ ...... ... ........ ............. ... .................................... . 10
Setting the Ring Gear to Pinion Backlash ........................................................................................................... 12
DIFFERENTIAL LOCK
Assembly ....... .. ....... ..................................... .... ..... .. .............. ......... ........ ............. ...... ............ ..... ..... ...... ..... .. .... .... 16
Cross Sectional Drawing of the Differential Lock ................................... ............................................. ...... ... ....... 17
DIFFERENTIAL LOCK SOLENOID .............. .... ........................................................................................ ....... .. ..... . 18
SM 8-10290 Issued 03-2001
SECTION 6012 3
SPECIFICATIONS
Differential Lock Selector Ring Clearance
(Engaged Position) ...... .... ............................................................................................................ 0.025 to 0.90 mm
Ring Gear to Pinion Backlash ........................ .. .............................................................................. 0.152 to 0.304 mm
Ring Gear to Differential Housing Run-out .................. ......... ....... .... .......... ................ ........................... 0 to 0.102 mm
Differential Bearing Rolling Pull .................... .... .......... ..... ............................................................. .......... 2.0 to 6.5 kg
SPECIAL TORQUES
Ring Gear Dowel Bolts ........................................................... ............................ ..... ............................ 156 to 170 Nm
Ring Gear Retaining Bolts ................................................................................................................... 156 to 170 Nm
Bearing Carrier Retaining Bolts ........................................................................................................... 156 to 170 Nm
SM 8-10290 Issued 03-2001
4 SECTION 6012
DIFFERENTIAL
Before removing the Differential carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Remove the Cab, refer to Section 9006.
• Remove the Hydraulic Lift Housing, refer to Section 8010.
Removal STEP 3
STEP 1
DP99J093
Remove differential lock assembly items (5) to (16) ,
DP99J091 refer to Page 5.
Disconnect and remove lubrication tubes (1) .
STEP 2
Remove fitting (2), retaining ring (3) and end cap (4).
8M 8-10290 Issued 03-2001
SECTION 6012 5
2. FITTING 7. SWITCH 12 . FORK
3. RETAINING RING 8. SUPPORT 13 . SPRING (DIFFERENTIAL LOCK APPLY)
4 . END CAP 9. SPRIN G (DIFFERENTIAL LOCK RETURN) 14. RETAINING RING
5 . a-RING 10. THRUST WASHER 15 . PISTON ASSEMBLY
6 . RETAINING RING 11 . RETAINING RING 16 . a-RING
NOTE: Discard o-rings (6) and (16).
STEP 4 STEP 6
Remove the Rear Axles, refer to Section 6018 .
STEP 5
Remove the Brake Pistons , refer to Section 7001 .
DP97G018
Attach suitable lifting equipment to the differential
assembly. Remove the differential bearing carriers
and remove the differential assembly.
SM 8-10290 Issued 03-2001
6 SECTION 6012
Disassembly
0-:
SM1250
1. DOWEL BOLT (4) 6. PLANETARY PIN 11. BEARING CONE
2. RETAINING BOLT (4) 7. PLANETARY GEAR 12. DIFFERENTIAL LOCK RING
3. RING GEAR 8. SIDE GEAR 13. SPRING (2)
4. THRUST WASHER 9. DIFFERENTIAL HOUSING
5. SIDE GEAR 10. BEARING CONE
IMPORTANT: The ring gear and pinion shaft are STEP 3
a matched set and cannot be serviced
separately. Refer to Section 6004 for tractors Put identification marks on planetary pins (6),
with Creep, 6007 for 2WD Tractors or Section planetary gears (7) and differential housing (9).
6008 for MFD Tractors if the ring gear and Remove planetary pins (6) and planetary gears (7)
pinion shaft are to be replaced. DO NOT install and second side gear (8).
the new pinion shaft until the differential
assembly is complete . NOTE: Transmissions with light duty rear axles
have two planetary gears and one long
STEP 1 planetary shaft.
Remove the four dowel bolts (1) and four retaining STEP 4
bolts (2).
Use a suitable puller and remove bearings (10) and
STEP 2 (11). Remove the differential lock ring (12) and
springs (13).
Remove ring gear (3), thrust washer (4) and side
gear (5) .
SM 8-10290 Issued 03-2001
SECTION 6012 7
Assembly STEP 8
STEP 5
DP97G016
Install thrust washer (4) onto ring gear (3), use
DP97G017 petroleum jelly to hold the washer in position.
Install the differential lock ring (12) and springs (13)
onto differential housing (9). NOTE: Make sure tab (B) on thrust washer (4)
locates into the hole in ring gear (3).
NOTE: Make sure pins (A) on the differential
lock ring (12) locate into the holes in differential STEP 9
housing (9) and springs (13) locate into the
holes in the differential lock ring (12).
STEP 6
Heat bearing cones (10) and (11) in a bearing oven
to a temperature of 110°C. Install bearing cones
(10) and (11) onto ring gear (3) and differential
housing (9). Make sure bearing cones (10) and (11)
are fully seated against the shoulders.
& WARNING: Always wear heat protective
gloves or mittens when handling heated
parts.
DD97J097
Install ring gear (3) and thrust washer (4) onto
housing (9). Install dowel bolts (1) and retaining
NOTE: If bearing cones (10) and (11) are to be bolts (2), make sure dowel bolts (1) locate into
replaced, new bearing cups MUST be installed planetary pins (6). Tighten, DO NOT TORQUE, the
into the differential bearing carriers. bolts (1) and (2) at this stage.
STEP 7
Install side gear (8) into differential housing (9),
install planetary gears (7) and planetary pins (6), as
marked on disassembly, install side gear (5).
8M 8-10290 Issued 03-2001
8 SECTION 6012
Positioning the Ring Gear onto the STEP 12
Differential Housing Remove the dial gauge. Use a soft faced hammer
to gently tap the outer surface of ring gear (3).
STEP 10 Install the dial gauge, slowly rotate the differential
assembly and check the run out, repeat the
procedure until the correct run out is obtained.
When the correct run out has been obtained further
tighten retaining bolts (2) and dowel bolts (1).
Check the run out after tightening retaining bolts (2)
and dowel bolts (1).
NOTE: Make sure the differential assembly is
supported when adjusting the ring gear
position.
STEP 13
DD97J098
Use suitable lifting equipment and remove the
Put the RH bearing carrier (14) on a clean differential assembly from the RH bearing carrier
workbench. Use suitable lifting equipment and (14), place the differential assembly onto a clean
position the differential assembly onto the RH workbench.
bearing carrier (14). Remove the lifting equipment
and make sure the differential assembly rotates NOTE: Care must be taken not to damage the
freely. differential bearing when removing the
differential assembly.
NOTE: Care must be taken not to damage the
differential bearing when positioning the STEP 14
differential assembly.
STEP 11
DD97J097
Remove the four dowel bolts (1) and apply Loctite
242 onto the threads. Install and tighten dowel bolts
DD97J099
(1) to a torque of 156 to 170 Nm Remove the four
Install bearing cup (A) onto the bearing cone on the retaining bolts (2) and apply Loctite 242 onto the
ring gear. Install a dial gauge onto the outer surface threads. Install and tighten retaining bolts (2) to a
of the bearing cup, as shown. Slowly rotate the torque of 156 to 170 Nm.
differential assembly and measure the total run out,
the total dial gauge reading must be between 0 and NOTE: DO NOT REMOVE dowel bolts (2) and
0.102 mm. If the run out is greater than 0.102 mm retaining bolts (1) at the same time.
the ring gear position must be adjusted, refer to
STEP 12.
SM 8-10290 Issued 03-2001
SECTION 6012 9
Cross Sectional Drawing of the Differential
For Heavy Duty Axle
~ ~
@I--....l..
:---1@
D197J095
For Light Duty Axle
--@
D197J096
8. DOWEL BOLT (4) 13. PLANETARY PIN 18. BEARING CONE
9. RETAINING BOLT (4) 14. PLANETARY GEAR 19. DIFFERENTIAL LOCK RING
10 . RING GEAR 15 . SIDEGEAR 20 . SPRING (2)
11 . THRUST WASHER 16. DIFFERENTIAL HOUSING
12. SIDE GEAR 17. BEARING CONE
SM 8-10290 Issued 03-2001
10 SECTION 6012
Setting the Differential Bearing STEP 17
Preload Install the RH bearing carrier (14) WITHOUT a shim
pack. Install the retaining bolts and tighten finger
IMPORTANT: The following Steps must be tight. Remove the lifting equipment.
carried out with the pinion shaft removed from
the transmission housing. STEP 18
Refer to Section 6004 for tractors with Creep,
Section 6007 for 2WD Tractors or Section 6008
for MFD Tractors for Removal and Installation of
the pinion shaft.
STEP 15
DP97G021
Rotate the differential assembly, to seat the
bearings, while evenly tightening the retaining bolts
in the LH bearing carrier (15) to a torque of 156 to
170 Nm.
DP97G018
STEP 19
Attach suitable lifting equipment to the differential
assembly. Install the differential assembly into the
transmission housing.
NOTE: Care must be taken not to damage the
differential bearings when installing the
differential assembly
STEP 16
DP97G025
Rotate the differential assembly, to seat the bearings,
while evenly tightening the retaining bolts in the RH
bearing carrier (14) to a torque of 5.5 Nm
STEP 20
Repeat STEP 19 until the RH bearing carrier
H06716
retaining bolts remain at a constant torque of 5.5
Nm.
Install the LH bearing carrier (15) and a 1.37 mm
shim pack (16) . Install the retaining bolts and
tighten finger tight.
NOTE: Make sure the drain holes (A) in the
bearing carrier (15) and shims (16) are aligned
and towards the bottom, as shown.
8M 8-10290 Issued 03-2001
SECTION 6012 11
STEP 21 STEP 23
Remove the support. Rotate the differential
assembly, to seat the bearings, while evenly
tightening the RH bearing carrier retaining bolts.
Tighten the retaining bolts to a torque of 156 to 170
Nm.
STEP 24
DP97G026
Measure the gap between the RH bearing carrier
(14) and the transmission housing, through the cut
outs (A) in the RH bearing carrier (14), to obtain an
average reading . ADD 0.076 mm to the average
read ing to obtain the correct shim pack thickness.
Example:
First Reading ....... ....... ........ ........... ............ 0.635 mm
Second Reading .... .. ............................... .. .. 0.457 mm DD97J1 00
Average ............. ........ .. ............. ... ............... 0.559 mm Wrap a cord around the differential lock ring, as
Add .. ,.............................................. ............ 0.076 mm shown, and attach a spring balance. Make a note of
Shim Pack required .. .... ........ .... ...... ............ 0.635 mm the rolling pull required to rotate the differential
assembly, this must be 2 to 6.5 kg . Remove or
NOTE: If the difference between the two install shims (17) behind the RH bearing carrier
measured readings is greater than 0.203 mm, (14) to adjust the rolling pull .
remove the RH bearing carrier (14) and check
for the correct seating of the bearing and cup. NOTE: Decreasing the shim pack (17) will
increase the rolling pull, increasing the shim
STEP 22 pack (17) will decrease the rolling pull.
NOTE: A 0.025 mm thickness change in the
shim pack (17) will change the rolling pull by
0.64 kg, shims are available in the following
sizes :
0.076, 0.17, 0.30 and 0. 76 mm.
IMPORTANT: Always support the differential
assembly when removing the bearing carriers.
STEP 25
Attach suitable lifting equipment to the differential
DP97G020 assembly after the differential bearing preload has
Support the differential assembly and remove the been carried out. Remove the differential bearing
RH bearing carrier (14). Install the shim pack (17) carriers and remove the differential assembly.
determined in STEP 21. Install the RH bearing
carrier (14), install the bolts and tighten finger tight. IMPORTANT: Keep the shim packs and bearing
carriers together.
NOTE: Make sure the drain holes (A) in the RH
bearing carrier (14) and shims (17) are aligned
and towards the bottom, as shown.
8M 8-10290 Issued 03-2001
12 SECTION 6012
Setting the Ring Gear to Pinion STEP 29
Backlash Install the RH bearing carrier (14) with a new o-ring
and the shim pack (17) determined in STEP 21.
STEP 26 Install the retaining bolts and tighten finger tight.
Remove the lifting equipment.
Install the pinion shaft, refer to Section 6004 for
tractors with Creep, Section 6007 for 2WD Tractors STEP 30
or 6008 for MFD Tractors.
STEP 27
DP97G021
Rotate the differential assembly, to seat the
DP97G018
bearings, while evenly tightening the retaining bolts
in the LH bearing carrier (15) .
Use suitable lifting equipment and install the
differential assembly into the transmission housing.
STEP 31
NOTE: Care must be taken not to damage the
differential bearings when installing the
differential assembly
STEP 28
DP97G025
Rotate the differential assembly, to seat the bearings,
while evenly tightening the retaining bolts in the RH
bearing carrier (14).
H0671 6
Install the LH bearing carrier (15) with a new o-ring
(18) and the 1.37 mm shim pack (16). Install the
retaining bolts and tighten finger tight.
NOTE: Make sure the drain holes (A) in the LH
bearing carrier (15) and shims (16) are aligned
and towards the bottom, as shown.
8M 8-10290 Issued 03-2001
SECTION 6012 13
STEP 32 STEP 33
Repeat STEP 32 with the dial gauge in two more
positions equally spaced around the ring gear to
obtain the average ring gear backlash. The correct
backlash must be between 0.152 and 0.304 mm.
NOTE: If the difference in the readings is
greater than 0.102 mm repeat STEP 32 and
STEP 33 and check the backlash reading.
If the backlash is more than 0.304 mm go to
STEP 34.
If the backlash is less than 0.152 mm go to STEP
40.
D197G066
Install a dial gauge onto the ring gear (3), as shown .
Lock the pinion gear and move the ring gear (3)
backwards and forwards, make a note of the
reading on the dial gauge.
8M 8-10290 Issued 03-2001
14 SECTION 6012
Backlash too High STEP 36
To calculate the correct RH bearing carrier shim
STEP 34
pack (17) thickness add the thickness of shims
Calculate the amount of shims to be removed from removed from the LH bearing carrier shim pack
the LH bearing carrier shim pack (16) and added to (16), determined in STEP 34, to the shim pack
the RH bearing carrier shim pack (17), calculated in determined in STEP 21.
STEP 21, to obtain the correct backlash. Subtract Example:
the average required backlash 0.229 mm from the Shims Determined in
average measured backlash: STEP 21 ................................................. 0.381 mm
Example: Add Shims removed from
Measured Backlash LH Bearing Carrier Determined
First Reading ........ .... ................................. 0.356 mm in STEP 34 .... .................. .. ........... .. .... ... . 0.152 mm
Second Reading .......... ... .... ........................ .0.381 mm Required RH Bearing Carrier
Third Reading ................. .. ... ...................... 0.406 mm Shim Pack Thickness ...... ... .................... 0.533 mm
Average .. .. ... .. ........ .. .... ............. .... .......... .... .0.381 mm
Subtract .......... ... ........... .... ............ ... ........... 0.229 mm STEP 37
Shims to be removed from
LH Bearing Carrier ................................. 0.152 mm
STEP 35
DP97G020
Remove the RH bearing carrier (14). Install the
shim pack (17) determined in STEP 34, make sure
the drain holes (A) are aligned with the drain hole in
DP97G01 9 the RH bearing carrier and install a new a-ring (19).
Attach suitable lifting equipment to the differential Install the RH bearing carrier (14) and install the
assembly and support the differential. Remove the retaining bolts with Loctite 242, tighten the bolts
LH bearing carrier (15) and remove the shim pack finger tight.
(16) installed in STEP 28. Subtract the thickness of
shims calculated in STEP 34 from the shim pack STEP 38
(16). Install the shim pack (16) onto the LH bearing
carrier (15), make sure the drain holes (A) are Remove the lifting equipment. Rotate the
aligned with the drain hole in the LH bearing carrier differential assembly and tighten the RH and LH
(15) and install a new a-ring (18). Install the LH bearing carrier retaining bolts diagonally to a torque
bearing carrier (15) and shim pack (16). Install the of 156 to 170 Nm.
retaining bolts with Loctite 242, tighten the bolts
finger tight. STEP 39
Repeat STEP 32 and STEP 33 and check the ring
gear backlash .
NOTE: If the backlash is correct go to Page 16.
NOTE: If the backlash is greater than 0.304 mm
repeat STEP 34 to STEP 37. If the backlash is
less than 0.152 mm go to STEP 40.
8M 8-10290 Issued 03-2001
SECTION 6012 15
Backlash too Low STEP 42
To calculate the correct RH bearing carrier shim
STEP 40 pack (17) thickness subtract the thickness of shims
added to the LH bearing carrier shim pack (16)
Calculate the amount of shims to be added to the determined in STEP 40 to the shim pack (17)
LH bearing carrier shim pack (16) and removed determined in STEP 21 .
from the RH bearing carrier shim pack (17), Example:
calculated in STEP 21, to obtain the correct Shims Determined
backlash. Subtract the average measured backlash in STEP 21 ................. ..... ..................... .. 0.381 mm
from the average required backlash of 0.229 mm: Subtract Shims added to
Example: LH Bearing Carrier Determined
Measured Backlash in STEP 40 ........ .. .... ..... ..... .... ......... ... .... 0.152 mm
First Reading ...... .. .. .... ... ......... .. .... .. ............ 0.051 mm Required RH Bearing Carrier
Second Reading .... .... ....................... .......... 0.076 mm Shim Pack Thickness ... ....................... ..(0 .229 mm
Third Reading ...... .... .. ................. .... .. .. ....... 0.102 mm
Average Required STEP 43
Backlash ... ......... .......... ........... ........ ........ 0.229 mm
Subtract Average Measured
Backlash .................. .............. ... ...... ........ 0.076 mm
Shims to be added to
LH Bearing Carrier .......... ..... ........... ...... 0.152 mm
STEP 41
H07219
Remove the RH bearing carrier (14). Install the
shim pack (17) determined in STEP 42 , make sure
the drain holes (A) are aligned with the drain hole in
the bearing carrier and install a new o-ring (19).
Install the bearing carrier (14) and install the
retaining bolts with Loctite 242 , tighten the bolts
DP97G019
finger tight. Remove the lifting gear.
Attach suitable lifting equipment to the differential
assembly and support the differential. Remove the STEP 44
LH bearing carrier (15) and add the thickness of Remove the lifting equipment. Rotate the
shims calculated in STEP 40 to the shim pack (16) differential assembly and evenly tighten the RH and
installed in STEP 28 . Make sure the drain holes (A) LH bearing carrier retaining bolts to a torque of 156
are aligned with the drain hole in the bearing carrier to 170 Nm.
and install a new o-ring (18). Install the bearing
carrier (15) and the shim pack (16). Install the STEP 45
retaining bolts with Loctite 242, tighten the bolts Repeat STEP 32 and STEP 33 and check the ring
finger tight. gear backlash .
NOTE: If the backlash is correct go to Page 16.
If the backlash is greater thanO.304 mm repeat
STEP 34 to STEP 38. If the backlash is less
than 0.152 mm go to STEP 40.
NOTE: If the reading is not correct remove the
differential assembly, check the differential
bearing cups and cones are correctly seated
and repeat STEP 15 to STEP 25.
SM 8-10 290 Issued 03-2001
16 SECTION 6012
DIFFERENTIAL LOCK
Assembly
D199J090
1. a-RING 6. RETAINING RING 11 . a-RING
2 . RETAINING RING 7. THRUST WASHER 12. END CAP
3. PISTON ASSEMBLY 8. SPRING (DIFFERENTIAL LOCK RETURN) 13. RETAINING RING
4. SPRING (DIFFERENTIAL LOCK APPLY) 9. RETAINING RING 14 . FITTING
5. FORK 10. SUPPORT 15. SWITCH
STEP 46 STEP 48
Lubricate and install o-ring (1) into the transmission Install spring (4) onto the piston assembly (3).
housing. Install fork (5) onto the differential lock ring and
push piston assembly (3) through the fork (5) .
STEP 47
STEP 49
Install retaining ring (2) and partially install piston
assembly (3). Install retaining ring (6) and washer (7) onto piston
assembly (3).
NOTE: Care must be taken when installing the
piston assembly not to damage o-ring (1).
SM 8-10290 Issued 03-2001
SECTION 6012 17
STEP 50 STEP 52
Fully install piston assembly (3) into the Apply Loctite 242 onto the threads of support (10).
transmission housing, install retaining ring (6) into Install and tighten support (10) into the
the groove in the piston assembly (3). Install transmission housing.
differential lock return spring (8) onto piston
assembly (3). STEP 53
STEP 51 Lubricate and install o-ring (11) into the
transmission housing, install end cap (12) and
Install retaining ring (9) into the transmission retaining ring (13) . Install and tighten fitting (14).
housing.
STEP 54
Install switch (15), refer to Section 9001 for Switch
Adjustment.
Cross Sectional Drawing of the Differential Lock
f
,
I
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"
I
7"
.'
Ii
/
DI99K072
3. PISTON ASSEMBLY 10 . SUPPORT
4. SPRING (DIFFERENTIAL LOCK APPLY) 12 . END CAP
5. FORK 15. SWITCH
8 . SPRING (DIFFERENTIAL LOCK RETURN)
After Installation of the Differential and Differential Lock carry out the following :
• Install the Brake Pistons, refer to Section 7001.
• Install the Rear Axles, refer to Section 6018.
• Install the Hydraulic Lift Housing, refer to Section 8010.
• Install the Cab, refer to Section 9006.
SM 8-10290 Issued 03-2001
18 SECTION 6012
DIFFERENTIAL LOCK SOLENOID
Before removing the Differential Lock Solenoid it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation, connect the positive (+)
terminal(s) first.
STEP 2
DD98M070
Remove the nut (3) and coil (4) from the solenoid
valve (5). Remove and discard the o-rings (6), (7)
and (8) .
NOTE: For Assembly, install and tighten nut (3)
to a torque of 5 to 8 Nm. Lubricate and install
DP98M023 new o-rings (6), (7) and (8).
Disconnect the electrical connector (1) and remove
the solenoid assembly (2). NOTE: For Installation, follow the same
procedure in reverse order.
NOTE: For Installation, install and tighten the
solenoid assembly (2) to a torque of 10 to 15 Nm.
SM 8-10290 Issued 03-2001
Section
6017
MFD CLUTCH, TRANSFER GEARBOX,
DRIVE SHAFT AND PARKING BRAKE
CX Series Tractors
~ © 2003 McCormick Tractors International Limited .
McCORMICK 8M 8-10301 July 2003
2 SECTION 6017
TABLE OF CONTENTS
SPECIFICATIONS .. .... .. ..... ............................ ......... ................................................................................................... 3
SPECIAL TORQUES .. ...................... ... ........ .. .. ...................... ........... ..................... ... ..... ........... ....... ...... ........ ..... ....... 3
SPECIAL TOOLS .......................................... ............................................................................................................ 3
CHECKING THE MFD CLUTCH TORQUE ............................................................................................................... 3
MFD DRIVE SHAFT
Removal and Installation .... .......... ... ..................................................................................... .. ......... ...................... 4
MFD TRANSFER GEARBOX
Removal and Installation .... ...................................................... .. ................................. ......... ................................. 6
Disassembly .......................................................................................................................................................... 7
MFD CLUTCH
Disassembly and Assembly ................................................................................................................................ 10
MFD TRANSFER GEARBOX
Assembly .............................. ........................................................................................ ...................... ................. 12
Setting the Bearing Preload ......... ............ .. ........................ ... ... ........... .......................... ........ ....................... ....... 14
Cross Sectional Drawing of the MFD Transfer Gearbox .... ............. ........................................................................ 16
8M 8-10301 Issued 07-2003
SECTION 6017 3
SPECIFICATIONS
MFD CLUTCH
Friction Plate Thickness (New) .. ....... ............................................................................................. 2.25 to 2.35 mm
Friction Plate Thickness (Minimum) ........... ... .... ...... ... .................. .... .. ... ... .......... ...... ... ... ..... .. .... ... ...... ... .... 2.00 mm
PARKING BRAKE
Front and Rear Brake Pads (New) ............ ........... .... ... ................. .. .. .... ..... .......... .. ... .......... .. ..... 10.70 to 10.90 mm
Front and Rear Brake Pads (Minimum) .... ............ ... ...... ...... ..... ... ........................... ......... ... .. .. ........... .... .. 10.50 mm
Central Brake Pads (New) .................... .... ......................................... ..... ............... .. ............ ... .... .. .4.00 to 4.10 mm
Central Brake Pads (Minimum) .............................................. ...... ......... ... .................... ....... .. ............ .... .... 3.50 mm
Output Shaft Bearing Preload (without oil seals) .......... .... ........... .... ..... .... ..... .......... .. ............. ........... .... ..... 20 to 40 N
MFD Drive Shaft Deflection (below the centre line of the shaft)
(measured at Centre Support Bearing) ... .. .... .. ............ ... .... ...... .. .... .......... ... .. .... .. ..... ..... ...... ... ... .... 0.50 to 0.55 mm
Transmission/Hydraulic (HY-TRAN ® ULTRA) Oil Capacity ..... .... ... .............. ............... ............... ............ .... .. 37 Litres
MFD Clutch Torque .......... .... ........... .... ........... ......... ..... ...... ......... .... ........... ................ .......... .. .... .......... 638 to 792 Nm
SPECIAL TORQUES
MFD TRANSFER GEARBOX
Mounting Bolts ........................... ..... ........ .............. '" ........... .... .............................. ....... ... ... .. .... ....... 117 to 133 Nm
Drain Plug ...... .... .......... ..... .......... .... ... ..... .. ................ ............... ...... ......... ...... ... ...... .. .. ........... ........ ..... ........... 80 Nm
Front Cover Retaining Bolts .................... .. ................. ........................... .. .............. ....... .... ... .......... .... ......... .. 23 Nm
Rear Cover Retaining Bolts .......... ..... ....... .. .... ........ ... ........... .......... ......... ... ........... .... ............ .. .......... ........... 23 Nm
Brake Pad Guide Pin Plug .......... ... ... ....... .. ........... ........ .......... ... ........... ......... ........ ... ............. .. ............. ...... 150 Nm
Solenoid Cover Retaining Bolts ................. ... .... .. .... ... .. ....... ....... ............ ..... .......... ................................ ........ 12 Nm
Solenoid Valve ................. ........... .... ........... .. ............ ... ............ ..... ..... ........ ............. .... ...... .... .............. ... ........ 27 Nm
Drive Shaft Coupling Locknut .......... ...... ............. ........ ... ............. ..... ... ........ .. .... ......... ... ............ ............. .. 54 to 61 Nm
SPECIAL TOOLS
MFD CLUTCH TORQUE ADAPTOR!
PINION SHAFT RETAINING TOOL MC3001
CHECKING THE MFD CLUTCH TORQUE
Before checking the MFD Clutch Torque it is
necessary to carry out the following :
• Park the tractor on hard level ground.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Remove the MFD Drive Shaft, refer to Page 4.
DP98A110
Install the adaptor, MC3001 , onto the MFD output
shaft. Apply the service brakes and use a torque
meter to check the torque required to turn the MFD
output shaft. The torque should be between 638
and 792 Nm.
SM 8-10301 Issued 07-2003
4 SECTION 6017
MFD DRIVE SHAFT
Before servicing the MFD Drive Shaft it is necessary to carry out the following :
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the front wheels.
o Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, install and tighten the positive (+) terminal first.
Removal and Installation STEP 5
Remove the drive shaft (4), upper bearing bracket
STEP 1
(13) and shims (14).
Remove the MFD drive shaft shield .
NOTE: The deflection on the drive shaft (4)
should be between 0.50 and 0.55 mm, below
STEP 2
the centre line of the shaft.
Remove the lock nuts (1) and bolts (2) and slide the Add or remove shims (14) between the bracket
coupling (3) along the drive shaft (4) . (13) and the transmission housing until the
deflection is correct, this prevents the inner
NOTE: For Installation, tighten the locknuts (1) race of the bearing (15) rotating on the drive
to a torque of 54 to 61 Nm . shaft (4) but does not preload the bearing.
The bearing (15) must not rotate in the bearing
brackets (12) and (13).
STEP 3
Remove the lock nuts (5) and bolts (6). Remove the NOTE: Items are numbered in order of
bolts (7) and washers (8) and slide the coupling (9) Removal, Installation is in the reverse order of
along the drive shaft (4). Removal.
NOTE: For Installation, tighten the locknuts (5)
to a torque of 54 to 61 Nm .
STEP 4
Support the drive shaft (4) and remove the bolts (10),
washers (11) and lower bearing bracket (12) .
SM 8-10301 Issued 07-2003
SECTION 6017 5
~
@-~~
®~
'11_~
®.~~
10
DI98A125
1. LOCKNUT 9 . COUPLING
2. BOLT 10. BOLT
3. COUPLING 11 . WASHER
4 . DRIVE SHAFT 12 . LOW ER BEARIN
13. UPPER G BRACKET
5. LOCKNUT BEARIN G
14. SHIM (0 BRACKET
6. BOLT .5 , 1.0 and 2 0
. BEARING . mm)
7. BOLT 15
8. WASHER
SM 8-10301 Issued 07-2003
6 SECT/ON 6017
MFD TRANSFER GEARBOX
Before servicing the MFD Transfer Gearbox it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, install and tighten the positive (+) terminal first .
Removal and Installation STEP 3
Put a container with a capacity of at least 40 Litres
STEP 1
(10.5 US Gal) under the transmission and drain the
oil. Install and tighten the drain plugs after draining
the oil.
NOTE: For Installation, add clean HY- TRAN ®
ULTRA to the correct level into the
transmission, refer to Specifications, Page 3
STEP 4
H07402
Remove the drive shaft shield (1) , disconnect the
MFD Drive Shaft, refer to Page 4 . Disconnect and
cap the hydraulic tube (2). Remove the retaining
bolts (3) and cover (4) . Disconnect the electrical
connector, disconnect the tube (5) and remove the
fitting (6).
STEP 2 H07411
Use a hydraulic jack to support the transfer
gearbox. Remove the mounting bolts and carefully
lower the hydraulic jack to remove the transfer
gearbox.
NOTE: For Installation, clean the surfaces of
the transmission housing and transfer gearbox.
Apply Loctite 515 to the transfer gearbox
mounting surface. Install and tighten the
transfer gearbox mounting bolts to a torque of
117 to 133 Nm.
DP98A111
Remove the pin (7) and disconnect the parking
brake cable.
8M 8-10301 Issued 07-2003
SECTION 6017 7
Disassembly STEP 8
NOTE: For Disassembly, refer to Page 9 for
reference numbers.
STEP 5
H07330
H07326
Remove the retaining bolts (8), front cover (9) and
shims (10).
STEP 6
H07334
Remove and discard the oil seal (15) and o-ring (16),
remove and discard the o-ring (17) from the housing
(20).
STEP 9
H07332
Remove and discard the oil seal (11) and o-ring (12).
STEP 7
H07336
Remove the output shaft (18) and front bearing (19),
in the direction shown, from the clutch assembly.
H07328
Remove the retaining bolts (13) and rear cover (14) .
SM 8-10301 Issued 07-2003
8 SECTION 6017
STEP 10 STEP 12
- -
H07326 H07326
Remove the clutch assembly from the gearbox Operate the brake lever (28) to push the pins (29)
housing (20). Remove the thrust washer (21) and towards the rear of the housing 20. Install suitable
cone from the rear bearing (22) . drifts into the holes in the pins (29), as shown,
release the brake lever (28).
STEP 11
STEP 13
Remove the snap ring (30) from the groove in the
brake lever shaft. Remove the brake lever (28),
operating cam (31) and spring (32). Remove and
discard the o-ring (33).
STEP 14
Remove the drifts from the pins (29). Remove the
snap rings (34), springs (35) and pins (29).
H07326
Remove the two plugs (23), sealing washers (24)
and guide pins (25). Remove the brake pads (26)
and (27).
8M 8-10301 Issued 07-2003
SECTION 6017 9
---I@
SM1255
8 . BOLT 15 . OIL SEAL 22 . REAR BEARING 29. PIN
9 . FRONT COVER 16. a - RING 23 . PLUG 30 . SNAP RING
10. SHIM 17 . a - RING 24 . SEALING WASHER 31 . OPERATING CAM
11 . OIL SEAL 18 . OUTPUT SHAFT 25 . GUIDE PIN 32. SPRING
12 . a - RING 19. FRONT BEARING 26 . BRAKE PAD 33 . a-RING
13 . BOLT 20. HOUSING 27 . BRAKE PAD 34.SNAP RING
14. REAR COVER 21 . THRUST WASHER 28 . BRAKE LEVER 35 . SPRING
SM 8-10301 Issued 07-2003
10 SECTION 6017
MFD CLUTCH
Disassembly and Assembly STEP 19
Remove the clutch plate (47), belleville springs
STEP 15 (48), retaining ring (49), piston (50) and retaining
Remove the gear assembly (36) and brake discs ring (51) from the shaft (52). Remove and discard
(37) from the clutch assembly, remove the thrust the o-ring (53) from the piston (50).
washer (38) from the gear assembly (36).
NOTE: For Assembly, follow the same
procedure in reverse order. 00 NOT install the
STEP 16
shims (43) between the reaction plate (44) and
Remove the retaining ring (39) and piston housing snap ring (42), refer to STEP 20 and STEP 21
(40). Remove and discard the o-ring (41) from the for the shimming procedure.
piston housing (40) .
STEP 20
STEP 17
HYDRAULIC
SM1278
Using a hydraulic press and suitable sleeve,
compress the clutch pack and remove the snap ring SM1266
(42) and shims (43) . Measure the distance (8) between the piston (50)
and clutch plate (47).
STEP 18 Use the following calculation to determine the
amount of shims (43) to be installed between the
snap ring (42) and reaction plate (44).
Measured Distance (8) ............................ .. 8.00 mm
Subtract (constant) .. .. ................................. 7.40 mm
Shims (43) to be Installed .......................... 0.60 mm
NOTE: Shims (43) are available in the following
sizes : 2.00, 0.50, 0.20 and 0.10 mm.
STEP 21
o <--c-@ Refer to STEP 17 and remove the snap ring (42).
/I ~ SM1266. 1
Install the shims (43) calculated in STEP 20 and
install the snap ring (42).
Remove the reaction plate (44), separator plates
(45) and friction plates (46), in the sequence
shown. There must be two separator plates (45)
installed in each of the four positions (A) shown.
SM 8-10301 Issued 07-2003
SECTION 6017 11
,
f
@~-
SM1269
36 . GEAR ASSEMBLY 42 . SNAP RING 48 . BELLEVILLE SPRING
37 . BRAKE DISC (3) 43 . SHIM 49 . RETAINING RING
38 . THRUST WASHER 44 . REACTION PLATE 50 . PISTON
39 . RETAINING RING 45 . SEPARATOR PLATE (14) 51 . RETAINING RING
40 . PISTON HOUSING 46 . FRICTION PLATE (9) 52 . SHAFT
41 . O-RING 47. CLUTCH PLATE 53. O- RING
SM 8-10301 Issued 07-2003
12 SECTION 6017
MFD TRANSFER GEARBOX
Assembly STEP 26
STEP 22
Install the pins (29), springs (35) and snap rings
(34).
STEP 23
Install the brake pads (26) and (27), install the
guide pins (25) through the brake pads. Install the
plugs (23) and new sealing washers (24) and
tighten to a torque of 150 Nm.
STEP 24
-
H07221
With the face of the operating cam (31) against the
faces of the pins (29) install the lever (28). Apply a
upward force of 65 to 85N on the lever (28) . The
measurement (8) between the housing (20) and
lever (28) should be between 56 and 73 mm, as
shown.
NOTE: If measurement (8) cannot be obtained,
remove the lever (28) and turn clockwise or
counterclockwise by one spline until the
measurement (8) is correct.
STEP 27
H07225
Install the brake discs (36) between the brake pads Remove the brake discs (36) and the drifts installed
(26) and (27). Push the guide pins (25) towards the in STEP 24.
brake pads and install suitable drifts (A), as shown.
STEP 28
STEP 25
Install the o-ring (33) into the housing (20). Install
the spring (32), operating cam (31) and snap ring
(30) into the housing (20).
H07216
Install the brake discs (36) onto the gear assembly
(37). Install the thrust washer (38) and clutch
assembly into the gear assembly (37).
SM 8-10301 Issued 07-2003
SECTION 6017 13
SM1255
20 . HOUSING 27. BRAKE PAD 32. SPRING 37. GEAR ASSEMBLY
23 . PLUG 28 . BRAKE LEVER 33. O-RING 38 . THRUST WASHER
24. SEALING WASHER 29. PIN 34 .SNAP RING
25. GUIDE PIN 30. SNAP RING 35 . SPRING
26 . BRAKE PAD 31 . OPERATING CAM 36. BRAKE DISC
SM8-10301 Issued 07-2003
14 SECTION 6017
STEP 29 Setting the Bearing Preload
Install the clutch assembly into the housing (20) .
STEP 33
Make sure the brake discs (36) are correctly
installed between the brake pads (26) and (27). Wrap a cord around the splines of the output shaft
(18). Attach a spring balance and make a note of
STEP 30 the pull required to turn the output shaft (18) , this
must be between 20 and 40 N. Install or remove
Use a bearing oven to heat the cone of the front shims (10) between the bearing (19) and front
bearing (19) to a temperature of 80 to 90°C. Install housing (9) until the bearing preload is correct.
the bearing cone onto the output shaft (18).
NOTE: Shims (10) are available in the following
sizes : 0.1 , 0.15, 0.3 and 0.5 mm.
~ CAUTION: Always wear heat protective
ill gloves when handling hot parts. STEP 34
STEP 31
--@
SM12671
When the bearing preload is correct, remove the
rear cover (14). Use a suitable seal installer and
liM install the oil seal (15), with the lip of the seal
H07334
towards the bearing as shown . Install the a-rings
Install the output shaft (18) into the clutch (16) and (17) and install the rear cover (14). Install
assembly, install the thrust washer (21) onto the and tighten the retaining bolts (13) to a torque of 23
output shaft (18). Use a bearing oven to heat the Nm.
cone of the rear bearing (22) to a temperature of 80
to 90°C. Install the bearing cone onto the output STEP 35
shaft (18).
~ CAUTION: Always wear heat protective [- -@
ill gloves when handling hot parts.
STEP 32
Install the front and rear bearing cups. Install the
front cover (9) , shims (10) (removed in Step 6) and SM12672
the rear cover (14) , without oil seals (11) and (15) . Remove the front cover (9) . Use a suitable seal
Install and tighten the cover retaining bolts (8) and installer and install the oil seal (11) , with the lip of
(13) to a torque of 23 Nm.
the seal towards the bearing as shown. Install the
a-ring (12) and install the front cover (9) and shims
(10), determined in STEP 33. Install and tighten the
retaining bolts (8) to a torque of 23 Nm.
8M 8-10301 Issued 07 -2003
SECTION 6017 15
0--
SM1255
8. BOLT 13 . BOLT 18 . OUTPUT SHAFT 26 . BRAKE PAD
9. FRONT COVER 14. REAR COVER 19. FRONT BEARING 27 . BRAKE PAD
10. SHIM 15. OIL SEAL 20. HOUSING 36. BRAKE DISC
11. OILSEAL 16 . a -RING 21. THRUST WASHER
12. a-RING 17. a -RING 22. REAR BEARING
SM 8-10301 Issued 07-2003
16 SECTION 6017
Cross Sectional Drawing of the MFD Transfer Gearbox
SM1267
9. FRONT COVER 27.BRAKE PAD
14.REAR COVER 31 .0PERATING CAM
18 .0UTPUT SHAFT 36 .BRAKE DISC
20 .HOUSING 37 .GEAR ASSEMBLY
26 .BRAKE PAD
SM 8-10301 Issued 07-2003
Section
6018
REAR AXLES AND PLANETARIES
ex Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10310 March 2001
2 SECTION 6018
TABLE OF CONTENTS
SPECiFiCATIONS ................................................... ................................. ................. .. ......... .. ................................... 3
SPECIAL TORQUES .................................... ............. ............. ...... ..... ......... ........... '" .... ..... .......... ........... ....... ........ .... 3
SPECIAL TOOLS ............... ......... ,.... ............ ........... ................ ........ .. ......... ..... ................... .. ......................... ............ 3
TOOL TO BE MADE ............................ ............................. ................ ................................. ............... ......................... 4
REAR AXLE
Removal and Installation .. ..... ................... .................... ........................................ .............. ............ .. ......... ..... ....... 4
Disassembly and Assembly ................................................................................... .............. ................................. 6
Planetary Gear Disassembly ................................................................................................................... .. ............ 7
Planetary Gear Adjustment ...................................................................................... .. ..... ...................................... 7
Planetary Gear Assembly ..... .. .............................................................................................................................. 8
Bearing Preload Adjustment .............................................................................................................. ....... ........ .... 9
Cross Sectional Drawing of the Rear Axle .............................................................................................. ...... .......... 11
8M 8-10310 Issued 03-2001
SECTION 6018 3
SPECIFICATIONS
Planetary Gear/Planetary Gear Carrier Shimming
Model Calculated Shim Pack Shims Required
Light Duty Axle 1.11 to 1.29 mm 1.067 mm
1.30 to 1.46 mm 1.245 mm
1.47 to 1.64 mm 1.422 mm
Heavy Duty Axle 1.24 to 1.30 mm 1.08 mm
1.31 to 1.37 mm 1.15 mm
1.38 to 1.44 mm 1.22 mm
1.45 to 1.51 mm 1.29 mm
1.52 to 1.58 mm 1.36 mm
1.59 to 1.65 mm 1.43 mm
1.66 to 1.72 mm 1.50 mm
1.73 to 1.80 mm 1.57 mm
TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTRA) OIL CAPACITY
MFD Tractors ... .......... .. ............................... ..... ...... ...... ........... ....... .......... .... ........................... .. ............ .. ... 37 Litres
2WD Tractors ..... ............ ... ........ ... ............... ... ............................ .. ....................... ...... .......... .... ................ 34.5 Litres
SPECIAL TORQUES
Planet Carrier Retaining Bol1.. .................................... ........ ........ ........................................ .. ........... 290 to 330 Nm
Rear Axle Mounting Bolt .......................................................... ....................................................... 270 to 305 Nm
Rear Wheel Nuts
Flange Axle ........................................................ ............ .... .. ..................... .............. .. .. ......... ....... 278 to 298 Nm
Bar Axle (5/8 inch) ........................................ .......... .. .......................... .. ...................................... 183 to 207 Nm
Bar Axle (3/4 inch) ............................... .. ........ .. ........ .. .................. ........................................ ....... 241 to 264 Nm
SPECIAL TOOLS
DI96N124
CAB LIFTING BRACKETS MC2529
DP97K122
CAB SUPPORT STANDS MC10281
8M 8-10310 Issued 03-2001
4 SECTION 6018
TOOL TO BE MADE oil. Install and tighten the drain plugs.
NOTE: After installation of the rear axle, fill the
transmission with clean HY- TRAN ® ULTRA to
the correct level.
IA
STEP 3
Raise the rear of the tractor, support the tractor on a
suitable stand or block and remove the rear wheel.
--..,
c
-+-
! NOTE: For Installation, install and tighten the
rear wheel nuts to the correct torque, refer to
Page 3.
STEP 4
SM1281
A50mm Remove the hitch lower link arm from the side of the
B12.7 mm tractor which the axle is to be removed .
C3 .175 mm
013.5 mm STEP 5
WASHER (for checking Planetary Gear Stack Height) 2
Required
Raise or remove the hood .
STEP 6
REAR AXLE
Removal and Installation
NOTE: For Installation follow the Removal
procedure in reverse order.
Before removing the Rear Axle it will be necessary
to carry out the following:
• Park the tractor on hard level ground and apply
the parking brake.
• Lower the rear three point hitch.
• Stop the engine and remove the key. DD97K098
• Put blocks in front of and behind the front wheels. Install the cab lifting brackets, MC2529, to the rear
• Put wooden blocks between the front axle bolster of the cab. Remove the rear cab mounting nuts (1)
and front axle. and washers (2) from both rear cab mountings.
Raise the cab approximately 50 mm.
STEP 1
NOTE: For Installation, install and tighten the
Disconnect the battery, negative (-) terminal first. cab mounting nuts (1) to a torque of 215 Nm.
NOTE: For Installation, connect and tighten the
positive (+) terminal first.
STEP 2
Put a container with a capacity of at least 40 litres
(10.5 U.S. gal) under the transmission and drain the
SM 8-10310 Issued 03-2001
SECTION 6018 5
STEP 6 STEP 8
DD97K098 DP97K11 9
Install the cab lifting brackets, MC2529 , to the rear Install a cab support stand (7), MC 10281 , lower the
of the cab. Remove the rear cab mounting nuts (1) cab onto the stand .
and washers (2) from both rear cab mountings.
Raise the cab approximately 50 mm. STEP 9
NOTE: For Installation, install and tighten the
cab mounting nuts (1) to a torque of 215 Nm .
DP97K120
Raise the rear of the tractor and remove the stand
installed in STEP 3. Install a suitable block or stand
(A) under the transmission.
DP97K11 8
STEP 10
Remove the bolts (3), nuts (4) and bolts (5), remove
the cab mounting bracket (6). Use suitable lifting equipment on the rear axle.
Remove the rear axle mounting bolts and carefully
NOTE: For Installation, install and tighten the remove the axle.
cab mounting bracket mounting bolts to a
torque of 217 to 244 Nm. NOTE: For Installation, clean the surfaces of
the axle and transmission housings and apply
Loctite 515, install a nd tighten the rear axle
mounting bolts to a torque of 270 to 305 Nm.
8M 8-10310 Issued 03-2001
6 SECTION 6018
Disassembly and Assembly
f
i :-@
11
SM1262
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
NOTE: Refer to Steps 6 to 8 for Disassembly and Steps 12 and 16 for Assembly of items 14 to 18.
1.BRAKE RING 12 .0UTER BEARING CONE
2.BOLT 13.01L SEAL
3.PLANETARY GEAR CARRIER 14. ROLL PIN (3)
4.SHIM (0.007, 0.012 AND 0.0299 inch) 15.SHAFT
5.RING GEAR 16.PLANETARY GEAR (3)
6.DOWEL (3) 17 .BEARING CONE (6)
7.AXLE SHAFT 18.SHIM (1 .067,1.245 AND 1.422 inch) LIGHT DUTY AXLE
8.INNER BEARING 18.SHIM (0.54, 0.61,0 .75 AND 0.82 inch) HEAVY DUTY AXLE
9.01L SEAL 19.5PACER
1 O.OIL SEAL SLEEVE 20.AXLE HOUSING
11.0UTER BEARING CUP
SM 8-10310 Issued 03-2001
SECTION 6018 7
Planetary Gear Disassembly Planetary Gear Adjustment
NOTE: Refer to illustration on Page 6 for item NOTE: This adjustment must be carried out
numbers. when replacing the gears (16) or bearings (17) .
STEP 11 STEP 14
Install the bearings (17) into the planetary gear (16) .
STEP 15
872203
Drive the roll pins (14) into the shafts (15).
STEP 12
872229
Install the washers (A), refer to Tools to be Made,
Page 4, on each side of the planetary gear (16)
with the square edges opposite. Install a 13 X 60
mm bolt and nut, to hold the assembly together.
While rotating the planetary gear (16) tighten the
nut to a torque of 5 Nm .
STEP 16
872206
Using a hydraulic press, remove the shafts (15) from
the planetary gear carrier (3). Remove th.e roll pins
(14) from the shafts (15) .
STEP 13
Remove the gears (16), bearing cones (17) and
shims (18). Remove the spacer (19) from the carrier
(3). 872236
Measure the stack height of the bearing assembly
NOTE: Make sure items (16) to (18) are kept and make a note of the measurement.
together for correct assembly.
SM 8-10310 Issued 03-2001
8 SECTION 6018
STEP 17 Planetary Gear Assembly
STEP 19
H09604
Measure the distance (A) in the planetary gear
carrier (3) and make a note of the measurement. 872440
Install the first planetary gear (16), bearings (17) and
STEP 18 shim (18), determined in STEP 18 into the planetary
gear carrier (3). Using a hydraulic press, install the
Use the following example to calculate the amount of shaft (15) and roll pin (14) .
shims to be installed between the bearing assembly
and planetary gear carrier. NOTE: Make sure the holes in the shaft (15)
and planetary gear carrier (3) are aligned
Planetary Gear Carrier before installing the rolf pin (14) .
Dimension (A) , STEP 17 .................... .. . 55 .36 mm
Height of Bearing Assembly, STEP 16 .. ..... 53 .74 mm
STEP 20
Calculated Shim Gap ........ .. ............ .. ...... .. .... 1.62 mm
Refer to Specifications, Page 3, for the correct
amount of shims (4) to be installed between the
bearing assembly and the planetary gear carrier (3).
NOTE: Repeat STEP 14 to STEP 18 for the
remaining planetary gear assemblies. Make
sure a/l parts are kept together for correct
assembly.
872405
Install the spacer (19), repeat STEP 19 and install
the remaining gears (16) , bearings (17) and shims
(18).
STEP 21
Using a soft hammer, tap the gears (16) on both
sides to back seat the bearings (17). Make sure the
gears (16) turn freely.
Measure the end play (clearance) between the
bearing and planetary gear carrier, the measurement
should be no more than 0.28 mm. If the
measurement is incorrect repeat STEP 14 to STEP
18.
8M 8-10310 Issued 03-2001
SECTION 6018 9
Bearing Preload Adjustment STEP 24
NOTE: Before adjusting the axle bearing
preload, install items (5) to (13), refer to
Page 6, into the axle housing (20).
STEP 22
~
/ \
" "
873014
~
Install the planetary gear assembly and bolt (2) . Lock
the planetary gear and tighten the bolt (2) . Measure
the end float, if necessary tighten the bolt (2) until an
end float of between 0.025 and 0.25 mm is obtained.
SM1285 STEP 25
The bearing cone (12) should be prepacked with
Multi-purpose Lithium grease, before assembly. Wrap cord around the axle shaft, measure and note
The cavities (A) on both sides of the bearing the free rolling pull.
assembly (11) and (12) in the axle housing (20)
should be 70 to 100% filled with Multi-purpose STEP 26
Lithium grease.
Lock the planetary gear and tighten the bolt (2) until
the free rolling torque is increased by 2.26 to 3.39
STEP 23
Nm.
STEP 27
872806
Install two pieces of lead or solder onto the end of the
axle shaft (7), as shown.
873019
Lock the planetary gear, remove the bolt (2) and
planetary gear assembly. Carefully remove the two
pieces of lead installed in STEP 23 and measure the
thickness to determine the correct amount of shims
(4) to be installed.
8M 8-10310 Issued 03-2001
10 SECTION 6018
STEP 28 STEP 29
Wrap the cord around the axle, refer to STEP 25 , and
check the free rolling torque, this should be the same
as the measurement obtained in STEP 26 .
STEP 30
Install the Rear Axle, refer to Page 4.
STEP 31
Remove air from the Brake System, refer to Section
9001.
873020
Install the shims (4), determined in STEP 27, and the
planetary gear assembly. Lock the planetary gear, as
shown, install and tighten the bolt (2) to a torque of
290 to 330 Nm.
SM 8-10310 Issued 03-2001
SECTION 6018 11
Cross Sectional Drawing of the Rear Axle
Flange Axle
Bar (Rowcrop) Axle
3.PLANETARY GEAR CARRIER 11 . 0UTER BEARING CUP
5.RING GEAR 12.0UTER BEARING CONE
7.AXLE SHAFT 13.0ILSEAL
8 . INNER BEARING 15.SHAFT
9.01L SEAL 16.PLANETARY GEAR (3)
10.01L SEAL SLEEVE 20.AXLE HOUSING
SM 8-10310 Issued 03-2001
Section
6019
NON SHIFTABLE PTO
ex Series Tractors
Xtrashift Prior to Pin JJE0200493
Synchronizer Prior to Pin JJE0902626
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10320 March 2001
2 SECTION 6019
TABLE OF CONTENTS
SPECIFICATIONS .. ...................................................... ............ .............. .. ......... ... .. ........................... .. ...................... 3
SPECIAL TORQUES .... .... ........................................ ................ ............. .. .............. .............. ... ............ ... .. ... ...... ... .... .. 3
SPECIAL TOOLS ..... ....................... ......................... ................. .. ........................ ..... ........... ... ............ .... ................... 3
PTO
Removal and Installation ............ .. ......... ... .......................... ... .. ......... ..................................................................... 4
Disassembly and Assembly .................... .............. ... ............ .............. ............... ... ..... ..... .. ............................ .. ....... 6
Cross Sectional Drawing of the PTO ............ ........................ ..... ............ .. ..... .. ........ .. ................................................. 7
PTO CLUTCH
Disassembly and Assembly .... ............... ... .... ....... ... .. ............. ............... ... ..................... .. .. ...... ..... .. .... ...... ...... ... .... 8
Cross Sectional Drawing of the PTO Clutch .... ............ .. .......................................... ........... ....................................... 9
8M 8-10320 Issued 03-2001
SECTION 6019 3
SPECIFICATIONS
PTa CLUTCH (Standard)
Number of Friction Plates .............................. .......... ................. .. ........................... .............. ............... .. ................. 5
Number of Steel Separator Plates (2 between each Friction Plate) ....... .. ................. ...... ..... .... ........ ................... .. 8
PTa CLUTCH (Heavy Duty)
Number of Friction Plates .......................... .............. .................................. .......................... .. ............. .... .......... .... . 6
Number of Steel Separator Plates ......................................................................................................................... 5
TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTRA) OIL CAPACITY
2WD Tractors .......................................................................................................... ..... ........ .. ............ ..... 34.5 Litres
MFD Tractors ................. ............ ............ ....... .............. ... ............................................................................ 37 Litres
SPECIAL TORQU ES
PTa Clutch Access Cover ...... .................................... ..... ......... ..... ....... .................. .. .......... ..... ... .. .. .. ... 117 to 133 N m
PTa Shaft Cover Retaining Bolts .................................... .... ...... ................ ........ ...... .. .. ............ .. ...... ...... .. 45 to 50 Nm
SPECIAL TOOLS
E05530
SNAP RING PLIERS, MC2194
SM 8-10320 Issued 03-2001
4 SECTION 6019
PTO
Removal and Installation STEP 4
NOTE: For Installation follow the Removal
procedure in reverse order.
Before removing the PTa it will be necessary to
carry out the following:
o Park the tractor on hard level ground and apply
the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
STEP 1
Disconnect the battery, negative (-) terminal first.
H08411
NOTE: For Installation, connect and tighten the
Remove the retaining bolts and cover (3), from the
positive (+) terminal first.
transmission, remove and discard the gasket.
STEP 2 NOTE: For Installation, install a new gasket and
tighten the retaining bolts to a torque of 117 to
Put a container with a capacity of at least 40 litres 133 Nm.
(10.5 U.S. gal) under the transmission and drain the
oil. Install and tighten the drain plugs. STEP 5
NOTE: After installation of the rear axle, fill the
transmission with clean HY- TRAN ® ULTRA to
the correct level.
2WD Tractors
STEP 3
852156
Remove the roll pin (4) from the PTa clutch and
shaft.
STEP 6
Support the PTa clutch and carefully remove the
PTa shaft, remove the PTa clutch.
DD97K121
Remove the retaining bolts (1) and remove the PTa NOTE: Refer to Page 6 for Disassembly and
shield . Remove the retaining bolts and remove the Assembly of the PTO Shaft and Page 8 for
PTa shaft cover (2), remove and discard the gasket. Disassembly and Assembly of the PTO Clutch.
NOTE: For Installation, install a new gasket and NOTE: For Installation, make sure the groove in
install and tighten the retaining bolts for PTa the PTO shaft and the hole in the PTO clutch
shaft cover (2) to a torque of 45 to 50 Nm. are aligned before fully installing the PTO shaft
and roll pin.
8M 8-10320 Issued 03-2001
SECTION 6019 5
M FD Tractors STEP 10
STEP 7
8732614
Support the PTO clutch and MFD idler gear and
DD97K121 carefully remove the PTO shaft, remove the PTO
Remove the retaining bolts (5) and remove the PTO clutch and MFD idler gear.
shield. Remove the retaining bolts and remove the
PTO shaft cover (6), remove and discard the gasket. NOTE: Refer to Page 6 for Disassembly and
Assembly of the PTO Shaft and Page 8 for
NOTE: For Installation, install a new gasket and Disassembly and Assembly of the PTO Clutch.
install and tighten the retaining bolts for PTO
shaft cover (6) to a torque of 45 to 50 Nm .
STEP 8
Remove the MFD Transfer Gearbox.
STEP 9
SM1354
NOTE: For Installation, install the MFD idler gear
assembly so that the groove in the bushing is at 90 °
to the roll pin hole in the PTO clutch.
NOTE: For Installation, make sure the groove in
the PTO shaft and the hole in the PTO clutch
are aligned before fully installing the PTO shaft
and roll pin.
2WD and MFD tractors
8732606
STEP 11
Remove the roll pin (7) from the PTO clutch and
shaft.
,-
"
... --
---------- - _ .---- ---- _
SM131 7
For Installation , make sure the lugs (8) on the PTO
brake ring are located in the transmission housing
in the position shown .
8M 8-10320 Issued 03-2001
6 SECTION 601 9
Disassembly and Assembly
NOTE: For Removal and Installation of the Lower PTa Shaft (items 1 to 10), refer to Steps 4 to 7 for 2WO Tractors
and Steps 8 to 12 for MFO Tractors.
NOTE: Use Snap Ring Pliers, MC2194, for Removal and Installation of the snap ring (16) .
01978214
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
1. CAP 11. CAP 21 . BEARING
2. BOLT (3) 12. BOLT (3) 22 . RETAINING RING
3. COVER 13. COVER 23 . RETAINING RING
4 . GASKET 14 . GASKET 24 . NEEDLE BEARING
5. OIL SEAL 15 . OIL SEAL 25 . PTO IDLER SHAFT
6. LOWER PTO SHAFT 16. SNAP RING 26 . O-RING
7. SNAP RING 17. UPPER PTO SHAFT 27. IDLER GEAR (24 Teeth)
8. LOWER DRIVEN GEAR (21 Teeth) 18. UPPER DRIVEN GEAR (38 Teeth) 28 . NEEDLE BEARING
9. RETAINING RING 19 . SNAP RING 29. WASHER (QTY 4)
10. BEARING 20 . THRUST WASHER 30. THRUST BEARING (QTY 2)
SM 8-10320 Issued 03-2001
SECTION 6019 7
Cross Sectional Drawing of the PTa
DI978213
3. COVER 15. OIL SEAL 25. PTa IDLER SHAFT
5. OIL SEAL 17. UPPER PTa SHAFT 27. IDLER GEAR (24 Teeth)
6. LOWER PTa SHAFT 18. UPPER DRIVEN GEAR (38 Teeth) 28 . NEEDLE BEARING
8. LOWER DRIVEN GEAR (21 Teeth) 21. BEARING 29. WASHER (QTY 4)
10. BEARING 24. NEEDLE BEARING 30. THRUST BEARING (QTY 2)
13. COVER
SM 8-10320 Issued 03-2001
8 SECTION 6019
PTa CLUTCH
Disassembl yandA
STEP 12 ssembly
NOTE' ' Items Aare numbered'
D Isassemblll
'
of D'Isassembl
J. y ssembl ' in fh e In
Y IS orderorder
reverse of
Fnction Discs (:;%~~ty PTa Clutch
N~TE1: For H
NOTE 2' F Separator Plate;S(~a)"
'
6
, , o r Sf '
Us~ a suitable puller as shown to co Fnction DISCS
' (4)andard PTa Clutch, install 5
and 8 Sep
sprongs and re move , m oe
the retaining r' mpress the clutch arator Plates (5) ,
mg (1),
STANDARD TO
~ " '~~
REFER TO NPO CLUTCH
TE 2
4
~ (4J "o
R...
~ ~ ~N=1
---_/
~I ~ ';:s~
~~~~ ~~
/' //
1
@ ~. ~~JJ ~
(?' "cD~ (!J
SM1346
1. RETAINING RING 7 RETURN PLATE
6. 11. PISTON
3 PLATE A SSEMBLY
2, . BRAKE RING 12. INNER SEAL
, RETURN SPRING 8, SNAP RING 13. OUTER S
4. FRICTION D (6) 14 EAL
5. SEPARATO~~~NOTES 1 AND 2)
IE (NOTES 1 AND 2)
9.
10 THRUST WASHER
. HUB
. CLUTCH CUP
SM 8-10320 Issued 03-2001
SECTION 6019 9
Cross Sectional Drawing of the PTO Clutch
na:-®
SM1318
Heavy Duty PTO Clutch
SM1319
1. RETAINING RING 6. RETURN PLATE 11 . PISTON
2. PLATE ASSEMBLY 7. BRAKE RING 12. INNER SEAL
3. RETURN SPRING (6) 8. SNAP RING 13. OUTER SEAL
4. FRICTION DISC (NOTES 1 AND 2) 9. THRUST WASHER 14. CLUTCH CUP
5. SEPARATOR PLATE (NOTES 1 AND 2) 10. HUB
SM 8-10320 Issued 03-2001
Section
6019
NON SHIFTABLE PTO
ex Series Tractors
XtraShift (Pin JJE0200494 and after)
Synchronizer (Pin JJE0902627 and after)
~ © 2004 McCormick Tractors International Limited.
McCORMICK 8M 8-14030 August 2004
2 SECTION 6019
TABLE OF CONTENTS
TABLE OF CONTENTS .. .. ....... .... ...... .. ....... ....... ... ....... .. ..... ................... ........................ .................................... ....... 2
SPECiFiCATIONS ..... ... ............................. .. ...... .. ........ .. ....... .. .......... ..... ......... .................. ......................................... 3
SPECIAL TORQUES ................................... ................................................. .. .. ..... .................................................... 3
SPECIAL TOOLS ........................... .. ......... .......... .................................. .. ..... .. ........................................................... 3
NON SHIFTABLE PTO
Removal and Installation ...... ......... ........................................................................................................................ 4
Disassembly and Assembly .......................................................................................................... ........... ..... ... ..... 6
Cross Sectional Drawing of the PTO .................................................................... ............................................ .... 7
PTO CLUTCH
Disassembly and Assembly .................. .. .................................................................................. .... .. ................ ...... 8
Cross Sectional Drawing of the PTO Clutch ......... .............................................................................................. 10
8M 8-14030 Issued 08-2004
SECTION 6019 3
SPECIFICATIONS
PTO CLUTCH
Number of Friction Plates ......... .. .. ............... ..... ................... ...... ................. ... .... ............ .. .. .... ................ .. .............. 4
Number of Steel Separator Plates ................... .. .. ................ .... ................... ... .. ... .............. .. .. ... .. .............. ... .. ......... 4
Number of Backing Plates ....... .. .... ..... .. .......... .. ....................... ................... ... ....... .. ........ ...... ............ .. ..... .............. 1
TRANSMISSION/HYDRAULIC (MCCORMICK HTX) OIL CAPACITY
2WD Tractors ....... .. ................... ............................................. .. ................. ... .... .. ................. ... ................. 34.5 Litres
MFD Tractors .... ....... ......... .. ....... ................... ..... ................... .. ................. ....... .. ..... .. ......... ...... ................... 37 Litres
SPECIAL TORQUES
PTO Clutch Access Cover Retaining Bolts .......... .... .................. .... .................. .... ......... 117 to 133 Nm (86 to 98 Ib ft)
PTO Housing
3/8 inch Retaining 80Its ............ .... .................... .. .................... .............. .. .... .. ................ 45 to 50 Nm (33 to 37 Ib ft)
1/2 inch Retaining 80Its ................ .. .................... ........ .. .. .......... .. ........ .... .. .. .... ...... 136 to 152 Nm (100 to 112 Ib ft)
SPECIAL TOOLS
E05530
SNAP RING PLIERS MC2194
8M 8-14030 Issued 08-2004
4 SECTION 6019
NON SHIFTABLE PTO
Removal and Installation
NOTE: For Installation follow the Removal procedure
in reverse order.
Before removing the PTa it will be necessary to carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 5
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect and tighten the
positive (+) terminal first.
STEP 2
Put a container with a capacity of at least 40 litres
(10.5 U.S. gal) under the transmission and drain the
oil. Install and tighten the drain plugs.
NOTE: After installation of the rear axle, fil/ the
transmission with clean MCCORMICK HTX to the
correct level.
STEP 3 H08411
Remove the retaining bolts and cover (3) or MFD
On Synchro transmissions remove the cab and split Transfer Gearbox depending on transmission.
the tractor between the speed and range housings.
NOTE: For Instal/ation, apply gasket eliminator
On Xtrashift transmissions split the tractor between (Loctite 515) and tighten the retaining bolts to a
the engine and speed housing allowing the removal torque of 117 to 133 Nm (86 to 98 Ib ft) .
of the IPTO shaft cover so the shaft can be pulled
forward. STEP 6
Remove the three point linkage and drawbar, as
equipped.
STEP 4
Support the PTa clutch (4) and carefully remove the
PTa shaft and the PTa Clutch .
NOTE: Refer to Page 8 for Disassembly and
DD97K1 21 Assembly of the PTa Clutch.
Remove the four retaining bolts (1) and remove the NOTE: For Installation, refer to STEP 8 for the
PTa shield. Remove the retaining bolts and PTa correct position of the brake ring.
shaft cover (2), remove and discard the gasket.
NOTE: For Installation, install on new gasket and
tighten PTa shaft cover bolts to a torque of 45 to 50
Nm (33 to 37 Ib ft).
SM 8-14030 Issued 08-2004
SECTION 6019 5
STEP 7 STEP 8
For Installation, install the MFD idler gear assembly
so that the groove in the bushing is inline with the pin ,
7-"
/
in the PTO shaft.
SM1317
For Installation, make sure the lugs (A) on the PTO
brake ring are located in the transmission housing in
the position shown.
8M 8-14030 Issued 08-2004
6 SECTION 6019
Disassembl y and Assembly
01978214
NOTE: Items are numbered'In orderofO' Y, ssembl . .
~~
1. CAP Isassembl A
. BOLT (3)
6. y IS In the reverse order of Di
4 COVER 111. CAP
2
. GASKET 2. BOLT (3) y
5. OIL SEAL 13 COVER 21 BEARING
6. LOWER PTa S 14 GASKET 22 RETAINING RING
7. SNAP RING HAFT 15. OIL SEAL
~4.
23. RETAINING RING
2~·
8. LOWER DRIVEN 16. SNAP RING NEEDLE BEARING
~
9. RETAINING RINGGEAR (21 Teeth) 17 UPPER PTa SHAF PTO IDLER SHAFT
10 BEARING 19 . UPPER
18. DRI VEN GEAR
SNAP RING T ( 38 Teeth) 27 .
2' IDLE R GEAR (24
a-RING
20. THRUST WASHER 2:'. NEEDLE BEARING
WASHER ( eeth)
30 TH QTY 4)
SM B-14030 . RUST BEARING (OTY 2)
Issued 08-2004
SECTION 6019 7
Cross Sectional Drawing of the PTO
®~-
01978'213
3. COVER 15. OIL SEAL 25 . PTa IDLER SHAFT
5. OIL SEAL 17. UPPER PTa SHAFT 27. IDLER GEAR (24 Teeth)
6. LOWER PTa SHAFT 18 . UPPER DRIVEN GEAR (38 Teeth) 28. NEEDLE BEARING
8. LOWER DRIVEN GEAR (21 Teeth) 21 . BEARING 29. WASHER (QTY 4)
10. BEARING 24 . NEEDLE BEARING 30. THRUST BEARING (QTY 2)
13. COVER
SM 8-14030 Issued 08-2004
8 SECTION 6019
PTa CLUTCH
Disassembly and Assembly STEP 13
NOTE: items are numbered in order of Disassembly. Using a suitable block, shock the piston (8) out of
Assembly is in the reverse order of Disassembly the PTa clutch housing (A) . Remove the seal ring
(9), o-ring (10), seal ring (11) and o-ring (12) from
STEP 9 the piston (8).
Remove snap ring (1) and backing plate (2). NOTE: For Installation, lubricate and install a new
o-ring (12) and sealing ring (11) into the inner
groove of the piston (8), lubricate and install a new
STEP 10
o-ring (10) and sealing ring (9) into the outer
Remove friction plates (3) and separator plates (4). groove of the piston (8). Make sure the o-rings are
Check the friction plates, separator plates and installed before the seal rings.
backing plate (2) for wear or damage, replace if not
within specification: STEP 14
Friction plate .... .... .. .. .. ..... .... .. .. ... .. 2.45 to 2.60 mm Remove snap ring (13). friction plate (14) belleville
washer(15) brake plate (16). and friction plate (17).
Separator plate .. ................ .. .. ..... .. 2.16t02.31 mm
IMPORTANT: If a new PTa clutch housing (A) is
Backing plate .. ........... .. ............ .. ... 5.58 to 5.71 mm to be installed, install a new snap ring (13) into the
inner groove on the splines of the PTa clutch
NOTE: For Installation, install one separator housing (A) .
plate (4) and one friction plate (3) into the PTa
clutch housing (A). Continue to install one STEP 15
separator plate and one friction plate until a Remove three piston pins (18), remove and discard
total of four separator plates (4) and four friction o-rings (19) .
plates (3) have been installed. The last plate
installed must be a friction plate. NOTE: For Installation , install new o-rings (19),
make sure the piston pins (18) are installed with
STEP 11 the flat head facing the friction plate (17) as
shown.
DD96N178
Install PTa clutch housing (A) onto a suitable
hydraulic press . Using the spring compressor (B)
MC 1992, compress the spring (7) and remove the
snap ring (5).
STEP 12
Release the pressure from the press, remove the
spring compressor (B) MC1992. Remove spring
retainer (6) and spring (7).
SM 8-14030 Issued 08-2004
SECTION 6019 9
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
1. SNAP RING 8. PISTON 15. BELLEVILLE WASHER
2. BACKING PLATE 9. SEAL RING 16. BRAKE PLATE
3. FRICTION PLATE (4) 10. O-RING 17. FRICTION PLATE
4. SEPARATOR PLATE (4) 11 . SEAL RING 18. PISTON PIN
5. SNAP RING 12. O-RING 19. O-RING
6. SPRING RETAINER 13. SNAP RING
7. SPRING 14. FRICTION PLATE
SM 8-14030 Issued 08-2004
10 SECTION 6019
Cross Sectional Drawing of the PTa Clutch
MI04H049
1. SNAPRING 8. PISTON 15. BELLEVILLE WASHER
2. BACKING PLATE 9. SEAL RING 16. BRAKE PLATE
3. FRICTION PLATE (4) 10. O-RING 17. FRICTION PLATE
4. SEPARATOR PLATE (4) 11 . SEAL RING 18. PISTON PIN
5. SNAP RING 12. O-RING 19. O-RING
6. SPRING RETAINER 13 . SNAP RING
7. SPRING 14. FRICTION PLATE
SM 8-14030 Issued 08-2004
Section
6020
SHIFTABLE PTa
ex Series Tractors
Xtrashift Prior to Pin JJE0200493
Synchronizer Prior to Pin JJE0902626
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10330 March 2001
2 SECTION 6020
TABLE OF CONTENTS
TABLE OF CONTENTS ........................ ............... .... .......... .. ........ .... ....... .......... .. ............ .. ............ .. ....... ................. .. 2
SPECiFiCATIONS ...... .. ... .. ... ... ....... ........ ..... .... ...... .......... ................ .. ............................... ................... '" ................... 3
SPECIAL TORQUES ......... ................ ...... ... .................. ............... ... ................... .............. .......................................... 3
TOOL TO BE MADE ................................................. ..... .. .......................................................................................... 3
SHIFTABLE PTO
Removal and Installation ...... .. ...................................................................... ... ...................................................... 4
Disassembly and Assembly .................................................................................................................................. 8
Cross Sectional Drawing of the Shiftable PTO ................................ .................... .. ............................................... 9
PTO CLUTCH
Disassembly and Assembly ........ .............. ................. ..................... .. ................................... ............................. .. 10
Cross Sectional Drawing of the PTO Clutch ....................................................................................................... 11
SM 8-10330 Issued 03-2001
SECTION 6020 3
SPECIFICATIONS
PTO CLUTCH
Number of Friction Plates .......... ... ................. ............ ... ......... ..... ........ .... .... ....... .. .. ... ......... ...... .. ....... ................ ..... 6
Number of Steel Separator Plates (2 between each Friction Plate) .... ....... ...... .. ... ... .. ..... .... .......... ..... .. ................. 5
TRANSMISSION/HYDRAULIC (HY-TRAN ® ULTRA) OIL CAPACITY
2WD Tractors ... ....... ..... ... .. .... ......... ........... .... ......... ...... ........... .. .... ......... .. ... .. ....... ... ....... ..... .... ...... ... ....... 34.5 Litres
MFD Tractors ..... ....... ....... ...... ........... ........ .......... .... .... .... ...... .......... .. ..... .............. ........... ..... ... ... .. .. .... ... ... .. 37 Litres
SPECIAL TORQUES
PTO Clutch Access Cover Retaining Bolts ............ .. ... ..... .... .. ... ... ... ............ ........ .... ... .. ........... .. ........... 117 to 133 Nm
PTO Housing
3/8 inch Retaining Bolts ............. .. ........... .. ........ ....... ...... .. .. ...... .......... ........ ...... .. ....... ......... .... ............ . 45 to 50 Nm
1/2 inch Retaining Bolts .. ............ .. .................................................................................................. 136 to 152 Nm
TOOL TO BE MADE
G
I~ E ·1
1 H
t ~==================~+
BEARING RETAINING TOOL
(Used when removing 540/1000 rpm Gear Cluster, Page 7)
A. .... 155mm
B ...... 75 mm
C ...... 38 mm
0 .. .. .. 42 mm
E .. .. .. 30 mm
F .. .... 55 mm
G ...... 15 mm
H ........ 2 mm
8M 8-10330 Issued 03-2001
4 SECTION 6020
SHIFTABLE PTO
Removal and Installation
NOTE: For Installation follow the Removal
procedure in reverse order.
Before removing the Shiftable PTa it will be
necessary to carry out the following:
• Park the tractor on hard level ground and apply
the parking brake.
Stop the engine and remove the key.
Put blocks in front of and behind the rear wheels.
STEP 1
Disconnect the battery, negative (-) terminal first.
H0831 7
NOTE: For Installation, connect and tighten the
Put a suitable container under the PTa housing,
positive (+) terminal first.
remove the six retaining bolts (2) and (3) and using
the levers in the cut-outs (A), carefully remove the
STEP 2 shiftable PTa housing.
Put a container with a capacity of at least 40 litres
NOTE: For Installation , install and tighten the
(10.5 U.S. gal) under the transmission and drain the
bolts (2) to a torque of 136 to 152 Nm and bolts
oil. Install and tighten the drain plugs.
(3) to a torque of 45 to 50 Nm .
NOTE: After installation of the rear axle, fill the
transmission with clean HY- TRAN ® ULTRA to STEP 6
the correct level.
STEP 3
Remove the three point linkage and drawbar, as
equipped .
•
STEP 4
- - ----
H08319
Remove the output shaft assembly, selector collar
and needle bearing.
NOTE: It is not necessary to remove the
selector fork and selector shaft to remove the
PTa Clutch. For PTa Clutch removal, refer to
STEP 11 to STEP 13 for 2WD Tractors or STEP
H0831 3 14 to STEP 16 for MFD Tractors.
Remove the four retaining bolts (1) and remove the
PTa shield.
8M 8-10330 Issued 03-2001
SECTION 6020 5
STEP 7 STEP 9
DD97K069 H08325
Remove the spring clip pin (4) from the clevis on the Carefully remove the selector shaft from the
control rod. selector fork and shift detent. Remove the selector
fork and shift detent.
STEP 8
IMPORTANT: Care must be taken when
removing the selector shaft from the shift
detent. the detent spring and ball are under
compression. Remove the roll pin after
removing the selector shaft.
STEP 10
H08323
Drive the roll pin (5) into the selector shaft.
-0
H08409
Remove the detent ball (6) and spring (7) from the
selector fork (8) .
8M 8-10330 Issued 03-2001
6 SECTION 6020
2WD Tractors MFD Tractors
STEP 14
Remove the MFD Transfer Gearbox.
STEP 15
H08411
Remove the retaining bolts and cover (9) from the
transmission, remove and discard the gasket.
NOTE: For Installation , install a new gasket and
8732606
tighten the retaining bolts to a torque of 117 to
Remove the roll pin (11) from the PTa clutch and
133 Nm .
shaft. Support the PTa clutch and MFD idler gear,
carefully remove the PTa shaft.
STEP 12
NOTE: For Installation, refer to Step 19 for the
correct position of the brake ring.
STEP 16
---
........
8521 56
Remove the roll pin (10) from the PTa clutch and
shaft.
STEP 13 8732614
Remove the PTa clutch and MFD idler gear.
Support the PTa clutch and carefully remove the
PTa shaft, remove the PTa clutch .
NOTE: Refer to Page 10 for Disassembly and
Assembly of the PTa Clutch.
NOTE: For Installation, make sure the groove in
the PTa shaft and the hole in the PTO clutch
are aligned before fully installing the PTO shaft
and roll pin.
SM 8-10330 Issued 03-2001
SECTION 6020 7
STEP 17 STEP 20 540/1000 rpm
SM 1354
For Installation, install the MFD idler gear assembly
so that the groove in the bushing is at 90° to the roll
pin hole in the PTO clutch.
H08331
NOTE: For Installation, make sure the groove in
the PTO shaft and the hole in the PTO clutch
are aligned before fully installing the PTO shaft
and roll pin.
2WD and MFD Tractors
STEP 18 :- --.,@
SM1316
SM1317
Remove the 540/1000 rpm gear cluster (13).
NOTE: When removing the 54011000 rpm gear
For Installation, make sure the lugs (A) on the PTO cluster (13) it will be necessary to use the
brake ring are located in the transmission housing bearing retainer tool (14), refer to Tools to be
in the position shown. Made, Page 3, to hold the front bearing (15) in
the transmission housing.
STEP 19 540/750 rpm
Hoa329
Remove the 540/750 rpm gear cluster (12).
8M 8-10330 Issued 03-2001
8 SECTION 6020
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
1.SHIFTABLE PTO HOUSING 11 .SPACER
2. BOLT (3) 12. PTO SHAFT
3.COVER 13 .NEEDLE BEARING
4.0ILSEAL 14 .COLLAR
5.BEARING 15 .PTO SHAFT
6. BEARING 16 .BEARING
7.RETAINING RING 17.GEAR CLUSTER (540/750 rpm - 33/39 Teeth)
8.WASHER 17.GEAR CLUSTER (540/1000 rpm - 33/43 Teeth)
9.GEAR (34Teeth) 18.FRONT BEARING
10 .NEEDLE BEARING 19 .REAR BEARING
SM 8-10330 Issued 03-2001
SECTION 6020 9
Cross Sectional Drawing of the Shiftable PTa
-~@
,,
SMI308
1.SHIFTABLE PTO HOUSING 15. PTO SHAFT
3.COVER 16.BEARING
6.BEARING 17.GEAR CLUSTER (540/750 rpm - 33/39 Teeth)
9 .GEAR (34Teeth) 17.GEAR CLUSTER (540/1000 rpm - 33/43 Teeth)
12 .PTO SHAFT 18.FRONT BEARING
14.COLLAR 19.REAR BEARING
SM 8-10330 Issued 03-2001
10 ___ SECTION 6020
PTO CLUTCH
Disassembly and
STEP 21 Assembly
NOTE: Items are
o.
Isassembly A numbered ·
Us~ a suitable puller of Disassembly. ssembly is in th e In
reverse
orderorder
of
springs and re move the
as shown to co
retaining ""'"
r· mpress the clutch
Ing (1)
1. RETAINING RING 6.RETURN PLATE 11 . PISTON
2.
3 PLATE ASSEM BLY 7. BRAKE RING 12. INNER SEAL
.RETURN SPRIN G 8.SNAP RING 13.0UTER SEAL
4.FRICTION DISC 6 (6) 9.THRUST WA 14.CLUTCH CUP
5.SEPARATOR PLATE
() (5) 10.HUB SHER
SM 8-10330 Issued 03-2001
SECTION 6020 11
Cross Sectional Drawing of the PTO Clutch
I,
SM1319
1. RETAINING RING 6. RETURN PLATE 11 . PISTON
2.PLATE ASSEMBLY 7. BRAKE RING 12. INNER SEAL
3.RETURN SPRING (6) 8.SNAP RING 13.0UTER SEAL
4.FRICTION DISC (6) 9. THRUST WASHER 14.CLUTCH CUP
5.SEPARATOR PLATE (5) 10. HUB
SM 8-10330 Issued 03-2001
Section
6020
SHIFTABLE PTO
ex Series Tractors
XtraShift (Pin JJE0200494 and after)
Synchronizer (Pin JJE0902627 and after)
~ © 2004 McCormick Tractors International Limited .
McCORMICK SM 8-14020 August 2004
2 SECTION 6020
TABLE OF CONTENTS
TABLE OF CONTENTS ... ................~ ........................................................................................................................ 2
SPECiFiCATIONS ........... .. ............................... .... ........... ................... ...... ..... ..... .......... ..... .... ............... ....... ...... .... ... . 3
SPECIAL TORQUES .. ....... ... .... ........ .. .......................... .............. ..... .......... ..... ........ .. ................. .................. .............. 3
TOOL TO BE MADE .. ................. ..... ................... .... .... .. ... ...... .... .. .... ... .... .. ... .... ............................................ .. ....... ..... 3
SHIFTABLE PTO
Removal and Installation .......................................................................................................................................4
Disassembly and Assembly .................... ................. .......................... .. ....... .................. ..... ... .. ................. ........ ..... 7
Cross Sectional Drawing of the Shiftable PTO .................................................... .. ............................................... 8
PTO CLUTCH
Disassembly and Assembly ...................................................................................................... .......................... 10
Cross Sectional Drawing of the PTO Clutch ....................................................................................................... 12
8M 8-14020 Issued 08-2004
SECTION 6020 3
SPECIFICATIONS
PTO CLUTCH
Number of Friction Plates ... .. ........................................ .... .......... .. ........ .. ... .. ..... .................... .. ........... ... ............. .... 4
Number of Steel Separator Plates .. ........... .... ........... ............... ..... .......... ... ...... ..... ..... ........... .. ............ ............. .... ..4
Number of Backing Plates ..... ........... ................ .... ........ ... ......... .. ......... ..... ............ .. .......... ............... ....... .. .......... .. . 1
TRANSMISSION/HYDRAULIC (MCCORMIK HTX) OIL CAPACITY
2WD Tractors .. ..... .......... .. ............. .... .......... ..... .......... .... ... ........... ........... ..... .... .. ... ..... .............. .. ............. 34.5 Litres
MFD Tractors ... ... ........ ... .. ... .......... .. ..... ...... ...................... ............ ............... .............................................. . 37 Litres
SPECIAL TORQUES
PTO Clutch Access Cover Retaining Bolts .... .................. ............ .... .......... ................. .. 117 to 133 Nm (86 to 98 Ib ft)
PTO Housing
3/8 inch Retaining Bolts ... ............ ...... .. ... ..... ... .... ...... .... ...... ... ... .......... .. .......... ... .... ..... .. 45 to 50 Nm (33 to 37 Ib ft)
1/2 inch Retaining Bolts ...... ......... ..... ........... .... .. ........ ..... ............ ............ .. .. .......... 136 to 152 Nm (100 to 112 Ib ft)
TOOL TO BE MADE
A
BEARING RETAINING TOOL
(Used when removing 540/1000 rpm Gear Cluster, Page 6)
A ..... 155mm
B ...... 75 mm
C ...... 38 mm
D ...... 42 mm
E .. ... . 30 mm
F .. ... . 55 mm
G ...... 15 mm
H ... ..... 2mm
SM 8-14020 Issued 08-2004
4 SECTION 6020
SHIFTABLE PTa
Removal and Installation
NOTE: For Installation follow the Removal procedure
in reverse order.
Before removing the Shiftable PTO it will be necessary to carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
STEP 1 STEP 5
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect and tighten the
positive (+) terminal first.
STEP 2
Put a container with a capacity of at least 40 litres
(10.5 U.S. gal) under the transmission and drain the
oil. Install and tighten the drain plugs.
NOTE: After installation of the rear axle, fill the
transmission with clean MCCORMICK HTX to the
correct level.
H08317
STEP 3 Put a suitable container under the PTO housing,
remove the six retaining bolts (2) and (3) and using
On Synchro transmissions remove the cab and split the levers in the cut-outs (A), carefully remove the
the tractor between the speed and range housings. shiftable PTO housing.
On Xtrashift transmissions split the tractor between NOTE: For Installation, install and tighten the bolts
the engine and speed housing allowing the removal (2) to a torque of 136 to 152 Nm (100 to 1121b ft) and
of the IPTO shaft cover so the shaft can be pulled bolts (3) to a torque of 45 to 50 Nm (33 to 37 Ib ft).
forward.
STEP 6
Remove the three point linkage and drawbar, as
equipped .
STEP 4
H08319
Remove the output shaft assembly, selector collar
and needle bearing.
H08313
NOTE: It is not necessary to remove the selector
fork and selector shaft to remove the PTO Clutch. For
Remove the four retaining bolts (1) and remove the
PTO Clutch removal, refer to STEP 11 to STEP 14
PTO shield .
8M 8-14020 Issued 08-2004
SECTION 6020 5
STEP 7 STEP 10
I"' ~---G
DD97K069 H08409
Remove the spring clip pin (4) from the clevis on the Remove the detent ball (6) and spring (7) from the
control rod. selector fork (8).
STEP 8 STEP 11
H08323 H08411
Drive the roll pin (5) into the selector shaft. Remove cover (9) or MFD Transfer Gearbox
depending on transmission.
STEP 9 NOTE: For Installation, apply gasket eliminator
(Loctite 515) and tighten the retaining bolts to a
torque of 117 to 133 Nm (86 to 98 Ib ft).
STEP 12
Carefully remove the selector shaft from the selector
fork and shift detent. Remove the selector fork and
shift detent.
IMPORTANT: Care must be taken when removing
Support the PTO clutch (10) and carefully remove
the selector shaft from the shift detent, the detent
the PTO shaft and the PTO clutch.
spring and ball are under compression. Remove the
roll pin after removing the selector shaft.
8M 8-14020 Issued 08-2004
6 SECTION 6020
NOTE: Refer to Page 10 for Disassembly and STEP 16 540/1000 rpm
Assembly of the PTO Clutch.
NOTE: For Installation, refer to STEP 14 for the
correct position of the brake ring.
STEP 13
For Installation, install the MFD idler gear assembly
so that the groove in the bushing is inline with the pin
in the PTO shaft.
STEP 14
H08331
SM1317
For Installation , make sure the lugs (A) on the PTO
brake ring are located in the transmission housing in
the position shown.
STEP 15 540/750 rpm
SM1 316
Remove the 540/1000 rpm gear cluster (13).
NOTE: When removing the 540/1000 rpm gear
cluster (13) it will be necessary to use the bearing
retainer tool (14), refer to Tools to be Made, Page 3,
to hold the front bearing (15) in the transmission
housing.
H08329
Remove the 540/750 rpm gear cluster (12).
8M 8-14020 Issued 08-2004
SECTION 6020 7
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly
1.SHIFTABLE PTO HOUSING 11.SPACER
2. BOLT (3) 12.PTO SHAFT
3.COVER 13. NEEDLE BEARING
4.0ILSEAL 14.COLLAR
5. BEARING 15 .PTO SHAFT
6. BEARING 16. BEARING
7. RETAINING RING 17.GEAR CLUSTER (5401750 RPM - 33139 TEETH)
8.WASHER 17.GEAR CLUSTER (54011000 RPM - 33143 TEETH)
9. GEAR (34TEETH) 18.FRONT BEARING
10.NEEDLE BEARING 19.REAR BEARING
SM 8-14020 Issued 08-2004
8 SECTION 6020
Cross Sectional Drawing of the Shiftable PTO
f
,
SM1308
1.SHIFTABLE PTO HOUSING 15.PTO SHAFT
3.COVER 16 .BEARING
6. BEARING 17.GEAR CLUSTER (540/750 RPM - 33/39 TEETH)
9. GEAR (34TEETH) 17 .GEAR CLUSTER (540/1000 RPM - 33/43 TEETH)
12. PTO SHAFT 18.FRONT BEARING
14.COLLAR 19.REAR BEARING
SM 8-14020 Issued 08-2004
SECTION 6020 9
THIS PAGE HAS BEEN LEFT BLANK
8M 8-14020 Issued 08-2004
10 SECT/ON 6020
PTO CLUTCH
Disassembly and Assembly STEP 21
NOTE: items are numbered in order of Disassembly Using a suitable block, shock the piston (8) out of
Assembly is in the reverse order of Disassembly the PTa clutch housing (A). Remove the seal ring
(9), o-ring (10) , seal ring (11) and o-ring (12) from
STEP 17 the piston (8).
Remove snap ring (1) and backing plate (2). NOTE: For Installation, lubricate and install a new
o-ring (12) and sealing ring (11) into the inner
groove of the piston (8), lubricate and install a new
STEP 18 a-ring (10) and sealing ring (9) into the outer
Remove friction plates (3) and separator plates (4). groove of the piston (8). Make sure the a-rings are
Check the friction plates, separator plates and installed before the seal rings.
backing plate (2) for wear or damage, replace if not
within specification: STEP 22
Friction plate .......... .... ............ .... .. 2.45 to 2.60 mm Remove snap ring (13), friction plate (14) belleville
washer(15) brake plate (16). and friction plate (17).
Separator plate .. .... ........ ............... 2.16t02.31 mm
IMPORTANT: If a new PTa clutch housing (A) is
Backing plate ... ............. ... ..... ........ 5.58 to 5.71 mm to be installed, install a new snap ring (13) into the
inner groove on the splines of the PTa clutch
NOTE: For Installation, install one separator housing (A).
plate (4) and one friction plate (3) into the PTa
clutch housing (A). Continue to install one STEP 23
separator plate and one friction plate until a Remove three piston pins (18) , remove and discard
total of four separator plates (4) and four friction o-rings (19).
plates (3) have been installed. The last plate
installed must be a friction plate. NOTE: For Installation, install new a-rings (19),
make sure the piston pins (18) are installed with
STEP 19 the flat head facing the friction plate (17) as
shown.
DD96N178
Install PTa clutch housing (A) onto a suitable
hydraulic press. Using the spring compressor (B)
MC 1992, compress the spring (7) and remove the
snap ring (5).
STEP 20
Release the pressure from the press , remove the
spring compressor (8) MC1992. Remove spring
retainer (6) and spring (7).
SM 8-14020 Issued 08-2004
SECTION 6020 11
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
1. SNAP RING 8. PISTON 15. BELLEVILLE WASHER
2. BACKING PLATE 9. SEAL RING 16. BRAKE PLATE
3. FRICTION PLATE (4) 10. O-RING 17. FRICTION PLATE
4. SEPARATOR PLATE (4) 11 . SEAL RING 18. PISTON PIN
5. SNAP RING 12. O-RING 19. O-RING
6. SPRING RETAINER 13. SNAP RING
7. SPRING 14. FRICTION PLATE
SM 8-14020 Issued 08-2004
12 SECT/ON 6020
Cross Sectional Drawing of the PTa Clutch
MI04H049
1. SNAP RING 8. PISTON 15 . BELLEVILLE WASHER
2. BACKING PLATE 9. SEAL RING 16 . BRAKE PLATE
3. FRICTION PLATE (4) 10. O-RING 17. FRICTION PLATE
4. SEPARATOR PLATE (4) 11 . SEAL RING 18 . PISTON PIN
5. SNAP RING 12. O-RING 19. O-RING
6. SPRING RETAINER 13 . SNAP RING
7. SPRING 14. FRICTION PLATE
SM 8-14020 Issued 08-2004
Section
6021
MFD AXLE
ex Series Tractors
~ © 2003 McCormick Tractors International Limited .
McCORMICK SM 8-10341 July 2003
2 SECTION 6021
TABLE OF CONTENTS
SPECiFiCATIONS .......... ... ... .... .................... .... ..... .... ...... .... .. ........... ... .... ... ... ... ....... .... ..... ........ .... .. ..... ..... .. ............... 3
SPECIAL TORQUES ..... .. ... .......... ...... .......... ... ...... .... ..... .. .. .. .. ... .. ..... .. ..... ... ... ... ...... .. .. ..... ...... ...... .... .. .. ... ..... ....... ....... 3
SPECIAL TOOLS ... ...... .......... .. ....... ........ .............. ................ ...... .. ...... ...... ................. ............ .. .............. ...... ... ... ....... 4
GENERAL INFORMATION .. .... .... ...... ...... .. .. ............ .. ..... ............ .................................... .. ............. .. ....... .. ................ 6
PLANETARY GEAR
Removal and Installation ............. ... ................... .. ..... ... ...... ...... ................. .. .. ...................... .. .............. .... ............... 6
Disassembly and Assembly ............................................................................ ................................... ... .. .............. 7
WHEEL HUB
Disassembly and Assembly .. ...... .............. ... ... .... ............. .. ........ .. ......................................................................... 8
SWIVEL HOUSING
Removal and Installation ....................................... ... ............................................ .. ..................... .............. ... .... .. . 10
Disassembly and Assembly ............................................................................................ ...... ....... .. .... ............ ..... 11
DRIVE SHAFT
Disassembly and Assembly .. ...... ............................................. ..................... .. ....... ............ ... ..... .. ....... .. ..... ..... .. .. 13
CROSS SECTIONAL DRAWING OF THE PLANETARY GEAR ASSEMBLY,
WHEEL HUB, SWIVEL HOUSING AND DRIVE SHAFT ......................... ...... .. .. .. ...... .. ... ...... ...... .......... ..... .. ....... 14
MFD AXLE
Removal and Installation ..................................................................................................................................... 15
Disassembly and Assembly .. ...... ... ................... .. ..... .. .. ..... ...... .. ..... ............................. .... ........... ......................... 16
DIFFERENTIAL HOUSING
Disassembly ........... ....... ........ ...... ................. ..... ... .......... .. ....... .. ...... ....... ..................... .. .................... ........ .. .. ..... . 18
DIFFERENTIAL
Disassembly and Assembly ........ .................................... .. ...... ....... ..................................................................... 20
Cross Sectional Drawing of the Differential ........ .. ..... ... ........... ............ ... .... ..... ... .............................. ...... .. ........... 21
Setting the Position of the Pinion Shaft ............. .. ............ .. ...... ............................................................................ 22
Pinion Shaft Assembly ....... ......... .. ....................... ..... ... ........... .. .. ... ... .... ...... .. ............ ................................ ....... ... 24
Differential Installation .......... ............................. .. ............ .. .................... ......................... ..................................... 26
Ring Gear Backlash Adjustment ........ .. ...... ... ... .. .............................. ............................ .. ..... .. ............ ....... ... ........ 27
Differential Bearing Preload Adjustment ................ .... ................... ....................... .. .. ....... ..... .. ............................. 28
STEERING CYLINDER
Disassembly and Assembly .............................. ... ............. .................................. ....................... ..................... .... 29
SM8-10341 Issued 07-2003 .
SECTION 6021 3
SPECIFICATIONS
DIFFERENTIAL
Separator Plate Thickness ......... ..... .. .. ..... ... .............. .. .. ......... ..... .. .. ....... ... ...... ....... .. .. .... ................... ..... ..... 1 .5 mm
Friction Disc Thickness .. .......... .... .. ........ .. .............. ...... ........ .. .. .. ........... ..... ........ .......... ................... 1.45 to 1.6 mm
Thrust Plate Thickness ......... ..... .. ... .. .......... .. ............ ... .. ....... .. ........ .. ....... .. .. ... .... ... ......... ....... ... .. ....... 2.7 to 2 .8 mm
Pinion Shaft Bearing Preload ..... .. ............... ... ......... ................. ... ............ .. ............ ... ......... .. ... .. ......... . 105 to 157 N
Pinion ShafUDifferential Bearing Total Preload ....... ...... .... .. ...... ............ ............... .. ... 105 to 157 (+ 29 .5 to 44 .1) N
Bevel Gear to Pinion Backlash ... ... ...... .. ......... .......... ........... .. .. .... .. ............ .. ....... ..... .... .............. .... 0.16 to 0.22 mm
LUBRICANTS
Planetary and Wheel Hub
Type ........ .. .... .. .. ..... .. .. ........... .......... ...... ... .. ...... .......... .. ........ .. ...... .. .... .. SAE 85W-140EP Gear Oil to APL GL-5
Capacity, per Hub .......... ... .. ... ...... ............... ............... .. .. ......... ..... ......... ..... ......... ...... ........... ... ............ .... .. 0.6 Litres
Differential/Axle Housing
Type ........ .. .. .... .......... .. .... ........ .... ........... .... ........... ........ ...... ... ...... .. .. .. .. SAE 85W-140EP Gear Oil to APL GL-5
Capacity .... .... ..... .............. .......... ... ......... .... ........ .. ..... .. ... ....... .. .. ... .... ....... ......... .. .. .. ......... .. ..... .... ....... .. .... 6 Litres
Grease ........... .. ....... .. ... .. .. .......... ..... .. .. ...... .... .......... ..... .... .... .... ...... .. ..... ... .. ... .. ....... Multi-Purpose lithium Grease
Front Wheel Toe-in .... .. ... .. ................................................................................ .... ...... ... .............. .. ......... ... .. . 0 to 2mm
SPECIAL TORQUES
Axle Support Housing Retaining Bolts .... .... .. .. ....... ... .. ............................ .......... .. ................. ...................... 200 Nm
Wheel Hub Drain/Filler Plug ...... ...... ........... .. ............. .. ............ ..... .......... ... .......... ... .. ........... .... ........... ..... ..... 80 Nm
Axle/Differential Housing Drain Plug ......... .. ... .. ...... .... .. .... ..... .... ...... ...... ... ..... ........ .... .. .......... .. ................ .. ... 70 Nm
Axle Dipstick ... .............. .. ..... ... .. .. ............ .. ..... .......... .. ... .......... ... .... ....... ..... ............ ..... ......... ..... .......... ... ....... 10 Nm
Wheel Hub to Planetary Gear Carrier Countersunk Screws ... ............................................ ............... .. ........ 25 Nm
Planetary Gear Carrier to Swivel Housing Retaining Bolts .... ................ .. ... .......... ... ............ ...... .......... .... .... 78 Nm
Upper and Lower King Pin Retaining Bolts ......... .. .. ...... ... .. ..... .. ... .... .. .... ........ ............. .. .. .. .. .... .... ....... .. .... .. 120 Nm
Differential Housing to Axle Retaining Bolts .. ........... ... ............ ....... .. ........ .. ... .... .... ... ............ .. ....... .. .. .. ... .... 169 Nm
Bevel Gear Retaining Bolts (with Loctite 270) .......... .. ................ .. ........................... ............ .. ............. .. ........ 78 Nm
Differential Bearing Cap Retaining Bolts ........ .... .......... .... .... .. ........ .......... ........ .......... .... ........ .... ...... .......... 266 Nm
Locking Plate Retaining Bolts ................... .... .. .......... .. ....... .. ... .. ............. ............... .. .. ............................ ........ 12 Nm
Ball Joint Assembly to Steering Cylinder Piston Rod .. .. ......... ....... .... ..... .. .. ... ...... ............... .... .... .... .... .. .. .... 300 Nm
Ball Joint Locknut ....... .... ............ ... .. .. .......... .. ....... ... .. ............... ... ... .. .. ... .. ..... ........... ................. .......... .. .... .. 165 Nm
Steering Cylinder Retaining Bolts .. ..................... ........... ... .. .... ....... .. .... .... .............. ..... ...... .. .. .. ................... 120 Nm
Front Wheel Nuts ........ ............................................. .. ............ .. .......................................... ... .......... 300 to 350 Nm
Front Weight Bracket .... .. ........... .... .... .. ...... .... ............ .. ........... ........... ...... .. .... .. ................................ 481 to 542 N m
Wheel Stud ..... ..... .. .. .. .. .... ... ............ .. .. ...... .... .... ... ..... .. ... ..... ...... ............. .. .. .. .......................... ....................... 70 Nm
SM 8-10341 Issued 07-2003
4 SECTION 6021
SPECIAL TOOLS
DP99E020 DP99E0 16
WHEEL HUB SEAL INSTALLER MC2705 AXLE HOUSING BUSHING INSTALLER MC2708
DP99E017 DR99F019
SWIVEL HOUSING BUSHING INSTALLER MC2707 AXLE HOUSING SEAL INSTALLER MC2711
DP99EOIB MP03G048
SWIVEL HOUSING SEAL INSTALLER MC2706 PINION SHAFT RETAINING TOOL
Up to PIN JJE1015542 MC1876
PIN JJE1015543 and After MC3001
SM8-10341 Issued 07-2003
SECTION 6021 5
OP99E021 0 30719
PINION NUT WRENCH MC2712 DIFFERENTIAL ADJUSTING NUT WRENCH MC1840C
030725 OP99EOI9
PINION SHAFT SETIING KIT PINION SEAL INSTALLER MC2704
A • PINION HEIGHT MEASURING GAUGE MC2039
B· HANDLE MC1596A-4
C • SCREW MC1596A·7
HANDLE MC1924
8M 8-10341 Issued 07-2003
6 SECT/ON 6021
GENERAL INFORMATION
NOTE: It is not necessary to remove the MFD Axle to service the following components:
• Planetary Gear Assembly, refer to Page 6.
• Wheel Hub, refer to Page 8.
• Swivel Housing, refer to Page 10.
• Drive Shaft, refer to Page 12.
PLANETARY GEAR
Removal and Installation
NOTE: Steps are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Planetary Gear assembly it will be necessary to carry out the following :
o Park the tractor on hard level ground, apply the parking brake.
• Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
• Loosen the front wheel nuts. Use a hydraulic jack under the centre of the front axle, raise the tractor and support
the tractor on suitable axle stands. Remove the front wheels.
NOTE: For Installation , tighten the front wheel nuts to a torque of 300 to 350 Nm.
STEP 1 STEP 2
DP99C254 DP99C254
Turn the wheel hub until the dra in/level plug (1) is Remove the two countersunk screws (2) and remove
at the bottom. Put a container with a capacity of at the planetary carrier assembly (3).
least 0.6 Litres (0.63 US Quarts) under the wheel Remove and discard the a-ring from the planetary
hub, remove the drainllevel plug (1) and drain the carrier assembly.
oil.
NOTE: For Installation, install a new o-ring onto
NOTE: For Installation, turn the wheel hub until the planetary carrier.
the drain/level plug is in the horizontal position.
NOTE: For Installation, tighten the screws (2) to
Fill the hub to the correct level with the correct
grade of oil, refer to Specifications, Page 3.
a torque of 25 Nm.
Install the drain/level plug (1) and a-ring, tighten NOTE: For Installation , follow the same
to a torque of 80 Nm. procedure in reverse order.
SM 8-10341 Issu ed 07-2003
SECTION 6021 7
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
SM1330
1. SNAP RING 4. NEEDLE ROLLER
2. PLATE 5. THRUST WASHER
3. PLANETARY GEAR 6. THRUST WASHER
STEP 3 STEP 5
Remove snap rings (1) and plate (2). Put Check thrust washer (6) for wear or damage and
identification marks on plate (2), planetary gears (3) replace if necessary.
and shafts (A). Check shafts (A) and planetary carrier (8) for wear
or damage and replace if necessary.
STEP 4 NOTE: The shafts (A) and planetary carrier (B)
Remove planetary gear (3). roller bearings (4) and are not serviced separately.
thrust washer (5).
STEP 6
NOTE: Keep all parts together as a set for
assembly. Clean all parts in cleaning solvent and dry with
compressed air. Face protection MUST be worn.
NOTE: For Assembly, use petroleum jelly to
DO NOT allow the bearings to rotate when drying.
hold roller bearings (4) in position on the shafts
(A). NOTE: For Assembly, follow the same
procedure in reverse order.
SM 8-10341 Issued 07-2003
8 SECTION 6021
WHEEL HUB
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
Before Disassembly of the Wheel Hub it will be necessary to carry out the following :
• Remove the Planetary Gear Assembly, refer to Page 6.
STEP 1 STEP 2
DP99C255 DP99C256
Remove snap ring (1) and thrust plate (2) and thrust Remove the six retaining bolts (4) .
washer (3) .
NOTE: For Assembly, tighten retaining bolts (4)
to a torque of 78 Nm.
SM1339
4. RETAINING BOLT 7. OIL SEAL 10. PLANETARY GEAR
5. WHEEL HUB 8. INNER BEARING 11 . RING GEAR
6. OUTER BEARING 9. RETAINING RING 12. BUSHING
SM 8-10341 Issued 07-2003
SECTION 6021 9
STEP 3 STEP 6
DP99C257
Install two retaining bolts (4) into the threaded holes
in the gear assembly, as shown . Evenly tighten
bolts (4) and remove the gear assembly.
STEP 4
Use a soft faced hammer to loosen the wheel hub
(5) on the bearings. Remove the cone from the
outer bearing (6) and remove the wheel hub (5) .
STEP 5
DP99E011
For Assembly, use handle MC1924 and seal
installer MC2705 to install a new oil seal (7) into the
wheel hub (5) .
STEP 7
Check bearings (6) and (8) for wear or damage and
replace if necessary. Use a suitable puller to
remove the cone of the inner bearing (8) from the
swivel housing if worn or damaged.
STEP 8
H09925 Remove retaining ring (9) , remove the planetary
Remove and discard oil seal (7) from the wheel hub gear (10) from the ring gear (11).
(5) . Check the bushings (12) for wear or damage and
replace if necessary.
NOTE: Refer to STEP 6 for installation of a new
oil seal (7). NOTE: For Assembly, follow the same
procedure in reverse order.
8M 8-10341 Issued 07-2003
10 SECTION 6021
SWIVEL HOUSING
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before Removal of the Swivel Housing it will be necessary to carry out the following:
• Remove the Wheel Hub, refer to Page 8.
SM1 352
1. LOCKNUT 5. RETAINING BOLT 9. SPACER WASHER 13. OIL SEAL
2. BALL JOINT 6. UPPER KING PIN 10. BELLEVILLE WASHER 14. BUSHING
3. RETAINING BOLT 7. SWIVEL HOUSING 11 . BUSHING 15. BUSHING
4. LOWER KING PIN 8. BELLEVILLE WASHER 12. BEARING 8. OIL SEAL
SM 8-10341 Issued 07-2003
SECTION 6021 11
STEP 1 Disassembly and Assembly
Remove locknut (1) from ball joint (2). Remove ball
joint (2) from the swivel housing (7). STEP 5
\l~
STEP 2
~7 I
~ ~ ~
" I'
SM1 3413
Remove the four retaining bolts (3) and lower king
pin (4) . Remove the four retaining bolts (5) and DI990045
upper king pin (6) . Remove and discard oil seal (13) from swivel
NOTE: Before installing king pins (4) and (6) housing (7) . Check bushing (14) for wear or
into the axle, fill cavities (A) with grease, refer damage and replace if necessary.
to "SPECIFICATIONS " on Page 3. NOTE: For Assembly, use handle MC1924 and
NOTE: For Installation , install and tighten bushing installer MC2707 to install bushing
retaining bolts (3) and (5) to a torque of 120 Nm. (14). Use handle MC1924 and seal installer
MC2706 to install the oil seal (13) into the
STEP 3 swivel housing (7) with the seal lip towards the
bushing (14) .
Carefully remove swivel housing (7) from the axle.
Remove belleville washer (8) and spacer washer(9) STEP 6
from the top of the axle and belleville washer (10)
from the bottom of the axle.
NOTE: For Installation, install spacer washer
(9) with the raised step towards belleville
washer (8).
STEP 4
Check bushing (11) and bearing (12) in the axle for
wear or damage. Use a blind hole puller to remove
the bushing (11) and bearing (12) if necessary.
NOTE: For Installation, put bushing (11) or
bearing (12) in a container of dry ice. When the DI 96K28 7
bushing (11) or bearing (12) have cooled, install
Check bearing cone (8) on lower king pin (4) for
into the axle.
wear or damage. Use a hydraulic press to remove
the bearing cone (8) if necessary.
A WARNING: Always wear gloves or NOTE: For Assembly, put the king pin (4) in a
Lll mittens when handling frozen parts. container of dry ice . When the king pin (4) has
cooled, install the bearing cone (B).
NOTE: For Installation, follow the same
procedure in reverse order.
A WARNING: Always wear gloves or
Lll mittens when handling frozen parts.
NOTE: For Assembly, follow the same
procedure in reverse order.
SM 8-10341 Issued 07-2003
12 SECTION 6021
DRIVE SHAFT
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Drive Shaft it will be necessary to carry out the following:
• Remove the Swivel Housing, refer to Page 10.
STEP 1 STEP 3
MC1924
DP99C258 DP99E015
Remove the drive shaft assembly from the axle. For Installation, use handle MC1924 and bushing
installer MC2708 to install bushing (2).
STEP 2
STEP 4
\
'-- /,
\
>--
I '
I /
, // / /
. \
'. MC1924
, .
"-, ... .1' /
DP99E015
Use handle MC1924 and seal installer MC2711 to
install oil seal (1), make sure the seal lip is towards
bushing (2).
01990 122
Remove and discard oil seal (1) from axle housing.
Check bushing (2) for wear or damage and replace
if necessary.
8M 8-10341 Issued 07-2003
SECTION 6021 13
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
'--...
>
./'
SM1353
1. SNAP RING (8) 3. BEARING 5. OUTER DRIVE SHAFT
2. INNER DRIVE SHAFT 4. BEARING 6. YOKE
SM 8-10341 Issued 07-2003
14 SECTION 6021
CROSS SECTIONAL DRAWING OF THE PLANETARY GEAR ASSEMBLY,
WHEEL HUB, SWIVEL HOUSING AND DRIVE SHAFT
_, _ _ _,/1 -,
I t , •
"
, -,
,I
<
l 1
,I .
'
,, - ..
--~ I
01990047
1. PLANETARY GEAR ASSEMBLY,REFER TO PAGE 6 3. SWIVEL HOUSING, REFER TO PAGE 10
2. WHEEL HUB, REFER TO PAGE 8 4. DRIVE SHAFT, REFER TO PAGE 12
SM 8-10341 Issued 07-2003
SECTION 6021 15
MFD AXLE
Removal and Installation
NOTE: Steps are numbered in order of Removal, Installation is in the reverse orde r of Removal.
Before removing the MFD Axle it will be necessary to carry out the following:
• Park the tractor on hard level ground, apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the MFD Drive Shaft, refer to Section 6017.
• Loosen the front wheel nuts. Use a hydraulic jack under the centre of the front axle, raise the tractor and support
the tractor on suitable axle stands . Remove the front wheels.
NOTE: For Installation, tighten the front wheel nuts to a torque of 300 to 350 Nm.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation , connect and tighten the
positive (+) terminal first.
STEP 2
Remove the front weights and bracket, if equipped.
NOTE: For Installation, tighten the weight
bracket retaining bolts to a torque of 481 to 542
Nm.
STEP 3
DP99C262
DP99C2 61
Put identification marks on and disconnect and cap
DP99C263
the hoses (1) from the steering cylinder, (both
sides). Put a hydraulic jack under the front axle. Remove the
four retaining bolts (2) from the rear axle support
housing and the four retaining bolts (3) from the front
axle support housing. Carefully lower the axle from
the tractor, put the axle on suitable stands.
NOTE: For Installation, tighten retaining bolts
(2) and (3) to a torque of 200 Nm.
NOTE: For Installation, follow the same
procedure in reverse order.
SM 8-1 0341 Issued 07-2003
16 SECTION 6021
Disassembly and Assembly STEP 7
NOTE: Items are numbered in order of
Disassembly, Assembly is in the reverse order
of Disassembly.
STEP 5
Put a container with a capacity of at least 6 Litres
(1.6 US gal) under the drain plug, remove the drain
plug and drain the oil.
NOTE: For Installation, install and tighten the
drain plug to a torque of 70 Nm. Fill the axle to
the correct level with the correct grade of oil,
refer to "SPECIFICATIONS" on Page 3. DP99C260
Loosen locknut (6) and remove the RH ball joint (7)
STEP 6 from the steering cylinder.
NOTE: For Assembly, install and tighten locknut
(6) to a torque of 120 Nm.
STEP 8
DP99C259
Remove locknut (4) from LH ball joint (5). Remove
the ball jOint (5) from the swivel housing. Repeat
the procedure for the RH ball joint.
NOTE: For Assembly, install and tighten DP99C231
locknuts (4) to a torque of 165 Nm. Remove fitting (8) from the RH side of the steering
cylinder. Remove the four retaining bolts (9) and
remove the steering cylinder.
NOTE: For Assembly, tighten retaining bolts (9)
to a torque of 120 Nm.
SM 8-10341 Issued 07-2003
SECTION 6021 17
STEP 9 STEP 10
DP99C264 DP99C265
Remove the retaining bolts from the upper and Turn the axle through 90° on the stands .
lower king pins. Attach suitable lifting equipment to Remove the retaining bolts and remove the
LH swivel housing assembly (10). Remove the king differential assembly from the axle.
pins and carefully remove LH swivel housing
NOTE: For Assembly, clean the faces of the
assembly (10) from the axle.
differential and axle housings and apply a continuous
Repeat the procedure to remove the RH swivel
bead of sealant, Loctite 515. Install and tighten the
housing assembly.
retaining bolts to a torque of 169 Nm.
NOTE: Refer to Page 10 for installation of the
upper and lower king pins.
SM8-10341 Issued 07-2003
18 SECTION 6021
DIFFERENTIAL HOUSING
Disassembly STEP 14
STEP 11
Put identification marks on bearing caps (4) and
differential housing (21). Remove bolts (1) , locking
plates (2), bolts (3) and bearing caps (4). Remove
locking rings (5) and remove the differential
assembly (6) from differential housing (21).
STEP 12
Remove retaining ring (7) and coupling (8) . Remove
and discard oil seal (9) and o-ring (10), remove
washer (11). DP99C228
Use a hydraulic press to remove pinion shaft (14)
STEP 13
from differential housing (21).
STEP 15
Remove bearing (15) , washer (16), collapsible
spacer (17) , washer (18) .
NOTE: Discard collapsible spacer (17).
STEP 16
Remove bearing (19) and shims (20) from
differential housing (21).
NOTE: For assembly of the differential housing
DP99C229 it will be necessary to set the position of the
Release the lock tab on ring nut (12). Install pinion pinion shaft, refer to "Setting the Position of
nut wrench MC2712 (A) onto ring nut (12) and the Pinion Shaft" on Page 22.
retaining tool MC3001 or MC1876 (8) onto the
splines of the pinion shaft. Remove and discard the
ring nut (12) , remove thrust washer (13).
SM8-10341 Issued 07-2003
SECTION 6021 19
NOTE: Items are numbered in order of Disassembly.
®~-:
1. BOLT 8. COUPLING 15. BEARING
2. LOCKING PLATE 9. OIL SEAL 16 . WASHER
3. BOLT 10. O-RING 17. COLLAPSIBLE SPACER
4. BEARING CAP 11. SPACER 18. WASHER
5. LOCKING RING 12. RING NUT 19. BEARING
6. DIFFERENTIAL ASSEMBLY 13. THRUST WASHER 20 . SHIM
7. RETAINING RING 14. PINION 21 . DIFFERENTIAL ASSEMBLY
SM8-10341 Issued 07-2003
20 SECTION 6021
DI F FERENTIAL
Disassembly and Assembly STEP 20
Remove thrust washers (8), planetary gears (9) and
STEP 17 planetary shafts (10).
Remove retaining bolts (1) and ring gear (2) .
STEP 21
NOTE: For Assembly, apply Loctite 270 and
tighten retaining bolts (1) to a torque of 78 Nm. Remove side gear (11), thrust plate (12), separator
plates (13) and friction plates (14). Replace the
STEP 18 following if not within specification.
Put assembly marks on and separate the two Thrust Plate (5) and (12) ...... .... .... 2.70 to 2.80 mm
halves of the differential carrier (3). Separator Plate (6) and (13) ..... ........ ....... 1.50 mm
Friction Plate (7) and (14) .. ... .... .... 1.45 to 1.60 mm
STEP 19 NOTE: There are 5 separator plates and 4
friction discs in either side of the differential
Remove side gear (4), thrust plate (5), separator
housing.
plates (6) and friction plates (7).
NOTE: For Assembly, use the same procedure
in reverse order.
SM1362
1. RETAINING BOLT 6. SEPARATOR PLATE 11 , SIDE GEAR
2. RING GEAR 7. FRICTION PLATE 12. THRUST PLATE
3. DIFFERENTIAL CARRIER 8. THRUST WASHER 13. SEPARATOR PLATE
4. SIDE GEAR 9. PLANETARY GEAR 14. FRICTION PLATE
5. THRUST PLATE 10. PLANETARY GEAR SHAFT
SM 8-10341 Issued 07-2003
SECTION 6021 21
Cross Sectional Drawing of the Differential
I
SM1363
2. RING GEAR 6. SEPARATOR PLATE
3. DIFFERENTIAL CARRIER 7. FRICTION PLATE
4. SIDE GEAR 9. PLANETARY GEAR
5. THRUST PLATE 11 . SIDE GEAR
SM 8-10341 Issued 07-2003
22 SECTION 6021
Setting the Position of the Pinion STEP 26
Shaft
STEP 22
Install bearing cups (1) and (2) into differential
housing (3).
STEP 23
Assemble gauge block (4), adapter (5) and stud (6)
together.
STEP 24
DP99C266
Install inner bearing cone (7) , special tools
assembled in STEP 23 , outer bearing cone (8) and Use a feeler gauge to measure the gap (8) between
handle (9). Tighten handle (9) until bearings (7) and gauge block (4) and gauge tube (10) , make a note
(8) become difficult to turn. of the measurement (8) .
STEP 27
STEP 25
Use the following calculation to determine the
Install gauge tube (10) and bearing caps (11) , amount of shims required to correctly position the
install and evenly tighten the bolts (12) to a torque pinion shaft:
of 266 Nm. A + B = C (pinion gear protrusion)
NOTE: Make sure the identification marks made C - 0 = E (required shim thickness)
on disassembly are correctly aligned. Example
A (pinion height constant) ..... ........... .. .... 95 .50 mm
B (measured in STEP 26) ......... .... ... ... . + 0 .20 mm
Total C (pinion gear protrusion) ........ .. ... 95.70 mm
o (etched on pinion shaft) ....... .... ..... ... - 93 .00 mm
Total E (required shim thickness) ...... ... ... . 2.72 mm
NOTE: There must always be a minimum shim
thickness of 2.5 mm. If the calculated shim
thickness (E) is less than 2.5 mm, repeat STEP
22 to STEP 27. If the calculated shim thickness
(E) is less than 2. 5 mm it may be necessary to
replace bearing cones (7) and (8) and bearing
cups (1) and (2) .
SM 8-10341 Issued 07-2003
SECTlON~6~O~21~ _ _ _ __ 23
MC1596A·7
MC1596A-4
SMl 364
4. GAUGE BLO CK NER BEARI NG CONE
INNER BEARING CUP 5. ADAPTER 7. IN G CONE
8. a UTER BEARIN
1. TER BEARING CUP 6. SCREW 2039
10. HANDLE
2. OU FERENTIAL HOUSING .. ShaN Setting Kit Me .
3. DIF t of Pmlon
NOTE: Items (4), (5) an d (10) are par
SM8-10341 Issued 07-2003
24 SECTION 6021
Pinion Shaft Assembly STEP 33
STEP 28
Remove the pinion setting tools and bearing cones
from the differential housing (7).
STEP 29
Install shims (1) calculated in STEP 27 onto pinion
shaft (6), make sure the chamfer side of shims (1)
is facing the pinion gear.
STEP 30
DP99C232
Heat bearing (2) and (7) in a bearing oven to a Install pinion nut wrench, MC2712 (A) onto nut (10)
temperature of 90°C. Install bearing (2) onto pinion and retaining tool, MC1876 or MC3001 (8) onto the
shaft (6). splines of the pinion shaft (6). Tighten the nut (10)
until the rolling pull is between 105 to 157 N.
NOTE: Make sure the bearing (2) is seated
against shims. NOTE: The torque required to collapse spacer
(4) may exceed 400 Nm. If nut (10) is
A WARNING: Always wear heat protective overtightened resulting in a rolling pull which
ili gloves or mittens when handling hot exceeds 105 to 157 N it will be necessary to
• parts. remove pinion shaft (6) from differential housing
(7), replace collapsible spacer (4) and repeat
STEP 31 to STEP 33.
STEP 31
Install washer (3), new collapsible spacer (4) and STEP 34
washer (5) onto pinion shaft (6). Install pinion shaft
(6) into the differential housing (7). Install bearing Using a suitable drift, lock the nut (10) into the
(8), lock washer (9) and new nut (10) onto pinion groove on pinion shaft (6). Remove the differential
shaft (6). housing (7) from the axle.
STEP 32
DP99C230
Put the axle housing on the floor. Install the
differential housing and secure in position with two
bolts. Attach a length of cord to the pinion shaft,
wrap the cord around the pinion shaft without
overlapping. Attach a spring balance to the end of
the cord and check the pinion shaft rolling pull. The
correct rolling pull must be 105 to 157 N.
SM 8-10341 Issued 07-2003
SECTlON~6~O::.2:.......-1_ __ 25
~ ! ,1,'3 45
~"
({Jr(([cd,- ~
.-/
./
DD99C219
::~~~RENTIAL HOUSING
1. SHIM N SHAFT
2. BEARING 6.
7.
3 WASHER 8 BEARING
4: COLLAPSIBLE SPACER 9.. LOCK WASHER
5. WASHER 10. NUT
SM 8-10341 Issued 07-2003
26 SECTION 6021
Differential Installation STEP 37
Install and evenly tighten bearing cap bolts (5) by
STEP 35 hand.
Install differential assembly (1) into differential NOTE: Before tightening bearing cap bolts (5)
housing (2). make sure there is clearance between the ring
NOTE: Make sure the ring gear is on the same gear and pinion.
side as the drain plug on differential assembly
(1 ).
STEP 36
Install locking rings (3). Install bearing caps (4) with
the assembly marks aligned.
NOTE: Make sure the threads in the bearing
caps (4) and locking rings (3) are aligned.
DD99C218
1. DIFFERENTIAL ASSEMBLY 4. BEARING CAP
2. DIFFERENTIAL HOUSING 5. RETAINING BOLT
3. LOCKING RING
SM 8-10341 Issued 07-2003
SECTION 6021 27
Ring Gear Backlash Adjustment STEP 40
STEP 38
DP99C269
Use a dial gauge on the edge of the ring gear tooth
DP99C267 and measure the backlash between the ring gear
Use nut wrench, MC1840C, to turn ring nut (A) at and pinion gear. Measure the backlash between the
the ring gear side of the differential clockwise until ring gear and pinion in four positions equally
the ring gear is in contact with the pinion. At the spaced around the ring gear, the backlash should
same time lightly tap the bearing caps (4) with a soft be between 0.16 and 0.22 mm .
faced hammer to align the bearings .
STEP 41
STEP 39 To decrease the backlash, turn nut (A), STEP 38 ,
counterclockwise and nut (8) , STEP 39 , clockwise
by the same amount. Check the backlash and if
necessary repeat the procedure until the backlash
is correct.
STEP 42
To increase the backlash, turn nut (8), STEP 39,
counterclockwise and the nut (A) , STEP 38,
clockwise by the same amount. Check the backlash
and if necessary repeat the procedure until the
backlash is correct.
DP99C268 STEP 43
Use nut wrench , MC1840C, to turn ring nut (8) on Tighten bearing cap bolts to a torque of 266 Nm.
the opposite side to the ring gear clockwise until all
the clearance in the bearings has been removed. At
the same time lightly tap the bearing caps (4) with
a soft faced hammer to align the bearings .
The clearance has been removed when the ring nut
(8) becomes difficult to turn.
5MB-10341 Issued 07-2003
28 SECTION 6021
Differential Bearing Preload STEP 46
Adjustment e
STEP 44
Make sure the ring gear and pinion shaft backlash
setting is correct and the bearing cap bolts are
"
tightened to a torque of 266 Nm.
STEP 45
With the ring gear and pinion in mesh and the
backlash correctly set check the differential bearing
preload as follows:
DP99C270
When the preload is correct, install locking plates
(A) and bolts (8). Tighten bolts (8) to a torque of 12
Nm.
STEP 47
DP99C233
Attach a length of cord to the pinion shaft splines .
Wrap the cord around the pinion shaft without
overlapping and attach a spring balance. The
correct rolling pull must be 29.5 N to 44.1 N.
If the rolling pull is more than specification it is
necessary to turn both ring nuts counterclockwise DP99 E010
by an equal amount.
Use seal installer MC2704 to install a new oil seal.
If the preload is less than specification it is
necessary to turn both ring nuts clockwise by an
equal amount. STEP 48
DP99C234
Install coupling (A) and retaining ring (8) onto the
pinion shaft.
SM 8-1034 1 Issued 07-2003
SECTION 6021 29
STEERING CYLINDER
Disassembly and Assembly STEP 2
Remove the ball joint assemblies from the steering
STEP 1 cylinder.
NOTE: For Assembly, tighten the ball joint
assemblies to a torque of 300 Nm.
DP99C2 61
Put identification marks on and disconnect and cap
the hoses from the steering cylinder. Remove the
Steering Cylinder, refer to Page 16.
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
0------' SM1369
1. END CAP 4. BACKUP WASHER 7. SEALING RING 10. BACKUP WASHER
2. O-RING 5. OIL SEAL 8. SEALING RING 11 . 0ILSEAL
3. DUST SEAL 6. PISTON ROD 9. DUST SEAL 12. CYLINDER
SM 8-10341 Issued 07-2003
Section
6025
FRONT PTO
ex Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK SM 8-10580 March 2001
2 SECTION 6025
TABLE OF CONTENTS
SPECiFiCATIONS ....................... .... ..... ... .. .... ........ ............ ............................... ... ....... .. ............................................. 3
SPECIAL TORQUES .............................. ...................... .... ......... ................ .. ........ .......... .. ...................... .... ..... ........... 3
FRONTPTO
Removal and Installation .......................................................................................................................................4
CX50 and CX60 Tractors
Disassembly and Assembly ........................... ..................... .. ................ ................. ......... ......... ........... .................. 6
Cross Sectional Drawing of the Front PTO ........................................................................................................... 7
CX70/75, CX80/85, CX90/95 and CX100/105 Tractors
Disassembly and Assembly .................................................... ........... .................... .. ....... .... ..... ................. ............ 8
Cross Sectional Drawing of the Front PTO .................................. .. ....................................................................... 9
SM 8-10580 Issued 03-2001
SECTION 6025 3
SPECIFICATIONS
Lubrication
Oil Type ............... ... ... .................................... .... .................. ............ .................... ............ ....... HY-TRAN ® ULTRA
Capacity .......... ... ........ .................... ...................................................................................................... .. 0.65 Litres
SPECIAL TORQUES
PTO Assembly Mounting Bolts ............ ......... ....... .................. .. ....... ................... ...... ...... .... ...... .. .......... 325 to 370 Nm
CX50 and CX60 Tractors
Clutch Assembly Retaining Bolt (with Loctite 242) ............... .. ......................................... ...... ........ ............... 70 Nm
Electro-Magnet to PTO Housing Retaining Screws
(with Loctite 242) ........................................ ... ........................................ ....... ... ............ .. ....... .. ............ .. .... 35 Nm
Bottom Plate Retaining Bolts (with Loctite 242) ....... .......... ........................ ...... .......... ....... .......... ................. 35 Nm
CX70/75, CX80/85 , CX90/95 and CX100/105 Tractors
Clutch Assembly Retaining Bolt (with Loctite 242) ............. ....... ................. .... ................. .. .. .......... ............... 90 Nm
Electro-Magnet to PTO Housing Retaining Bolts
(with Loctite 242) ................................................................ ................... ... .................................................. 4 Nm
Bottom Plate Retaining Bolts (with Loctite 242) .................. ....................... .................. .. .. ....... ........ .. ..... .... .. 35 Nm
8M 8-10580 Issued 03-2001
4 SECTION 6025
FRONT PTO
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal. After
installation fill the Front PTO gearbox with clean HY- TRAN ® ULTRA to the correct level.
Before removing the Front PTO it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the side panels and raise the hood.
STEP 1 eX70175, eX80/85, eX90/95 and eX100/105
Disconnect the battery, negative (-) terminal(s) first. STEP 3
NOTE: For Installation, connect the positive (+)
terminal(s) first.
ex50 and eX60
STEP 2
DD98K085
Remove the four drive shaft retaining bolts (2).
DD98M099
Remove the three drive shaft retaining bolts (1).
SM 8-10580 Issued 03-2001
SECTION 6025 5
All Models STEP 5
STEP 4
DD98K083
Support the PTO assembly, remove the four
DD98K084 mounting bolts (6) and carefully remove the PTO
Remove the bolts (3) and nuts (4), remove the front assembly.
cover (5).
NOTE: For Installation, install and tighten the
NOTE: For Installation, install and tighten the bolts (6) to a torque of 325 to 370 Nm.
bolts (3) to a torque of 257 Nm.
NOTE: Items are numbered in order of
Removal, Installation is in the reverse order of
Removal.
SM 8-10580 Issued 03-2001
6 SECTION 6025
ex 50 and eX60 Tractors
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
:------.@
o
of ~"-.. ___
.< ~ WITH LOCTITE 515
DI98K088
1. BOLT (6) 10. O-RING 19. BEARING
2. BOTTOM PLATE 11 . 0ILSEAL 20 . OIL SEAL
3. BOLT 12. RETAINING RING 21 . RETAINING RING
4. WASHER 13. CAP 22 . CAP
5. CLUTCH ASSEMBLY (REFER TO NOTE 1) 14. RETAINING RING 23. RETAINING RING
6. RETAINING SCREW (10) 15. OUTPUT SHAFT 24 . INPUT SHAFT
7. ELECTRO-MAGNET (REFER TO NOTE 1) 16. GEAR 25 . BEARING
8. KEY 17 . KEY 26 . BEARING
9. SLEEVE 18. BEARING 27. PTa HOUSING
NOTE 1: Items (5) and (7) are not serviced separately and are only available as an assembly.
SM 8-10580 Issued 03-2001
SECTION 6025 7
Cross Sectional Drawing of the Front PTO
16
DI98K241
5. CLUTCH ASSEMBLY
7. ELECTRO-MAGNET
15. OUTPUT SHAFT
16. GEAR
24. INPUT SHAFT
27 . PTO HOUSING
SM 8-10580 Issued 03-2001
8 SECTION 6025
CX70/75, CX80/85, CX90/95 and CX1 00/1 05 Tractors
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
90 NM
(WITHL~~2J
Y Y
I.:'\ttfo
/~
23
:-~@
DI98K243
1. BOLT (6) 10. O-RING 19 . BEARING
2. BOTTOM PLATE 11 . OIL SEAL 20 . OIL SEAL
3. BOLT 12 . RETAINING RING 21 . RETAINING RING
4. WASHER 13 . CAP 22 . CAP
5. CLUTCH ASSEMBLY (REFER TO NOTE 1) 14. RETAINING RING 23 . RETAINING RING
6. RETAINING SCREW (3) 15 . OUTPUT SHAFT 24 . INPUT SHAFT
7. ELECTRO-MAGNET (REFER TO NOTE 1) 16 . GEAR 25 . BEARING
8. KEY 17. KEY 26 . BEARING
9. SLEEVE 18 . BEARING 27. PTO HOUSING
NOTE 1: Items (5) and (7) are not serviced separately and are only available as an assembly.
SM 8-10580 Issued 03-2001
SECTION 6025 9
Cross Sectional Drawing of the Front PTa
,
f
.~
16
DI98K242
5. CLUTCH ASSEMBLY
7. ELECTRO-MAGNET
15. OUTPUT SHAFT
16 . GEAR
24. INPUT SHAFT
27 . PTO HOUSING
SM 8-10580 Issued 03-2001
Intentionally blank
Section
7001
SERVICE BRAKES
CX Series Tractors
~ Copyright © 2001 McCormick
Tractors International Limited
McCORMICK 8M 8-10360 March 2001
2 SECTION 7001
TABLE OF CONTENTS
SPECiFiCATIONS .................... .. .. ...... .... .. ............................. .... .. ........................................ .... ... .... .......................... 3
SPECIAL TORQUES ................... .......... ............................... ....... .................................... ..... .... .... .................... ........ 3
SPECIAL TOOLS ......... .. .......... ...... ... ........................ .. .... ..... ..... ............ ..... ........................ .... .................................. 3
TOOLS TO BE MADE ...... .... ... .. ............ ....... ............ .......... .... ... .... .......... .. ...... .. .. ......... ....... ........... .... ........... ........... 3
BRAKE DISC
Removal and Installation .... ... .. ...... ......................................... ......................................... .... ............................. .... 4
BRAKE PISTON
Removal ......................... ........... .. .... ..................... ........ .. .... .. ... ....... ... ....................... ... ... .... ... ......... ... ...... ......... .. .. 5
Installation and Pressure Testing ................................. .... .......... ....................... .. ........... .... ... ..... .......................... 6
BRAKE SYSTEM LEAKAGE TEST ... ... ............. ... ..... ....... ... ... .... ..... .............. .. ....... ..... ....... .. ..... ..... .. ... ..................... 7
MASTER CYLINDER
(Tractors without Hydraulic Trailer Brake Valve)
Removal ....................................... ................................. ....... ....... ......................... ......... .. .... .. ......... ...................... 8
Installation ................................... ...................................... ... ................................................................................ 9
MASTER CYLINDER (Tractors with Hydraulic Trailer Brake Valve)
Removal ........................... .. ..... ....... ................................. ... ......... ......... ........................... ..... ..................... ......... 10
Installation ........................................................................................................................... ............................... 11
MASTER CYLINDER
Disassembly and Assembly .............. .. ... ... .... ....... .. ............ .. ....... .. ......... ... ... ... .... ... ......... .. ................................. 12
SM 8-10360 Issued 03-2001
SECTION 7001 3
SPECIFICATIONS
Type .. ................... .. .... ............ .... ...... ..... ............. .... ..... ......... ... .... .. ........... ... ... Hydraulically Operated Oil Cooled Disc
Inner Brake Ring Backlash ...... ... ................. .......... ........... ..... .............. ... .. ... ................. ... .......... 0.127 to 0.635 mm
Brake Piston Test Pressure
Low Pressure Test.. .......... .... ..... .. .. .... .... .... .. ................ .. ...... .. ...... .. ...... ...... ........ .. 4 Steps of 3.4 bar up to 13.8 bar
High Pressure Test ................................................ ..... ..... ... ...... ... .. ... ................ ........ .. ...... ... .. ............ ... .. .... ... 34 bar
SPECIAL TORQUES
Differential Bearing Carrier Bolts ........ ...... .... .. .......... ...... .... .. ........ ...... .. .......... .. ............................ .... .. . 156 to 170 Nm
SPECIAL TOOLS
HYDRAULIC HAND PUMP TEST KIT, MC1913 BRAKE INSTALLATION TOOL, MC2862
HOSE 3121754R92
FITTING 218-5352 BRAKE PISTON REMOVAL TOOL, MC2863
(7/16-20 O-Ring Boss to 9116-18 JIC)
CONNECTOR 218-433
(9/16-18 JIC to 1/4 NPT)
TOOLS TO BE MADE
8.0 mm DIAMETER
450 FLARE
DS99C087
BRAKE SYSTEM LEAKAGE TEST TUBES (2 Required)
8 mm ID x 300 mm CLEAR PLASTIC HOSE (2 Required)
TUBE ADAPTOR (Part Number 3129671R1, (2 Required)
SM 8-10360 Issued 03-2001
4 SECTION 7001
BRAKE DISC
Before removing the Brake Discs it will be necessary to carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch and front hitch (if equipped).
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the Rear Axles, refer to Section 6018.
NOTE: If new friction discs are to be installed, it is recommended the new discs are soaked in clean HY-
TRAN ® ULTRA for 24 hours prior to installation.
Removal and Installation STEP 4
STEP 1
Remove drive shaft (1) and friction disc (2).
STEP 2
Remove inner brake ring (3).
NOTE: For Installation, make sure the side of
the inner brake ring (3) marked "Piston Side
Only" is towards the piston. Refer to STEP 4 to
check the backlash of inner brake ring (3).
DD99C125
STEP 3 Measure between the inner brake ring lug and
differential bearing carrier, as shown. The
Remove the outer brake ring (4) from the axle. measurement must be between 0.127 and 0.635 mm
NOTE: Before Installation, check friction disc
(2), inner brake ring (3) and outer brake ring (4)
for wear or damage. Use a straight edge to
check the surfaces of the inner and outer brake
rings are flat, replace as necessary.
NOTE: For Installation, follow the same
procedure in reverse order.
DS99C088
8M 8-10360 Issued 03-2001
SECTION 7001 5
BRAKE PISTON
Before removing the Brake Pistons it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch and front hitch (if equipped).
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the Rear Axles, refer to Section 6018.
• Remove the Brake Disc and Inner Brake Ring, refer to Page 4.
Removal STEP 2
Support the differential assembly, remove bolts (6)
STEP 1
and differential bearing carrier (7).
NOTE: Only one bearing can be removed at any
one time to prevent damage to the differential.
STEP 3
Remove and discard a-rings (8) and (9), retain the
shim pack (10) for installation.
STEP 4
Check piston for wear or damage, use a straight
edge and make sure the outer face of the piston is
DD99C124
flat.
Install the brake piston removal tool, MC2863, and
impact hammer as shown. Remove brake piston
(5), remove and discard the o-ring from the
transmission housing.
8
DS99C089
8M 8-10360 Issued 03-2001
6 SECTION 7001
Installation and Pressure Testing STEP 7
STEP 5
SM1154
Install the inner brake ring (3) and brake installation
tool (A).
DS99C089
Install and tighten fitting 218-5352 (8) into the
Lubricate new o-rings (8) and (9) with clean transmission housing . Using hose 3121754R92
transmission oil and install onto the bearing carrier and connector 218-433 , connect the test pump
(7). Install bearing carrier (7) and shim pack (10) , assembly MC1913 to fitting 218-5352, refer to
retained in STEP 3, make sure the shims (10) are "SPECIAL TOOLS" on page 3.
aligned and the drain holes are at the bottom. Apply Loosen brake bleed screw (C), open the shut off
Loctite 272 to bolts (6), install and tighten to a valve on the test pump assembly and operate the
torque of 156 to 170 Nm. pump until oil flows from the brake bleed screw
tighten the bleed screw. '
STEP 6
STEP 8
Operate the test pump until a pressure gauge reading
of 3.4 bar is obtained. Close the shut off valve and
check for leaks or a pressure drop on the gauge.
Repeat the above procedure at pressures of 6.9 bar,
10.4 bar and 13.8 bar.
NOTE: A pressure drop without any visible sign of a
leak will indicate a leak from the differential bearing
carrier o-ring.
STEP 9
DD99C126
Open the shut off valve on the test pump assembly
Lubricate a new o-ring with clean transmission oil
and operate the pump until a pressure of 34 bar is
and install into the transmission housing. Install the
obtained . Close the shut off valve and check for
brake piston (5) and brake installation tool (A),
leaks or a pressure drop on the gauge.
MC2862, as shown, evenly tighten the four bolts to
fully install the brake piston (5). Remove the brake
installation tool (A).
Disconnect and cap the brake supply hose (11) and
remove fitting (12).
8M 8-10360 Issued 03-2001
SECTION 7001 7
STEP 10 STEP 11
Open the shut off valve and release the pressure, Install the Brake Disc, refer to Page 4.
remove the test pump assembly MC 1913 and brake Install the Rear Axle, refer to Section 6018.
installation tool (A). Remove the fitting 218-5352 Remove air from the Brake System, refer to Section
from the transmission housing and install and 9001.
tighten fitting (12), removed in "STEP 6" on page 6.
Remove the cap and connect and tighten the brake
hose (11).
BRAKE SYSTEM LEAKAGE TEST
Before carrying out the Brake System Leakage Test it will be necessary to carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
DD99C136
Disconnect and cap the LH and RH brake supply Install clear plastic hoses (0) onto
hoses (1). screws, fill the test tubes (C) with clean oil until oil
flows freely without air from the bleed screw hoses
STEP 2 (0) . Tighten the bleed screws.
STEP 4
Mark the level of the oil in the leakage test tube
hose, leave overnight and check the level.
If the oil level has dropped replace the brake piston
and differential bearing carrier o-rings, refer to
Page 5.
STEP 5
Remove the brake system leakage test tubes (C)
and plastic hoses (0) .
DR99C137 Remove air from the Brake System, refer to Section
Remove the hose fitting from the transmission 9001.
housing and install the brake system leakage test
tubes (C), refer to Tools to be Made Page 3, and
plastic hoses in the vertical position.
Fill the plastic hoses and test tubes (C) with clean
HY-TRAN ® ULTRA.
SM 8-10360 Issued 03-2001
8 SECTION 7001
MASTER CYLINDER
(Tractors without Hydraulic Trailer Brake Valve)
Before removing the Master Cylinders it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch and front hitch (if equipped) .
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
Removal STEP 2
STEP 1
DD98C117
Release the hose clips and disconnect reservoir fill
hose (1) and dump hose (2) . Release hose clips (3)
and remove the brake reservoir (4) . Disconnect the
LH brake tube (5), RH brake tube (6) and balance
tube (7) . Cap all tubes, hoses and fittings.
DI98C267
Remove the retaining clip (8) and clevis pin (9) from
the brake pedal. Remove the master cylinder
retaining lock nuts (10) and bolts (11), instrument
panel harness chassis ground wires (12) , chassis
ground cable and master cylinders (13) . Discard
the lock nuts (10).
SM 8-10360 Issued 03-2001
SECTION 7001 9
Installation STEP 4
STEP 3
DD98C117
Remove the caps from the tubes and fittings. Install
and tighten balance tube (7), RH brake tube (6) and
LH brake tube (5).
Remove the caps from the hoses and fittings . Install
brake reservoir (4) and tighten hose clips (3) .
Connect dump hose (2) and reservoir fill hose (1),
tighten clips.
STEP 5
Remove the air from the Braking System, refer to
DI98C267 Section 9001.
Install the master cylinders (13). Install the bolts
(11) and chassis ground cable, instrument panel
harness chassis ground wires (12). Make sure
chassis ground wires are connected to the LH
master cylinder lower mounting bolt (11). Install and
tighten new lock nuts (10) onto bolts (11).
Adjust the push rod clevis (B) to give a clearance of
1.00 mm between the push rod and master cylinder
piston, refer to Section 9001.
8M 8-10360 Issued 03-2001
10 SECTION 7001
MASTER CYLINDER (Tractors with Hydraulic Trailer Brake Valve)
Removal STEP 7
STEP 6
DD98C116
Release the hose clips and disconnect reservoir fill
hose (14) and dump hose (15). Release hose clips
(16) and remove the brake reservoir (17).
Disconnect the LH brake tube (18), RH brake tube
(19), balance tube (20), trailer brake valve supply
hose (21) and crossover tube (22). Cap all tubes,
hoses and fittings.
DI99C118
Remove the retaining clip (23) and clevis pin (24)
from the brake pedal. Remove the master cylinder
retaining lock nuts (25) and bolts (26), instrument
panel harness chassis ground wires (27), chassis
ground cable and master cylinders (28). Discard
the lock nuts (25).
8M 8-10360 Issued 03-2001
SECTION 7001 11
Installation STEP 9
STEP 8
DD98C116
Remove the caps from the tubes and fittings. Install
and tighten crossover tube (22). trailer brake valve
supply hose (21). balance tube (20), RH brake tube
(19) and LH brake tube (18).
Remove the caps from the hoses and fittings. Install
brake reservoir (17) and tighten hose clips (16).
Connect dump hose (15) and reservoir fill hose
(14), tighten clips .
STEP 10
Remove the air from the Braking System. refer to
Section 9001.
DI99C118
Install the master cylinders (28). Install the bolts
(26) and chassis ground cable. instrument panel
harness chassis ground wires (27). Make sure
chassis ground wires are connected to the LH
master cylinder lower mounting bolt (26) . Install and
tighten new lock nuts (25) onto bolts (26) .
Adjust the push rod clevis (B) to give a clearance of
1.00 mm between the push rod and master cylinder
piston. refer to Section 9001.
8M 8-10360 Issued 03-2001
12 SECTION 7001
MASTER CYLINDER
Disassembly and Assembly STEP 5
NOTE: Items are numbered in the order of
Disassembly, for Assembly follow the
Disassembly procedure in reverse order.
STEP 1
Remove tube (1), fittings (2) and (3), discard the 0-
rings and seal ring.
NOTE: For Installation, lubricate and instafl new
o-rings and seal ring.
STEP 2
Remove adapter (4), remove and discard seal ring DI98C315
(5). Remove flow valve (6), seal (7) and ball (8), Bend tab (A) up to release spring retainer (17) from
discard seal (7). piston (15) . Compress spring (18) and release
valve stem (20) from spring retainer (17) . Remove
NOTE: For Installation, lubricate and instafl a spring retainer (17), spring (18) and valve stem
new seal ring (5) and seal (7). (20).
STEP 3 NOTE: For Installation, bend tab (A) down
behind the lip of piston (15) to lock spring
Loosen locknut (10) and remove clevis (9). Remove retainer (17) to piston (15).
locknut (10), dust cover (11), retaining ring (12),
washer (13) and rod (14). STEP 6
NOTE: For Installation, make sure the cupped Remove valve spacer (21), spring washer (19) and
side of the washer (13) is towards the piston seal (22) . Discard spring washer (19) and seal (22).
assembly (15).
NOTE: For Instaflation, lubricate and instafl a
STEP 4 new spring washer (19) and seal (22).
Remove the piston assembly (15), remove and
discard seal (16).
NOTE: For Installation, lubricate and instafl a
new seal (16) .
SM 8-10360 Issued 03-2001
SECTION 7001 13
DI99C133
1.FITTING 8.BALL 15.PISTON 22.SEAL
2. FITTING 9.CLEVIS 16.SEAL 23 .MASTER CYLINDER BODY (WITHOUT
3.FITTING 10. LOCKNUT 17.SPRING RETAINER HYDRAULIC TRAILER BRAKE VALVE)
4. ADAPTER 11 . DUST COVER 18.SPRING 24 .MASTER CYLINDER BODY (WITH
5.SEAL RING 12. RETAINING RING 19. VALVE STEM HYDRAULIC TRAILER BRAKE VALVE)
6. FLOW VALVE 13. CUPPED WASHER 20 .VALVE SPACER 25 .FITTING
7.SEAL 14. ROD 21.SPRING WASHER
SM 8-10360 Issued 03-2001
Section
7002
PARKING BRAKE
2 Wheel Drive Tractors
ex Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10370 March 2001
2 SECTION 7002
TABLE OF CONTENTS
SPECiFiCATIONS ................................... .. .......................................... ..................... ................................................ 3
SPECIAL TORQUES ......... ............................................ ...................... .. ................................................................... 3
PARKING BRAKE
Removal and Installation ............................................. ....................................... .. ....................... ......................... 4
Disassembly and Assembly ............................................................................................................................... .. 6
Cross Sectional Drawing of the Parking Brake ........ .. .......................................................................................... 7
8M 8-10370 Issued 03-2001
SECTION 7002 3
SPECIFICATIONS
Number of Friction Discs ........... .. ............................................. .... .................... ................... .. .................. ... .. ............. 3
Number of Stationary Discs ........ ... .. ................ ... .. ................. ..... ..................... .................... .. .................................... 3
Friction Disc (New) .... .................. ... ..... .. ............. ... ................ ... ............. .. ........ ........ ........... ........................... 2.90 mm
Stationary Disc Thickness (New) ...................... .. ....... ......... .. ................................ .......... .. .. ....... .......... ... .. ..... 1.80 mm
SPECIAL TORQUES
Parking Brake Cable Bracket Bolts ............ .. .. .. .. .. ...... .. ............. .. ................... .. ..................... .. ................. 45 to 50 Nm
Parking Brake Support Bolts ... ... ..... ................ .. .. ... ..... ........... .... ........... ... ................... ........ .... ......... ... .. .. 45 to 50 Nm
Parking Brake Assembly Support Nuts ..................................... .. ......................................... ................ 156 to 176 Nm
8M 8-10370 Issued 03-2001
4 SECTION 7002
PARKING BRAKE
Before servicing the Parking Brake it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Put wooden blocks between the front axle bolster and front axle.
• Remove the front tractor weights, if equipped.
• Remove the Pinion Shaft, refer to Section 6007 .
Removal and Installation STEP 3
STEP 1
DP99C175
Remove the parking brake support.
DP99C173
Remove parking brake cable bracket (1) NOTE: For Installation, clean the mounting
surfaces of the parking brake support and
transmission housing, apply Loctite 515 and install
STEP 2
the parking brake support. Install and tighten the
retaining bolts to a torque of 45 to 50 Nm.
STEP 4
Remove cotter pin (2), clevis pin (3) and actuating
rod assembly (4).
DP99C176
Remove and discard seal (5).
NOTE: For Installation, use a suitable seal
installer to install a new seal (5).
8M 8-10370 Issued 03-2001
SECTION 7002 5
STEP 5
DP99C177
Remove the parking brake assembly.
NOTE: For Installation, follow the same
procedure in reverse order.
8M 8-10370 Issued 03-2001
6 SECTION 7002
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse of Disassembly.
REFER TO SECTION 6007 FOR
REMOVAL AND INSTALLATION
DS99C179
1. BOLT 7. ACTUATOR ASSEMBLY
2. WASHER 8 . PLATE
3. WASHER 9. FRICTION PLATE (3)
4. NUT 10. SEPARATOR PLATE (3)
5. BOLT 11 . SUPPORT
6. SPACER 12. O-RING
SM 8-10370 Issued 03-2001
SECTION 7002 7
Cross Sectional Drawing of the Parking Brake
--0
OS99C178
1. BOLT 7 . ACTUATOR ASSEMBLY
2. WASHER 8 . PLATE
3 . WASHER 9 . FRICTION PLATE (3)
4. NUT 10. SEPARATOR PLATE (3)
5. BOLT 11 . SUPPORT
6.SPACER
SM 8-10370 Issued 03-2001
Section
7004
HYDRAULIC TRAILER BRAKE
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK 8M 8-10380 March 2001
2 SECTION 7004
TABLE OF CONTENTS
SPECIAL TORQUES ..... ........................................... ................ .............................. .. .......................................... ....... 3
HYDRAULIC TRAILER BRAKE
Removal and Installation ...... ... ..... .... .. ... ..... ........... ................ ....... ... .. .. .... ....... ... ... .. ... .................... ... ..................... 4
Disassembly and Assembly ................... ............... ............................ .. ............................... ............. .. ........... ..... .... 5
8M 8-10380 Issued 03-2001
SECTION 7004 3
SPECIAL TORQUES
End Cap Socket Head Screws ........................... ....................................................................... .......... .. ........... 10 Nm
Bleed Valve ........ .................. .......................................... .......................... .. .............. ... .. ......... .. .. ............. .... ..... 2.5 Nm
8M 8-10380 Issued 03-2001
4 SECTION 7004
HYDRAULIC TRAILER BRAKE
Before servicing the Hydraulic Trailer Brake Valve it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
Removal and Installation STEP 2
STEP 1
Raise the rear of the tractor, support the LH rear
axle on a suitable axle stand and remove the LH
rear wheel.
NOTE: For Installation, install the LH rear
wheel, install and tighten the wheel nuts to a
torque of 278 to 298 Nm .
DP99C209
Disconnect and cap tubes and hoses from hydraulic
trailer brake valve (1) Remove valve retaining bolts
(2) nuts (3) and washers (4). For Installation, follow
the same procedure in reverse order.
8M 8-10380 Issued 03-2001
SECTION 7004 5
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse of Disassembly.
DI99C191
1. BLEED VALVE 13.RETAINING RING
2.BOLT 14.SLEEVE
3. END CAP 15.WASHER
4 .0-RING 16.SPRING
5. PISTON 17. PLUG
6.SEAL 18.0-RING
7.BLOCK 19.5PRING
8.GASKET 20.SPOOL
9.SPOOL 21 .PLUG
10.SPRING 22 .0 -RING
11.SLEEVE 23.SPRING
12.SPRING
SM 8-10380 Issued 03-2001
Section
8001
HYDRAULIC TROUBLESHOOTING AND SCHEMATICS
CX Series Tractors
~ © 2004 McCormick Tractors International Limited.
McCORMICK SM 8-10401 March 2001 (Revised September 2004)
2 SECTION 8001
TABLE OF CONTENTS
SPECIAL TOOLS .......... ....... .. ... ..... .... .................... ... .... ..... .. ... ............ ............................ ...... ........ '" ...... ................ .. 3
SPECiFiCATIONS .. .................. ............. .. ... ........ ...... ...... .. ........ .................................... ................ .... .................... .... 3
HYDRAULIC SYSTEM TROUBLESHOOTING
Steering System Problems ... ..... ......... ... ............... ... .. ......................... ........ ..... .. ..... .. ...... .... .. ..... ...... ..... ................ 4
Powershift Problems ................................................................. ............ .. ..... .. ......... ... ......... ... ......... .. ........ .. ......... 5
MFD Problems ............... .............................................................. ... ..... .. ..... .................... ... ... .. .. .. ............. ............ 6
PTO Problems ............ ... .. ... ... ...... ..... ........................................................ .. ...... .......................... ........... ... ... ..... .... 6
Differential Lock Problems ..................... ............ .. .................... .... ........ ............................... ..... ...... ........... .. .. ....... 7
Oil Cooler Problems .. ................ ....... ... .. .. ... .. ... .... ... ..... .. ....... ... .... .. ... .... ..... .............. ......... .... .. ........................ ...... 7
Brake Problems ....... .................... .... ................ .................... ................. ...... .................. .. ................................ ...... 7
Hydraulic Trailer Brake Problems (if equipped) .. .... ...... ........ .... ..... ..... .. .. .... .... ... ..... ........ .. .. ....... ... .. .. .. .. .. .. ......... .. 7
Rear Hitch System Problems ..... .... ....... ... .... ............................................. ...... ...... ..... ....... ................. ...... ..... ....... 8
Remote Valve Circuit Problems ...... ..... .. ........ ............. .. ... ........ .. ..... .. ... .. ............ ........... ........ .. ......... .................... 9
HYDRAULIC SYSTEM DIAGNOSTIC TESTING
Test 1 - Main Hydraulic Pump Efficiency .. .. ... ... .... ..... .... ........ .. ............ .. .. ..... .. .. .... .. .. .. ..... ..... ........ ....... .... .. .. .. .. .. 10
Test 2 - Main Relief Valve ... ... ...... .... ....... ... ....... .. ............ .. ...... .. ....... ................ ....... .... .. ....... .. ....... ........... ..... ..... 12
Test 3 - Steering Relief Valve Pressure and Cylinder Internal Leakage ......... .... .... .. ............. ..... ..... .................. 14
Test 4 - Steering Hydraulic Pump Efficiency ... ........... .. .......... .. ...... ...... .. .......... ........... ........... .. ........... ... ............ 16
Test 5 - Regulated Pressure ...... .... .......... ......... .. .................... .. ........................ .. ......... .. ..... ... ....... .... ........ .. ....... 18
Test 6 - PTO Pressure ........ ................................ ....... ............................................... .. .. ... .. ........ ..... .. ... ..... .... ..... 20
Test 7 - Oil Cooler Flow ............ ..... ......... ...................... .......... .. ........................................... .. ....... .... ................. 22
Test 8 - Regulated Circuit Leakage Test ............ .. ........ .... ........ .. ......... .. ........ ... ........ .... ........ .. ........ ... ................. 24
Test 9 - Remote Detent Kick-out .... .. ... .. .......................................... ... ............ .......... .... ........ ... ... ..... ..... .. .. .......... 26
CROSS SECTIONAL DRAWINGS AND INDIVIDUAL SCHEMATICS
Hydraulic Filter ..... .... .. .. ..... .. ..... .. ............. .. ... ...... .. ... .......... ......... .... ................. .. ... ........ ......... .. ........ .. ................. 28
Main Hydraulic Pump ........ ..... ..... .. .. ................................................................................................ .. ................. 29
Filter Manifold .. .... .. .. ...... ........... ..... ....... ... .. .... ........ ..... ................... ... .... ...... .... ............ .. ... .. ......... ..... ... ... .. .. .... .. ... 30
Unloading Valve .... .. ... .......... .. ..... .. ......... ........................................................................................... ................. 31
Remote Valves ........ .. .................... .. ....... .. .......... .. ... .. ... ..... ...... ............ .. ........ .. ........ .. ........... .. ............ ....... ...... ... 32
Hitch Valve ....... .. .... ....... ..... ... .. ..... .. .... ..... ...... ... .. .. ...... .... .. ................. .. ... ..... .. ...... .... .............. ............................. 33
EDC Manifold .......... .......... ... ......... .. .................. .. ... .. ....................................................................... .. ... .............. 34
Hitch Cylinder and Hitch Relief Valve ...... .. ......... ......... ..... ...... .. .... .... .... ....... ... .. ......... .. ... .. ........ ..... ...... .......... .. .. 35
Steering Hydraulic Pump .. ... ......... .. ....... ........... .. ... .. ... .. .......... .. ..................... ...................... .. ......... ... ....... .... ..... 36
Steering Hand Pump .................. .. ................................. .. ........ .. ............. ......................................... .. ..... .. .......... 37
Pressure Regulator Valve Block ... ........................ ... ... ....... .... .... .... ....... .. .... ..... .... .. .. ... .. ....... ........ .. ......... .. .. ... ... . 38
MFD Solenoid and Clutch ... .................... .. ..................... .. .................. .. ............ ... .................. ... ... .. .. ... ........ ........ 39
CX Hydraulic Schematic, Two Speed Power Shift ... .. .. .......... ... .. .... .. ....... .. .. ............ ...... ...... .. .. ...... ....... .. .. .. ....... 40
CX XtraShift, Hydraulic Schematic .. ..... ................................... ............. ............ .. ........ .. ........ .... ..... ..... ...... ... ... .... 42
CX XtraShift, Hydraulic Schematic .. ....... ... ......... ... ....... .. ......... ... ........ ............ ... .......... ........ ... ... ... ... .. ..... .. ..... ..... 44
8M 8-10401 Issued 09-2004
SECTION 8001 3
SPECIAL TOOLS
FLOWMETER OEM1238, 0-300 UMIN OR EQUIVALENT
TUBE (PART NO. 539835R2)
CAP, 9/16-18 JIC (PART NO. 218-754)
MALE COUPLER, QUICK DISCONNECT (PART NO. 1272399C2)
HYDRAULIC TEST KIT (PART NO. 1094059-R92)
SPECIFICATIONS
HYDRAULIC SYSTEM CX50,60 CX70/75, 80/85,90/95, 100/105
Hydraulic system type Open
Steering Hydraulic Pump 27.7 Llmin. 30 .3 Llmin.
at 2250 engine rpm at 2200 engine rpm
Transfer Pump 36 Llmin .
Transfer Pump (XtraShift) 52 .5 Llmin.
Flow to 540/750 PTO 50.2 Llmin .
Remotes 59.4 Llmin.
540/1000 PTO 51.7 Llmin .
Main Hydraulic 540/750 PTO 50 .2 Llmin.
Pump 59.4 Llmin.
540/1000 PTO 51.7 Llmin.
Pump gear 540/750 PTO 23 19
(No. of teeth)
540/1000 PTO 27 23
Pump mounting N/A 5.31 to 5.43 mm
plate thickness
Main Relief Valve Pressure .................. ... .... .... ................. ..... ..... ......... .. .. ... ......... .. ... .. ....... ....... ... .... ..... ..... ... 172.5 bar
Remote Detent Kick-out Pressure .. .......... ........................................................................ ............ .. 144.7 to 172.3 bar
Steering Relief Valve Pressure ........ ... .. .. .. .............. ......... ............ .......... ................. .................. ....... .... 141 to 148 bar
Regulated Pressure .. .. ........................... ................ .. ......................................... ... ................... .. ....................... . 20 bar
Oil Cooler By-pass Pressure .......... ... .. .. ... .. ............. ..... ..... .. ........ ....... .............. .... ... ....... .. ............... ... .. .......... 10.4 bar
Steering Return Flow
CX50 ,60 at 2250 engine rpm ........... .. ................ ... .... .. ................... ... .. ........ .. .. ....... .. ............ ... .... ........... 27 .7 Llmin.
CX70/75, 80/85 , 90/95, 100/105 at 2200 engine rpm .... .. ........ .. .. ............... ............ .............. .. ...... ........ .30 .3 Llmin.
Oil Cooler Flow
CX50,60 at 2250 engine rpm ...... ..................... ..... ................ ..... ................... .... ................. ..... .... ........... 23.7 Llmin.
CX70/75 , 80/85, 90/95,100/105 at 2200 engine rpm ............. ...... ... .. .............. .. ...... ......... .. .. ...... ........... 26 .3 Llmin.
Hydraulic Oil Test Temperature ................... ... ........ .. ............... .. .... ... .. ..... ..... .. ..... .. ... ....... ....... ... .. .. ..... ...... ....... ... 49° C
Hydraulic Oil Type .. ... ....... .... .. ........... .... .. ........ ........ ... ................. ......... .. ............ ..... ... ....... .... .. ..... .. ... McCormick HTX
8M 8-10401 Issued 09-2004
4 SECTION 8001
HYDRAULIC SYSTEM TROUBLESHOOTING
When troubleshooting an electro-hydraulic system problem check for electrical power to the solenoid coils as they
are activated. This will isolate hydraulic system problems from electrical problems. Use a high impedance multime-
ter for any electrical checks. Refer to Sections 4001 and 10002.
Before making any hydraulic system tests make sure that the hydraulic oil reservoir is full , hydraulic filters are clean
and the hydraulic oil temperature is above 49°C.
Steering System Problems
PROBLEM: Excessive effort required for steering
POSSIBLE CAUSE PROCEDURE
A. Mechanical interference in steering mechanism. A . Inspect and repair as necessary.
B. Steering relief valve adjustment. B. Carry out Test 3 - Steering Relief Valve Pressure
and Cylinder Internal Leakage .
C. Steering hydraulic pump worn. C. Carry out Test 4 - Steering Hydraulic Pump
Efficiency.
D. Cylinder piston moved on ram (2WD only). D. Inspect and repair as necessary.
PROBLEM: No power steering
POSSIBLE CAUSE PROCEDURE
A. Steering relief valve adjustment. A . Carry out Test 3 - Steering Relief Valve Pressure
and Cylinder Internal Leakage .
B. Cylinder piston moved on ram (2WD only). B. Inspect and repair as necessary.
PROBLEM: Excessive turns lock to lock
POSSIBLE CAUSE PROCEDURE
A. Steering cylinder internal leakage. A. Carry out Test 3 - Steering Relief Valve Pressure
and Cylinder Internal Leakage.
B. Steering hand pump faulty. B. Refer to Steering Hand Pump, Section 5001 .
PROBLEM: Intermittent Steering
POSSIBLE CAUSE PROCEDURE
A. Steering cylinder internal leakage. A. Inspect and repair as necessary.
B. Steering hand pump faulty. B. Refer to Steering Hand Pump, Section 5001.
SM 8-1 0401 Issued 09-2004
SECTION 8001 5
Powershift Problems
IMPORTANT: When troubleshooting an electro-hydraulic system problem check for electrical power to
the solenoid coils as they are activated. This will isolate hydraulic system problems from electrical
problems. Use a high impedance multimeter for any electrical checks. Refer to Section 4001.
PROBLEM: Does not change to high speed when selected (remains in low speed)
POSSIBLE CAUSE PROCEDURE
A. Low or incorrect regulated pressure. A. Carry out Test 5 - Regulated Pressure.
B. Excessive leakage in the regulated circuit. B. Carry out Test 8 - Regulated Circuit Leakage
Test.
C. Worn powershift clutch plates. C. Refer to Powershift and Forward/Reverse
Transmission Servicing . Section 6003.
PROBLEM: Does not change to low speed when selected (remains in high speed)
POSSIBLE CAUSE PROCEPURE
A. Powershift solenoid spool is stuck in high position. A. Replace the powershift solenoid spool.
PROBLEM: Does not drive in low speed
POSSIBLE CAUSE PROCEDURE
A. Mechanical failure of sprag clutch and overrun A. Replace the sprag clutch and overrun clutch.
clutch. refer to Powershift and Forward/Reverse
Transmission Servicing. Section 6003.
PROBLEM: No engine braking
POSSIBLE CAUSE PROCEDURE
A. Mechanical failure of overrun clutch. A. Replace the overrun clutch assembly. refer to
Powershift and Forward/Reverse Transmission
Servicing. Section 6003.
8M 8-10401 Issued 09-2004
6 SECTION 8001
MFD Problems
IMPORTANT: When troubleshooting an electro-hydraulic system problem check for electrical power to
the solenoid coils as they are activated. This will isolate hydraulic system problems from electrical
problems. Use a high impedance multimeter for any electrical checks. Refer to Section 4001.
PROBLEM: MFD does not engage
POSSIBLE CAUSE PROCEDURE
A. MFD solenoid spool faulty. A. Replace MFD solenoid spool
B. MFD clutch faulty. B. Service MFD Transfer Gearbox.
PROBLEM: MFD does not disengage
POSSIBLE CAUSE PROCEDURE
A. Low or incorrect regulated pressure. A. Carry out Test 5 - Regulated Pressure .
B. Excessive leakage in the regulated circuit. B. Carry out Test 8 - Regulated Circuit Leakage
Test.
C. MFD solenoid spool faulty. C. Replace MFD solenoid spool.
D. a-rings in MFD solenoid leaking. D. Replace o-rings in MFD solenoid spool.
E. Clutch pack or shaft seals leaking. E. Service MFD Transfer Gearbox.
PTa Problems
PROBLEM: PTO will not operate
POSSIBLE CAUSE PROCEDURE
A. Incorrect adjustment of mechanical linkage. A. Refer to Pedal, Lever and Switch Adjustment,
Section 9001 .
B. Low or incorrect regulated pressure. B. Carry out Test 5 - Regulated Pressure.
C. Excessive leakage in the regulated circuit. C. Carry out Test 8 - Regulated Circuit Leakage
Test.
D. Low or incorrect PTa pressure. D. Carry out Test 6 - PTa Pressure.
E. Excessive PTa load. E. Inspect and correct problem as necessary.
F. PTa clutch plates worn . F. Service PTO.
PROBLEM: PTO will not disengage
POSSIBLE CAUSE PROCEDURE
A. Incorrect adjustment of mechanical linkage. A. Refer to Pedal, Lever and Switch Adjustment,
Section 9001 .
B. PTO spool sticking. B. Remove and inspect PTO spool.
8M 8-10401 Issued 09-2004
SECT/ON 8001 7
Differential Lock Problems
IMPORTANT: When troubleshooting an electro-hydraulic system problem check for electrical power to
the solenoid coils as they are activated. This will isolate hydraulic system problems from electrical
problems. Use a high impedance multimeter for any electrical checks. Refer to Section 4001.
PROBLEM: Differential lock will not engage/disengage.
POSSIBLE CAUSE PROCEDURE
A. Mechanical linkage seized. A. Inspect and correct problem as necessary.
B. Differential lock solenoid spool stuck or faulty. B. Replace differential lock solenoid spool.
C. Low or incorrect regulated pressure. C. Carry out Test 5 - Regulated Pressure.
D. Excessive leakage in the regulated circuit. D. Carry out Test 8 - Regulated Circuit Leakage
Test.
Oil Cooler Problems
PROBLEM: Transmission oil overheating
POSSIBLE CAUSE PROCEDURE
A. External blockage of oil cooler. A. Clean external fins of oil cooler.
B. Incorrect oil cooler flow. B. Carry out Test 7 - Oil Cooler Flow.
C. Oil cooler by-pass valve faulty. C. Remove and inspect oil cooler by-pass valve.
D. Overfilling the transmission with hydraulic oil. D. Check oil level and correct problem as necessary.
Brake Problems
PROBLEM: Poor brake response
POSSIBLE CAUSE PROCEDURE
A. Blocked screen/orifice to brake reservoir. A. Inspect and clean brake reservoir screen/orifice.
B. Air in brake system. B. Remove air from the brake system, refer to
Section 9001 .
C. Faulty brake master cylinder. C. Refer to Service Brakes, Section 7001.
D. Excessive leakage past brake pistons. D. Refer to Service Brakes, Section 7001.
Hydraulic Trailer Brake Problems (if equipped)
PROBLEM: Trailer brakes are NOT operating (other hydraulic systems are operating)
POSSIBLE CAUSE PROCEDURE
A. Brake pedal out of adjustment. A. Adjust brake pedal, refer to Section 9001.
B. Trailer brake valve spool is binding. B. Refer to Hydraulic Trailer Brake, Section 7004.
8M 8-10401 Issued 09-2004
8 SECTION 8001
Rear Hitch System Problems
NOTE: Always check the built in diagnostic error codes for the hitch control module first.
PROBLEM: Hitch will not raise
POSSIBLE CAUSE PROCEDURE
A. Unloader valve faulty (hitch only raises when A. Service Unloading Valve.
remote valves are operated).
B. Main relief valve faulty. B. Carry out Test 2 - Main Relief Valve.
C. Main hydraulic pump worn . C. Carry out Test 1 - Main Hydraulic Pump
Efficiency.
D. Hitch relief valve faulty. D. Replace hitch relief valve.
E. Primary raise and secondary raise spools stuck E. Service the Hitch Valve.
or faulty.
F. Low or incorrect regulated pressure. F. Carry out Test 5 - Regulated Pressure.
G. lnternalleakage. G. Replace gaskets and o-rings between hitch valve,
EDC manifold and transmission housing.
PROBLEM: Hitch will not hold (hiccuping)
POSSIBLE CAUSE PROCEDURE
A. Hitch relief valve faulty (hitch lowers fully when A . Replace hitch relief valve.
engine is switched OFF) .
B. Primary or secondary lower spool not seated B. Service the Hitch Valve.
correctly or check valve in hitch valve not seated
correctly.
C. Internal leakage (hitch lowers fully when the C. Replace gaskets and o-rings between hitch valve,
engine is switched OFF). EDC manifold and transmission housing.
PROBLEM: Hitch will not lower
POSSIBLE CAUSE PROCEDURE
A. Three point linkage mechanical seizure. A. Inspect and correct problem as necessary.
B. Primary lower and secondary lower spools stuck B. Service the Hitch Valve.
or faulty.
C. Low or incorrect regulated pressure. C. Carry out Test 5 - Regulated Pressure.
PROBLEM: System remains on high pressure when hitch is raised
POSSIBLE CAUSE PROCEDURE
A. Mechanical interference preventing lift linkage A. Inspect and correct problem as necessary.
being fully raised.
B. Secondary raise spool stuck or faulty. B. Service the Hitch Valve.
SM 8-10401 Issued 09-2004
SECTION 8001 9
Remote Valve Circuit Problems
PROBLEM: Load raises slowly or not at all
POSSIBLE CAUSE PROCEDURE
A. Control linkage faulty. A. Inspect and correct problem as necessary.
B. Restriction in implement pipework. B. Inspect and correct problem as necessary.
C. Remote coupler faulty. C. Replace the remote coupler.
D. Main relief valve faulty. D. Carry out Test 2 - Main Relief Valve.
E. Main hydraulic pump worn . E. Carry out Test 1 - Main Hydraulic Pump
Efficiency .
PROBLEM: Load does not lower
POSSIBLE CAUSE PROCEDURE
A. Control linkage faulty. A. Inspect and correct problem as necessary.
B. Implement linkage mechanical seizure. B. Inspect and correct problem as necessary.
C. Restriction in implement pipework. C. Inspect and correct problem as necessary.
D. Remote coupler faulty. D. Replace the remote coupler.
E. Mechanical check valve faulty. E. Service mechanical check valve.
PROBLEM: Load does not hold with spool in neutral
POSSIBLE CAUSE PROCEDURE
A. Mechanical check valve faulty. A. Service mechanical check valve .
B. Internal leakage of implement cylinder. B. Inspect and correct the problem as necessary.
PROBLEM: Load drops momentarily before raising
POSSIBLE CAUSE PROCEPURE
A. Hydraulic or mechanical load check valve faulty. A. Service hydraulic or mechanical check valve.
PROBLEM: Remote detent kickout does not function
POSSIBLE CAUSE PROCEDURE
A. Detent kickout pressure incorrect. A. Carry out Test 9 - Remote Detent Kick-out.
B. Internal leakage or sticking detent poppet or B. Inspect and correct the problem as necessary.
spool.
SM 8-10401 Issued 09-2004
10 SECTION 8001
HYDRAULIC SYSTEM DIAGNOSTIC TESTING
Test 1 - Main Hydraulic Pump Efficiency
Ol97K169
1. NUMBER ONE REMOTE VALVE
8M 8-10401 Issued 09-2004
SECTION 8001 11
TOOLS REQUIRED
Two male couplers, quick disconnect (part no. 1272399C2).
Two flowmeter connectors, (7/8-14 JIC male onto quick disconnect couplers).
One flowmeter.
TEST CONNECTIONS
Install the flowmeter into number one remote valve (1) coupler stack.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at rated speed.
• Record the flow as flow 'A'.
• Turn the restrictor on the flowmeter and restrict the flow to a pressure of 137.9 bar.
• Record the flow as flow 'B'.
• Calculate the pump efficiency using the formula below. The efficiency must not be less than 85%.
• PUMP EFFICIENCY FORMULA
Flow 'B' divided by Flow 'A' x 100 =% of pump efficiency
Example - Flow 'A' = 50 Llmin Flow 'B'= 47 Llmin
47
50 x 100 = 94%
• If the flow is less than 85% , refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Pump Flow Low:
Hydraulic oil level low (faulty transfer pump).
Hydraulic filter in filter manifold blocked
Intake of air around the filter bowl.
Pump drive gear key failed.
Seals between pump and filter manifold leaking .
Pump inlet in range housing blocked.
Pump worn.
Main relief valve faulty.
Main relief valve o-rings leaking.
8M 8-10401 Issued 09-2004
12 SECTION 8001
Test 2 - Main Relief Valve
Ol97K169
1. NUMBER ONE REMOTE VALVE
SM 8-10401 Issued 09-2004
SECTION 8001 13
TOOLS REQUIRED
One male coupler, quick disconnect (part no. 1272399C2).
One Number 4 adaptor, 7/8-14 JIC male - 1/8 BSPF female (part no. FT1605).
One Minimess test point 1/8 BSPF (part no. 8172671).
One high pressure hose (part no. 8172694) .
One gauge 0-275 bar (part no. FT5274-8).
TEST CONNECTIONS
Install the pressure gauge into number one remote valve coupler raise port (1).
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at rated speed.
• Operate number 1 remote lever in the raise position.
• The pressure must be 172.5 bar.
• If the pressure is not correct, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Main Relief Valve Pressure Low:
Damaged o-rings on main relief valve in Filter Manifold.
Seals between hydraulic pump and Filter Manifold leaking.
Main relief valve faulty.
Main hydraulic pump worn.
SM 8-10401 Issued 09-2004
14 SECTION 8001
Test 3 - Steering Relief Valve Pressure and Cylinder Internal Leakage
, .r ~ "" ': =: 3
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\'.v .'f' """" .....:. .....;.....
~- -
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DI9 7E338
1. LEFT HAND STEERING HOSE
2. STEERING CYLINDER ELBOW
SM 8-10401 Issued 09-2004
SECTION 8001 15
STEERING RELIEF VALVE
TOOLS REQUIRED
One cap, 9/16-18 JIC (part no. 218-754).
One Number 2 adaptor, 9/16-18 JIC male - 1/8 BSPF female (part no. FT1607).
One Minimess test point, 1/8 BSPF (part no. 8172671).
One high pressure hose (part no. 8172694) .
One gauge (0-275 bar (part no. FT5274-8).
TEST CONNECTIONS
Disconnect the left hand steering hose (1) and install the pressure gauge. Cap the elbow (2) on the steering
cylinder.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at 1000 rpm .
NOTE: Make sure the regulated pressure is 20 bar, if the pressure is incorrect refer to Test 5 -
Regulated Pressure
• Turn the steering wheel counterclockwise with a minimum force to obtain steering relief pressure.
• Record the pressure. The pressure must be 141 to 148 bar.
• If the pressure is not correct, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Steering relief valve in steering hand pump set to low. Refer to Steering Hand Pump, Section 5001.
- Steering hydraulic pump faulty. Carry out Test 4 - Steering Hydraulic Pump Efficiency
- Steering hand pump faulty. Refer to Steering Hand Pump, Section 5001.
INTERNAL LEAKAGE
TEST CONNECTIONS
Turn the steering wheel clockwise against the steering stops. Disconnect the left hand steering hose (1) and place
the end in a suitable container. Place a suitable container below the steering cylinder elbow (2).
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at 1000 rpm.
• Hold the steering wheel against the steering stops with a minimum force. Check for leakage from the steering
cylinder.
• If there is leakage from the steering cylinder, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Internal leakage in the steering cylinder.
8M 8-10401 Issued 09-2004
16 SECTION 8001
Test 4 - Steering Hydraulic Pump Efficiency
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D197K170
CX50 AND CX60 TRACTORS
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CX70, CX80, CX90 AND CX100 TRACTORS
DI97K171
1. OUTLET OF STEERING HYDRAULIC PUMP
SM 8-10401 Issued 09-2004
SECTION 8001 17
TOOLS REQUIRED
Two flowmeter connectors.
One flowmeter.
TEST CONNECTIONS
Install the flowmeter at the outlet of the Steering Hydraulic Pump (1).
IMPORTANT: The flowmeter restrictor must be fully open to allow full flow, otherwise damage to the
Steering Hydraulic Pump will result.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C
• Run the engine at rated speed.
• Make sure the restrictor on the flowmeter is FULLY OPEN to allow full flow. Record the flow as flow 'A' .
• Turn the restrictor on the flowmeter and restrict the flow to a pressure of 150 bar.
• Record the flow as flow '8'.
• Calculate the pump efficiency using the formula below. The efficiency must not be less than 85%.
• PUMP EFFICIENCY FORMULA
Flow 'B' divided by Flow 'A' x 100 =% of pump efficiency
Example - Flow 'A' =30 Llmin. Flow '8'= 28 Llmin .
28 x 100 =93%
30
• If the flow is less than 85%, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Pump Flow Low:
Hydraulic oil level low (faulty transfer pump) .
Hydraulic filter in filter manifold blocked
Intake of air around the filter bowl.
Pump drive gear key failed.
Pump inlet blocked.
Pump worn .
SM 8-10401 Issued 09-2004
18 SECTION 8001
Test 5 - Regulated Pressure
1
- - ---
---
-- --
DI97E338
1. LEFT HAND STEERING HOSE
2. STEERING CYLINDER ELBOW
SM 8-10401 Issued 09-2004
SECTION 8001 19
TOOLS REQUIRED
One cap, 9/16-18 JIC (part no. 218-754).
One Number 2 adaptor, 9/16-18 JIC male - 1/8 BSPF female (part no. FT1607).
One Minimess test point, 1/8 BSPF (part no. 8172671).
One high pressure hose (part no. 8172694).
One gauge 0-20 bar (part no. FT5274-2).
TEST CONNECTIONS
Disconnect the left hand steering hose (1) and install the pressure gauge. Cap the elbow (2) on the steering
cylinder.
On XtraShift tractors the regulated pressure can also be tested at port (A) on the XtraShift valve.
NOTE: Regulated pressure can also be checked by carrying out Test 6 - PTO Pressure.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at low idle.
• DO NOT turn the steering wheel.
• The pressure must be 20 bar.
• If the pressure is not correct, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Pressure regulator valve adjustment is incorrect.
NOTE: Turn the adjustment screw on the pressure regulator valve block one complete turn to increase
or decrease the pressure 1.7 bar.
- Excessive leakage in regulated circuits, refer to Test 8 - Regulated Circuit Leakage Test.
SM 8-10401 Issued 09-2004
20 SECTION 8001
Test 6 - PTa Pressure
DI97K003
1. BLANKING PLUG AT PTO SUPPLY TUBE TEE
2. PTO SUPPLY TUBE
SM 8-10401 Issued 09-2004
SECTION 8001 21
TOOLS REQUIRED
One tube (part no. 539835R2)
One Number 3 adaptor, 7/16-20 JIC male - 1/8 BSPF female (part no. FT1604).
One Minimess test point, 1/8 BSPF (part no. 8172671) .
One high pressure hose (part no. 8172694).
One gauge 0-20 bar (part no. FT5274-2) .
TEST CONNECTIONS
TEST 1 - Remove the blanking plug (1) from the PTa supply tube tee, install the pressure gauge.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at low idle.
• Engage the PTa fully and record the pressure.
• The pressure must be 20 bar.
• Disengage the PTa.
• The pressure must be zero.
• If the pressures are not correct, carry out Test 2.
TEST CONNECTIONS
TEST 2 - Disconnect the PTa supply tube (2) at the Filter Manifold, install the pressure gauge.
TEST REQUIREMENTS
• Engage the PTa fully and record the pressure.
• The pressure must be 20 bar.
• Disengage the PTa .
• The pressure must be zero.
• If the pressure is correct there is excessive internal leakage in the PTa clutch circuit, refer to POSSIBLE CAUSE
table.
• If the pressures are not correct, refer to POSSIBLE CAUSE table.
POSSIBLE CAUSES
TEST 1 PRESSURE TEST 2 PRESSURE
POSSIBLE CAUSES
CORRECT INCORRECT CORRECT INCORRECT
V V A
V V B, C, D or E
A - PTa clutch pack or hook rings leaking.
B - PTa spool adjustment incorrect, refer to Pedal, Lever and Switch Adjustments, Section 9001.
C - PTa spool sticking .
D - Pressure regulator valve faulty or requires adjustment, refer to Test 5 - Regulated Pressure.
E - Excessive leakage in regulated pressure circuits, refer to Test 8 - Regulated Circuit Leakage Test.
SM 8-10401 Issued 09-2004
22 SECTION 8001
Test 7 - Oil Cooler Flow
o
o
OUT IN
Ol97E337
1. OIL COOLER SUPPLY HOSE
2. FLOWMETER INLET TO OIL
COOLER SUPPLY HOSE
3. FLOWMETER OUTLET TO OIL
COOLER SUPPLY TUBE
4. OIL COOLER SUPPLY TUBE
SM 8-10401 Issued 09-2004
SECTION 8001 23
TOOLS REQUIRED
One flowmeter inlet connector (3/4-16 JIC male onto oil cooler inlet hose).
One flowmeter outlet connector (3/4-16 JIC female onto oil cooler inlet tube).
One flowmeter.
TEST CONNECTIONS
Disconnect the oil cooler supply hose (1), install to the inlet (2) of the flowmeter. Connect the outlet (3) of the
flowmeter to the oil cooler supply tube (4).
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at high idle.
• The flow must be to the following specifications:
CX50, 60 at 2250 engine rpm ......................... 23.7 Llmin.
CX70/75, 80/85, 90/95, 100/105 at 2200 engine rpm26.3 Llmin.
• Turn the restrictor on the flowmeter until the flow drops and record the pressure.
• The pressure must be 10.4 bar oil cooler bypass opening pressure.
• If the flow or pressure is not correct, refer to POSSIBLE CAUSES.
POSSIBLE CAUSES
- Oil cooler bypass valve is faulty, refer to Pressure Regulator Valve, Section 8004.
- Accumulation of leaks in other regulated circuits (if equipped), carry out Test 8 - Regulated Circuit Leakage Test.
- Oil cooler supply/return pipes restricted.
- Oil cooler is blocked.
8M 8-10401 Issued 09-2004
24 SECTION 8001
Test 8 - Regulated Circuit Leakage Test
o
o
Ol97E337
1. OIL COOLER SUPPLY HOSE
2. FLOWMETER INLET TO OIL COOLER SUPPLY HOSE
3. FLOWMETER OUTLET TO OIL COOLER SUPPLY HOSE
4. OIL COOLER SUPPLYTUBE
SM 8-10401 Issued 09-2004
SECTION 8001 25
TOOLS REQUIRED
One flowmeter inlet connector (3/4-16 JIC male onto oil cooler inlet hose).
One flowmeter outlet connector (3/4-16 JIC female onto oil cooler inlet tube) .
One flowmeter.
TEST CONNECTIONS
Disconnect the oil cooler supply hose (1), install to the inlet (2) of the flowmeter. Connect the outlet (3) of the
flowmeter to the oil cooler supply tube (4). The flowmeter restrictor must be fully open to allow free flow.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 65 to 85° C.
• Run the engine at 750 rpm.
• Put the MFD switch in the ON position and differential lock switch in the OFF position. Put the powershift switch
in the LOW SPEED position. Put the PTO lever in the disengaged position.
• Record the flow reading. This is your baseline reading . All future recorded flows will be compared to this
baseline reading .
IMPORTANT: The baseline reading must be to the following specifications:
CX50, 60 at 750 engine rpm ....... .............. .. .. ..... ............... ....... .................. ....................... .................... .. 5.4 Llmin.
CX70/75 , 80/85, 90/95, 100/105 at 750 engine rpm .............. ...... ............... ..... .............. ...... .... ......... .. ... ... .. 6.5 Llmin.
If the baseline reading is not correct, carry out Test 7 - Oil Cooler Flow.
• Operate each feature of the regulated circuit individually and observe the drop in flow readings. When a feature
is operated, the flow should drop momentarily and then return to the baseline reading . Record the flow readings
using the table below.
FLOW TEST FLOW DROP FLOW RECORDED
Baseline flow reading - MFD ON , diff lock OFF, N/A
powershift in LOW SPEED and PTO disengaged.
Switch OFF MFD (return switch to ON position). YES/NO
Operate differential lock (return switch to OFF position). YES/NO
Operate powershift in HIGH SPEED (return switch to LOW SPEED). YES/NO
Put PTO lever in the engaged position. YES/NO
Operate the hitch in RAISE and LOWER modes YES/NO
• When a feature is operated constant flow drop below the baseline reading indicates a leak in that particular
circuit, refer to POSSIBLE CAUSES.
• If the flow reading DOES NOT drop when a feature is operated , this indicates that circuit is not operating. When
troubleshooting an electro-hydraulic system problem check for electrical power to the solenoid coils
as they are activated. This will isolate hydraulic system problems from electrical problems. Use a
high impedance multimeter for any electrical checks. Refer to Section 4001.
POSSIBLE CAUSES
- PTO spool sticking or requires adjustment, carry out Test 6 - PTO Pressure .
- Leakage in MFD circuit; o-rings in MFD solenoid leaking , MFD clutch pack or hook rings leaking.
- Leakage in differential lock circuit; seals in differential lock solenoid leaking .
- Leakage in powershift circuit; o-rings on powershift clutch supply tube leaking, powershift clutch pack or shaft
seals leaking.
8M 8-10401 Issued 09-2004
26 SECTION 8001
Test 9 - Remote Detent Kick-out
DI97K169
1. NUMBER ONE REMOTE VALVE COUPLER
8M 8-10401 Issued 09-2004
SECTION 8001 27
TOOLS REQUIRED
One male coupler, quick disconnect (part no. 1272399C2).
One flowmeter inlet connector (7/8-14 JIC male onto coupler).
One flowmeter.
TEST CONNECTIONS
Install the inlet of the flowmeter into number 1 remote valve coupler (1) and the outlet into the transmission filler.
TEST REQUIREMENTS
• Heat the hydraulic oil to a temperature of 49° C.
• Run the engine at 1200 rpm.
• Turn the restrictor on the flowmeter until the detent kicks-out and record the pressure.
• The pressure must be 144.7 to 172.3 bar.
• If the pressure is not correct, refer to POSSIBLE CAUSES.
• Repeat test on the remaining remote valve couplers.
POSSIBLE CAUSES
- Main relief valve faulty. Carry out Test 2 - Main Relief Valve.
- Detent kick-out on valve set to low.
8M 8-10401 Issued 09-2004
28 SECTION 8001
CROSS SECTIONAL DRAWINGS AND INDIVIDUAL SCHEMATICS
Hydraulic Filter
. - - - - --.--- -1- ®
2. SUCTION FJLTER ELEMENT
3. BY-PASS VALVE AND SCREEN
PORTS
A. SUCTION
B. TO PUMP
L - - - - + - - -- ------il- ®
DI97K006
DI97K 168
SM 8-10401 Issued 09-2004
SECTION 8001 29
Main Hydraulic Pump
® 1. GEAR
PORTS
A. INLET
B. OUTLET
DI97K007
DS97E373
SM 8-10401 Issued 09-2004
30 SECTION 8001
Filter Manifold
® 1. MAIN RELIEF VALVE
2. PTO VALVE SPOOL
®---t---.;----,
I i=l=il=ri==r=. A
PORTS
A. INLET FROM HYDRAULIC PUMP
B. SUPPLY TO HITCH AND REMOTE VALVES
C. INLET TO MAIN HYDRAULIC PUMP
'--____I_® D. INLET AT REGULATED PRESSURE TO PTO
VALVE
E. RETURN FROM REMOTE VALVES
r-------+- @ F. SUPPLY AT REGULATED PRESSURE TO PTO
CLUTCH
G. INLET TO HYDRAULIC FILTER
@ H. SUPPLY FROM HYDRAULIC FILTER
J . SUPPLY TO MAIN HYDRAULIC PUMP
T. RETURN TO TANK
® -I-~-4--,
,
---- 1--
----' -I- ®
o CI97K008
('--*.:--".-'l-~lIl----~ ®
@--
:-~®
----~®
®--
CI97K10e
SM 8-10401 Issued 09-2004
SECTION 8001 31
Unloading Valve
1. UNLOADING VALVE
PORTS
A. INLET FROM MAIN HYDRAULIC PUMP
B. SIGNAL LINE FROM HITCH VALVE
C. SUPPLY TO REMOTE VALVES
DI97K010
\, j,
,
©
DI97K110
SM 8-10401 Issued 09-2004
32 SECTION 8001
Remote Valves
1. RAISE CHECK VALVE (IF EQUIPPED)
2. LOAD CHECK VALVE (IF EQUIPPED)
3. NEUTRAL RETURN
PORTS
A . INLET FROM UNLOADING VALVE
B. RETURN TO FILTER MANIFOLD
C. RAISE PORT
D. LOWER PORT
T. RETURN TO TANK
DI97K01 1
f
® DI97K111
SM 8-10401 Issued 09-2004
SECTION 8001 33
Hitch Valve
-
'-~- - t-.~
,.
,,:
-J!~ __ , ___ .r
I 1.
2.
PRIMARY RAISE SPOOL
SECONDARY RAISE SPOOL
_________J
I I I
~ 1r==F;rI~IIp
'
3.
4.
PRIMARY LOWER SPOOL
SECONDARY LOWER SPOOL
PORTS
A. INLET FROM MAIN HYDRAULIC PUMP
'8. SUPPLY TO HITCH LIFT CYLINDER AND
HITCH RELIEF VALVE
C. RETURN TO HITCH CYLINDER
(LUBRICATION)
D. INLET AT REGULATED PRESSURE FROM
STEERING HYDRAULIC PUMP
E. SIGNAL LINE TO UNLOADING VALVE
DI97K012
DS97E375
SM 8-10401 Issued 09-2004
34 SECTION 8001
EDC Manifold
~~, ~ ,~ r,
c~_ ®
1. EDC MANIFOLD
2. DIFFERENTIAL LOCK SOLENOID AND
SPOOL
PORTS
A . INLET FROM MAIN HYDRAULIC PUMP TO
@ HITCH VALVE
B. INLET FROM HITCH VALVE TO HITCH LIFT
CD CYLINDER AND HITCH RELIEF VALVE
C. INLET FROM HITCH VALVE TO HITCH
® CYLINDER (LUBRICATION)
D. SIGNAL LINE FROM HITCH VALVE TO
UNLOADING VALVE
E. INLET AT REGULATED PRESSURE FROM
STEERING HYDRAULIC PUMP TO HITCH
VALVE AND DIFFERENTIAL LOCK VALVE
F. TO DIFFERENTIAL LOCK CYLINDER
T. RETURN TO TANK
DI97K013
--------------- - -- - ,
/
----~--/~----------------~~,---,.~-------------r--~
=====: ~L'----------------------------'~I---------------------4 r=====:
I I I
=====~ _c=====
o 10
o
!CD
DI97K167
SM 8-10401 Issued 09-2004
SECTION 8001 35
Hitch Cylinder and Hitch Relief
Valve
®® 1. HITCH RELIEF VALVE
2. HITCH CYLINDER
PORTS
A. INLET FROM HITCH VALVE
B. SUPPLY TO HITCH CYLINDER
(LUBRICATION)
® r- - '
I
T. RETURN TO TANK
I
-
CD
LJ
® Ol97K014
OS97E382
SM 8-10401 Issued 09-2004
36 SECTION 8001
Steering Hydraulic Pump
®
PORTS
A. INLET
B. OUTLET
® DI97K01S
® ®
D197K172
SM 8-10401 Issued 09-2004
SECTION 8001 37
Steering Hand Pump
1. CH ECK VALVE
2. RELIEF VALVE
3. CHECK BALL
4. SPOOL
PORTS
A. INLET FROM STEERING HYDRAULIC PUMP
B. SUPPLY TO PRESSURE REGULATOR VALVE
BLOCK
L. LEFT TURN
R. RIGHT TURN
Ol97K016
Ol97K113
SM 8-10401 Issued 09-2004
38 SECTION 8001
Pressure Regulator Valve Block
Two Speed Powershift
1. OIL COOLER BY-PASS VALVE
10.4 BAR (150.8 PSI)
,
Y5l I
2. REGULATED PRESSURE VALVE
20 BAR (290 PSI)
3. POWERSHIFT SOLENOID SPOOL
PORTS
J
A. SUPPLY TO OIL COOLER
B. INLET FROM STEERING HYDRAULIC PUMP
C. SUPPLY TO POWERSHIFT CLUTCH
T. RETURN TO TANK
©
DI97K017
DI97K114
SM 8-10401 Issued 09-2004
SECTION 8001 39
MFD Solenoid and Clutch
~®
- -f-- - 1. MFD SOLENOID AND SPOOL
2. MFD CLUTCH
PORTS
A. INLET FROM STEERING HYDRAULIC PUMP
B. RETURN TO TANK
'----- - 0
01971<018
0197K115
SM 8-10401 Issued 09-2004
40 SECTION 8001
ex Hydraulic Schematic, Two Speed Power Shift
1. TRANSFER PUMP 20A . REGULATED PRESSURE 20 BAR (290 PSI)
1A. BEVEL PINION LUBE 20B. POWERSHIFT SOLENOID SPOOL
2. HYDRAULIC FILTER 20C . OIL COOLER BYPASS VALVE 10.4 BAR (150.8 PSI)
3. SCREEN AND BYPASS VALVE 21. POWERSHIFT CLUTCH
4. MAIN HYDRAULIC PUMP 22 . MFD VALVE
5. FILTER MANIFOLD 23 . PTO VALVE
6. MAIN RELIEF VALVE 172.5 BAR (2502 PSI) 24 . PTO CLUTCH
7. TRAILER BRAKE VALVE 25. EDC MANIFOLD
8. UNLOADING VALVE 26 . DIFF LOCK VALVE
9. INLET PLATE 27. DIFF LOCK CYLINDER
10. REMOTE VALVES 28. OIL COOLER
11. BREAKAWAY COUPLERS 29. SCREEN AND ORIFICE
12. END COVER 30. BRAKE RESERVOIR
13. HITCH VALVE 31. BRAKE VALVES
14. HITCH BOOSTER CYLINDERS 32. RACTOR BRAKE PISTONS
15. HITCH PISTON AND CYLINDER 33A. FORWARD AND REVERSE SYNCHRO LUBE
16. HITCH RELIEF VALVE 33B . SPEED SYNCHRO LUBE
17. STEERING HYDRAULIC PUMP 33C. RANGE SYNCHRO LUBE
18. STEERING HAND PUMP 33D. PARK BRAKE LUBE
19. STEERING CYLINDER 33E. BRAKE LUBRICATION
20. PRESSSURE REGULATOR VALVE BLOCK
SM 8-10401 Issued 09-2004
SECTION 8001 41
(--1----1----
1
~
I
- 'I
I
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I __ I
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I
l- - f--- - - - - - - - i--'
FINAL DRIVE/RANGE HOUSING I
TRANSMISSION HOUSING
I
I
'---------- - MI04J053
8M 8-10401 Issued 09-2004
~ SECnON8001
ex XtraShift, Hydraulic Schematic
Prior to PIN JJE2053339 (30 kph)
Prior to PIN JJE2053288 (40 kph)
1. TRANSFER PUMP 22. MFD VALVE
1A. BEVEL PINION LUBE 23 . PTO VALVE
2. HYDRAULIC FILTER 24 . PTO CLUTCH
3. SCREEN AND BYPASS VALVE 25 . EDC MANIFOLD
4. MAIN HYDRAULIC PUMP 26 . DIFF LOCK VALVE
5. FILTER MANIFOLD 27 . DIFF LOCK CYLINDER
6 . MAIN RELIEF VALVE 172.5 BAR (2502 PSI) 28 . OIL COOLER
7. TRAILER BRAKE VALVE 29. SCREEN AND ORIFICE
8. UNLOADING VALVE 30 . BRAKE RESERVOIR
9. INLET PLATE 31 . BRAKE VALVES
10. REMOTE VALVES 32 . TRACTOR BRAKE PISTONS
11 . BREAKAWAY COUPLERS 33A. XTRASHIFT CLUTCH LUBRICATION
12. END COVER 33B. SPEED SYNCHRO LUBE
13 . HITCH VALVE 33C. RANGE SYNCHRO LUBE
14. HITCH BOOSTER CYLINDERS 330. PARK BRAKE LUBE
15. HITCH PISTON AND CYLINDER 33E . BRAKE LUBRICATION
16 . HITCH RELIEF VALVE 34. XTRASHIFT VALVE BLOCK
17. STEERING HYDRAULIC PUMP 34A . FORWARD POWERSHIFT SOLENOID
18. STEERING HAND PUMP 34B . REVERSE POWERSHIFT SOLENOID
19. STEERING CYLINDER 34C . SECONED POWERSHIFT SOLENOID
20 . PRESSSURE REGULATOR VALVE BLOCK 340. FIRST POWERSHIFT SOLENOID
20A. REGULATED PRESSURE 20 BAR (290 PSI) 34E . THIRD POWERSHIFT SOLENOID
20C. OIL COOLER BYPASS VALVE 10.4 BAR (150.8 PSI)
21 . FORWARD CLUTCH
21 A. REVERSE CLUTCH
21 B. SECONED CLUTCH
21 C. FIRST CLUTCH
21 D. THIRD CLUTCH
SM 8-10401 Issued 09-2004
SECTION 8001 43
: ~O
" -......-.L-t-It-t - - -.., ,
I
r-==I=~~_J~I1 :
LJ
I -~I~-'- --
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FINAL DRIVE/RANGE HOUSING ,
TRANSMISSION HOUSING
I
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'---------------
MI04JOS4
8M 8-10401 Issued 09·2004
44 SECTION 8001
ex XtraShift, Hydraulic Schematic
PIN JJE2053340 and after (30 kph)
PIN JJE2053289 and after (40 kph)
1. TRANSFER PUMP 22. MFD VALVE
1A. BEVEL PINION LUBE 23. PTO VALVE
2. HYDRAULIC FILTER 24. PTO CLUTCH
3. SCREEN AND BYPASS VALVE 25. EDC MANIFOLD
4. MAIN HYDRAULIC PUMP 26 . DIFF LOCK VALVE
5. FILTER MANIFOLD 27. DIFF LOCK CYLINDER
6. MAIN RELIEF VALVE 172.5 BAR (2502 PSI) 28. OIL COOLER
7. TRAILER BRAKE VALVE 29. SCREEN AND ORIFICE
8. UNLOADING VALVE 30. BRAKE RESERVOIR
9. INLET PLATE 31. BRAKE VALVES
10. REMOTE VALVES 32 . TRACTOR BRAKE PISTONS
11. BREAKAWAY COUPLERS 33A. XTRASHIFT CLUTCH LUBRICATION
12. END COVER 33B. SPEED SYNCHRO LUBE
13. HITCH VALVE 33C. RANGE SYNCHRO LUBE
14. HITCH BOOSTER CYLINDERS 33D. PARK BRAKE LUBE
15. HITCH PISTON AND CYLINDER 33E. BRAKE LUBRICATION
16. HITCH RELIEF VALVE 34 . XTRASHIFT VALVE BLOCK
17 . STEERING HYDRAULIC PUMP 34A . FORWARD POWERSHIFT SOLENOID
18. STEERING HAND PUMP 34B. REVERSE POWERSHIFT SOLENOID
19. STEERING CYLINDER 34C. SECONED POWERSHIFT SOLENOID
20A. REGULATED PRESSURE 20 BAR (290 PSI) 34D. FIRST POWERSHIFT SOLENOID
20C. OIL COOLER BYPASS VALVE 10.4 BAR (150.8 PSI) 34E. THIRD POWERSHIFT SOLENOID
21 . FORWARD CLUTCH
21 A. REVERSE CLUTCH
21 B. SECONED CLUTCH
21 C. FIRST CLUTCH
21 D. THIRD CLUTCH
SM 8-10401 Issued 09-2004
SECTION 8001 45
-----,
($")
-- ,i
I
(§)
1-0> _ - - - - - -
.
,.----r--.,--, ~I
.....-
~4-<o-I-IEt·- -
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l_ __ r--
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T (f~------------------,
.---/-- -- -- -- - .
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- ---- --- -.
_____ L~------., ___ -~---~---____,
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rg .I
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t _______ _ LJ _ __ ' _ _ _ _ __ --1 __ j_
FINAL DRIVE/RANGE HOUSING TRANSMISSION HOUSING
MI04J055
8M 8-10401 Issued 09-2004
Section
8002
FILTER MANIFOLD AND
MAIN HYDRAULIC PUMP
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10410 March 2001
2 SECTION 8002
TABLE OF CONTENTS
SPECiFiCATIONS .................................................................................................................................................... 3
SPECIAL TORQUES ................................................................... .................................. .. .................. ............... .. ...... 3
FILTER MANIFOLD
Removal and Installation ...................................................................................................................................... 4
Disassembly and Assembly ................................................................................................................................. 6
MAIN HYDRAULIC PUMP
Disassembly and Assembly ...................................................................................................... ........................... 8
CROSS SECTION OF FILTER MANIFOLD AND HYDRAULIC FILTER ................................................................. 9
CROSS SECTION OF MAIN HYDRAULIC PUMP ...................... ... ........................................................................ 10
8M 8-10410 Issued 03-2001
SECTION 8002 3
SPECIFICATIONS
PTa Control Spool Assembly
Return Spring
Free Length ... ...... .. ........ ......... ................................ ............ .. ... ... ...... ... ........... ... ... ............. .. ........... .... . 79.63 mm
High Pressure Spring
Free Length ... ........... .............. ... .. .. ... .................................... ............ ... ............ ..... ........... .. ............ .. ... 29.65 mm
Low Pressure Spring
Free Length .. .. ..... ....... ..... .............. ............. ..... ... ............ .... .. ... ......... ..... ... ....... ........... ................... .. ... 24.42 mm
Main Relief Valve Pressure ... ................... .......... ....... .. ............ ............ .. ................................................... 172.5 bar
HYDRAULIC SYSTEM CX50/60 CX70/80/90/100
Hydraulic system type Open
Flow to 5401750 PTO 50 .2 Llmin .
Remotes 59.4 Llmin.
540/1000 PTO 51 .7 Llmin.
Main Hydraulic 540/750 PTO 50.2 Llmin .
Pump 59.4 Llmin .
540/1000 PTO 51 .7 Llmin .
Pump gear 540/750 PTO 23 19
(No. of teeth)
540/1000 PTO 27 23
Pump mounting N/A 5.31 to 5.43 mm
plate thickness
SPECIAL TORQUES
Filter Manifold Retaining Bolts ..... .... ...... ........ .. ........... .... ......... ... .. ............ ..... ............ ... ........... .............. 45 to 50 Nm
Hydraulic Filter Retaining Bolt ......... .... .......... .. ............ .... ............ ... .. .. ........ ... .. .......... .. ........... .... ..... ...... 16 to 21 Nm
Main Hydraulic Pump Retaining Bolts ...... ........ .... .......... ... .... ......... ....... ..................................... ...... ..... 24 to 28 Nm
Main Hydraulic Pump Drive Gear Locknut ..................... .......................... ... .. .......... ......... ........ ... .. ......... 61 to 68 Nm
Main Hydraulic Pump End Plate
Retaining Bolt ... ........................... .. ............. .. ............ ... ........... ... ....... .. ....... .... ........... .. ......... ... ......... ... 27 to 31 Nm
Cap Screw .. .......... .. .............. ...... ......... .... ....... ... .... .......... ......... .. ... ......... ............ ........ .... .......... .. .. ..... . 24 to 27 Nm
Main Relief Valve ............................................................. ....... .. ... .. .......... .. ................ ...... ....... .. ............. 34 to 54 Nm
Fitting, PTO Spool Supply .. ......... ...... ........... .. ............ .... ............. .. .......... ... .. .......... .... ............. .. ............ 34 to 54 Nm
Elbow, Filter Manifold Inlet.... ........ .... .... ............ .... .. .. ......... .... ................ ......... ....... ........ .......... ........ ...... 34 to 54 Nm
Plug, PTO Spool .. .. .......... ..... .......... .... ................. .. ......... ............. .. .............. ..... .. ..... .... .. .. ..................... . 34 to 54 Nm
SM 8-10410 Issued 03-2001
4 SECTION 8002
FILTER MANIFOLD
Removal and Installation
NOTE: For Installation, follow the Removal procedure in reverse order.
Before removing the Filter Manifold and Main Hydraulic Pump carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the Fuel Tank, refer to Section 3001.
STEP 1 STEP 2 MFD Tractors
Put a container with a capacity of at least 40 litres
under the transmission and drain the oil. Install and
tighten the drain plugs.
NOTE: After installation of the filter manifold, fiJI
the transmission with clean HY- TRAN ® ULTRA
to the correct level.
OP98A138
Disconnect parking brake cable cotter pin (1).
Loosen adjuster nut (2) and remove the parking
brake cable from the bracket. Remove retaining
bolts (3) and remove bracket (4).
8M 8-10410 Issued 03-2001
SECTION 8002 5
STEP 3
DP98A139A
Disconnect and remove PTO operating lever (5) . Disconnect PTO clutch supply tube (6) , remote valve return tube
(7), hitch and remote valve supply tube (8) , PTO valve supply tube (9) and filter manifold inlet tube (10). Cap
tubes and fittings .
Remove two retaining bolts (11) and install alignment studs (3/8"-16 UNC x 5" long) . Remove remaining bolts
(12). Carefully remove the filter manifold.
NOTE: For Installation, tighten retaining bolts (11) and (12) to a torque of 45 to 50 Nm.
STEP 4 STEP 5
DP98A119 DI97N144
Remove and discard o-ring (13) and gasket (14) . Remove filter assembly (15) to (20), discard o-ring
(19), gasket (20) and filter (16) .
NOTE: For Installation, clean all mating For Installation, follow the removal procedure in
surfaces and install new gasket (14) and new 0- reverse order. Install new filter (16), o-ring (19)
ring (13) onto the transmission housing. and gasket (20).
8M 8-10410 Issued 03-2001
6 SECTION 8002
Disassembly and Assembly STEP 8
CX70/75,CX80/85,CX90/95 and CX100
STEP 6
DP98A137
DP98A120
Remove mounting plate (7) . Remove and discard 0-
Remove retaining bolts (1) with washers. On later rings (8) .
models a filter centring bracket (2) (not shown) is
installed using retaining bolt (1A). Remove roll pin NOTE: For Assembly, lubricate and install new
(3) and collar (4). a-rings (8).
NOTE: For Assembly, install retaining bolts (1) STEP 9
with new washers and tighten to a torque of 24
to 28 Nm .
STEP 7
DP98A122
Remove manifold plate (9), remove and discard
manifold gasket (10). Remove and discard sealing
ring (11) from the filter manifold .
DP98A121
Remove main hydraulic pump (5). Remove and For Assembly, clean all mating surfaces, install
discard o-rings (6). new gasket (10) and new sealing ring (11).
IMPORTANT: For CX50 and CX60 Tractors go to
STEP 9 as mounting plate (7) and o-rings (8)
are not installed.
NOTE: For Assembly, if main hydraulic pump (5)
has been replaced, using a suitable adhesive
install new seal (A) onto the pump body before
installing the main hydraulic pump onto the filter
manifold. Lubricate and install new o-rings (6).
Refer to Page 8 for Disassembly and Assembly
of the main hydraulic pump.
SM 8-10410 Issued 03-2001
SECTION 8002 7
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
34 to 54 Nm
~,---@
~,---@
.-----®
®---,,~,\ ~
\ ~ ,/"
34 to 54 Nm
.,~
34to54Nm ~
NOTE: For Assembly, lubricate and install new a-rings and back-up ring .
12. ELBOW 19. O-RING 26. PLUG 33, LOW PRESSURE SPRING
13. O-RING 20. ELBOW 27 , O-RING 34, RETAINING RING
14. FITTING 21 . O-RING 28 . RETURN SPRING 35. RETAINING RING
15. O-RING 22 . MAIN RELIEF VALVE 29 , WASHER 36. PIN
16. FITTING 23 . O-RING 30. BALL (4) 37, SPOOL
17. O-RING 24 . BACK-UP RING 31 . ROD 38, SEAL
18. FITTING 25 , O-RING 32 , HIGH PRESSURE SPRING
SM 8-10410 Issued 03-2001
8 SECTION 8002
MAIN HYDRAULIC PUMP
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
NOTE: Items marked (*) must be replaced. If other parts are worn or damaged, renew the pump.
STEP 10 STEP 11
Use a suitable puller to remove drive gear (2), DO
NOT use levers as this could result in damage to
the pump assembly. Remove woodruff key (3) from
the drive rotor shaft.
85-738
Hold the drive gear in a vice fitted with soft jaws.
Remove and discard locknut (1).
NOTE: For Assembly, install a new locknut (1) and
tighten to a torque of 61 to 68 Nm.
~~~
I "@
4. RETAINING BOLT (8) 8. BACKUP RING' 12. DRIVEN ROTOR 16. END PLATE
5. WASHER (8) 9 . OIL SEAL' 13. RETAINING BOLT (6) 17. SEAL'
6 . END PLATE 10. BEARING 14. WASHER (6) 18. BACKUP RING'
7. SEAL' 11 . DRIVE ROTOR 15. CAP SCREW (2) 19. BEARING
20 . PUMP HOUSING
SM 8-10410 Issued 03-2001
SECTION 8002 9
CROSS SECTION OF FILTER MANIFOLD AND HYDRAULIC FILTER
°L,- ---@
-------@
~---@
~----~~~~~~t~ OJ97K108
Ol97K168
16, FILTER 31, ROD
17 , BY-PASS VALVE AND SUCTION SCREEN 32 . HIGH PRESSURE SPRING
22, MAIN RELIEF VALVE 33 . LOW PRESSURE SPRING
26, PLUG 36. PIN
28, RETURN SPRING 37. SPOOL
SM 8-10410 Issued 03-2001
10 SECTION 8002
CROSS SECTION OF MAIN HYDRAULIC PUMP
DS97E373
10. BEARING
11. DRIVE ROTOR
12. DRIVEN ROTOR
19. BEARING
8M 8-10410 Issued 03-2001
Section
8003
STEERING HYDRAULIC PUMP
(Engine Driven)
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10420 March 2001
2 SECTION 8003
TABLE OF CONTENTS
SPECiFiCATIONS ............. ............. ............. ............ .................................................................................................. 3
SPECIAL TORQUES ....... ............ ... ............ .. ............... ............ ...................................... ... .. ... ...... ................ ..... ... ...... 3
STEERING PUMP
Removal and Installation
CX50 and CX60 Tractors ...... ........ ................ ...... .......... ..... ............... .. ...... ...... ............ ........ .... ...... .... ........ ........ 4
CX70/75, CX80/85, CX90/95 and CX100/105 Tractors ... ............................................... .................................. 5
SM 8-10420 Issued 03-2001
SECTION 8003 3
SPECIFICATIONS
CX50 and CX60
Direction of Rotation ..... ........ ........ ......... ... ..... ..... ..... ....... .......... .. ......... .... .. ............................ .. ............. ... Clockwise
Flow at 2250 engine rpm .. .... ......... ........ ... ............ .. ....... .. ....... ... ........... .......... .... ........ .... ............... ...... .. 27 .7 L/min.
Rated Working Pressure ...... ................. .... ......... ........ ... .. ....... ... .... ..... ....... .. ... ..... .... ................... ... ..... ......... 160 bar
CX70/75 , CX80/85, CX90/95 and CX 100/105
Direction of Rotation .......... ... ................ ... .. .... ... .. .. ... .. .. .. ........ ...... ...... .. .. .... ..... ............ ...... ..... .. .... Counterclockwise
Flow at 2200 engine rpm ............. .. ........... .... ....... .. ........ .............. .................... ... ............ ....................... 30.3 L/min.
Rated Working Pressure .... ........... ... ............ ...... .. ..... ...... .. .. ...... .. ...... ... .. ......... ........... .. ....... .... ... ... ... .. ......... 160 bar
SPECIAL TORQUES
Steering Pump to Engine Retaining Screws .................................. ................. .... .................. .............. 41 to 48 Nm
Inlet Tube Retaining Screws ........... ......... .. ....... .... ......... .. ........ .... ........ .. ............ ................. ..... ........ .... 23 to 31 Nm
8M 8-10420 Issued 03-2001
4 SECTION 8003
STEERING PUMP
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Steering Pump it will be necessary to carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• For CX70, CX80, CX90 and CX100 tractors raise the hood.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation, connect the positive (+)
terminal(s) first.
CX50 and CX60
STEP 2
Remove the RH engine side panel.
STEP 3
DP98K118
Remove the retaining screws (4) and washers,
remove the steering pump (5).
NOTE: For Installation , clean the mounting
faces of the steering pump and engine, apply a
continuous bead of Loctile 515 to the face of
the steering pump (5). Install and tighten the
retaining screws (4) and washers to a torque of
41 to 48 Nm .
DP98K097
Disconnect supply hose (1) from the fitting. Discard
the a-ring, cap the hose (1) and fitting.
Remove the retaining screws (2) and inlet tube (3),
discard the o-ring and cap the tube (3).
NOTE: For Installation, install a new o-ring onto
the supply hose fitting .
NOTE: For Installation install a new o-ring onto
inlet tube (3), install and tighten the retaining
screws (2) to a torque of 23 to 31 Nm.
8M 8-10420 Issued 03-2001
SECTION 8003 5
CX70/75, CX80/85, CX90/95 and CX100/105 STEP 6
STEP 5
DP98K99
Remove the retaining screws (4) and washers,
DP98K100 remove the steering pump.
Disconnect supply hose (1) from the fitting, cap the
hose (1) and fitting. NOTE: For Installation, clean the mounting
Remove the retaining screws (2), washers and inlet faces of the steering pump and engine, apply a
tube (3), discard the o-ring and cap the tube (3). continuous bead of Loctite 515 to the face of
the steering pump. Install and tighten the
NOTE: For Installation, install a new o-ring onto retaining screws (4) and washers to a torque of
the inlet tube (3), install and tighten the 41 to 48 Nm.
retaining screws to a torque of 23 to 31 Nm.
8M 8-10420 Issued 03-2001
Section
8004
REGULATOR VALVE
ex Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK SM 8-10430 March 2001
2 SECTION 8004
TABLE OF CONTENTS
SPECIAL TORQUES ............................... .... ............. ........................................................................................... ...... 3
REGULATOR VALVE
Removal and Installation ..................... .................. .............. ..... ....... ..................... ....... ... ....... ...... ...... ....................4
Disassembly and Assembly ......... ...... ......................... ........ ............ .. ............ ............. .. ....... .. ......... .. ......... ..... ... .... 5
Cross Sectional Drawing of the Regulator Valve ......... ................... .......................................... ... ................... .... .. 6
8M 8-10430 Issued 03-2001
SECTION 8004 3
SPECIAL TORQUES
Regulator Valve Retaining Bolts .............................................................................................................. 42 to 47 Nm
Solenoid Valve to Regulator Valve ... ............... ............................. .. .......................................................... 10 to 15 Nm
Coil to Solenoid Retaining NuL .................................................................................................................. 5 to 8 Nm
Regulator Pressure Valve Locknut .. ..... ............ ............ ................. .. ... ........ .. .......... ..... ... ......................... 34 to 54 Nm
Oil Cooler By-Pass Valve Plug .... ............................................................................................................ 34 to 54 Nm
Solenoid Valve Plug (8 Speed Transmission) .......................................................................................... 34 to 54 Nm
8M 8-10430 Issued 03-2001
4 SECTION 8004
REGULATOR VALVE
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Regulator Valve it will be necessary to carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
STEP 1 STEP 2
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation, connect the positive (+)
terminal(s) first.
DD97J085
Remove the cab floor mat and panel.
Disconnect and cap the tubes (1) and (2) from the
regulator valve (5). Disconnect the harness from
the solenoid (3), if equipped. Remove the bolts (4)
and regulator valve (5), discard the a-rings.
NOTE: For Installation, install new o-rings into
the regulator valve (5). Install the valve, install
and tighten the bolts (4) to a torque of 42 to 47
Nm.
8M 8-10430 Issued 03-2001
SECTION 8004 5
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
34 TO 54 NM 0~--:
01----~
34 TO 54NM
34 TO 54 NM
5TO 8 NM
:- --0 34 TO 54 NM
DI98K039
1. REGULATOR VALVE REGULATED PRESSURE VALVE (9) TO (14) OIL COOLER BYPASS VALVE (15) TO (18)
2. O-RING 9. NUT 15. PLUG
3. PLUG 10. ADJUSTING PLUG 16. O-RING
4 . O-RING 11 . O-RING 17. REGULATOR SPRING (OUTER)
5. POWERSHIFT SOLENOID 12. REGULATOR SPRING (OUTER) 18. REGULATOR SPOOL
ASSEMBLY 13. REGULATOR SPRING (INNER)
SA. PLUG 14. REGULATOR SPOOL
(WITHOUT POWERSHIFT)
6. O-RING
7. O-RING
8. O-RING
NOTE: Solenoid assembly (5) is for tractors equipped with a 16 speed transmission. Plug (SA) is for
tractors equipped with an 8 speed transmission.
SM 8-10430 Issued 03-2001
6 SECTION 8004
Cross Sectional Drawing of the Regulator Valve
DI98K040
1. REGULATOR VALVE 14. REGULATOR SPOOL
5. POWERSHIFT SOLENOID ASSEMBLY 15. PLUG
5A. PLUG (WITHOUT POWERSHIFT) 18. REGULATOR SPOOL
10. ADJUSTING PLUG
SM 8-10430 Issued 03-2001
Section
8006
UNLOADING VALVE
ex Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10440 March 2001
2 SECTION 8006
TABLE OF CONTENTS
SPECIAL TORQUES .... .......... ... ....... ... ...................................................................................................................... 3
UNLOADING VALVE
Removal and Installation .................. ............................................................................. ....... ........... ............. .. ....... 4
Disassembly and Assembly .................................. .................................. ..... .. ... ...... .............. .. ......... .. ....... ... ......... 5
Cross Sectional Drawing of the Unloading Valve ........ .... .................... .. .................... .. ........ .. .. ............ .................. 6
8M 8-10440 Issued 03-2001
SECTION 8006 3
SPECIAL TORQUES
Unloader Valve Retaining Bolts .... .......... ........ ... ......................... .. ...... ........... .. ................... ....... .............. 42 to 47 Nm
Regulator Valve Plug ...... ....................... ........................................... .... .... ........... .......... ..... .......... .......... . 34 to 54 Nm
8M 8-10440 Issued 03-2001
4 SECTION 8006
UNLOADING VALVE
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Unloading Valve it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 2
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation , connect the positive (+)
terminal(s) first.
DP98M022
Remove the seat, floor mat and panel. Disconnect
and cap the tubes (1) and (2) from the unloading
valve (4) . Remove the bolts (3) and unloading valve
(4), discard the o-rings .
NOTE: For Installation, install new o-rings into
the unloading valve (4). Install the valve, install
and tighten the bolts (3) to a torque of 42 to 47
Nm.
SM 8-10440 Issued 03-2001
SECTION 8006 5
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
DI98KOBO
1. UNLOADING VALVE 4. UNLOADING SPRING (OUTER)
2. PLUG 5. UNLOADING SPRING (INNER)
3. PLUG 6. UNLOADING VALVE SPOOL
8M 8-10440 Issued 03-2001
6 SECTION 8006
Cross Sectional Drawing of the Unloading Valve
DI97K110
1. UNLOADING VALVE 4. UNLOADING SPRING (OUTER)
2. PLUG 5. UNLOADING SPRING (INNER)
3. PLUG 6. UNLOADING VALVE SPOOL
SM 8-10440 Issued 03-2001
Section
8007
REMOTE VALVES
ex Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK SM 8-10450 March 2001
2 SECTION 8007
TABLE OF CONTENTS
SPECiFiCATIONS ........... ............................. ............................................ ................................................................. 3
SPECIAL TORQUES ................................................................................................................................................. 3
REMOTE VALVE
Removal and Installation .......................................................................................................................................4
Disassembly and Assembly ..... ............. ................ .......... ...... ........ ...... .............. ......... ...... .............. ............. ... ....... 5
REMOTE VALVE WITH NO CHECK VALVES
Disassembly and Assembly ............................................................................................. ..................................... 6
REMOTE VALVE WITH ONE CHECK VALVE
Disassembly and Assembly .................................................................................................................................. 8
REMOTE VALVE WITH TWO CHECK VALVES
Disassembly and Assembly .................................... .. ...... .................................................................................... 10
SM 8-10450 Issued 03-2001
SECTION 8007 3
SPECIFICATIONS
Type ....... ....... ......... .......... .. ....... ............................. ......... ........ ..................... ................. ........... Bosch, Double Acting
Maximum Working Pressure .. ........ ................................. ............................. ............ ... ................................... . 250 bar
Kick Out Pressure ................................................................................................................................ 145 to 160 bar
Flow Rate ........................... ........................................... ..... .. ............ ........................ .. ... .............................. 70 L/min.
Location of Check Valve
Remote Valve with 1 Check Valve................ .. ............ ........ .. ................ ...................... .... .............. ..... In Raise Port
Remote Valve with 2 Check Valves ...... .. .. .... .............. .............. ................ .............. .... .... In Raise and Lower Ports
SPECIAL TORQUES
Remote Valve to Adapter Plate Retaining Bolts .. .................................................. ...... ........................... 16 to 20 Nm
Rear Wheel Nuts ............................................................. .... .. ............................................. ................ 278 to 298 Nm
8M 8-10450 Issued 03-2001
4 SECTION 8007
REMOTE VALVE
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Remote Valves it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation, connect the positive (+)
terminal(s) first.
STEP 2
Raise the rear of the tractor, support the RH rear
axle on a suitable axle stand and remove the RH
rear wheel.
NOTE: For Installation, install the RH rear
wheel and tighten the nuts to a torque of 278 to DP98C200
298 Nm. Remove the axle stand. Remove and cap the return tube (4). Remove the
screw (5) and two bolts (6) . Remove the adapter
STEP 3 plate (7), remove and discard the a-ring from the
hydraulic housing .
NOTE: For Installation, lubricate and install a
new a-ring into the housing, install and evenly
tighten the bolts (6) and screw (5).
STEP 5
Put the remote valve assembly on a clean
workbench . Separate the remote valve assembly
and remove and discard the a-rings.
NOTE: For Installation , lubricate and install new
DP98M025 a-rings onto the remote valves and end cover.
Disconnect and cap the hoses (1) from the remote
valves . Disconnect the linkage (2) from the levers, NOTE: For Installation, follow the same
remove the retaining bolts (3) and carefully remove procedure in reverse order.
the remote valves.
NOTE: For Installation, install and evenly
tighten the retaining bolts (3) to a torque of 16
to 20 Nm .
SM 8-10450 Issued 03-2001
SECTION 8007 5
Disassembly and Assembly STEP 8
STEP 6
o
\ i'
/~
o
H05213
Remove the retaining screws (4) and detent spring
H05207 assembly cover (5) .
Remove the retaining screws (1) and lever bracket
(2). STEP 9
Refer to Page 6 for Disassembly and Assembly of
STEP 7 remote valves with no check valves .
Refer to Page 8 for Disassembly and Assembly of
remote valves with one check valve.
Refer to Page 10 for Disassembly and Assembly of
remote valves with two check valves.
~\
e
H05211
Remove and discard the wiper seal (3) from the
lever bracket (2) .
8M 8-10450 Issued 03-2001
6 SECTION 8007
REMOTE VALVE WITH NO CHECK VALVES
Disassembly and Assembly
SM1202
1 to 5, refer to Page 5 13. BACKUP WASHER 20. O-RING
6. SPACER 14. O-RING 21 . RING
7. WASHER 15, RING 22 . PLUG
8. SPOOL ASSEMBLY (REFER TO STEP 10) 16. PLUG 23. SPRING
9. SHIM (REFER TO STEP 11) 17. SPRING 24. BALL
10. SPRING 18. BALL 25. RING
11. POPPET 19. RING 26. O-RING
12. BALL
SM 8-10450 Issued 03-2001
SECTION 8007 7
STEP 10 STEP 11
Adjust the maximum working pressure of the
o remote valve by adding or removing shims (9).
NOTE: The maximum working pressure must
always be lower than the main relief valve
~\ pressure.
e
H05121
Hold the spool (8) on the flats (A) in a soft jawed
vice. Remove the retaining screw (8) and detent
assembly (C), remove and discard the o-ring.
Remove the collar (D), remove and discard the 0-
rings.
IMPORTANT: DO NOT disassemble the detent
assembly (C), service parts are not available
and special equipment is needed for Assembly.
8M 8-10450 Issued 03-2001
8 SECTION 8007
REMOTE VALVE WITH ONE CHECK VALVE
Disassembly and Assembly
~(28)
(2s)~ @ ~~ ~
~~~ ~'@ @) ., ~
20
SM1203
1 to 5, refer to Page 5 13. BALL 21 . BACK-UP WASHER
6. SPACER 14. CHECK VALVE 22. O-RING
7. WASHER 15. PIN 23. RING
8. VALVE RETAINER (REFER TO STEP 12) 16 . SPOOL ASSEMBLY (REFER TO STEP 14) 24. PLUG
9. RETAINING CLIP 17. SHIM (REFER TO STEP 15) 25. SPRING
10 . SPRING 18. SPRING 26. BALL
11 . WASHER 19. POPPET 27. RING
12. SPRING 20. BALL 28. O-RING
SM 8-10450 Issued 03-2001
SECTION 8007 9
STEP 12 STEP 14
~\
e
851264 H05123
Bend both ends of the retaining clip (9) inwards and Hold the spool (16) on the flats (A) in a soft jawed
turn clockwise. vice. Remove the retaining screw (8) and detent
assembly (C) , remove and discard the o-ring .
NOTE: For Installation, turn the retaining clip Remove the collar (D), remove and discard the 0-
(9) counterclockwise and bend the ends rings .
outwards.
IMPORTANT: DO NOT disassemble the detent
STEP 13 assembly (C), service parts are not available
and special equipment is needed for Assembly.
STEP 15
Adjust the maximum working pressure of the
remote valve by adding or removing shims (17).
NOTE: The maximum working pressure must
always be lower than the main relief valve
pressure.
851266
Push down on the valve retainer (8) and turn it
counterclockwise 90 degrees, remove the valve
retainer (8).
NOTE: For Installation, install the valve retainer
(8) into the large grooves of the remote valve
body, push down and turn 90 degrees clockwise
so the valve retainer (8) is seated in the smaller
grooves.
SM 8-10450 Issued 03-2001
10 SECTION 8007
REMOTE VALVE WITH TWO CHECK VALVES
Disassembly and Assembly
SM1204
1 to 5, refer to Page 5 14. CHECK VALVE 23 . PIN
6. SPACER 15 . PIN 24. SPOOL ASSEMBLY
7. WASHER 16. VALVE RETAINER (REFER TO STEP 16) (REFER TO STEP 18)
8. VALVE RETAINER (REFER TO STEP 16) 17. RETAINING CLIP 25 . SHIM (REFER TO STEP 19)
9. RETAINING CLIP 18. SPRING 26. SPRING
10. SPRING 19. WASHER 27 . POPPET
11 . WASHER 20. SPRING 28 . BALL
12. SPRING 21. BALL 29. BACK-UP WASHER
13. BALL 22. CHECK VALVE 30. O-RING
SM 8-10450 Issued 03-2001
SECTION 8007 11
STEP 16 STEP 18
" \e
851264 H05123
Bend both ends of the retaining clip (9) or (17) Hold the spool (24) on the flats (A) in a soft jawed
inwards and turn clockwise. vice. Remove the retaining screw (B) and detent
assembly (C), remove and discard the o-ring.
NOTE: For Installation, turn the retaining clip Remove the collar (0) , remove and discard the 0-
(9) or (17) counterclockwise and bend the ends rings.
outwards.
IMPORTANT: DO NOT disassemble the detent
STEP 17 assembly, service parts are not available and
special equipment is needed for Assembly.
STEP 19
Adjust the maximum working pressure of the
remote valve by adding or removing shims (25) .
NOTE: The maximum working pressure must
always be lower than the main relief valve
pressure.
851266
Push down on the valve retainer (8) or (16) and turn
it counterclockwise 90 degrees, remove the valve
retainer (8) or (16).
NOTE: For Installation, install the valve retainer
(8) or (16) into the large grooves of the remote
valve body, push down and turn 90 degrees
clockwise so the valve retainer (8) or (16) is
seated in the smaller grooves.
8M 8-10450 Issued 03-2001
Section
8009
HITCH VALVE AND EDC MANIFOLD
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10460 March 2001
2 SECTION 8009
TABLE OF CONTENTS
SPECiFiCATIONS .... ...................... ............. ... ......... ..... ... ............. ............... ........................ .. .............. ............... ...... 3
SPECIAL TORQUES .... .... .... .... ... .. ............... ....... ..... .. ... ... .. ....... ..... .. .... ..... .... ........ ... ............ .. ............. .. .... ........... .... 3
GENERAL INFORMATION ......... .... ......... ...... ............. .......... .. ................. ............... ............. ... .......... .... ................... 3
HITCH VALVE AND EDC MANIFOLD
Removal and Installation ........ .. .............. ........................... ... .............. .. .......... ..... .......................... .. ..................... 4
Disassembly and Assembly ... ..... ......... .. ... ......... .. ............................ ..... ......... ............................... .... .......... ..... .... 6
Cross Sectional Drawing of the Hitch Valve .... .............................. ............ .................................... .......... ............. 8
8M 8-10460 Issued 03-2001
SECTION 8009 3
SPECIFICATIONS
LOAD CHECK SPRING
Free Length ... ......... ............... .... .... ............. .. ... .... .............. ....... ... .............. ..... ............. ................... ... ... .... 29.7 mm
SECONDARY RAISE SPRING
Free Length ..... .. ... .... ........... .. .. ..... ...... ..... .... .. ..... .. ............. ...... ..... ........... ............ ... ....... ..... ..... ...... ....... .... 40.4 mm
SPECIAL TORQUES
Hitch Valve
Socket Head Cap Screw (item 6, Page 5, with Loctite 271) ... .. .... .. ........ ....... .. ........ ....... .............. ....... 47 to 54 Nm
Socket Head Cap Screw (item 7, Page 5) ................................................. ..... .............. ....... ... ............. 47 to 54 Nm
Socket Head Cap Screw (item 8, Page 5) .. ... ...... ........... ... ...... ... ............. .... ... ... .......... ..... .................. .46 to 52 Nm
Plug (items 7, 9 and 11 on Page 6) ........... ..... .... ................ ....... ................................ .... ...................... 15 to 16 Nm
Solenoid Core Tube (items 22 and 29 on Page 6) .... .. .... ....... .... .. ....... ... .. ........... .. ......... ..................... 30 to 36 Nm
Load Check Plug (item 1 on Page 6) .................. .. .. ..... .. ........................... .... .. ................. .... .. .. ...... ..... 75 to 82 Nm
Plug (items 5 and 15 on Page 6) ................. ...... .......... .. ...... .. .. ................ .... .... ............. .... .................. 54 to 59 Nm
Secondary Raise Plug (item 37 on Page 7) ....................... ..... .................. ................... .. .. .. ... .. ............ 75 to 82 Nm
Secondary Lower Plug (item 42 on Page 7) .... ..... ........ .. .... .. .... .. ............ ............................................ 21 to 27 Nm
Plug (items 13 and 17 on Page 6) .............. ...... ...... .. .... .... ... .. .................. ... ................... ........ .. ....... ... . 12 to 13 Nm
Plug (item 33 on Page 6) .... ............................. .. .. ...... ................................................ .... ................. .. 97 to 106 Nm
EDC Manifold
Socket Head Cap Screw (item 11, Page 5) ..... ...... ........ ............................................... ............ ........... 56 to 62 Nm
Bolt (item 12, Page 5) ............ ...................... .. ... ................ ..... ... ............... ...... ................ ..................... 47 to 54 Nm
Nut (item 13, Page 5) ............ .. ................... .. ............... .. ... ... ............... .................. ............... ................ 47 to 54 Nm
GENERAL INFORMATION
Parts in the hydraulic system are machined to very close tolerances . Any dirt in the system will result in
component damage and incorrect operation of the hydraulic system. Always work in clean conditions and follow
all cleaning and drying procedures.
IMPORTANT: Use petroleum jelly and clean transmission oil (HY- TRAN ® ULTRA) ONLY to lubricate
parts.
8M 8-10460 Issued 03-2001
4 SECTION 8009
HITCH VALVE AND EDC MANIFOLD
Removal and Installation
NOTE: For Installation, follow the Removal procedure in reverse order.
Before removing the Hitch Valve and EDC Manifold carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
DP97N128 DP97N126
Remove four retaining bolts (1) and remove the Clean the area around the hitch valve. Mark for
seat. Remove rear floor matting (2). identification and disconnect lower solenoid
connector (4) and raise solenoid connector (5) from
STEP 2 the transmission harness.
DP97N127
Remove six retaining bolts (3) and remove the floor
plate.
8M 8-10460 Issued 03-2001
SECTION 8009 5
STEP 4 NOTE: Before removing the EDC Manifold it will
be necessary to remove the hydraulic housing,
refer to Section 8010.
STEP 6
DP97N126
Mark for identification and remove the three socket
head cap screws (6), (7) and (8). Remove hitch
valve (9) .
NOTE: For Installation, apply Loctite 271 to the
threads of socket head cap screw (6) only,
install socket head cap screws (6), (7) and (8).
Tighten socket head cap screws (6) and (7) to a
torque of 47 to 54 Nm .
Tighten socket head cap screw (8) to a torque
of 46 to 52 Nm.
STEP 5
DP98M018
Remove socket head cap screw (11), bolt (12) and
two nuts (13). Disconnect the tubes (14) and (15)
(from the underside of the hydraulic housing),
remove the EDC manifold (16) .
NOTE: For Installation, clean the surfaces of
the EDC manifold and hydraulic housing. Apply
DD97N047 Loctite 515 to the surface of the hydraulic
Remove and discard the five o-rings (10) from the housing and install the EDC manifold.
hitch valve. Install and tighten the socket head cap screw
(11) to a torque of 56 to 62 Nm.
NOTE: For Installation, lubricate and install new Install and tighten bolt (12) and nuts (13) to a
o-rings (10) into the hitch valve. torque of 47 to 54 Nm. Install and tighten tubes
(14) and (15).
NOTE: Refer to Page 6 for Disassembly and
Assembly of the Hitch Valve . NOTE: For Installation, follow the Removal
procedure in reverse order.
8M 8-10460 Issued 03-2001
6 SECTION 8009
Disassembly and Assembly
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
54 TO 59 NM
15TO 16 NM
12TO 13 NM
54 TO 59 NM
72 TO 82 NM
30 TO 36 NM
MI01B016
NOTE: For Assembly, lubricate and install new o-rings.
1. LOAD CHECK PLUG 13 . PLUG 25 . PRIMARY RAISE SPOOL
2. O-RING 14. O-RING 26. NUT
3. LOAD CHECK SPRING 15. PLUG 27 . SOLENOID (LOWER)
4. LOAD CHECK BALL 16. O-RING 28. O-RING
5. PLUG 17. PLUG 29. SOLENOID CORE TUBE (LOWER)
6. O-RING 18. O-RING 30. PIN
7. PLUG 19. NUT 31. O-RING
8. O-RING 20. SOLENOID (RAISE) 32. PRIMARY LOWER SPOOL
9. PLUG 21 . O-RING 33. CAP
10. O-RING 22. SOLENOID CORE TUBE (RAISE) 34 . O-RING
11. PLUG 23 . PIN
12. O-RING 24. O-RING
SM 8-10460 Issued 03-2001
SECTION 8009 7
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly
~ @). 41
r~Q ~~~
f ~
~
75 TO 82 NM
~ .. a ~~
46 45~/~
@,I
@ 21T027NM
OlS7N14 1
37. SECONDARY RAISE PLUG 43. O-RING
38. O-RING 44 . O-RING
39 . SHIMS 45 . PILOT POPPET
40. SE CONDARY RAISE SPRING 46 . SEAL
41. SE CONDARY RAISE SPOOL 47. O-RING
42. SECONDARY LOWER PLUG 48. MAIN POPPET
NOTE: For Assembly, lubricate and install new seal (46) and all o-rings.
NOTE: Check all parts of the Hitch Valve for wear or damage and replace if necessary. If the Secondary
Raise Spool (items 39, 40 and 41) or Secondary Lower Spool (items 42, 45, and 48) require replacing,
the hitch valve MUST be replaced.
IMPORTANT: Always re-calibrate the hitch if the Hitch Valve is replaced, refer to Section 10002.
8M 8-10460 Issued 03-2001
8 SECTION 8009
Cross Sectional Drawing of the Hitch Valve
45 48
4. LOAD CHECK BALL 39. SHIMS
20 . SOLENOID (RAISE) 40 . SECONDARY RAISE SPRING
22 . SOLENOID CORE TUBE (RAISE) 41 . SECONDARY RAISE SPOOL
23. PIN 42 . SECONDARY LOWER PLUG
25. PRIMARY RAISE SPOOL 45 . PILOT POPPET
32. PRIMARY LOWER SPOOL 48. MAIN POPPET
SM 8-10460 Issued 03-2001
Section
8010
HYDRAULIC LIFT HOUSING SERVICING
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK SM 8-10470 March 2001
2 SECTION 8010
TABLE OF CONTENTS
SPECIAL TORQUES .. .................... .......................................... ,............................... ................................................. 3
HYDRAULIC HOUSING
Removal and Installation .......................................................................................................................................4
Disassembly and Assembly .............. .............................................................................................................. ...... 6
8M 8-10470 Issued 03-2001
SECTION 8010 3
SPECIAL TORQUES
Hydraulic Housing Retaining Bolts
3/8 inch .............. ...... .................... ................................................................. .................... .. ... .............. 45 to 50 Nm
1/2 inch .............. .... ...................... .................................................................................................... 110 to 122 Nm
Draft Control Cylinder to Hydraulic Housing .......... ... .. ............................................ ........................................ 115 Nm
Adaptor Block to Draft Control Cylinder Retaining Bolts ................. ...... .. .. ...... ........ ................................. 45 to 50 Nm
EDC Manifold to Hydraulic Housing
Retaining Bolt .... .... .............................................................................................................................. 47 to 53 N m
Retaining Nuts ..................................................................................................................................... 47 to 53 Nm
Lift Arm Retaining Bolt. .................. .. ........................ .. .............................................................. ............ 133 to 149 Nm
8M 8-10470 Issued 03-2001
4 SECTION 8010
HYDRAULIC HOUSING
Removal and Installation
NOTE: Items are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Hydraulic Housing it will be necessary to carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the front wheels.
• Remove the Cab, refer to Section 9006.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal(s) first.
NOTE: For Installation, connect the positive (+)
terminal(s) first.
STEP 2
Disconnect the three point linkage from the lift
arms.
STEP 3
DP98M020
Disconnect and cap the following tubes and hoses :
differential lock supply (2), remote valve return (3),
remote valve return to MCV (4), MCV to unloading
valve (5), unloading valve supply (6), regulator
valve to EDC manifold (7), PTO supply to MCV from
regulator valve (8) and MFD supply from regulator
valve (9).
STEP 5
DD98M059
Disconnect the PTO linkage (1).
NOTE: For Installation, refer to Section 9001 for
adjustment of the PTa linkage.
DD98M061
Remove the rear retaining bolts (10) from the
hydraulic housing and remove the remote valve
coupling bracket (11) .
NOTE: For Installation, install and tighten the
retaining bolts to torque of 110 to 122 Nm.
8M 8-10470 Issued 03-2001
SECTION 8010 5
STEP 6 STEP 7
Remove the remaining hydraulic housing retaining Install suitable lifting equipment and raise the
bolts. hydraulic housing. Make sure all tubes and hoses
have been disconnected and remove the hydraulic
NOTE: For Installation, install and tighten the housing. Remove and discard the brake o-rings.
retaining bolts to torque of 45 to 50 Nm.
NOTE: For Installation, clean the surfaces of
the range transmission and hydraulic housing.
Apply Loctite 515 to the mounting surface of the
transmission housing and install new brake 0-
rings.
NOTE: Items are numbered in order of
Removal, Installation is in the reverse order of
Removal.
SM 8-10470 Issued 03-2001
6 SECTION 8010
Disassembly and Assembly STEP 10
NOTE: Items are numbered in order of
Disassembly, Assembly is in the reverse order
of Disassembly.
STEP 8
Remove the Unloading Valve, refer to Section 8006.
Remove the Hitch Valve, refer to Section 8009.
STEP 9
DP98M013
DR99C040
DP98M015
Remove the plug (8) and cushion valve. Support the
draft control cylinder (9) and remove the three
retaining bolts (10) and sealing washers (11).
Remove the draft control cylinder (9), remove and
discard the o-rings .
NOTE: For Installation , lubricate and install new
o-rings onto the draft control cylinder (9). Install
and tighten the retaining bolts (10) to a torque
of 115 Nm.
DP98M018
Loosen the hose clip and disconnect the differential
lock return hose (1) from the EDC manifold (7).
Remove socket head cap screw (2), bolt (3) and two
nuts (4). Disconnect the tubes (5) and (6) (from the
underside of the hydraulic housing), remove the
EDC manifold (7).
NOTE: For Installation, clean the surfaces of
the EDC manifold and hydraulic housing. Apply
Loctite 515 to the surface of the hydraulic
housing and install the EDC manifold.
Install and tighten the socket head cap screw
(2) to a torque of 56 to 62 Nm.
Install and tighten bolt (3) and nuts (4) to a
torque of 47 to 54 Nm. Install and tighten tubes
(5) and (6).
8M 8-10470 Issued 03-2001
SECTION 8010 7
STEP 11 STEP 13
DP98M014 DP98M012
Remove the retaining bolts (12) and draft control Remove the setscrew (16) from the rockshaft
cylinder adaptor block (13), remove and discard the bellcrank lever (17).
o-rings.
STEP 14
NOTE: For Installation, lubricate and install new
o-rings onto the draft control cylinder adaptor
block (13). Install and tighten the retaining bolts
(12) to a torque of 45 to 50 Nm .
STEP 12
DP98M011
Remove the LH lift arm retaining bolt and washer.
Put an identification mark (A) on the lift arm (18)
opposite the timing mark (8) on the rocks haft (19)
and remove the lift arm (18) .
DI98M026 STEP 15
Remove the piston (14) from the draft control
cylinder (9), remove and discard the seal (15). Remove the retaining bolt, washer and RH lift arm.
NOTE: For Installation, lubricate and install a NOTE: For Installation, install and tighten the /ift
new seal (15) onto the piston (14). arm retaining bolts to a torque of 133 to 149 Nm.
STEP 16
Remove the rockshaft (19) from the LH side of the
hydraulic housing. Remove the rocks haft bellcrank
lever (17) and connecting rod assembly.
SM 8-10470 Issued 03-2001
8 SECTION 8010
STEP 17 STEP 19
DP98M010 DS98M008
Remove and discard the rockshaft oil seals (20) Install the rockshaft bushings (21) into the hydraulic
housing level with the counterbore (C) and the joint
NOTE: For Installation, fully install the rockshaft (0) at 45 ° from horizontal, facing forward , as
oil seal (20) into the hydraulic housing. shown.
NOTE: The rockshaft oil seal (20) with the NOTE: Items are numbered in order of
smallest fD should be installed in the hydraulic Disassembly, Assembly is in the reverse order
housing on the RH side. of Disassembly.
STEP 18
DP98M009
Remove the rocks haft bushings (21).
NOTE: Refer to STEP 19 for installation of the
rockshaft bushings (21) .
8M 8-10470 Issued 03-2001
Section
8011
FRONT HITCH
CX Series Tractors
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10480 March 2001
2 SECTION 8011
TABLE OF CONTENTS
SPECIAL TORQUES ..... ........ .................................................................................................................................... 3
FRONT HITCH
Removal and Installation ......... ........... ........ ........ .................... ...... ................................... .......... .. ....... ...................4
Disassembly and Assembly .............. .. ................................................ ... .......................... .. .......................... ....... .. 5
HITCH CYLINDER
Removal and Installation ......... ................................. ... .. ........ ...... ..................... ............... ....... ................. ..... .... .... . 6
Disassembly and Assembly .... .. ....... ......... .. ...... .. ........ ....... ................... ... ..... .. ....... .. ..... .. ............ .............. ... ....... .. 7
SM 8-10480 Issued 03-2001
SECTION 8011 3
SPECIAL TORQUES
Front Hitch Mounting Bolts .................................. .. ...... .. .... .................................. ....... .. ..... .. ................ 406 to 490 Nm
Front Cover Bolts .......... .............. ............................ ......... ... .................................. .. ....... ..... .................... ........ 257 Nm
Piston Retaining Nut ................. ... ................................... ............................... ..... ..... .... .... .............................. . 776 Nm
8M 8-10480 Issued 03·2001
4 SECTION 8011
FRONT HITCH
Before servicing the front hitch it is necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Lower the rear three point hitch.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Put wooden blocks between the front axle bolster and front axle.
• Lower the front hitch.
Removal and Installation STEP 2
STEP 1
DP99C224
Remove drawbar (4), bolts (5) and bracket (6) (if
DD98K084 equipped). Remove bolts (7), bolts (8) and nuts (9)
Use suitable lifting equipment to support the front from the LH side. Remove bolts (5), (7) (8) and nuts
hitch assembly. Remove bolts (1), nuts (2) . Remove (9) from RH side. Carefully remove the front hitch
front cover (3). Disconnect and cap the supply hose assembly.
to the lift cylinders.
NOTE: For Installation, follow the same
NOTE: For Installation, Install and tighten the procedure in reverse order. Install the front
bolts (1) to a torque of 257 Nm. hitch, install and tighten the mounting bolts to a
torque of 406 to 490 Nm.
SM 8-10480 Issued 03-2001
SECTION 8011 5
Disassembly and Assembly
(D--
0---------
®~-:
DS99C227
1. TOP LINK FRAME 12. LOCKING PIN ASSEMBLY
2. TOP CYLINDER PIN 13. FLOAT AND TRAVEL PIN
3. ROLL PIN 14. BELLE VILLE WASHER
4. RH SIDE PLATE 15. NUT M22
5. LH SIDE PLATE 16. NUT M20
6. RH PIVOTASSEMBLY 17. BOLT M20 X 55
7. LH PIVOT ASSEMBLY 18.NUTM16
8. LH SWING ARM 19. BOLT M16 X 60
9. RH SWING ARM 20. BOLT M16 X 50
10. SWING FRAME 21. PIVOT PIN
11. ROLL PIN
SM 8-10480 Issued 03-2001
6 SECTION 8011
HITCH CYLINDER
Removal and Installation STEP 2
STEP 1
DP99C226
Disconnect and cap hose (4) from cylinder (5).
Remove roll pin (6) securing bolt (7) and mounting
Remove nuts (1) and bolts (2). Remove front PTO pins (8) . Remove cylinder (5).
cover (3).
NOTE: For Installation, follow the same
procedure in reverse order.
8M 8-10480 Issued 03-2001
SECTION 8011 7
Disassembly and Assembly
DP99C252
1. RETAINING RING 6 . O-RING
2. PISTON ROD 7. END CAP
3. RETAINING NUT 8 . O-RING
4. PISTON 9 . SEAL RING
5. PISTON SEAL ASSEMBLY 10 . WIPER SEAL
NOTE: Items are numbered in order of Disassembly, Assembly is in the reverse order of Disassembly.
SM 8-10480 Issued 03-2001
Section
9001
PEDAL, LEVER AND SWITCH ADJUSTMENTS
CX Series Tractors
~ © 2003 McCormick Tractors International Limited.
McCORMICK 8M 8-10491 June 2003
2 SECTION 9001
TABLE OF CONTENTS
SPECIAL TOOLS ..................... ........ ..... .. .... ................ .. ................ .... ...... ....................... ..... .. ............ ......... ........ ....... 3
SPECIAL TORQUES ....... ......... .. .......... ... ..... .............. ... ...... ........ ........ .................. .... ... .. ... ............ ............. ... ... .... ..... 3
FORWARD/REVERSE LEVER ADJUSTMENT ........... .. ... ................. ....................... ........ ..... ....... ..... ... ....... ......... ... .4
Forward Position Switch Setting ........ .. .......................... ............ .. ..... .. .............. ..... .................... .... ........... ... ..... .... 5
BRAKE PEDAL ADJUSTMENT ........... ... .... .... .. ...... ... ....... ... ........... ..... ... .............. ... ......... ............ ............................ 6
Brake Pedal Stop Adjustment ....... ........... ..... ...... .. ......... ........ ...... .. ... .. ................... ... .......... ....................... .... ... .... 6
Cylinder Rod Adjustment ................................. .. ....... ... ........... ... .... ..... .......... ..... .. .... ................. ..... ..... .... .............. 6
Brake Pedal Maximum Travel Adjustment ........ ... .... .. ........................................................................................... 6
Brake Light Switch Adjustment ........ ....... ............... .. .. ... ............... ....... ................. .. ..................... ...................... .. .. 6
PTO ADJUSTMENT ......... .. ................... ........................... .. ............ ............ ........... ... ..... .. ................ ...................... .... 8
PTO Neutral Start Switch Adjustment .. .......... ....... ... ......... ...... ... ................. .. ......... .. .................... .. ........... ........ .... 8
SHIFTABLE PTO ADJUSTMENT ............ .. ................... .. ...................... ................. ....... .................. ................. .. ... .. 10
HAND AND FOOT THROTILE ADJUSTMENT ............ .... ................. .. ...... ............... .... .................. ................ ....... . 12
SPEED/RANGE LINKAGE ADJUSTMENT ............. .. .................... .. .... ....... .......... .. ................................................. 14
1st/2nd Speed Linkage ...... ................... .. ........... .. .......... .......... ...... ... .... .......... .. ... ...... ... .............. ........................ 14
3rd/4th Speed Linkage ....... .............. ....... ... .... .................. ............... ...... .......... .......... .. .... .......... .. ...................... .. 14
Range Linkage .. ........................................................................................................................... ....... .... ........ .... 15
Range Switch Adjustment .. .. .. ... ........ .... .. .. .. .......... ...... .. ....... .. ............... ..... ... ... .... .. ... ...... ..... ... .... ... .. ... .. ..... ...... ... 15
CREEP LINKAGE ADJUSTMENT ........ ....... ... ......... ....... ..... .......... ....... ..... .. .......... .. .. .. ....... .................................. .. 16
DIFFERENTIAL LOCK SWITCH ADJUSTMENT .......... ...................... ......................... ................... .................... .... 17
CLUTCH PEDAL ADJUSTMENT
(Tractors Without XtraShift) .............. ..... ................... ... .. .. ............ .... .... ................................................................ 18
Clutch Slave Cylinder Rod Adjustment ...... ............... .. .................... .. ........................ .............. ......... ...... ........... .. 18
Clutch Cylinder Rod Adjustment ........................ ..... ........................ ............................................................ ... ..... 18
Interlock Cable Adjustment ................ .... .... ...... ....... ........... ..... ....... ... .... ................. ... .......... ........ ................. ... .... 18
Clutch Pedal Position Switch ............................ .................................................................................................. 18
PARKING BRAKE ADJUSTMENT (MFD) ............................................................................................................... 20
PARKING BRAKE ADJUSTMENT (2WD) .......................................... ... ....... .... ..... ... .... .......... .. ..... .... ..... ................. 21
REMOVING AIR FROM THE BRAKE SYSTEM ..... .. ....... ................................................ ............... .. ...................... 22
SM 8-10491 Issued 06-2003
SECTION 9001 3
SPECIAL TOOLS
~I
~
11m fH
?fL J)
DD98H120 DS99N011
MULTIMETER KIT MC2616 HYDRAULIC HAND PUMP TEST KIT MC1913
CONNECTOR 218-433 (9/16·18 JIC TO 9/19·18 JIC)
CONNECTOR 218-443 (9/16·18 JIC TO 1/4 NPT)
HOSE 3121754R92
DDGGA051
TEST PROBE KIT MC2656
SPECIAL TORQUES
Flange Axle - Wheel Nuts ... .......... .. ............................ .. .. .. .... ........ .. ............. ....... .......... .... .. ............ 278 to 298 Nm
Bar Axle - Wheel to Hub Bolts ............ ......................... ..... .. ........... .................. ......................... .. ..... 183 to 207 Nm
SM 8-10491 Issued 06-2003
4 SECTION 9001
FORWARD/REVERSE LEVER ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
Put the forward/reverse control lever in the neutral Put the transmission forward/reverse lever (1) in the
position (interlocked). neutral position. Apply grease onto the ball studs on
the lever (1) and arm (3). Install the rod assembly
STEP 2 (2) between the transmission forward/reverse lever
(1) and arm (3), install the retaining clips (4). Check
Remove the cab floor mat and floor plate. Remove the collar (5) on the control shaft is centred between
the steering column cover. the flats on the pawl (6), if necessary adjust the turn
buckle (7) on the rod assembly (2) to centre the
collar (5). Tighten the lock nuts (8)
NOTE: The rod assembly (2) should measure
302.5 to 305.5 mm between centers in the
neutral position.
:-~®
DI97J182
SM 8-10491 Issued 06-2003
SECTION 9001 5
Forward Position Switch Setting Point of Switch Closure
Before any adjustments or troubleshooting to the ®
_ .. 1"",,-
Forward Position Switch are made carry out the
follow ing:
• Park the tractor on hard level ground and apply
the parking brake.
,-- ---
• Stop the engine and remove the key.
~l
\
Neutral Position
_ ..I ® "",,_ \
1
\
\
\
\
, \
~1"\
1 \
\
\
\
\
\
\
\ 0 198804 1
\-
) STEP 3
Move the forward/reverse control lever towards the
I
FORWARD position to the point where the forward
~
:or': position switch (9) closes (multimeter reading of
1 I approximately 4 Ohms) and hold in this position .
I
I
Measure and make a note of the distance (B)
0198B036 between the rear edge of the vane on the lever (1)
and the rear face of the forward position switch (9).
STEP 1
STEP 4
Put the lever (1) in the NEUTRAL position .
Measure and make a note of the distance (A) Calculate the difference between the
between the rear edge of the vane on the lever (1) measurements taken in STEP 1 and STEP 3, this
and the rear face of the forward position switch (9). must be between 12.5 and 17.5 mm.
STEP 2 NOTE: If the rear edge of the vane on the lever
(1) is inside the forward position switch (9) add
Disconnect the forward position switch (9) from the together dimensions (A) and (B).
harness. If the rear edge of the vane on the lever (1) is
outside the forward position switch (9) subtract
NOTE: Use a HIGH IMPEDENCE multimeter dimension (B) from dimension (A).
MC2616 and test probes MC2656 when
carrying out the following check, DO NOT use a NOTE: Replace the forwa rd position switch (1) if
test light or damage to the switch may occur. it does not close between the above
dimensions.
STEP 5
From the point of forward position switch closure (B)
move the lever (1) towards the NEUTRAL position ,
the forward position switch (9) should open within 3
mm of travel.
NOTE: Replace the forward position switch (1) if
it does not open within the above dimension .
8M 8-10491 Issued 06-2003
6 SECTION 9001
BRAKE PEDAL ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
NOTE: All adjustments must be carried out before connection of brake tubes and hoses.
Brake Pedal Stop Adjustment Brake Pedal Maximum Travel
Adjustment
STEP 1
STEP 4
Engage the brake pedal latch to lock both brake
pedals together. Fully depress the RH brake pedal, adjust the bolt
(6) until it is in contact with the brake pedal.
STEP 2 Release the brake pedal and turn the bolt (6) one
full turn clockwise, tighten the locknut (7).
Make sure one of the brake pedals is in contact with
surface (1). Adjust the bolts (2) until they are in NOTE: The master brake cylinder will be
contact with both brake pedals and the latch can be damaged if excessive force is used to depress
removed without moving the other brake pedal. the brake cylinder.
Tighten the lock nuts (3).
STEP 5
Cylinder Rod Adjustment
Repeat Step 4 for the LH brake pedal.
STEP 3
Brake Light Switch Adjustment
Adjust the clevis (4) so that the cylinder is fully
extended and there is 1.0 mm of free travel between
STEP 6
the cylinder rod and piston when the brake pedals
are fully against the bolts (2) . Tighten the locknut Loosen the locknut (8) and adjust the switch (9)
(5). until the plunger is fully depressed by the brake
pedal when the brake pedal is against the stop bolt
(2). Turn the switch (9) half to one turn
counterclockwise so the locating tabs on the
switches are facing away from each other.
SM 8-10491 Issued 06-2003
_ _ __ _ _ _ _ _ _ _~S~ECTION 9001 7
0197J179
8M 8-10491 Issued 06-2003
8 SECTION 9001
PTa ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
• Remove the RH console.
STEP 1 PTa Neutral Start Switch
Measure rod (1), this should be 191.7 mm.
Adjustment
Measure rod (2), this should be 139.7 mm .
Measure the distance between the stop bolt (3) and NOTE: Use a HIGH IMPEDENCE multimeter
bracket (4), this should be 26.8 mm. MC2616 and test probes MC2656 when
carrying out the following check, DO NOT use a
test light or damage to the switch may occur.
STEP 2
Put the PTa lever (5) in the engaged position and STEP 5
check the movement (A) of the PTa spool. The
movement (A) should be 17.13 mm, if necessary
adjust rod (1) to obtain this measurement.
STEP 3
Check the angle of the PTa lever (5), this must be
20° from the vertical when disengaged, if
necessary adjust rod (1) to obtain this
measurement.
STEP 4
Install the RH console. Check the movement of the
PTa lever (5) between the disengaged and Put the PTO lever in the disengaged position.
engaged positions, if necessary adjust rod (1) or Disconnect the harness from the switch (7). Attach
loosen the bolts (6) and move the lever (5) to obtain the multimeter MC2616 and test probes MC2656 to
full movement. the switch and check for continuity, adjust the lock
nuts (8) on switch (7) to the point where switch (7)
NOTE: After all adjustments have been carried closes (multimeter reading of approximately 4
out, make sure the PTa lever (5) will move Ohms) and tighten lock nuts (8). Remove the
freely to the disengaged position from the multi meter and connect the harness.
engaged position.
8M 8-10491 Issued 06-2003
SECTION 9001 9
, :---...
(
\ _4
\
\
\ : I I
\
, \
\
\
:I /
~~--.
\
\
\ I
I
\ I
\
, I
,
I
, :I / 12)
I I
\ I
I
I
I
I
I
/
17.13 mm
D198M117
8M 8-10491 Issued 06-2003
10 SECTION 9001
SHIFTABLE PTO ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
Adjust the control cable (6) on the bracket (7) as
necessary to centre the lever (1) in the slot in the
console cover.
STEP 4
_~II....- [I)
9mm ~
- ~
Put the shiftable PTO lever (1) in the "Slow"
DI97K030
~
__~I I...._-
10mm
position , position the lever 9 mm from the end of the
slot in the console cover.
STEP 2 '======!) ~ "
-
- DI97K030
Put the shiftable PTO lever (1) in the "Fast" position,
the arm (2) should be in the "Fast" position when
the shiftable PTO lever (1) is 10 mm from the end of
the slot in the console cover.
STEP 5
Adjust the control cable (6) on the bracket (7) as
necessary to centre the lever (1) in the slot in the
console cover.
NOTE: Make sure both "Slow" and "Fast"
DD97K069 positions can be engaged after the adjustment
Put the arm (2) in the "Slow" position and install the has been carried out.
spring clip pin (3) through the clevis (4) . Tighten the
lock nuts (5) on the control cable (6) onto the
bracket (7).
8M 8-10491 Issued 06-2003
SECTION 9001 11
Spring Adjustment Switch Adj ustment
STEP 6 STEP 7
21mm-~
DI97J193
DI97J194
Adjust the springs (8) on the lever (9) to 21 mm. Adjust the switch (10) to obtain dimensions (A) and
(8). Tighten the locknut (11) when adjustment is
correct.
8M 8-10491 Issued 06-2003
12 SECTION 9001
HAND AND FOOT THROTTLE ADJUSTMENT
Before any adjustments are made carry out the following:
o Park the tractor on hard level ground and apply the parking brake.
o Stop the engine and remove the key.
o Put blocks in front of and behind the rear wheels.
STEP 1 STEP 4 CX50 and CX60
Put the hand throttle lever in the high idle position
(fully forward in the slot in the console cover).
STEP 2
Install the hand throttle cable (1) into the bracket
(2). Adjust the cable (1) using the lock nuts (3) until
the cable stop (A) is against the pivot assembly (4).
Tighten the lock nuts (3).
NOTE: In this position the distance (B) between
the bracket (2) and pivot assembly (4) should be
between 91 and 95 mm. DD97K070
Install the control cable (9) into the bracket on the
STEP 3 fuel injection pump, adjust the lock nuts (10) until
the spring clip pin (11) can be easily installed
through the clevis and inner hole of the fuel
injection pump arm. Tighten the lock nuts (10) onto
the bracket.
STEP 5 CX70175, CX80/85, CX90/95 and CX100/105
DD97MOO5
Install the control cable (5) into the bracket (2) .
Adjust the flange nut (6) until a dimension of 12 to
16 mm (C) is obtained, tighten the locknut (7).
Adjust the lock nuts (8) until a dimension of 20 to 24
mm (D) is obtained.
NOTE: For eX70, eX80 and eX90 Tractors,
Install the control cable (12) into the bracket on the
install the control cable (5) into the upper
fuel injection pump, adjust the lock nuts (13) until
groove of the bracket (2) and upper slot of the
the spring clip pin (14) can be easily installed
pivot assembly (4), as s~own.
through the clevis and- inner hole of the fuel
injection pump arm. Tighten the lock nuts (13) onto
NOTE: For eX50, eX60 and eX100 Tractors,
the bracket.
install the control cable (5) into the lower groove
of the bracket (2) and lower slot of the pivot
assembly (4). STEP 6
Make sure low idle and high idle can be obtained on
the foot throttle and hand throttle.
SM 8-10491 Issued 06-2003
SECTfON .9001 13
:---~®
DI97J180
VIEWED FROM RH FRONT UNDERSIDE OF CAB
SM 8-10491 Issued 06-2003
14 SECTION 9001
SPEED/RANGE LINKAGE ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
STEP 1 3rd/4th Speed Linkage
Support the RH rear axle on a suitable axle stand
STEP 5
and remove the RH rear wheel.
NOTE: For Installation, install and tighten the
rear wheel nuts to the correct torque, refer to
Page 3.
1st/2nd Speed Linkage
STEP 2
DD97M009
Put the 3rd/4th speed lever (8), on transmission top
cover, in the neutral position. Put the 3rd/4th speed
pivot arm (9) in a vertical position.
STEP 6
Apply Multi-Purpose Lithium grease onto the pin on
lever (8) and pin on pivot arm (9). Install the control
DD97M009 rod (10) onto lever (8) and install the retaining clip
Putthe 1st/2nd speed lever (1), on transmission top (11) .
cover, in the neutral position. Put the 1stl2nd speed
pivot arm (2) in a vertical position. STEP 7
STEP 3 Adjust the joint (12) on control rod (10) until it
can be easily installed onto the pin on the pivot
Apply Multi-Purpose Lithium grease onto the pin on arm (9). Install the retaining clip (13) and tighten
lever (1) and pin on pivot arm (2) . Install the control the locknut (14).
rod (3) onto lever (1) and install the retaining clip
(4).
STEP 4
Adjust the joint (5) on control rod (3) until it can be
easily installed onto the pin on the pivot arm (2).
Install the retaining clip (6) and tighten the locknut
(7).
SM 8-10491 Issued 06-2003
SECTION 9001 15
Range Linkage Range Switch Adjustment
STEP 8 STEP 11
MP03F059
Put the range lever (15), on hydraulic housing, in Put the range lever (15) in the hi range position.
the neutral position. Put the range pivot arm (16) in loosen the lock nuts (22). Adjust the switch (23)
a vertical position. until the plunger is fully depresed then back off one
full turn. Tighten locknuts (22).
STEP 9
NOTE: Make sure when hi range is selected
Apply Multi-Purpose Lithium grease onto the pin on that the range lever (15) dose not make contact
lever (15) and pin on pivot arm (16). Install the with the body of the switch (23).
control rod (17) onto lever (15) and install the
retaining clip (18) .
STEP 10
Adjust the joint (19) on control rod (17) until it can
be easily installed onto the pin on the pivot arm
(16). Install the retaining clip (20) and tighten the
locknut (21).
jj ,
y ,
1,
VIEWED FROM REAR OF CAB
8M 8-10491 Issued 06-2003
16 SECTION 9001
CREEP LINKAGE ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Before carrying out the Creep Linkage Adjustment, refer to "SPEED/RANGE LINKAGE ADJUSTMENT" on
page 14.
STEP 1 STEP 2
Apply Multi-Purpose Lithium grease onto the pin on
lever (1) and pin on pivot arm (2) . Install the control
rod (3) onto lever (1) and install the retaining clip
(4).
STEP 3
Adjust the joint (5) on control rod (3) until it can be
easily installed onto the pin on the pivot arm (2).
Install the retaining clip (6) and tighten the locknut (7).
DD98N066
Put the creep lever (1), on hydraulic housing, in the
neutral position. Put the creep pivot arm (2) in the
position shown.
3
1
Ol98M131
VIEWED FROM REAR OF CAB
8M 8-10491 Issued 06-2003
SECTION 9001 17
DIFFERENTIAL LOCK SWITCH ADJUSTMENT
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
STEP 1 STEP 4
Raise the rear of the tractor and support the LH rear
axle on a suitable axle stand.
STEP 2
DP99N013
Disconnect the harness from switch (2). Loosen the
locknut and turn switch (2) fully clockwise into
support (3) until the switch body contacts the piston
assembly (switch plunger fully depressed). Turn
D099III012
switch (2) counterclockwise 1/2 to 1 turn and check
Disconnect the differential lock supply tube (1) and there is continuity across the terminals of the
cap the fitting. Connect the hydraulic hand pump switch, tighten the locknut and connect the
test kit, MC1913, to the differential lock supply tube harness.
(1) using connector 218-433, hose 3121754R92
and connector 218-443, refer to "SPECIAL TOOLS" IMPORTANT: Only use a HIGH IMPEDENCE
on page 3. multimeter MC2616 and test probes MC2656
when adjusting the differential lock warning
NOTE: Care must be taken not to bend the lamp switch (2). DO NOT use a test lamp or
differential lock supply tube. damage to the switch may occur.
NOTE: The seat has been removed for STEP 5
photographic purposes only. Access to the
differential lock supply tube (1) can be gained Release the hydraulic pressure to disengage the
from the rear LH side of the cab. differential lock and check there is no continuity
across the terminals of switch (2), if there is
STEP 3 continuity repeat STEP 4.
Apply approximately 20 bar (290 psi) to fully NOTE: When the differential lock is engaged
engage the differential lock. the differential lock warning lamp on the
instrument cluster will illuminate.
NOTE: It may be necessary to turn the LH
wheel to fully engage the differential lock.
8M 8-10491 Issued 06-2003
18 SECTION 9001
CLUTCH PEDAL ADJUSTMENT
(Tractors Without XtraShift)
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
NOTE: All adjustments must be carried out before connection of clutch tubes and hoses.
Clutch Slave Cylinder Rod Interlock Cable Adjustment
Adjustment
STEP 3
STEP 1
Install the interlock cable (3) into the clutch pedal (4)
and bracket (5), do not tighten the adjusting nuts (6).
STEP 4
With the clutch pedal (4) in the fully released
position, tighten the adjusting nuts (6) onto the
bracket (5) on the firewall.
NOTE: The gearshift levers should not be able
to change from one moving gear to another
without first depressing the clutch pedal, the
gearshift levers should drop into neutral
MR01B017
position if moved out of gear without depressing
the clutch pedal.
Disconnect the clutch slave cylinder linkage and
fully retract rod (A). Measure the distance (B)
between the centre lines of the mounting bolts and Clutch Pedal Position Switch
clevis pin hole, this should be 88 mm. If necessary
loosen the locknut and adjust the clevis until STEP 5
distance (B) is obtained, tighten the locknut.
Disconnect the harness from switch (7). Loosen the
locknut and turn switch (7) clockwise until the end
Clutch Cylinder Rod Adjustment is in contact with the clutch pedal. Turn switch (7)
counterclockwise 1/4 turn and tighten the locknut,
STEP 2 connect the harness onto the switch.
Loosen lock nut (1) and adjust joint (2), on the NOTE: After adjusting the position of switch (7)
master cylinder rod, so that with the cylinder fully make sure only the switch plunger is protruding
extended there is 1.0 mm of free travel between the through the weld nut and the body of switch (7)
end of the master cylinder rod and the cylinder is not acting as the stop for the clutch pedal.
piston when the clutch pedal is fully against the
stop. Tighten the locknut (2).
8M 8-10491 Issued 06-2003
SECTION 9001 19
MI01B020
SM 8-10491 Issued 06-2003
20 SECTION 9001
PARKING BRAKE ADJUSTMENT (MFD)
Before any adjustments are made carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
Remove the cotter pin (1) , washer (2) and clevis pin Install the clevis pin (3), washer (2) and new cotter
(3) . pin (1) .
STEP 2 NOTE: When the parking brake is engaged the
warning lamp on the instrument cluster will
Loosen the lock nuts (4) on the parking brake cable illuminate and the master warning lamp will
(5). Adjust the cable (5) until the measurement on flash on and off.
the lever (6), between disengaged position and
engaged position, is 10 mm. Tighten the lock nuts
(4).
10 mm
~
i - - - - ENGAGED POSITION
, - - DISENGAGED POSITION
SM1094
8M 8-10491 Issued 06-2003
SECTION 9001 21
PARKING BRAKE ADJUSTMENT (2WD)
Before any adjustments are made carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 3
Remove the cotter pin (1), washer (2) and clevis pin Loosen the lock nuts (6) and adjust the parking
(3) . Loosen the locknut (4), turn the locknut (4) and brake cable (7), the parking brake must be fully
clevis (5) fully onto the inner cable. Tighten the applied when the lever has travelled no more than
locknut (4) . 4 notches. Tighten the lock nuts (6) .
STEP 2 NOTE: When the parking brake is engaged the
warning lamp on the instrument cluster will
Install the clevis pin, washer and new cotter pin. illuminate and the master warning lamp will
flash on and off.
SM1098
SM 8-10491 Issued 06-2003
22 SECTION 9001
REMOVING AIR FROM THE BRAKE SYSTEM
Before removing air from the brake system carry out the following :
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 4
Check the brake pedal adjustment, refer to Page 6. Slowly pump both brake pedals 10 times. Tighten
the LEFT hand bleed screw, hold the RIGHT hand
STEP 2 brake pedal halfway down. Slowly pump the LEFT
hand brake pedal until the oil flowing through the
RIGHT hand bleed screw is free of air. Tighten the
RIGHT hand bleed screw.
STEP 5
Open the LEFT hand bleed screw. Hold the LEFT
hand brake pedal halfway down . Slowly pump the
RIGHT hand brake pedal until the oil flowing
through the LEFT hand bleed screw is free of air.
Tighten the LEFT hand bleed screw.
STEP 6
Install clear plastic hoses (1) onto the RH and LH
bleed screws. Remove the transmission oil filler
cap, install the open ends of the hoses into the oil
filler.
STEP 3
MD0 1B01 8
Remove the clamp from the reservoir return hose
(3) and check the operation of the brakes.
MD01B018
Start and run the engine at 1500 rpm, make sure
the reservoir (2) is full of oil. Stop the engine and
check the reservoir oil level. Clamp the reservoir
return hose (3), start and run the engine at high
idle. Open both bleed screws and check the flow of
oil through the clear plastic hoses.
8M 8-10491 Issued 06-2003
Section
9008
CAB MOUNTINGS
CX Series Tractors
~ © 2001 McCormick Tractors International Limited.
McCORMICK 8M 8-10540 March 2001
2 SECTION 9008
TABLE OF CONTENTS
SPECIAL TORQUES ............. .................................................................................................................................... 3
SPECIAL TOOLS ........................................................................................................................................... .. ......... 3
CAB MOUNTINGS
Inspection .... .. ...................... .......... ... ....... ...................................................................... ........ ........ ... ........... .......... 4
Removal and Installation .......................................................... .. ........................................................................... 4
8M 8-10540 Issued 03-2001
SECTION 9008 3
SPECIAL TORQUES
Cab Mounting Nut. ............................................................................................................................... 190 to 244 Nm
Cab Mounting Bolt to Threaded Plate ......... ........................................................................................... 47 to 61 Nm
Rear Wheel Nuts
Flange Axle ......... ................................................ ................................ ........................................ 278 to 298 Nm
Bar Axle (5/8 inch) ...................................................................................................................... 183 to 207 Nm
Bar Axle (3/4 inch) ........ ... ....................... ... ..... .. ............ ........ ...................................................... 241 to 264 Nm
SPECIAL TOOLS
1
DD98G288
CAB SUPPORT STANDS, MC10281
8M 8-10540 Issued 03-2001
4 SECTION 9008
CAB MOUNTINGS
Inspection
• Visually check the cab mountings for signs of the bonded rubber separating from the steel bushings, also for
signs of the rubber deteriorating.
• Visually check the position of the cab in the mountings for signs of the cab leaning.
• During operation of the machine, knocking or scraping noises from the cab mountings will also indicate worn
mountings.
IMPORTANT: Performance of the cab mountings will be seriously affected if wear or damage has
occurred. Worn or damaged cab mountings must be replaced. Follow the Removal and Installation
procedure and install new cab mountings.
Removal and Installation
NOTE: Items are numbered in order of Removal. For Installation follow the Removal procedure in
reverse order.
Before removing the cab mountings it will be necessary to carry out the following:
• Park the tractor on hard level ground. Stop the engine and remove the key.
• Put blocks in front of and behind the front wheels.
• Raise the rear of the tractor onto suitable axle stands. For tractors equipped with a flange type axle remove the
rear wheels. For tractors equipped with a bar axle move the rear wheels to the maximum tread width position.
NOTE: For Installation, tighten the rear wheel nuts to the correct torque, refer to "SPECIAL
TORQUES" on page 3.
• Remove the Fuel Tank, refer to Section 3005 .
STEP 1 STEP 2
Disconnect the battery, negative (-) terminals first.
Remove the battery retaining clamps and remove
the batteries.
NOTE: For Installation, connect the positive (+)
terminals first.
DP99A006
Remove front cab mounting nuts (1) with washers,
(both sides).
NOTE: For Installation, tighten the front cab
mounting nuts (1) to a torque of 190 to 244 Nm
(140 to 180 Ib ft) .
SM 8-10540 Issued 03-2001
SECTION 9008 5
STEP 3 STEP 5
DP99A001 DP99A002
Remove rear cab mounting nuts (2) with washers
(both sides).
NOTE: For Installation, tighten the rear cab
mounting nuts (2) to a torque of 190 to 244 Nm
(140 to 180 Ib ft).
STEP 4
®-i\\~
~'f=i"
~~
~ D198G179
Remove cab mounting bolt (3), washer (4), spacer
(5) and threaded plate (6) . Remove top mounting
(7) and lower mounting (8) from the cab mounting
bracket. Remove spacer (9) from inside the cab
DP99A003
frame.
Position cab support stands (A), MC10281, under NOTE: For Installation, make sure spacer (9) is
the RH cab frame as shown. Using cab support positioned in the cab frame and is correctly
stands (A), MC 1028, raise the cab until there is a installed onto cab mounting bolt. Hold threaded
clearance (8) of 75 mm (3 inch) between the cab plate (6) and tighten cab mounting bolt (3) to a
frame and the threaded plate on cab mounting torque of 47 to 61 Nm (35 to 45 Ib ft).
brackets.
NOTE: For Installation, make sure the cab
frame is correctly positioned on the front and
rear cab mountings before removing the cab
support stands (A), MC10281.
SM 8-10540 Issued 03-2001
6 SECTION 9008
STEP 6 STEP 8
DP99A004 DP99A008
Repeat STEP 5 to remove and install rear cab
mounting.
NOTE: For Installation of the RH cab mountings
follow the removal procedure in STEP 4 to
STEP 6 in reverse order.
STEP 7
DP99A007
Repeat STEP 5 and STEP 6 to replace the LH cab
mountings.
NOTE: For Installation of the LH cab mountings
follow the Removal procedure in STEP 7 to
STEP 8 in reverse order.
DP98A005
Position cab support stands (A) , MC10281, under
the LH cab frame as shown. Using cab support
stands, MC 10281 , raise the cab until there is a
clearance (8) of 75 mm between the cab frame and
the threaded plate on cab mounting brackets.
NOTE: For Installation, make sure the cab
frame is correctly positioned on the front and
rear cab mountings before removing the cab
support stands (AJ, MC10281.
8M 8-10540 Issued 03-2001
Section
10002
HITCH CONTROLLER
Calibration, Error Codes,
Troubleshooting and Schematics
CX Series Tractors
(Not Equipped With Ride Control)
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10550 March 2001
2 SECTION 10002
TABLE OF CONTENTS
SPECIAL TOOLS .................................................................................... ... ........... ................. .. ........ ...... .... .... .......... 4
TOOLS TO BE MADE ........ ........................ .. ... ............ .. ..... .. ..... .. ... .. ....... ............... .... ... .... .. ... .. ..... .. ... ................ ...... 4
GENERAL INFORMATION FOR ELECTRONIC HITCH CIRCUIT
Hitch Operation ........ .. ......... ..... ..... ......... .. ............ ... ............ ...... ............ ........... ... .... ........ .. ........................... .. ...... 5
Hitch Electrical Supply and Ground ...................... ..... ....... ... .. .. ... ......... ... .... ........... .. ............ ....... ..... ..... ......... ...... 6
Hitch Component Supply ........ .. ........... ... ... ........... ..... ...... ....... ............ ... ........... ..... .......... ..... ........... ... ...... ..... ...... 6
HITCH CALIBRATION ........ ................. ... .................. ....... .......... ..... .. ............ .... ..... ..... .......... .......... ......... .... .. ..... ..... . 7
GENERAL INFORMATION FOR HITCH ERROR CODES
Normal Operation ....... .... ........................... ........... ..... .......... ... ........... .... ............ .............. ...... .... ...... ........ ....... ..... . 9
No Error Codes Displayed But Hitch Is Not Working Correctly ......... ....... .. ... .......... .......... .... .. ........... ....... ...... .. ... 9
Diagnostic Display is Blank ..... ..... ......... .. ... ........... ... ............ .. ............. .. ............... .. .......................... .. ... .... ... .. ... ... 9
Failure Modes ............ .. .......... .. .......................................................................... .. ................... .. ................... ... .. .. . 9
General Notes ... .... .. ........................................... ... ........ ...... .. .. ....... ..... ... .. ... .. .. ....... ......... ................................... 10
Error Codes That Disable Hitch Motion ... ........................ ... .. .. .. ...... ... .. .... ........... .. ......... ...... ............ .. ........ .. .. .. ... 10
Other Possible Error Indications .......... .. ............ .. .... ....... .. ... .. ............ .. ............ ..... ........... ........................ .. ...... .. 10
Error Codes That Allow Hitch Operation .... .............. .. .......... .... ...... ........... .. .... .. ............ ... .. .. ........ .... ........ .. .... .. .. 11
Failures That Are Checked Once .. .. .. ... .. ... .. ... ....... .. .......... .. .............. .... ..... ... .. .. ....... ... .... ..... ........................... ... 11
Double Failures Involving The UP/DOWN Switch .. .......... ...... ............ .. .............. .... ......................... .. ........ .. .. .. ... 11
CALIBRATION ERROR CODE CHART ................. .. .............................................................. ........ ... .. ..... ... .. ......... 12
READING AND ERASING ERROR CODES .. ........ ....................................................... ......................................... 14
HITCH SYSTEM PERFORMANCE CODE CHART .. ............. .... ............... .. .. ........ .. ................. ........... .... ......... ...... 15
CIRCUIT TESTING
General Information .......... .. ... .. ... .... ... .... ..................... ....... ......... ..... .... ............ ..... ....... ... ................ ....... .... .. ..... . 18
Hitch Operating Circuit
Test 1 - No Power to Controller (Power and Clean Ground) .................................................... .... ............ .. ... 19
Test 2 - Circuit Shorted to Ground ..... ...... .................. .. ..... ...... .... ....................... .. .......................................... 20
Test 3 - Hitch Up/Down Switch and Hitch Enable Lamp .. ................ ......................................... .... .... ..... .. ...... 22
Test 4 - Hitch Up/Down Switch Circuit ........... ...... ......... ...... ........ .... ............. .......... .. .. .... ................... .. .... .. ..... 24
Test 5 - Hitch Enable Relay Circuit .. .... ........... .. .............. .. ...... .............. ...... .. .. .. .......... .... ........... .... ............ .... 25
Test 6 - Hitch Solenoids Circuit ............ ... .. .. .... .. .. ...... .... ...... ...... ..... .... ........... .......... .... ............... .. ........... .... ... 27
Test 7 - R/H Hitch Remote Switch .... .. ............ .. ............ .. .......................................... .. .. ........ .. .. .. ............. .. .... 29
Test 8 - LlH Hitch Remote Switch .... ...... .... .. ... ................ .. .. .. .. .. ...... ............ .. ............ .... ...... .. ... .... .. .. .............. 31
Hitch Position Control Circuit
Test 9 - Hitch Position Potentiometer .... .......... .... ........ ... .... ......... ........ .. ..... .... ............ .... ....... ....... ......... .... .... 33
Test 10 - Hitch Position Command Potentiometer ............................. .......... .... .......... .... ........ .. .. .. ............ .. .... 36
Test 11 - Hitch Drop Speed Potentiometer .. .... .............. .. .......... .. ...... .. .......... .... ...................... .. ........... ....... .. 38
Test 12 - Hitch Upper Height Potentiometer ... .... ............. .. ............................ ............. .... .......... .... ........... .... .. 40
Hitch Load Control Circuit
Test 13 - Load Pin ............. ..... ............. .. ......................... ... ............... .............. ............. .. ............ ..... ........... ... .. 42
Test 14 - Hitch Load Command Potentiometer ................................. ... .... ........ ...... .. ........... .. .... .. .... .. ........... .. 44
Test 15 - Hitch Travel Potentiometer .. ......................................... .... .............. ........ ........ ........ ....... ........... .. .... 46
Test 16 - Hitch Response Potentiometer ............ ...... .. .. .... ............. ................................ ...... ....... .......... ...... .. .48
Test 17 - Wheel Speed Sensor ........ .. .......... .. ........ ...... .... ................ .... .......... .. ........................................ ...... 50
8M 8-10550 Issued 03-2001
SECTION 10002 3
HARNESS LAYOUT, SCHEMATICS AND CONNECTORS
Right Hand Console Harness Components ....... .... ... .... .. ............................ ....... ............ .................................... 52
Transmission and Rear Fender Harness Components .......... .................. .... ... ........... .... ...... .............................. 53
Hitch Control Schematic Circuit .................. .. .... ....................... ........................................... .. .......................... '" 54
Schematic Legend .................... .................... .............. ..... .... .... .... ............. ... .. .. ............... .. ....................... .......... 57
Wire Colour Code ..... ................ ............. ....... .... ............. ........... ................. .... ................. .......... ............ ..... ......... 57
Main Connectors .. ... ........... .... .. ... ...... ..... ....... .... ................ ......... .......... ... .... ... ......... ... .... .. ...... ... .... .... ......... ..... ... 58
8M 8-10550 Issued 03-2001
4 SECTION 10002
SPECIAL TOOLS
DD98H120 DD99A051
MC2616 MULTIMETER KIT includes: MC2656 TEST PROBE KIT
MC2616·1 MULTIMETER ONLY
MC2616-2 TEST LEADS
MC2616·3 TEMPERATURE PROBE
.'
----- T
DD97E383
MC31000A HARNESS REPAIR KIT
TOOLS TO BE MADE
353870A1
B A B
c c
LOAD PIN AND POTENTIOMETER TEST HARNESS (VIEWED FROM WIRE INSERTION SIDE)
PARTS REQUIRED
1. HARNESS (PIN 353870A1) 1 OFF 4. MC31105 PINIWIRE 3 OFF (FROM MC31000-2)
2. CONNECTOR BLOCK (PI N 225294C!) 1 OFF 5. MC31 011 SPLICE 3 OFF (FROM MC31000- 2)
3. WEDGE (PIN 225297C1) OR EQUIVALENT
• Install wires MC31105 into connector block 225294C1 and secure with wedge 225297C1.
• Splice wires MC31105 from connector 225294C1 into the harness 353870A1 approximately 10 cm from one
of the connectors. Make sure the wires from connector 225294C 1splice into harness 353870A 1 as follows:
Pin A of 225294C 1 into wire 485A.
Pin B of 225294C 1 into wire 485B
Pin C splices into the Brown wire.
SM 8-10550 Issued 03-2001
SECTION 10002 5
GENERAL INFORMATION FOR ELECTRONIC HITCH CIRCUIT
NOTE: The battery must be at full charge and all connections must be clean and tight before testing. Only use
a HIGH IMPEDANCE multlmeter for the tests. Do not use a test lamp or damage to the switches may occur.
H itch Operation
The electronic hitch provides the operator with precise control of the three point linkage in draft and position
control. It includes operator control of the hitch drop speed, response speed, hitch travel and upper height
control under the lower right hand console panel. The load control knob and position control knob are located
on the upper right hand console, see Page 7.
The hitch up/down switch allows an easy way to raise the hitch to a preset maximum height as set by the
UPPER HEIGHT LIMIT control and then lower to a preset working depth set by the POSITION control or load
set by the LOAD control. This switch also has a spring loaded momentary position. Double clicking and holding
this position enables the operator to override the present DROP RATE control and POSITION control bottom
setting and fast lower the hitch to a desired or maximum depth. Releasing the switch will allow the system to
return to the preset settings.
External remote hitch switches (if equipped) located on the rear of the RH and LH fenders give the operator the
opportunity to slowly lift or lower the hitch from outside the cab. For safety reasons the internal hitch controls
are disabled when operating the external hitch controls.
A hitch enable light which is integral in the hitch up/down switch and will illuminate in the following conditions.
• Light will illuminate for approximately 1 second when the key switch is turned to the ON position to test the
light.
• Light will flash when the hitch needs to be enabled .
• Light will illuminate (not flashing) when a failure of the electronic hitch circuit occurs.
To enable the hitch, check that it is safe to operate the hitch . Then slowly rotate the POSITION control knob in
the direction necessary to match the POSITION control knob with the actual hitch position, which will extinguish
the hitch enable light. The hitch is now enabled and can be operated as required.
The hitch diagnostic display will indicate a hitch system fault as a code and is also used when calibrating the
hitch after repairs have been made.
For full details about the hitch controls and the operation of the hitch control valve refer to Section 8.
8M 8-10550 Issued 03-2001
6 SECTION 10002
Hitch Electrical Supply and Ground
Switched power flows through fuse 33 to the hitch up/down switch terminal 5, the LH and RH external remote
hitch switches terminal B, the implement down switch, the hitch enable relay terminal 3 and the hitch controller
terminal 14.
The hitch controller ground terminal 1 is connected directly to a clean ground at the battery negative terminal.
Hitch Component Supply
A supply is connected to the load control, drop speed, hitch response and upper height control potentiometers
at terminal A. With the potentiometer disconnected this voltage will be 8 volts DC. With the potentiometer
connected, the voltage will no longer measure 8 volts DC.
Terminal C will measure 0 volts DC with the potentiometer disconnected. Terminal C will measure between 0.3
and 1.0 volt DC with the potentiometer connected.
The voltage at terminal B is directly related to the position of the control knob.
All voltage measurements must be made between the wire/terminal and chassis ground NOT terminal C of the
potentiometer.
A supply voltage at 8 volts DC is connected to the load pin sensor at terminal C. Ground is connected at terminal
A. The load sensor signal returns to the control module from terminal B.
A ground speed sensor is connected to the controller at terminal 27.
8M 8-10550 Issued 03-2001
SECTION 10002 7
HITCH CALIBRATION
Before starting the calibration procedure make sure:
1. 46 to 91 kg of weight is mounted on the lift
arms.
2. Transmission oil temperature must be above
38 °C.
3. Remove the Auto Hitch lift rods (if equipped) .
IMPORTANT: If an unexpected code appears on
the diagnostic display during any Step of
calibration there is an error in the electronic
hitch system. Error codes must be identified
and corrected before hitch calibration can
proceed. Refer to CALIBRATION ERROR CODE
CHART on page 12. DP97NOO8
YES and NO are signaled by using the hitch up/down
1. HITCH UPIDOWN SWITCH
switch (1) as follows: AND HITCH ENABLE LAMP
YES = Push hitch up/down switch into the DOWN 2. POSITION CONTROL KNOB
3. LOAD CONTROL
MOMENTARY position and release.
NO = Push hitch up/down switch into the UP position
then back to the DOWN (centre) position.
NOTE: The DOWN MOMENTARY position is
below the centre position and spring loaded to
return to the centre position when released.
DOWN and UP positions are detented.
The calibration procedure may be exited at any
time by toggling the hitch up/down switch UP
then DOWN except when answering a YES or
NO question.
DP97N009
STEP 1
4. HITCH RESPONSE CONTROL
Push and hold the hitch up/down switch (1) in the 5. DIAGNOSTIC DISPLAY
DOWN MOMENTARY position while starting the 6. UPPER LIMIT CONTROL
engine. Release the hitch up/down switch when the 7. TRAVEL CONTROL
8. HITCH DROP SPEED
first character after the 8 appears in the diagnostic
display (4) of the hitch control panel. If the hitch up/
down switch is NOT released, the calibration
sequence will terminate.
STEP 2 STEP 3
The diagnostic display will read c, do you want to The diagnostic display will read c, do you want to
calibrate the hitch? continue calibration?
Answer YES to calibrate the hitch and continue to Answer YES.
STEP 3 or NO to display error codes, refer to
Page 14. STEP 4
The diagnostic display will read g, does the tractor
have two load sensing hitch pins?
Answer NO.
SM 8-10550 Issued 03-2001
8 SECTION 10002
STEP 5 STEP 9
The diagnostic display will read II, does the tractor The diagnostic display will read 6 . Turn the Position
have an upper limit potentiometer? Control Knob (2) fully clockwise to the hitch raised
position.
Answer YES.
IMPORTANT: DO NOT move the Position
STEP 6 Control Knob fully clockwise to the Transport
Position.
The diagnostic display will read 7, do you want to
enter tractor type? Answer YES.
Answer YES. The hitch will begin calibrating. It may take several
minutes before the hitch raises .
To select the correct model code answer YES until
the correct model code is shown in the diagnostic NOTE: If for any reason calibration must be
display. Enter the model code by answering NO. stopped at this point, place the hitch up/down
switch in the UP position. The digital display will
TRACTOR TYPE MODEL CODE read 0 USER QUIT. If other codes appear on
No booster cylinders the display indicating errors, refer to
CALIBRATION ERROR CODE CHART on page
One booster cylinder 2 12 or HITCH SYSTEM PERFORMANCE CODE
Two booster cylinders 3 CHART on page 15.
STEP 7 STEP 10
The diagnostic display will read c, was the correct When the hitch is fully raised the diagnostic display
model code selected? will read 9. Turn the Position Control Knob (2) fully
counterclockwise to the hitch lowered position.
Answer YES for correct model code or NO to repeat
STEP 6. Answer YES.
The hitch will immediately lower for one second after
STEP 8 which the hitch will begin calibrating. It may take
The diagnostic display will read 8, do you want to several minutes before the hitch lowers.
lower the hitch? NOTE: If for any reason calibration must be
Answer YES holding the hitch UP/DOWN switch stopped at this point, place the hitch up/down
down in the DOWN MOMENTARY position until the switch in the UP position. The digital display will
hitch is fully lowered. read 0 USER QUIT. If other codes appear on
the display indicating errors, refer to
IMPORTANT: The hitch will continue to lower CALIBRATION ERROR CODE CHART on page
while the hitch up/down switch is held in the 12 or HITCH SYSTEM PERFORMANCE CODE
DOWN MOMENTARY position. CHART on page 15.
STEP 11
When the hitch is lowered the diagnostic display will
read U, is the hitch fully lowered?
IMPORTANT: DO NOT answer YES until all
hitch movement has stopped and the hitch is
fully lowered or the hitch calibration procedure
will have to be repeated.
When the hitch is fully lowered answer YES.
STEP 12
The diagnostic display will read the system normal
code O.
SM 8-10550 Issued 03-2001
SECTION 10002 9
GENERAL INFORMATION FOR HITCH ERROR CODES
Normal Operation
The diagnostic display shows error codes which assist in troubleshooting the Electronic Hitch Control System .
When the key switch is placed in the ON position the diagnostic display will self test showing 8 for 2 seconds.
If '.' appears on the diagnostic display the hitch position is above the upper limit setting, carry out the following :
1. Press and hold the hitch up/down switch in the DOWN MOMENTARY position to lower the hitch until the
upper limit is reached or,
2. Adjust the upper limit control (6) until the hitch position is matched .
The diagnostic display code for System Normal is 0 or O. There will be a dot. on the lower right hand side of the 0 if
the tractor is stationary or travelling at less then 0.5 m.p.h. (0.8 km/h).
There will be no dot. for speeds of more than 0.5 m.p.h. (0.8 km/h).
No Error Codes Displayed But Hitch Is Not Working Correctly
1. Potentiometer retaining nut loose. Check Hitch Position, Position Control, Load Control, Hitch Response,
Upper Limit Control, Travel Control and Drop Speed Control potentiometers . Repeat calibration .
2. Hitch will not fully raise or fully lower. Potentiometer retaining nut loose. Check Hitch Position, Position
Control and Upper Limit Control potentiometers. Repeat calibration .
3. Hitch does not lower or drop rate is too slow for the application. Adjust Drop Speed Control (8).
4. Hitch will not raise or lower. Possible contamination of hydraulic oil causing hitch valve spool to stick.
Attempt re-calibration before further investigation .
Diagnostic Display is Blank
If the diagnostic display is blank and the hitch enable lamp is not illuminated, there is no power to the control
module.
If the diagnostic display is blank, the hitch enable lamp is illuminated and the hitch operates normally, the
diagnostic display may be defective. Test the diagnostic display by disconnecting the tractor diagnostic display from
the control module and connecting a good secondary diagnostic display. If the diagnostic display still does not work
disconnect secondary diagnostic display and then replace the control module. Connect the original tractor
diagnostic display to the control module.
Failure Modes
1. HALT - Hitch is totally disabled and no electronic actuation is possible. The diagnostic display will flash H
and an error code. The hitch enable lamp will be illuminated .
2. LIMP - Hitch can only be actuated by repeated operation of the hitch up/down switch or the hitch remote
switch . The hitch will operate for 1.5 seconds. The tractor must be stationary. The hitch enable lamp will be
illuminated and an error code will be displayed.
3. DEGRADED 2 - Due to a failure, the draft control (if equipped) is not operational. The hitch enable lamp will
be illuminated and an error code will be displayed.
4. DEGRADED 1 - The hitch enable lamp is illuminated, hitch is operational and an error code will be
displayed. Default hitch settings have replaced the operators hitch settings due to component failure.
NOTE: Most DEGRADED 1 settings are intermittent and will clear. If errors continue corrective action
must be taken.
8M 8-10550 Issued 03-2001
10 SECTION 10002
General Notes
1. When an error code is displayed the hitch enable lamp must be illuminated . If the hitch enable lamp is not
illuminated , the lamp or lamp circuit may be damaged.
2. All error codes resulting in HALT or LIMP failure modes (including intermittent errors) are saved by the
control module memory. Restart the tractor and observe the diagnostic display for repeated error codes .
Errors must be corrected before normal hitch operation can continue .
3. When the hitch up/down switch error U is displayed the hitch up/down switch is disabled . Hitch operation
may continue using the Position Control Knob.
4. If the hitch raises or lowers momentarily then stops and the hitch enable lamp is not illuminated , check for
recorded error codes, refer to READING AND ERASING ERROR CODES on page 14.
EXAMPLE: If battery voltage is low and the Position Control Knob is used to raise or lower the hitch, the current
draw may momentarily lower battery voltage below 9.8 volts DC and cause a momentary LIMP condition. The
LIMP condition momentarily disables the Position Control Knob and stops the hitch. When this occurs the
voltage then increases above 9.8 volts cancelling the LIMP condition restoring normal hitch operation. The error
will be recorded as an A (low voltage). No error code will be displayed until all error codes are recalled from the
memory.
5. Before before carrying out any further investigation , restart the tractor and observe the diagnostic display
for error codes. Errors can be intermittent and will be cleared at start up.
Error Codes That Disable H itch Motion
HALT Conditions
When a HALT condition occurs the letter H will flash and alternate with the letter for the error code. Hitch motion will
be fully disabled. If failures are detected during calibration, the system will switch to the HALT failure mode and the
error code will be displayed. Refer to the CALIBRATION ERROR CODE CHART on page 12 and HITCH
SYSTEM PERFORMANCE CODE CHART on page 15.
Calibration Errors
All failures detected during calibration will be classed as HALT failure modes, although they may not be classified
as HALT failure modes in the HITCH SYSTEM PERFORMANCE CODE CHART on page 15.
Always re-calibrate the hitch if the control module, position control potentiometer, hitch position potentiometer,
load sensing hitch pin (if equipped) or the hitch valve are replaced.
Other Possible Error Indications
There are certain conditions that if detected may display an incorrect error code or fail to display an error code.
1. If battery voltage momentarily drops below 9.8 volts no error code will be displayed but the error will be
recorded . When errors are recalled , A (low battery voltage) will be displayed. Refer to HITCH SYSTEM
PERFORMANCE CODE CHART on page 15.
2. A shorted coil may also result in a combination of failures such as "A" and either "H", "2" or "H", "3". The
hitch controller will show such a sequence. The reason is that if the coil is shorted to ground, the battery
voltage will drop momentarily.
3. The system may not detect a short or open circuit in the hitch enable lamp circuit because it is only tested
at start up.
SM 8-10550 Issued 03-2001
SECTION 10002 11
Error Codes That Allow Hitch Double Failures Involving The UPI
Operation DOWN Switch
The following failures are self healing operational When the hitch up/down switch and a second
failures (they do not necessarily indicate signal (shown below) have failed, the display will
component failure) which are NOT written to the flash the letter "F" and alternate with the code for
memory: the other failure. Hitch motion is available only
through the remote fender switches.
1. The hitch position is above the upper limit.
1. Position Sensor
2. A remote switch failure (on fender).
3. DOWN/MOMENTARY switch failure.
"F","H" 337L96A
Refer to Test 9 - Hitch Position Potentiometer on
page 33.
The following are operational failures that are self
healing and ARE written to the memory: 2. Position Command
1. Low battery voltage. " F", "p " 337L96B
2. High battery voltage. Refer to Test 10 - Hitch Position Command
Potentiometer on page 36.
3. Drop rate. 3. High Battery Voltage
4. Travel " F" , "E "7L96C
5. Draft pin errors . Refer to Section 4004, Battery Servicing and Testing.
4.5 Volt Regulator
NOTE: Most DEGRADED 1 failures (component
failures) occur intermittently during operation
and will be cleared at start up.
"F", "r " 337L96D
Hitch controller has failed.
Failures That Are Checked Once 5. Relay
The following failures are checked once at start up. "F", "F " 337L96E
Hitch controller has failed.
1. Relay contacts being welded closed.
6. Watchdog
2. Hitch switch lamp failure .
"F", "c: "
337L96F
3. Memory failure.
Hitch controller has failed.
4. Watchdog timer failure.
7. Low Battery Voltage
"F", "R " 337L96G
Refer to Section 4004, Battery Servicing and Testing,
also check alternator output voltage.
SM 8-10550 Issued 03-2001
" ' V 'oI ,", v . \JIIIJUIt UII I-Id~t: LI .
Current to raise hitch is above
3. Refer to Section 8009, Hitc r
srv . :fied limits.
Valve and EDC Manifold.
I--
1. Battery voltage is high. 1. Check battery condition, refer to
" H", J" " 2. Bad raise solenoid or solenoid
resistance is low.
Section 4004 , Battery Servicing
and Testing.
334 L96C 2. Go to Test 6 - Hitch Solenoids
Current to raise hitch is below Circuit on page 27.
specified limits.
r"
1. Battery voltage is high. 1. Check battery condition, refer to
" H", " Section 4004, Battery Servicing
and Testing.
334L96D 2. Raise solenoid resistance is low. 2. Go to Test 6 - Hitch Solenoids
Circuit on page 27.
Full raise current detection out of
range (with position command
knob in the full raise position).
" H", " a" 334L96E
1. Hitch position potentiometer is
defective or retaining nut is
loose.
1. Go to Test 9 - Hitch Position
Potentiometer on page 33.
I
Hitch position is not at maximum.
1. Position command knob is not at 1. Move position command knob to
" H", -I " " full lower.
2. Position command potentiometer
full lower.
2. Go to Test 10 - Hitch Position
334L96F is defective or retaining nut is Command Potentiometer on I
loose. page 36.
Position command is not at full
lower.
SM 8-10550 Issued 03-2001
SECTION 10002 13
ERRQR ~QDE
CAUSE CORRECTIVE ACTION
AND PRQBLEM
" H", " --- " 1.. Battery voltage is low.
2. No power to lower solenoid or
solenoid resistance is high.
1. Check battery condition, refer to
Section 4004, Battery Servicing
and Testing .
334 L96G 3. Hitch valve lower spool is stuck 2. Go to Test 6 - Hitch Solenoids
Current to lower hitch is above closed . Circuit on page 27.
specified limit. 3. Refer to Section 8009, Hitch
Valve and EDC Manifold .
1. Battery voltage is high . 1. Check battery condition , refer to
" H", e" "
334L96H
2. Bad LOWER solenoid or
solenoid resistance is low.
Section 4004, Battery Servicing
and Testing .
2. Go to Test 6 - Hitch Solenoids
Current to lower hitch is below Circuit on page 27.
specified limit.
1. Operator did not acknowledge 1. Re-calibrate hitch.
" H", " d" when hitch was fully lowered and
the module was displaying U
Refer to HITCH CALIBRATION
on page 7.
334 L96J within six minutes.
Calibration time expired.
" H", "
n "
334 L96K
1. Position potentiometer is
defective or retaining nut is
loose.
1. Go to Test 9 - Hitch Position
Potentiometer on page 33 .
Hitch position is not at minimum
1. Position potentiometer is 1. Go to Test 9 - Hitch Position
"
H" " n" defective or retaining nut is
loose.
Potentiometer on page 33.
334L96L
Hitch position range is out of limits.
H"," -
1. Position command 1. Go to Test 9 - Hitch Position
" " potentiometer, hitch position Potentiometer on page 33 and
potentiometer or both are Test 10 - Hitch Position
334 L96M defective or retaining nuts are Command Potentiometer on
loose. page 36 .
Position command and hitch position
potentiometers are not aligned.
8M 8-10550 Issued 03-2001
14 SECTION 10002
READING AND ERASING ERROR CODES
YES and NO are signaled by using the hitch up/down STEP 2
switch as follows:
The diagnostic display will read C, do you want to
YES = Push hitch up/down switch into the DOWN calibrate the hitch?
MOMENTARY position and release.
Answer NO to display error codes.
NO =Push hitch up/down switch into the UP position
then back to the DOWN (centre) position. STEP 3
NOTE: The DOWN MOMENTARY position is If no error codes are recorded the diagnostic display
below the centre position and spring loaded to will read n. Answer NO and go to STEP 5.
return to the centre position when released.
DOWN and UP positions are detented. If error codes are recorded the first recorded error
code will be displayed (for example c).
Answer YES , the next recorded error code will be
displayed (for example r) . Continue to answer YES to
display all recorded error codes.
STEP 4
When all recorded error codes have been displayed
the diagnostic display will read n, do you want to read
the error codes again?
Answer YES to repeat the error codes or NO to
continue.
STEP 5
DP97NOOB
The diagnostic display will read e , do you want to
keep error codes?
Answer YES to KEEP ERROR codes in the control
module memory.
Answer NO to ERASE ERROR codes in the control
module memory.
STEP 6
The diagnostic display will return the system normal
code O.
DP97NOO9
1. HITCH UPIDOWN SWITCH
AND HITCH ENABLE LAMP
2. DIAGNOSTIC DISPLAY
STEP 1
Push and hold the hitch up/down switch (1) in the
DOWN MOMENTARY position while starting the
engine. Release the hitch up/down switch when the
first character after the 8 appears in the diagnostic
display (2) of the hitch control panel. If the hitch up/
down switch is NOT released, the calibration
sequence will terminate.
SM 8-10550 Issued 03-2001
SECTION 10002 15
HITCH SYSTEM PERFORMANCE CODE CHART
These are error codes and corrective actions used in troubleshooting the electronic hitch system. The codes are
listed from the highest priority to the lowest priority. When more than one failure exists simultaneously the highest
priority failure will be displayed. All failures are recorded in the control module memory and can be retrieved in
order of priority.
E~IL!.!RE
ER!3QB CODE ~AUSE CORRE~TIVE ACTIQN
MQDE
NO ERROR 1. Controller power DEGRADED 1. Go to Test 1 - No Power to Controller
(BLANK failure. 1 (Power and Clean Ground) on page 19.
DISPLAY) AND 2. Go to Test 2 - Circuit Shorted to Ground on
2. Circuit has shorted to
HITCH ENABLE page 20.
ground.
LAMP IS NOT
3. Replace display.
ILLUMINATED 3. Display circuit failure.
NOTE: If the fault remains replace the hitch
controller. Calibrate the hitch to the new
controller, refer to HITCH CALIBRATION on
page 7.
Open circuit or short to HALT Go to Test 6 - Hitch Solenoids Circuit on page
" H", "2 " ground of lower solenoid
or lower solenoid circuit.
27.
336L96A
Open circuit or short to 12 HALT Go to Test 6 - Hitch Solenoids Circuit on page
" H", "
U
" volts DC of lower solenoid
or lower solenoid circuit.
27.
336L968
Open circuit or short to HALT Go to Test 6 - Hitch Solenoids Circuit on page
" H", "3 " ground of raise solenoid
or raise solenoid circuit.
27 .
336L96C
Open circuit or short to HALT Go to Test 6 - Hitch Solenoids Circuit on page
ground of both raise and 27.
" H", "9 " lower solenoids or both
336L96D raise and lower solenoid
circuits.
Control module memory HALT Re-calibrate the hitch , refer to HITCH
failure . The system CALIBRATION on page 7.
" H"," ~" cannot read calibration
DI98A1 33 values.
Short to 12 volts DC of HALT Go to Test 6 - Hitch Solenoids Circuit on page
" H", "b " the raise solenoid or raise
solenoid circuit failure.
27.
336L96F
Short to 12 volts DC of HALT Internal short to 12 volts of the hitch controller.
" ", " " the raise solenoid driver Replace the hitch controller and calibrate the
H h circuit. hitch to the new controller, refer to HITCH
CALIBRATION on page 7.
336L96G
8M 8-10550 Issued 03-2001
16 SECTION 10002
EAILYBE
t;BRQB ~QD~ ~AUSE ~ORBECTI~E ACTIQN
MODE
Short to 12 volts DC of HALT Internal short to 12 volts of the hitch controller.
the lower coil driver Replace the hitch controller and calibrate the
" H", "J "
circuit. hitch to the new controller, refer to HITCH
336L96H CALIBRATION on page 7.
Internal memory failure HALT Calibration time expired or controller memory
failed. Replace the hitch controller only after
" H","d" restarting tractor to verify error code.
D1 98A134
Tractor has never been HALT Calibrate hitch, refer to HITCH CALIBRATION
calibrated. on page 7.
" J"
338L96A
Open or shorted hitch LIMP Check the Hitch Position Control Circuit, go to
" H" 338L96B
position circuit. Test 9 - Hitch Position Potentiometer on page
33.
Open or shorted position LIMP Check the Hitch Position Control Circuit, go to
Test 10 - Hitch Position Command
" P" 338L96C
control circu it.
Potentiometer on page 36 .
Loss of 5 volt regulator. LIMP Replace the hitch controller and calibrate the
hitch to the new controller, refer to HITCH
" r " CALIBRATION on page 7.
338L96D
Low battery voltage (less LIMP Check battery condition, refer to Section 4004,
A"
than 9.8 volts). Battery Servicing and Testing also check the
" alternator output voltage.
Short circuit of load pin
338L96E Go to Test 13 - Load Pin on page 42.
causing momentary low
battery voltage
Relay primary circuit or LIMP Go to Test 5 - Hitch Enable Relay Circuit on
contact problem or coil page 25.
"F " DI98A1 35
shorted to system
voltage.
Watchdog circuit LIMP Replace the hitch controller and calibrate the
problems. hitch to the new controller, refer to HITCH
" C " CALIBRATION on page 7.
338L96G
High battery voltage LIMP Check battery condi!ion, refer to Section 4004,
'" "
E (greater than 18 volts) . Battery Servicing and Testing also check the
alternator output voltage.
338L96H
Upper limit circuit failed. LIMP Go to Test 12 - Hitch Upper Height
Potentiometer on page 40.
" ["
338L96J
SM 8-10550 Issued 03-2001
SECTION 10002 17
FAILIJRE
ERRQB CODE CA!.!~~ CORRE~TIVE A~TION
MODE
Load control circuit has DEGRADED Check the Hitch Load Control Circuit, carry
" " failed . 2 out the following :
L 340L96A
Test 13 - Load Pin on page 42 .
Test 14 - Hitch Load Command Potentiometer
on page 44.
Test 15 - Hitch Travel Potentiometer on
page 46.
Test 17 - Wheel Speed Sensor on page 50 .
Draft pin sensor has DEGRADED Go to Test 13 - Load Pin on page 42.
failed. 2
" 5"
340L96B
Hitch up/down switch has DEGRADED Go to Test 3 - Hitch Up/Down Switch and Hitch
failed . 1 Enable Lamp on page 22 .
"
U"
338L9SK
Hitch drop speed circuit DEGRADED Go to Test 11 - Hitch Drop Speed
has failed. 1 Potentiometer on page 38.
" 6"
338L96L
Hitch response circuit DEGRADED Go to Test 16 - Hitch Response Potentiometer
" 1" DI96A13S
failed . 1 on page 48.
Hitch travel circuit has DEGRADED Go to Test 15 - Hitch Travel Potentiometer on
failed . 1 page 46 .
"q "
339L96D
Hitch enable lamp circuit DEGRADED Go to Test 3 - Hitch Up/Down Switch and Hitch
failure 1 Enable Lamp on page 22 .
" 1-1"
335L96A
Hitch position is above DEGRADED Push and hold the hitch up/down switch in the
" -" 335L96B
upper limit. 1 DOWN MOMENTARY position to lower the
hitch until the hitch upper limit is reached .
Hitch up/down switch has DEGRADED Error code will stop when switch is released
" failed . 1 from DOWN MOMENTARY position.
"
II If the fault remains go to Test 3 - Hitch Up/
335L9SD Down Switch and Hitch Enable Lamp on page
22.
Fender remote switch(es) DEGRADED Error code will stop when remote switch is
released.
"
-- " has failed when: 1
If the fault remains go to Test 7 - R/H Hitch
335L96C Remote Switch on page 29 and Test 8 - L/H
Hitch Remote Switch on page 31 .
8M 8-10550 Issued 03-2001
18 SECTION 10002
CIRCUIT TESTING
General Information
A WARNING: Never operate the engine in a closed building. Proper
ili ventilation is required under all circumstances.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with the parking
brake engaged and the engine OFF unless otherwise stated.
IMPORTANT: Put blocks in front of and behind the rear wheels.
IMPORTANT: The battery must be at full charge and all connections must be clean and tight before
testing. Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage to the
switches may occur.
IMPORTANT: Use test probe kit MC2656 when making electrical checks at connectors to avoid the risk
of shorting between the connector pins or terminals.
IMPORTANT: Follow the Error Code corrective action BEFORE replacing any components.
IMPORTANT: Replace the controller if the fault remains only after all necessary checks have been
made.
NOTE: When measuring resistance values, always measure the resistance of the multimeter leads
before testing components. Subtract the resistance of the multimeter leads from the component
resistance to obtain a true resistance value.
NOTE: When testing diodes and diode modules use the multimeter diode test function.
NOTE: All components, wires and connectors disconnected during any electrical checks must be
connected when the checks are completed.
SM 8-10550 Issued 03-2001
SECTION 10002 19
Hitch Operating Circuit
Test 1 - No Power to Controller (Power and Clean Ground)
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Check fuse 33, if the fuse has blown refer to "Test 2 - Circuit Shorted to Ground" on page 20.
NOTE: Turn the key to the ON position.
IMPLEMENT CONNECTOR HITCH UP/DOWN SWITCH
Check Point Reading Possible Cause of Bad Reading
Check 1: Implement switch connector 12 volts Bad circuit between switched power stud
terminal B for wire 528 Red to ground. and the implement switch connector. Go to
check 2.
NOTE: If the reading is correct go to Check 3.
NOTE: Remove the hitch up/down switch from the right hand console top cover. Do not disconnect the
switch from the harness.
Check 2: Hitch up/down switch connector 12 volts Bad circuit between switched power stud
terminal 5 for wire 500 Red to ground. and the hitch up/down switch. Also check
the switched power stud connections and
connector 26 .
NOTE: Turn the key to the OFF position and disconnect connector 40 (right hand console harness to
transmission harness).
Check 3: Between connector 40 pin 7 Continuity Bad clean ground circuit. Check wire 500
(transmission harness side) for wire 500 Brown/White between connector 40 and
Brown/White to ground. the battery negative terminal.
NOTE: Connect connector 40 and remove the right hand console side cover. Disconnect connector J1
from the hitch controller.
Check 4: Connector J 1 pin 1 for wire 500 Continuity Check wire 500 Brown/White between
Brown/White to ground. connector J 1 and connector 40.
Also check connector 40.
Continued ....
8M 8-10550 Issued 03-2001
20 SECTION 10002
NOTE: Turn the key to the ON position .
Check point Reading Possible Cause of Bad Reading
Check 5: Connector J1 pin 14 for wire 500 12 volts Check wire 500 Red between the hitch
Red to ground . enable relay and the hitch controller. Also
check the hitch enable relay.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
calibrate the hitch , refer to "HITCH CALIBRATION" on page 7.
Test 2 - Circuit Shorted to Ground
NOTE: Before carrying out the following tests, refer to Circuit Testing "Genera/Information " on page 18.
NOTE: Turn the key to the OFF position and remove fuse 33.
NOTE: Disconnect the hitch up/down switch from the right hand console harness.
NOTE: Disconnect the implement (if connected) from the tractor harness.
HITCH UP/DOWN SWITCH
Check Point Reading Possible Cause of Bad Reading
Check 1: Hitch up/down switch connector No continuity Circuit shorted to ground.
terminal 5 for wire 500 Red to ground. Go to Check 2.
NOTE: If the reading at Check 1 is correct check the hitch up/down switch circuit refer to "Test 4 -
Hitch Up/Down Switch Circuit" on page 24 .
NOTE: Disconnect connector 52 (fender harness to right hand console harness).
NOTE: Disconnect connector 40 (transmission harness to right hand console harness) and disconnect the
wheel speed sensor from the harness.
Check 2: Hitch up/down switch connector No continuity Circuit shorted to ground between fuse 33
terminal 5 for wire 500 Red to ground. connector 52 or connector 40.
Go to Check 3.
NOTE: If the reading at Check 2 is correct go to Check 5.
Continued .. ..
8M 8-10550 Issued 03-2001
SECTION 10002 21
NOTE: Remove the right hand console side cover and disconnect connector 26.
Check Point Reading Possible Cause of Bad Reading
Check 3: Hitch up/down switch connector No continuity Check wires 500 between the following:
terminal 5 for wire 500 Red to ground. Connector 26 pin 0 and the hitch up/down
switch .
Hitch up/down switch and the splice.
Splice and the hitch enable relay terminal 3.
Hitch enable relay terminal 3 and hitch
controller connector J2 pin 1.
Splice and connector 52 pin H.
Check 4: Connector 26 pin 0 (instrument No continuity Check wire 500 between connector 26 and
panel harness side) for wire 500 Red to the fuse 33.
ground .
Check 5: Connector 40 terminal 43 No continuity Check wire 215 Red between connector 40
(transmission harness side) for wire 215 wheel speed sensor.
Red to ground .
Check 6: Connector 52 terminal H (fender No continuity Check the fender harness wire 528 Red
harness side) for wire 528 Red to ground. between connector 52 and the left and right
hand remote hitch switches. Also check the
implement switch connector, splice and wires
528 Red between the splice and the switch
connector.
Check 7: Connector 52 terminal C (fender No continuity Check the fender harness wire between
harness side) for wire 563 Light Blue to connector 52 and the implement switch
ground . connector.
NOTE: If the readings at Check 6 and 7 are correct check the implement switch and harness. Then go
to Check 8.
NOTE: Disconnect the instrument cluster connector C2 from the harness.
CONNECTOR C2
Check 8: Instrument cluster connector C2 No continuity Circuit shorted to ground between the
pin B-3 for wire 563 Light Blue to ground. instrument cluster connector C2 and
connector 52.
Go to Check 8.
Continued ....
8M 8-10550 Issued 03-2001
22 SECTION 10002
NOTE: Remove the right hand console side cover and disconnect connector 27.
Check Point Reading Possible Cayse of Bad Reading
Check 9: Instrument cluster connector C2 No continuity Check wire 563 between the instrument
pin B-3 for wire 563 Light Blue to ground. cluster connector C2 and connector 27.
Check 10: Connector 27 pin 4 (right hand No continuity Check wire 563 between connector 27 and
console harness side) for wire 563 Light connector 52 .
Blue to ground.
Test 3 - Hitch Up/Down Switch and Hitch Enable Lamp
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Check fuse 33.
NOTE: Remove the hitch switch from the right hand console top cover, do not disconnect the switch
from the harness. Check the hitch enable lamp bulb.
NOTE: Put the hitch up/down switch in the UP position and turn the key to the ON position.
HITCH UP/DOwN SWITCH
Check Point Reading Possible Cayse of Bad Reading
Check 1: Hitch up/down switch connector 12 volts Bad circuit between switched power stud
terminal 5 for wire 500 Red to ground. and the hitch up/down switch. Also check
the switched power stud connections and
connector 26.
Check 2: Hitch upldown switch connector 12 volts Bad hitch up/down switch.
terminal 7 for wire 510 Light Blue to ground.
Check 3: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground.
Check 4: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 4 for wire 562 Light Blue to ground.
NOTE: When carrying out checks 3 and 4 a voltage of 0 to 0. 14 mV may be detected.
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 23
NOTE: Put the hitch up/down switch in the DOWN (middle) position.
Check Point Reading Possible Cause of Bad Reading
Check 5: Hitch up/down switch connector 12 volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground.
Check 6: Hitch up/down switch connector o volts Bad hitch up/down switch .
terminal? for wire 510 Light Blue to ground.
Check 7: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 4 for wire 562 Light Blue to ground .
NOTE: Hold the hitch up/down switch in the FAST DOWN (momentary) position.
Check 8: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal? for wire 510 Light Blue to ground .
Check 9: Hitch up/down switch connector 12 volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground.
Check 10: Hitch up/down switch connector 12 volts Bad hitch up/down switch.
terminal 4 for wire 562 Light Blue to ground .
Check 11: Hitch up/down switch connector o volts Bad circuit between the hitch up/down
terminal 9 for wire 508 Light Blue to switch and the hitch controller connector
ground . J 1. Refer to "Test 4 - Hitch Up/Down Switch
Circuit" on page 24 .
NOTE: If the readings are correct check the hitch up/down switch circuit, refer to "Test 4 - Hitch
Up/Down Switch Circuit" on page 24.
8M 8-10550 Issued 03-2001
24 SECTION 10002
Test 4 - Hitch Up/Down Switch Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position. Remove the right hand console side cover and disconnect
connector J1 from the hitch controller.
NOTE: Remove the hitch switch from the lower right hand console top cover, disconnect the switch from
the harness.
HITCH UP/DOWN SWITCH CONNECTOR J1
Check Point Reading Possible Cause of Bad Reading
Check 1: Hitch up/down switch connector No continuity Wire 510 shorted to ground. Check wire
terminal 7 for wire 510 Light Blue to ground. 510.
Check 2: Between the hitch up/down Continuity Check wire 510 between the hitch up/down
switch connector terminal 7 and connector switch and connector J 1.
J1 pin 10 for wire 510 Light Blue.
Check 3: Between the hitch up/down Continuity Check wire 562 between the hitch up/down
switch connector terminal 4 and connector switch and connector J 1.
J1 pin 5 for wire 562 Light Blue.
Check 4: Hitch up/down switch connector No continuity Wire 562 shorted to ground. Check wire
terminal 4 for wire 562 Light Blue to ground. 562.
NOTE: Disconnect connector 26 (instrument panel harness to right hand console harness) .
Check 5: Hitch up/down switch connector No continuity Wire 509 shorted to ground. Check wire
terminal 2 for wire 509 Light Blue to ground. 509 between the hitch up/down switch and
connector 26 pin Z. Also check wire 509
between the hitch up/down switch and
connector J 1.
Check 6: Connector 26 (instrument panel No continuity Wire 509 shorted to ground. Check wire
harness side) pin Z for wire 509 Light Blue 509 between connector 26 pin Z and the
to ground. instrument cluster connector C2 pin B - 4 .
Check 7: Between the hitch up/down Continuity Check wire 509 between the hitch up/down
switch connector terminal 2 and connector switch and connector J 1.
J 1pin 2 for wire 509 Light Blue.
Check 8: Between hitch up/down switch Continuity Check wire 508 between the hitch up/down
connector terminal 9 and connector J 1 pin 4 switch a nd connector J 1.
for wire 508 Light Blue to ground.
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 25
Check Point Reading Possible Cause of Bad Reading
Check 9: Hitch up/down switch connector Continuity Check wire 508 Brown and the chassis
terminal 10 for wire 508 Brown to ground. ground connection .
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes calibrate
the hitch, refe r to "HITCH CALIBRATION " on page 7.
Test 5 - Hitch Enable Relay Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: The hitch enable relay will energize approximately 5 seconds after the key is switched to the ON
position and the hitch controller has completed the self test procedure.
NOTE: Turn the key to the OFF position. Remove the lower right hand console side cover and remove relay 1 Hitch
Enable.
DS98M1 97
RELAY 1 HITCH ENABLE RELAY CONNEcTOR BLOCK
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal 2 of the hitch enable Continuity Check the chassis ground wire and the
relay connector block for Brown wire to chassis ground connection.
ground .
NOTE: Turn the key to the ON position.
Check 2: Terminal 3 of the hitch enable 12 volts Check wire 500 between the hitch up/down
relay connector block for wires 500 Red to switch and the hitch enable relay. Also
ground . check the hitch up/down switch, refer to
"Test 3 - Hitch Up/Down Switch and Hitch
Enable Lamp" on page 22.
Continued ....
8M 8-10550 Issued 03-2001
26 SECTION 10002
NOTE: Turn the key to the OFF position and disconnect connector J1 from the hitch controller.
Disconnect connector 40 (right hand console harness to transmission harness).
CONNECTOR J1
Check Point Reading Possible Cause of Bad Reading
Check 3: Between 1 of the hitch enable Continuity Check wire 561 between the hitch enable
relay connector block and connector J 1 relay and connector J 1.
pin 3 for wire 561Light Blue.
Check 4: Between 1 of the hitch enable No Continuity Wire 561 shorted to ground. Check wire 561
relay connector block for wire 561 Light between the hitch enable relay and
Blue to ground. connector J1.
Check 5: Between terminal 5 of the hitch Continuity Check wire 511 between the hitch enable
enable relay and connector J 1 pin 7 for relay and connector J1.
wire 511 Red.
Check 6: Between terminal 5 of the hitch No Continuity Check wire 511 between the hitch enable
enable relay for wire 511 Red to ground. relay and connector J1 and between the
hitch enable relay and connector 40.
NOTE: If the readings are correct check the hitch solenoid circuit, refer to "Test 6 - Hitch Solenoids
Circuit" on page 27.
8M 8-10550 Issued 03-2001
SECTION 10002 27
Test 6 - Hitch Solenoids Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
IMPORTANT: Put blocks in front and behind the rear wheels.
NOTE: Disconnect the hitch raise and lower solenoids from the harness.
RAISE SOLENOID LOWER S'OLENOID
Check Point Reading Possible Cause of Bad Reading
Check 1: Between terminals 1 and 2 of the 5 to 12 Ohms Bad raise solenoid coil. Also check the
raise solenoid. solenoid harness.
Check 2: Between terminals 1 and 2 of the 5 to 12 Ohms Bad lower solenoid coil. Also check the
lower solenoid. solenoid harness.
NOTE: Disconnect connector 40 (transmission harness to right hand console harness). Disconnect
the raise and lower solenoids from the harness.
Check 3: Connector 40 pin 10 for wire 511 No continuity Wire 511 shorted to ground between
Red to ground. connector 40 and the Raise or lower
solenoid connector.
Check 4: Between connector 40 pin 10 and Continuity Check wire 511 between connector 40
pin 1 of the lower solenoid connector for and the lower solenoid connector. Go to
wire 511 Red. check 5.
Check 5: Between connector 40 pin 10 and Continuity Check wire 511 between connector 40
pin 1 of the ra ise solenoid connector for wire and the raise solenoid connector.
511 Red.
NOTE: If one of the readings at checks 4 or 5 is correct, check wire 511 between the solenoid with the
bad reading and the splice.
NOTE: If both readings at checks 4 or 5 are not correct, first check wire 511 between connector 40
and the splice.
Check 6: Pin 2 of the raise solenoid No continuity Wire 513 shorted to ground between the
connector for wire 513 Light Blue to ground. splice and the raise solenoid connector.
Check 7: Pin 2 of the lower solenoid No continuity Wire 512 shorted to ground between the
connector for wire 512 Light Blue to ground. splice and the lower solenoid connector.
Continued ... .
8M 8-10550 Issued 03-2001
28 SECTION 10002
Check 8: Between pin 2 of the lower Continuity Check wire 513 between the lower
solenoid connector and pin 17 of connector solenoid connector and connector 40 .
40 for wire 513 Light Blue.
Check 9: Between pin 2 of the raise Continuity Check wire 512 between the raise solenoid
solenoid connector and pin 11 of connector connector and connector 40 .
40 for wire 512 Light Blue.
NOTE: Connect connector 40 (transmission harness to right hand console harness).
NOTE: Remove the lower right hand console side cover and disconnect connector J2 from the hitch
control/er.
CONNECTOR J2
Check pOint Reading Possible Cause of Bad Reading
Check 10: Between hitch controller Continuity Bad circuit between the hitch controller and
connector J 1 pin 7 and terminal 1 of the the hitch solenoids, check the following:
raise or lower solenoid connector for wire Wire 511 between connector 40 and hitch
511 Red. enable relay terminal 5.
Wire 511 between connector J1 and hitch
enable relay terminal 5.
Connector 40.
Check 11: Connector J 1 pin 11 for wire No continuity Wire shorted to ground. Check the right
513 Light Blue to ground. hand console harness for damage.
Check 12: Connector J 1 pin 15 for wire No continuity Wire shorted to ground. Check the right
512 Light Blue to ground. hand console harness for damage.
Check 13: Between connector J1 pin 15 Continuity Check wire 512 between the hitch controller
and the lower solenoid connector terminal connector J 1 and the raise solenoid
2 (harness side) for wire 512 Light Blue or connector.
512 Brown. Also check connector 40.
Check 14: Between connector J1 pin 11 Continuity Check wire 513 between the hitch
and the raise solenoid connector terminal controller connector J 1 and the raise
2 (harness side) for wire 513 Light Blue or solenoid connector.
513 Brown. Also check connector 40 .
SM 8-10550 Issued 03-2001
SECTION 10002 29
Test 7 - R/H Hitch Remote Switch
NOTE: Before carrying out the fol/owing tests, refer to Circuit Testing "General Information" on page 18.
IMPORTANT: Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage
to the hitch remote switches may occur.
NOTE: Turn the key to the OFF position and disconnect the RIH hitch remote switch from the harness.
Turn the key to the ON position.
RIH HITCH REMOTE SWITCH CONNECTOR
Check Point Reading possible Cause of Bad Reading
Check 1: Terminal B of the R/H hitch switch 12 volts Bad circuit between Hitch Up/Down switch
connector for wire 528 Red to ground. and the R/H hitch switch connector. Go to
check 4.
NOTE: If the LlH hitch remote switch operates correctly check wire 528 Red between the RIH hitch
remote switch and the line splice.
NOTE: Turn the key to the OFF position and hold the RIH hitch remote switch in the RAISE position.
Check 2: Between terminals Band C of the 3.9 Ohms Bad R/H hitch switch.
R/H hitch switch. approximately
NOTE: Hold the RIH hitch remote switch in the LOWER position.
Check 3: Between terminals B and A of the 3.9 Ohms Bad R/H hitch switch .
R/H hitch switch . approximately
NOTE: Disconnect connector 52 (fender harness to right hand console harness).
Check 4: Between connector 52 pin Hand Continuity Check wire 528 between connector 52 and
terminal B of the R/H hitch switch connector the R/H hitch switch connector.
for wire 528 Red .
NOTE: If the reading at check 4 is correct check wire 528 Red between the Hitch UplOown switch and
connector 52. Also check the Hitch UplOown switch.
Check 5: Between connector 52 pin J and Continuity Check wire 528 between connector 52 and
terminal C of the R/H hitch switch connector the R/H hitch switch connector.
for wire 528 Light Blue.
NOTE: If the LlH hitch remote switch works correctly, check wire 528 Light Blue between the RIH
switch connector and the line splice.
Continued ....
8M 8-10550 Issued 03-2001
30 SECTION 10002
Check Point Reading Possible Cayse of Bad Reading
Check 6: Between connector 52 pin K and Continuity Check wire 529 between connector 52 and
terminal A of the R/H hitch switch connector the R/H hitch switch connector.
for wire 529 Light Blue.
NOTE: If the L/H hitch remote switch works correctly. check wire 529 Light Blue between the RIH
switch connector and the line splice.
NOTE: Connect connector 52.
NOTE : Remove the lower right hand console side cover. Disconnect connector J1 from the hitch
controller.
CONNECTOR J1
Check 7: Between connector J 1 pin 9 and Continuity Check wire 528 between the hitch
the R/H hitch remote switch connector controller connector and connector 52 .
terminal C for wire 528 Light Blue. Also check connector 52 .
Check 8: Between connector J1 pin 13 and Continuity Check wire 529 between the hitch
the R/H hitch remote switch connector controller connector and connector 52.
terminal A for wire 529 Light Blue. Also check connector 52 .
SM 8-10550 Issued 03-2001
SECTION 10002 31
Test 8 - L/H Hitch Remote Switch
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
IMPORTANT: Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage
to the hitch remote switches may occur.
NOTE: Turn the key to the OFF position and disconnect the UH hitch remote switch from the harness.
Turn the key to the ON position. Turn the key to the ON position.
LlH HITCH REMOTE SWITCH CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal B of the LlH hitch switch 12 volts Bad circuit between Hitch UpIDown switch
connector for wire 528 Red to ground. and the LlH hitch switch connector. Go to
check 4.
NOTE: If the RIH hitch remote switch operates correctly check wire 528 Red between the UH hitch
remote switch and the line splice .
NOTE: Turn the key to the OFF position and hold the UH hitch remote switch in the RAISE position.
Check 2: Between terminals B and A of the 3.9 Ohms Bad LlH hitch switch.
LlH hitch switch . approximately
NOTE: Hold the UH hitch remote switch in the LOWER position.
Check 3: Between terminals Band C of the 3.9 Ohms Bad LlH hitch switch.
LlH hitch switch. approximately
NOTE: Disconnect connector 52 (fender harness to right hand console harness).
Check 4: Between connector 52 pin Hand Continuity Check wire 528 between connector 52 and
terminal B of the LlH hitch switch connector the LlH hitch switch connector.
for wire 528 Red .
Check 5: Between connector 52 pin J and Continuity Check wire 529 between connector 52 and
terminal A of the LlH hitch switch connector the LlH hitch switch connector.
for wire 528 Light Blue.
NOTE: If the RIH hitch remote switch works correctly, check wire 528 Light Blue between the UH
switch connector and the line splice.
Continued ....
SM 8-10550 Issued 03-2001
32 SECTION 10002
Check 6: Between connector 52 pin K and Continuity Check wire 528 between connector 52 and
terminal C of the LlH hitch switch connector the LlH hitch switch connector.
for wire 528 Light Blue.
NOTE: If the RIH hitch remote switch works correctly, check wire 528 Light Blue between the UH
switch connector and the line splice.
NOTE: Connect connector 52.
CONNECTOR J1
NOTE: Remove the lower right hand console side cover. Disconnect connector J1 from the hitch
controller.
Check 7: Between connector J1 pin 9 and Continuity Check wire 528 between the hitch
the LlH hitch remote switch connector controller connector and connector 52.
terminal C for wire 528 Light Blue. Also check connector 52 .
Check 8: Between connector J1 pin 13 and Continuity Check wire 529 between the hitch
the LlH hitch remote switch connector controller connector and connector 52 .
terminal A for wire 529 Light Blue. Also check connector 52 .
8M 8-10550 Issued 03-2001
SECTION 10002 33
Hitch Position Control Circuit
Test 9 - Hitch Position Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Lower the rear three point hitch .
NOTE: Disconnect the hitch position potentiometer from the harness and connect the test harness ,
refer to 'TOOLS TO BE MADE" on page 4 between the potentiometer harness and transmission
harness.
NOTE: Turn the key to the ON position.
HARNESS SIDE POTENTIOMETER SIDE
DI98N034
HITCH POSITION POTENTIOMETER CONNECTOR PIN' IDENTIFICATION
CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Pin A of the open connector of 5 volts Bad feed circuit between hitch controller
the test harness to ground. approximately. connector J2 and the potentiometer
connector. Go to check 5 and 6.
Check 2: Between pins A and C of the 5 volts Bad ground circuit between hitch controller
open connector of the test harness. approximately. connector J2 and the potentiometer
connector. Go to check 5 and 6.
NOTE: Readings at checks 1 and 2 may not be of the same value.
NOTE: Turn the key to the OFF position. Disconnect the test harness from the transmission harness
connector.
Check 3: Between pins A and C of the 0.9 to 1.1K Ohms. Bad potentiometer.
open connector of the test harness.
NOTE: Start and run the engine at low idle, use the hitch remote switches when carrying out Check 4.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 4: Between pins Band C of the Steadily Make sure the potentiometer body tab is
open connector of the test harness. increasing Ohms correctly located into the housing and the
reading with no retaining nut is tight or replace the
intermittent potentiometer as necessary.
readings
Continued .. ..
SM 8-10550 Issued 03-2001
34 SECTION 10002
NOTE: Stop the engine and turn the key to the OFF position. Connect the test harness to the
transmission harness and disconnect the test harness from the potentiometer connector.
NOTE: Disconnect connector 40 (right hand console harness to transmission harness).
Check Point Reading Possible Cause of Bad Reading
Check 5: Between pin A of the open Continuity Check wire 507 Red between connector 40
connector of the test harness and connector and the potentiometer connector.
40 pin 3 for wire 507 Red.
Check 6: Between pin B of the open Continuity Check wire 507 Light Blue between
connector of the test harness and connector connector 40 and the potentiometer
40 pin 4 for wire 507 Light Blue. connector.
Check 7: Between pin B of the open No continuity Wire 507 Light Blue shorted to ground
connector of the test harness to ground. between connector 40 and the
potentiometer.
Check 8: Between pin C of the open Continuity Check wire 507 Brown between connector
connector of the test harness and connector 40 and the potentiometer connector.
40 pin 5 for wire 507 Brown .
NOTE: Connect connector 40. Remove the lower right hand console side cover and disconnect
connector J2 from the hitch controller.
CONNECTOR J2
Check Point Reading Possible Cause of Bad Reading
Check 9: Between pin A of the test harness Continuity Check wire 507 Red between connector 40
and connector J2 pin 34 for wire 507 Red . and the hitch controller connector J2 .
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 35
Check 10: Between pin B of the open Continuity Check wire 507 Light Blue between
connector of the test harness and connector connector 40 and the hitch controller
J2 pin 2 for wire 507 Light Blue. connector J2.
Check 11: Between pin B of the open No continuity Wire 507 Light Blue shorted to ground
connector of the test harness to ground . between connector 40 and the hitch
controller connector J2.
Check 12: Between pin C of the open Continuity Check wire 507 Brown between connector
connector of the test harness and connector 40 and the hitch controller connector J2.
J2 pin 12 for wire 507 Brown.
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
"Test 10 - Hitch Position Command Potentiometer" on page 36.
"Test 11 - Hitch Drop Speed Potentiometer" on page 38.
"Test 12 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
calibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
8M 8-10550 Issued 03-2001
36 SECTION 10002
Test 10 - Hitch Position Command Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18:
NOTE: Turn the key to the OFF position. Make sure the hitch position command potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch position command potentiometer from the harness and connect the test
harness, refer to 'TOOLS TO BE MADE" on page 4 between the potentiometer and right hand console
harness.
NOTE: Turn the key to the ON position.
HITCH COMMAND'POTENTIOMETER HITCH COMMAND' POTENTIOMETER
CONNECTOR
HARNESS SIDE POTENTIOMETER SIDE
Ol98NOJ.<l
CONNECTOR PIN' IDENTIFICATION
Check Point Reading POSsible Cause of Bad Reading
Check 1: Pin A of the open connector of 5 volts Check wire 504 Red between hitch
the test harness to ground. approximately. controller connector J2 and the
potentiometer connector.
Check 2: Between pins A and C of the 5 volts Check wire 504 Brown between hitch
open connector of the test harness. approximately. controller connector J2 and the
potentiometer connector.
NOTE: Readings at checks 1 and 2 may not be of the same value.
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 37
NOTE: Turn the key to the OFF position. Disconnect the right hand console harness connector from the
test harness.
Check Point Reading Possible Cause of Bad Reading
Check 3: Between pins A and C of the 0.9 to 1.1 K Ohms. Bad potentiometer.
open connector of the test harness.
NOTE: Turn the hitch position command control knob from fully counterclockwise to fully clockwise
when carrying out Check 4.
Check 4: Between pins Band C of the Steadily increasing Make sure the potentiometer body tab is
open connector of the test harness. Turn Ohms reading with correctly located into the housing and the
the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings . potentiometer as necessary.
NOTE: Remove the test harness and disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check 5: Between potentiometer connector Continuity Check wire 504 Red between the
pin A and hitch controller connector J2 pin 1 potentiometer connector and the hitch
for wire 504 Red . controller connector J2.
Check 6: Between potentiometer connector Continuity Check wire 504 Light Blue between the
pin B and hitch controller connector J2 pin 7 potentiometer connector and the hitch
for wire 504 Light Blue. controller connector J2.
Continued ... .
8M 8-10550 Issued 03-2001
38 SECTION 10002
Check pOint Reading Possible Cause of Bad Reading
Check 7: Pin B of the potentiometer No continuity Wire 504 shorted to ground between the
connector for wire 504 Light Blue to ground. hitch controller connector J2 and the
potentiometer.
Check 8: Between potentiometer connector Continuity Check wire 504 Brown between the
pin C and hitch controller connector J2 pin 6 potentiometer connector and the hitch
for wire 504 Brown. controller connector J2.
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
"Test 9 - Hitch Position Potentiometer" on page 33.
"Test 11 - Hitch Drop Speed Potentiometer" on page 38.
'Test 12 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
calibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
Test 11 - Hitch Drop Speed Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position . Make sure the hitch drop speed potentiometer body tab is correctly
located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch drop speed potentiometer from the harness. Turn the key to the ON
position.
HITCH DROp SPEED POTENTIOMETER' CONNECTOR 59A
POTENTIOMETER
Check point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59A 8 volts Check wire 502 Red between hitch
(right hand console harness side) pin 1 for approximately. controller connector J2 and the
wire 502 Red to ground. potentiometer connector 59A.
Go to check 4 .
Continued .. ..
8M 8-10550 Issued 03-2001
SECTION 10002 39
NOTE: Turn the key to the OFF position.
Check Point Reading Possible Cause of Bad Reading
Check 2: Between potentiometer connector 9K to 11 K Bad potentiometer.
(potentiometer harness side) pins 1 and 3. Ohms
NOTE: Turn the hitch drop rate control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins 1 and 2. Ohms reading with correctly located into the housing and the
Turn the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings . potentiometer as necessary.
NOTE: Disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check 4: Between potentiometer connector Continuity Check wire 502 Red between the
pin 1 and hitch controller connector J2 pin 16 potentiometer connector 59A and the
for wire 502 Red . hitch controller connector J2 .
Check 5: Between potentiometer connector Continuity Check wire 502 Light Blue between the
pin 2 and hitch controller connector J2 pin 3 potentiometer connector 59A and the
for wire 502 Light Blue. hitch controller connector J2.
Check 6: Between potentiometer connector Continuity Check wire 502 Brown between the
pin 3 and hitch controller connector J2 pin 35 potentiometer connector 59A and the
for wire 502 Brown . hitch controller connector J2.
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
'Test 9 - Hitch Position Potentiometer" on page 33.
"Test 10 - Hitch Position Command Potentiometer" on page 36 .
"Test 12 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
calibrate the hitch , refer to "HITCH CALIBRATION" on page 7.
8M 8-10550 Issued 03-2001
40 SECTION 10002
Test 12 • Hitch Upper Height Potentiometer
NOTE: Before carrying out the following tests. refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position . Make sure the hitch upper height potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch upper height potentiometer from the harness. Turn the key to the ON
position.
HITCH UPP'ER HEIGHT POTENTIOMETER 'CONNECTOR 59A .
POTENTIOMETER
Check Point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59A 8 volts Check wire 560 Red between hitch controller
(right hand console harness side) pin 4 for approximately. connector J2 and the potentiometer
wire 560 Red to ground. connector 59A. Go to Check 4.
NOTE: Turn the key to the OFF position.
Check 2: Between potentiometer connector 9K to 11K Bad potentiometer.
(potentiometer harness side) pins 4 and 6. Ohms
NOTE: Turn the hitch upper height control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins 4 and 5. Ohms reading with correctly located into the housing and the
Turn the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings. potentiometer as necessary.
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 41
NOTE: Disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 560 Red between the
pin 4 and hitch controller connector J2 pin 24 potentiometer connector 59A and the
for wire 560 Red . hitch controller connector J2.
Check 5: Between potentiometer connector Continuity Check wire 560 Light Blue between the
pin 5 and hitch controller connector J2 pin 14 potentiometer connector 59A and the
for wire 560 Light Blue. hitch controller connector J2.
Check 6: Between potentiometer connector Continuity Check wire 560 Brown between the
pin 6 and hitch controller connector J2 pin 26 potentiometer connector 59A and the
for wire 560 Brown. hitch controller connector J2.
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
'Test 9 - Hitch Position Potentiometer" on page 33.
"Test 10 - Hitch Position Command Potentiometer" on page 36.
"Test 11 - Hitch Drop Speed Potentiometer" on page 38.
NOTE: Check the operation of the hitch controller if the fault remains erase a/l error codes and
calibrate the hitch, refer to "HITCH CALIBRATION" on page 7
8M 8-10550 Issued 03-2001
42 SECTION 10002
Hitch Load Control Circuit
Test 13 - Load Pin
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position. Disconnect the load pin connector 49 from the harness.
HARNESS SIDE LOAD PIN SIDE
LOAD PIN CONNECTOR 49 DI98N034
CONNECTOR
IDENTIFICATION
Check Point Reading Possible Cause of Bad Reading
Check 1: Between load pin connector 49 See Note Below Bad load pin.
(load pin harness side) pins A and B.
NOTE: Depending on the amplifier installed in the load pin a reading of approximately 203 K Ohms or
a reading of 80 to 90 K Ohms should be obtained at check 1.
Check 2: Between load pin connector 49 approximately Bad load pin .
(load pin harness side) pins A and C. 217 to
263 Ohms
NOTE: Connect the test harness, refer to "TOOLS TO BE MADE" on page 4 between the
potentiometer and right hand console harness.
Check 3: Pin C of the open connector of 8 volts Bad feed circuit between the load pin
the test harness to ground. approximately connector 49 and hitch module connector
J2. Go to checks 9 and 10.
Check 4: Between pins C and A of the 8 volts Bad ground circuit between the load pin
open connector of the test harness. approximately connector 49 and hitch module connector
J2. Go to checks 9 and 10.
NOTE: Readings at checks 3 and 4 may not be of the same value.
Check 5: Between pins C and B of the 3 volts Bad load pin.
open connector of the test harness. approximately
Continued .. ... .
SM 8-10550 Issued 03-2001
SECTION 10002 43
NOTE: Turn the key to the OFF position. Disconnect connector 40 (right hand console harness to
transmission harness) and remove the test harness.
Check Point Reading Possible Cause of Bad Reading
Check 6: Between connector 40 pin 14 and Continuity Check wire 514 Brown between connector
connector 49 pin A for wires 514 Brown. 40 and connector 49 .
Check 7: Between connector 40 pin 12 and Continuity Check wire 514 Red between connector 40
connector 49 pin C for wires 514 Red . and connector 49 .
Check 8: Between connector 40 pin 15 and Continuity Check wire 514 between connector 40 and
the load pin connector 49 pin B for wire 514 the load pin connector 49 .
Light Blue.
NOTE: Connect connector 40. Remove the right hand console side cover and disconnect connector J2
from the hitch controller.
CONNECTOR J2
Check 9: Between connector J2 pin 20 and Continuity Check wire 514 Black between connector
pin A of the load pin for wires 514 Brown. 40 and connector J2.
Check 10: Between connector J2 pin 11 Continuity Check wire 514 Red between connector 40
and pin C of the load pin for wire 514 Red. and connector J2.
Check 11: Between connector J2 pin 33 Continuity Check wire 514 between LlH load pin
and the load pin connector 49 pin B for wire connector 49 and connector J2.
514 Light Blue.
8M 8-10550 Issued 03-2001
44 SECTION 10002
Test 14 - Hitch Load Command Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position. Make sure the hitch load command potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the upper right hand console cover.
NOTE: Disconnect the hitch load command potentiometer from the harness. Turn the key to the ON
position.
HITCH LOAD COMMAND HITCH LOAD pOTENTIOMETER
POTENTIOMETER CONNECTOR
Check point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector (right 8 volts Check wire 505 Red between hitch
hand console harness side) pin A for wire approximately. controller connector J 1 (Black) and the
505 Red to ground. potentiometer connector.
NOTE: Turn the key to the OFF position .
Check 2: Between potentiometer connector 990 to 1100 Bad potentiometer.
(potentiometer harness side) pins A and C. Ohms
NOTE: Turn the hitch load command control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins A and B. Ohms reading with correctly located into the housing and the
no intermittent retaining nut is tight or replace the
readings. potentiometer as necessary.
Continued ....
8M 8-10550 Issued 03-2001
SECTION 10002 45
NOTE: Disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 505 Red between the
pin A and hitch controller connector J2 pin 17 potentiometer connector and the hitch
for wire 505 Red. controller connector J2.
Check 5: Between potentiometer connector Continuity Check wire 505 Light Blue between the
pin B and hitch controller connector J2 pin 4 potentiometer connector and the hitch
for wire 505 Light Blue. controller connector J2 .
Check 6: Between potentiometer connector Continuity Check wire 505 Brown between the
pin C and hitch controller connector J2 pin potentiometer connector and the hitch
31 for wire 505 Brown. controller connector J2.
NOTE: If the readings are correct check the hitch load control circuit, carry out the following :
'Test 13 - Load Pin" on page 42.
NOTE: Check the operation of the hitch controller if the fault remains erase a/l error codes and
calibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
SM 8-10550 Issued 03-2001
46 SECTION 10002
Test 15 - Hitch Travel Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position. Make sure the hitch travel potentiometer body tab is correctly located
into the housing and the retaining nut is tight.
NOTE: Remove the lower right hand console top cover.
NOTE: Disconnect the hitch travel potentiometer from the harness. Turn the key to the ON position.
HITCH TRAVEL POTENTIOMETER POTENTIOMETER ' CONNECTOR 59B
Check Point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59B 8 volts Check wire 506 Red between hitch
(right hand console harness side) pin 4 for approximately. controller connector J2 and the
wire 506 Red to ground . potentiometer connector. Go to check 4.
NOTE: Turn the key to the OFF position .
Check 2: Between potentiometer 990 to 1100 Bad potentiometer.
connector 59B (potentiometer harness Ohms
side) pins 4 and 6.
NOTE: Turn the hitch travel control knob from fully counterclockwise to fully clockwise when carrying
out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
59B (potentiometer harness side) pins 4 Ohms reading with correctly located into the housing and the
and 5. Turn the potentiometer slowly no intermittent retaining nut is tight or replace the
clockwise. readings. potentiometer as necessary.
Continued ....
SM 8-10550 Issued 03-2001
SECTION 10002 47
NOTE: Disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check Point Reading Possible Cayse of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 506 Red between the
pin 4 and hitch controller connector J2 pin potentiometer connector and the hitch
18 for wire 506 Red. controller connector J2.
Check 5: Between potentiometer connector Continuity Check wire 506 Light Blue between the
pin 5 and hitch controller connector J2 pin potentiometer connector and the hitch
13 for wire 506 Light Blue. controller connector J2.
Check 6: Between potentiometer connector Continuity Check wire 506 Brown between the
pin 6 and hitch controller connector J2 pin potentiometer connector and the hitch
25 for wire 506 Brown. controller connector J2.
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
"Test 13 - Load Pin" on page 42.
"Test 14 - Hitch Load Command Potentiometer" on page 44.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
recalibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
8M 8-10550 Issued 03-2001
48 SECTION 10002
Test 16 - Hitch Response Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Turn the key to the OFF position. Make sure the hitch response potentiometer body tab is correctly
located into the housing and the retaining nut is tight.
NOTE: Remove the lower right hand console top cover.
NOTE: Disconnect the hitch response potentiometer from the harness. Turn the key to the ON position.
HITCH TRAVEL POTENTIOMETER POTENTIOMETER' CONNECTOR 59B
Check point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59B 8 volts Check wire 503 Red between hitch
(right hand console harness side) pin 1 for approximately. controller connector J2 and the
wire 503 Red to ground. potentiometer connector. Go to check 4.
NOTE: Turn the key to the OFF position.
Check 2: Between potentiometer connector 990 to 1100 Bad potentiometer.
59B (potentiometer harness side) pins 1 and Ohms
3.
NOTE: Turn the hitch travel control knob from fully counterclockwise to fully clockwise when carrying
out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
59B (potentiometer harness side) pins 1 Ohms reading with correctly located into the housing and the
and 2. Turn the potentiometer slowly no intermittent retaining nut is tight or replace the
clockwise. readings. potentiometer as necessary.
Continued .. ..
8M 8-10550 Issued 03-2001
SECTION 10002 49
NOTE: Disconnect connector J2 from the hitch controller.
CONNECTOR J2
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 503 Red between the
pin 4 and hitch controller connector J2 pin potentiometer connector and the hitch
23 for wire 503 Red . controller connector J2.
Check 5: Between potentiometer connector Continuity Check wire 503 Light Blue between the
pin 2 and hitch controller connector J2 pin 8 potentiometer connector and the hitch
for wire 503 Light Blue. controller connector J2.
Check 6: Between potentiometer connector Continuity Check wire 503 Brown between the
pin 6 and hitch controller connector J2 pin potentiometer connector and the hitch
36 for wire 503 Brown. controller connector J2.
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
'Test 13 - Load Pin" on page 42.
"Test 14 - Hitch Load Command Potentiometer" on page 44.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
recalibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
8M 8-10550 Issued 03-2001
50 SECTION 10002
Test 17 - Wheel Speed Sensor
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 18.
NOTE: Refer to the schematic on Page 54.
NOTE: Turn the key to the OFF position and check fuse 33.
NOTE: If the instrument cluster is reading the wheel speed correctly (m .p .h. or Km/h) go to Check 7.
NOTE: Disconnect the wheel speed sensor from the transmission harness. Turn the key to the ON
position .
Check point Reading Possible Cause of Bad Reading
WHEEL SPEEP SENSOR CONNECTOR CONNECTOR C2
Check 1: Terminal C of the wheel speed 12 Volts Bad circuit between the hitch up/down
sensor connector (transmission harness switch and the wheel speed sensor. Go to
side) for wire 215 Red to ground. check 2.
NOTE: If the reading is correct go to check 3.
NOTE: Turn the key to the OFF position and disconnect connector 40.
Check 2: Between terminal C of the wheel Continuity Check wire 215 Red between the wheel
speed sensor connector (harness side) and speed sensor connector 40.
pin 43 of connector 40.
NOTE: If the reading at check 2 is correct, connect connector 40 and check the operation of the hitch
remote circuit. If the hitch remote switches operate correctly check wire 215 between connector 40
and the right hand console splice. If the remote switches do not operate correctly check the hitch
up/down switch circuit and the hitch enable relay.
NOTE: Turn the key to the OFF position. If not already carried out, disconnect connector 40.
Check 3: Between terminal B of the wheel Continuity Check wire 215 Brown/White between the
speed sensor connector (harness side) for wheel speed sensor connector and the
wire 215 Brown/white to ground. battery negative terminals. Also check the
battery negative terminal connections.
Continued .. ..
8M 8-10550 Issued 03-2001
SECTION 10002 51
NOTE: Disconnect connector 40 and disconnect the instrument cluster from the harness.
Check Point Reading Possible Cause of Bad Reading
Check 4: Between terminal A of the wheel Continuity Check wire 215 Yellow between the wheel
speed sensor connector (harness side) and speed sensor and connector 40.
pin 18 of connector 40 .
NOTE: Connect connector 40 and disconnect the instrument cluster from the harness.
Check 5: Between terminal A of the wheel Continuity Bad circuit between connector 40 and the
speed sensor connector (harness side) the instrument cluster connector C2 . Go to
instrument cluster connector C2 pin A-5 . Check 6.
NOTE: Remove the lower right hand console side cover and disconnect connector 27.
Check 6: Between terminal A of the wheel Continuity Check wire 215 Yellow between the
speed sensor connector (harness side) and connectors 40 and 27 . Also check
pin 7 of connector 27 (right hand console connector 40.
harness side) for wire 215 Yellow.
Check 7: Between pin 7 of connector 27 Continuity Check wire 215 Yellow between connector
(instrument panel harness side) and 27 and the instrument cluster connector
instrument cluster connector C2 pin A-5 for C2.
wire 215 Yellow.
NOTE: If not already carried out, remove the lower right hand console side cover and disconnect
connector 27. Also connector J2 from the hitch controller.
CONNECTOR J2
Check 8: Between pin 7 of connector 27 Continuity Check wire 215 Yellow between the splice
(right hand console harness side) and hitch and the hitch controller connector J2 .
controller connector J2 pin 27 for wire 215
Yellow.
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
"Test 13 - Load Pin " on page 42.
"Test 14 - Hitch Load Command Potentiometer" on page 44.
"Test 15 - Hitch Travel Potentiometer" on page 46.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
calibrate the hitch, refer to "HITCH CALIBRATION" on page 7.
8M 8-10550 Issued 03-2001
52 SECTION 10002
HARNESS LAYOUT, SCHEMATICS AND CONNECTORS
Right Hand Console Harness Components
I
I
I
I
...
...
--- -~-- -- - ......
,
"
(-"
I
I
,-
--- D197N011
1. HITCH UPIDOWN SWITCH AND HITCH ENABLE LAMP 10. DIAGNOSTIC DISPLAY
2. HITCH POSITION CONTROL POTENTIOMETER 11 . HITCH UPPER LIMIT POTENTIOMETER
3. LOAD CONTROL POTENTIOMETER 12. CONNECTOR #G2 (CHASSIS GROUND)
4. CONNECTOR J1 (16 PIN) 13. CONNECTOR #52 (TO REAR FENDER HARNESS)
5. HITCH CONTROL MODULE 14. CONNECTOR J2 (37 PIN)
6. CONNECTOR J3 (9 PIN) 15. CONNECTOR #40 (TO TRANSMISSION HARNESS)
7. HITCH DROP SPEED POTENTIOMETER 16. CONNECTOR #26 (TO INSTRUMENT PANEL HARNESS)
8. HITCH RESPONSE POTENTIOMETER 17. CONNECTOR #27 (TO INSTRUMENT PANEL HARNESS)
9. HITCH TRAVEL POTENTIOMETER 18. HITCH ENABLE RELAY
SM 8-10550 Issued 03-2001
SECTION 10002 53
1. CONNECTOR #40 (TO RIGHT HAND CONSOLE) 6. HITCH POSITION POTENTIOMETER
2. HITCH LOAD SENSING PIN CONNECTOR 7. HITCH LOAD SENSING PIN
3. HITCH LOWER SOLENOID 8. LEFT HAND HITCH REMOTE SWITCHES
4. HITCH RAISE SOLENOID 9. RIGHT HAND HITCH REMOTE SWITCHES
5. HITCH POSITION POTENTIOMETER CONNECTOR 10. CONNECTGR #52 (TO RIGHT HAND CONSOLE)
SM 8-10550 Issued 03-2001
54 SECTION 10002
Hitch Control Schematic Circuit
WHEEL SPEED SENSOR, HITCH SOLENOIDS AND LOAD PIN INSTRUMENT CLUSTER HITCH POSITION POTENTIOMETER AND HITCH UP/DOWN SWITCH REMOTE SWITCHES AND HITCH COMMAND POTENTIOMETERS
BATTERY POWER B+ ------------------------------------
---------------------------------S~TCHEDPOWER:----------------------------------_eT 562LB,755---- - -- - - -- - - - - - - - - - -- - - -- - - - - - - - - - - - - -- - - - - --562lB 75--
~
,.--- ---------- 509LB.7>---_/_---, 509LB. 75 509lB 75- -
TERM } TO AFS CONNECTOR en
:::l 510L8.75 510lB 7 5 - -
"
1 ' - - - -----iC> TERM 4 C!l
508lB 75 508lB.75----
I INSTRUMENT CLUSTER
f
FUNCTION PIN NO,
q "' FUSE
~ ~ HITCH UPOOWN S~TCH C2·B·4 509LB. 7~
#33
II: "' IMPLEMENT UPiOOWNSWITCH C2·B·3 75A
C!l N
~
11
CLEAN GROUND C2·A-a
HITCH POSITION LOAD
WHEEL SPEED SJG NAL C2·A·5 q UP/DOWN
... ": a:o S~TCH
COMMAND
POTENTIOMETER
COMMAND
POTENTIOMETER
1'ti ~
I
75-ti:~~~=====~iFt=-a"
215Y 75
2OOBRIW1 .0
N II>f:l '------505BR.7 5 - -
~ 2OOBRIW1,S-=l--
....I--------- - - 200BRIW.75--- - - - - + - - - d j
509lB
'--------505lB 7 5 - -
'--------- ----505R 7 5 - -
~ ~ SOOR1 0 - - - - - - - - - ' o
a:
~ r-------------------------- 21 SY75
§
504BR75---------------5~BR75 --
~
/;j
"'
I';
r------------ 563 LB.75 4 H f - - - - 563 LB,75 504LB.75 504lB.75--
~ V
r- ~6B~7~5---------------------------------------------------------------------- 508BR7
l 504~75 504R 7 5 - - -
~215Y75 ---+---+--------------------------------------------------------------------------- 215Y75 2l5Y75 - - - - - - - - -- - - - - - - - - - -- - - -- - - - - - 2 l 5 Y 75 - - --
TO DIFFERENTIAL lOCK , . - - - - - -- - -- - - - - - 5l2lB75 5l2lB 75 5l2lB 75 - -
WARNING LIGHT SWITCH , - - - - - - - - - - - - - -- 5l3LB,7 5 513LB 75 5l3LB 75 - -
, . - - -- -- -- - - -- - 5l4BR 75 5l4BR.75 5l4BR75----
511Rl 0------------------, , . - - - - - - - - - -- - - 5l4lB,75 5l4lB75 5l4lB75--
,--- - - - - - - - - 5l4Rl ,0 5l4Rl0 5l4Rl 0 - -
511Rl.0 -_e-- --, ,.-- -- -------- - 507BR.7 5 507BR.75 507BR 75 ----
,.-- -- ----- - 507lB.75 507lB 75 507LB.75 - -
,.--------- 507R,75 507R 75 507R.75 - - -
- - - 528LB.75 528LB 75 528lB.75--
- - 529LB.75 529lB.75 529lB.75- - -
q 511Rl ,
"'
l"-
> RAISE LOWER
~ "'
I'-
ai
in
"'
N SOLENOID
5 ·l 20HMS
SOLENOID
5 ·1 20HMS
-'
'" 215R.75 215R76 ~ 511Rl .0---- -- - - - -- - -- -- - -- -- - - -- - - - - -51 1Rl .0-----
528R.75 SOOR1 .0 500Rl 0 - - - -
' - - - - - -- -- - 512LB1 .0
- - -- - -- - - -- -- - - --513LBl 0
a:~
C!l
~ ~ ~ ~
HITCH
POSITION
r ,529LB.7S----------- -- ----
.
RE~f~f~~CH
lHHITCH[SJ=
528LB.7
~ !~:~~5---_/__I__.1---::~~:
=Jm
R----------------- 529LB.7 R
RH HITCH
REMOTE SWITCH
~::::::~:~~~~=::;:JI----------:~:~~7:~f I
WITH390
POTENIOMETER RESISTORS
;
SEE NOTE 1
A IE-bL----<61"\ L 53 53 L
-------------------2l5R, 75~
B 1E-1-e-~'~
r------------- 528R 75
'--- - --I C IH~-ev
L-_+---I~ J 0--------528~75
1--------628~75 ---------~----------------
43
H IMPLEMENT UPA:>OWN
---------------------------------563LB75 -----------------------------------------~ C I---------------------------------~~~~--------~ SWITCH CONNECTOR
--1-------------r--------i~--------~""""~---------------- CHASSIS GROUND----~»"n"~~~~Z~»~----------------------~»~n~n~n"n"7~----CHA SS I SG ROUND---------------I."n"n"~~Z~n~;-------------------------------;"~~Z~n~n~n~7----------------------.. CHASSISGROUND---;"~~Z~n~n~n"7
- I. .-----------iJ-- -- - - -- -- - -- - - - - -- - -- CLEAN GROUND CLEAN GROUND CLEAN GROUND _ ___
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits . Do not use a test
lamp or damage to the switches may occur.
SM 8-10550 Issued 03-2001
SECTION 10002 55
HITCH ENABLE RELAY HITCH CONTROLLER HITCH CONTROL POTENTIOMETERS
- 562La75--- - - - - - - - -- - - - - - - - - - - - - - - - - - - - -- - - - - - 56 2LB.75- H JI-5 MOMENTARY SWITCH FERRITE RING
HITCH
HITCH RESPONSE
~ .....
-509LB 75 509 LB,75- :-( JI-2 DOWN SWITCH
DAOP
-510LBJ5 51 OLB.75- H Jl-l0 UP SWITCH SPEED
-506LB.75 508LB.7S- H JI-4 ENABLE LAMP r;;s / HITCH
:< 'a' SEGMENT 1 J3-1
I
\
I
BR DIAGNOSTICS
E-< 'b' SEGMENT 2 J3-2 R
lBJ
I I
is:<< 'c' SEGMENT 3
'd' SEGMENT 4
J3-3
J3-4 I I
0
Y
I I
< 'e' SEGMENT 5 J3-5 LG
7 SEGMENT
:< 'I' SEGMENT 6 J3-6 I LB LED DISPLAY
;<E-< 'g' SEGMENT 7
DEC POINT 8
J3-7
J3-6
V
G
_505BR .75 _ __ __ _ _ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 50
5BR ,75-
5< J2-31 HITCH LOAD COMMAND POTENTIOMETER LOW + UDC J3-9
\
I
W
-505L8.75
- - - 505R 75
505LS,7S-
505R75-
K
K
J2-4
J2-17
HITCH LOAD COMMAND SIGNAL
HITCH LOAD COMMAND POTENTIOMETER HIGH
.....
-
- 504BR.75 5048R.75- K J2-6 HITCH POSITION COMMAND POTENTIOMETER LOW
HITCH
-504LS.75 5 04LB.75- K J2-7 HITCH POSITION COMMAND POTENTIOMETER SIGNAL TRAVEL
I
- 504R.75 504 R.75- K J2-1 HITCH POSITION COMMAND POTENTIOMETER HIGH
a: '"
...J
a:
CD tr':'l a:
CD a: ':'l a:
CD
co a:
a: ...J CD
- 215 Y75 - - - - - - - - - - - -- - - -- - - - - - - -- - -- - 215Y75 - K J2-27 WHEEL SPEED SIGNAL
- 512LB 75 SEE NOTE 2 51 2LB.75- K J,.,5 HITCH VALVE LOWER [ ' L
- 513LB 75 SEE NOTE 2 51 3LB.75- K Jl-ll HITCH VALVE RAISE
A
- - 514BR.75 51 4BR.75 - K J2-20 DRAFT SENSOR GROUND
LS
J2-33
-~~~ ~ 4LB75 - K DRAFT SENSOR SIGNAL SR
--~~O ~ 4Rl0- K J2-11 DRAFT SENSOR +6 VOLTS
- 50lBR 75 507BR.75 - K J2-12 HITCH POSITION ROCKS HAFT POTENTIOMETER LOW
J2-2 HITCH POSITION ROCKS HAFT POTENTIOMETER SIGNAL I I' A I
- 507LB75 507LB.75 - K co a:
a: ...J ro a:: CD
...J
a:
CD
- 507R75 507R.75 - ~ J2-34 HITCH POSITION ROCKS HAFT POTENTIOMETER HIGH
HITCH DROP SPEED POTENTIOMETE HIGH J2-16 502R 75
-526LB75 52 6LB7S- K J1-9 REMOTE UP SWITCH
HITCH DROP SPEED POTENTIOMETER SIGNAL J2-3
-529LB.75 529 LB.lS- ~ JI-13 REMOTE DOWN SWITCH
HITCH DROP SPEED POTENTIOMETER LOW J2-35 502BR ,75 - -- - - '
~ J2-24 560R ,75 - -- - - - '
HITCH UPPER LIMIT POTENTIOMETER HIGH
~ HITCH UPPER LIMIT POTENTIOMETER SIGNAL J2-14
560LS.75 __________...1
~ HITCH UPPER LIMIT POTENTIOMETER LOW J2-26 560BA75 - - - - - - - - - '
- S11RlO-- - - - , <
- S O O R 1 0 - - - - + - - - -- - - -- ~
r----+--561LB.7 5 - -- - -- - - 56 lLBJ5- ~ JI-3 RELAY ENABLE
SOOR 75 50 OR ,l 5 - - :-< Jl-14 SWB+
HITCH RESPONSE POTENTIOMETER HIGH J2-23 503RJ5 - - - - - -- - - -- 503A.75
~ HITCH RESPONSE POTENTIOMETER SIGNAL J2-6 503LB.75 - - - - - -- - -- - 503LB 75
< HITCH RESPONSE POTENTIOMETER LOW J2-36 503BRJ5
_ _ _ __ __ _ _ __ 503BR.75
,------------511 Rl JI-7 PWM DIODE CLAMP
HITCH ENABLE HITCH TRAVEL POTENTIOMETER HIGH J2-16 )..:: 1 - -506R75 - - - - - -- -- - 506A.75-- - - - '
RELAY "1 K HITCH TRAVEL POTENTIOMETER SIGNAL J2-13 506LB.75 · - -- - - - - - - - - 506LB75 - -- - - '
SEE NOTE 3 AND ~ 560B RIWI ()- K Jl-l CLEAN GROUND
HITCH TRAVEL POTENTIOMETER LOW J2-25 506BR75 - - - - - - - - - - - 5 0 6 B R.75 - -- - - - - '
IMPORTANT
I~ ~ ~
HITCH CONTROLLER
q
'----- - - - 51 1A1 0------1--' ~
CBRI . g
CD
---------CHASSISGROUND ---G.~~--------~~~~~7.~»~»."»~----------i----------------------)"»"»~~~~~w~------------------------~»."»~~~~~z~»~-----CHASSISGROUND----------------~)~»"»."»."»"w~----------------------------)"~"~"~"Z~»."I-----------------CHASSISGROUND -------------------------
--------CLEAN GROUND - CLEAN GROUND CLEAN GROUND - - - - - - - - - - - - -
DlOOG043
SM 8-10550 Issued 03-2001
56 SECTION 10002
Schematic Symbols
ACTUATORS
T LEVER
T HAND
..l
FOOT
~
TEMPERATURE
6
LIQUID LEVEL FLOAT
9
PRESSURE
~
COIL
-k1-
DIODE
CONTACTS
-+~
VARIABLE RESISTOR
~
RESISTOR
cru
MAGNETIC
....
0
MOMENTARY
MAINTAINED
HOUSINGS
® ® @ @ ®
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LIGHT
SWITCH CONTACT CONFIGURATION
~
/0 ~O ~ ~0
o
S.P.S.T. S.P.D.T. D.P.S.T D.P.D.T
(SINGLE POLE SINGLE (SINGLE POLE DOUBLE (DOUBLE POLE SINGLE (DOUBLE POLE DOUBLE
THROW) THROW) THROW) THROW)
MISCELLANEOUS SYMBOLS
O\y 00
FUSE CIRCUIT BREAKER
NOTE: Schematic symbols shown with tractor parked and power OFF.
SM 8-10550 Issued 03-2001
SECT/ON 10002 57
Schematic Legend
123 Y 1.0--- --- CIRCUIT TAG IF REQUIRED
NUMB~ 1
CIRCUIT
CONNECTOR TERMINAL
COLOUR
'" WIRE SIZE mm 2
"'..~(I
00
CONNECTOR TYPE
INDICATES INLINE CONNECTION WITH
TERMINALS
--------~()~-------- INDICATES CIRCUIT CONNECTION
INDICATES CIRCUIT CROSSING NOT
CONNECTED
INTERNAL INDICATES CHASSIS GROUND CONNECTIONS
GROUND
Wire Colour Code
R .................. .............................................. ............... RED
T ......... .. .......... .... ... ......... .. ......... ... ... .. .. ... .... ..... .... .. .... . TAN
W ... ....................... .. .......... .............. .......... .. ......... .. WHITE
Y ...... .. .......... ..... ............ .. .... ......... ... ................... YELLOW
B ................... ............................ .. .............. ............ BLACK
G ........ ..... ....... ..... ....... .. ... ............. ................... ..... .. GREY
o ....................................................................... ORANGE
P .................. ..... .......... .... .......... ... ............. ... .. ....... .... PINK
V .... .. .......... .... .......... ... ....... ....... ...... .. .. VIOLET (PURPLE)
BR .. ... ....... .. .. ..... ........................ ..... ......... ... .. ...... BROWN
DB ..... .. ....... .... .............................. ............... . DARK BLUE
DG ..... .............. ............. .. ........... .. ... .......... . DARK GREEN
LB .. .. ....... ... .. ........ .. ..... ....... ............ ... .. ........ LIGHT BLUE
LG ... ............ ..... ...... .... ................. ............ . LIGHT GREEN
SM 8-10550 Issued 03-2001
58 SECTION 10002
Main Connectors Connector 26
Location: Right Hand Console
Connector 10
Location: Cab Firewall
J
o -
f- I-- f-- r-
~ F F=
'--- -
478196
ENGINE TO INSTRUMENT PANEL HARNESS
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire Circuit
Cavity Wire Circuit
No
No
A 8020 AlC HIGH PRESSURE SWITCH
A 542 LB MFD INDICATOR LIGHT
B 624 W B+ FROM STARTER
B 707 P LH TAIUPOSITION LIGHT
C 8040 AlC HIGH PRESSURE SWITCH
C 708 P RH TAIUPOSITION LIGHT
D 162 R UNSWITCHED B+ (CLOCK)
D 500 R HITCH B+
E 200 INSTRUMENT CLUSTER CLEAN
E 624 W NEUTRAL START
BR/W GROUND (BATTERY - TERMINAL)
F 735 LB DIFF LOCK INDICATOR LIGHT
F 8030 AlC COMPRESSOR CLUTCH
G ........ .. - OPEN
G 784 V REAR FENDER WORK LIGHTS
H 810 R SEAT B+
H 551 LB FRONT PTO
J 530 R MFD AND DIFF LOCK B+
J 231Y COOLANT LEVEL
K 134 R AUXILIARY POWER CONNECTOR
K 216 Y ALTERNATOR 'W' TERMINAL,
SWITCHED B+
ENGINE RPM
L 757 P RH TURN SIGNAL
L 235 Y ENGINE COOLANT TEMPERATURE
M 756 P LH TURN SIGNAL
M 255 Y ENGINE OIL PRESSURE SWITCH
N 539 LB BRAKE RELAY (EITHER)
N 266 Y AIR FILTER RESTRICTION SWITCH
P 133 R AUXILIARY POWER
P 121 Y ALTERNATOR D+ TERMINAL,
FENDER HARNESS CONNECTOR
WARNING LIGHT AND EXCITE
(EUR)
R ...... - .. OPEN 7 PIN CONNECTOR (NAO)
S 890 R HORN FEED R 135 R RH CONSOLE AUXILIARY POWER
T 890 BR HORN GROUND UNSWITCHED B+
U - - .. -- OPEN S 817 R CIGAR LIGHTER
V 738 P RH HEADLIGHT (LOW BEAM) T 269Y PARK BRAKE WARNING LIGHT
W 741 P RH HEADLIGHT (HIGH BEAM) U 702 P BRAKE LIGHT (EUR)
AA _ .. .. -- OPEN V 545 LB BRAKE RELAY (BOTH)
BB 737 P LH HEADLIGHT (LOW BEAM) W 785 R REAR FOG LIGHTS (EUR)
CC 740 P LH HEADLIGHT (HIGH BEAM) X 622 W NEUTRAL START SWITCH
DD 606W FUEL SHUT-OFF Y 296Y 1000 RPM PTO SWITCH
EE 280 BR GROUND SPEED RADAR GROUND Z 509 LB HITCH DOWN SWITCH
FF 281 Y GROUND SPEED RADAR SIGNAL
GG 280 R GROUND SPEED RADAR B+
HH 282Y GROUND SPEED RADAR PRESENT
1 641 W ETHER START/THERMOSTART
2 ... -- - - OPEN
3 784 V WORK LIGHTS (FROM JJE1013119)
4 -....... - OPEN
SM 8-10550 Issued 03-2001
SECTION 10002 59
Connector 27 Connector 29
Location: Right Hand Console Location: Right Hand Console
W
OD
IL
OD
OD
OD
480196 482196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 240Y AIR TRAILER BRAKE PRESSURE A 8350 FRONT WINDSCREEN WASHER
SWITCH
B 8450 REAR WINDSHIELD WASHER
2 151 R LOADER CONTROLS B+ 550 R FRONT PTO B+
C
3 562 T CLUTCH PEDAL SWITCH FRONT PTO CLUTCH
D 551 R
4 563 LB IMPLEMENT DOWN SWITCH
E 279 R PARK BRAKE ALARM
5 ...... - - .. OPEN F .. . . ..... . . OPEN
6 233 Y FUEL LEVEL SENDER ROTARY BEACON LIGHT
G 776R
7 215 Y WHEEL SPEED SENSOR ROTARY BEACON LIGHT
H 775 R
8 .. - ...... OPEN
9 .. .......... OPEN
10 .. .. ........ OPEN
11 ..... .... .. OPEN
12 550 R POWERSHIFT RELAY B+
SM 8-10550 Issued 03-2001
60 SECTION 10002
Connector 30 Connector 31
Location: Instrument Cluster Location: Instrument Cluster
= DO iIS5
DO
DO DO
DO DO
DO DO
DO DO
DO DO
DO DO
DO 00
DO DO
DO 00
DO DO
DO DO
Si:I! Iii8
483196 483195
INSTRUMENT CLUSTER CONNECTOR C1 INSTRUMENT CLUSTER CONNECTOR C2
Cavity Wire Circuit Cavity Wire Circuit
No No
A1 770P 2ND TRAILER TURN SIGNAL A1 ...... ......... OPEN
A2 200 R SWITCHED POWER B+ A2 280 BR GROUND SPEED RADAR GROUND
A3 280 R GROUND SPEED RADAR B+ OUT A3 ...... ......... OPEN
A4 .............. OPEN A4 216 Y ALTERNATOR 'W' TERMINAL,
769 P 1ST TRAILER TURN SIGNAL ENGINE RPM
A5
A6 735 LB DIFF LOCK WARNING LIGHT A5 215 Y WHEEL SPEED SIGNAL
750 BR TURN SIGNAL COMMON A6 266Y AIR FILTER RESTRICTION
A7
...... . . ...... OPEN A7 121 Y ALTERNATOR D+ TERMINAL,
A8
WARNING LIGHT AND EXCITE
A9 202 R UNSWITCHED B+ (CLOCK)
A8 200 CLEAN GROUND
A10 754 P RH TURN SIGNAL WARNING LIGHT BR/W
A11 542 LB MFD A9 723 P HIGH BEAM WARNING LIGHT
A12 ............. OPEN A10 GROUND SPEED RADAR SIGNAL
281 Y
B1 240Y AIR TRAILER BRAKE PRESSURE A11 255 Y ENGINE OIL PRESSURE
B2 -- ... -- OPEN A12 ............... OPEN
B3 201 R ACCESSORY POWER B+ B1 726 P BACK LIGHTING
B4 235 Y ENGINE COOLANT TEMPERATURE B2 282Y GROUNDSPEED RADAR PRESENT
B5 269Y PARK BRAKE WARNING LIGHT B3 563 LB TRAILED IMPLEMENT SWITCH
B6 ...... ...... - OPEN B4 509 LB HITCH IMPLEMENT SWITCH
B7 784 V LOWER WORK LIGHT WARNING B5 ...... ... ...... OPEN
B8 231Y COOLANT LEVEL B6 ...... ... ... ... OPEN
B9 ... - ........ OPEN ... ............
B7 OPEN
B10 276Y 1000 PTO WARNING LIGHT B8 ............... OPEN
B11 233 Y FUEL LEVEL B9 ............... OPEN
B12 755 P LH TURN SIGNAL WARNING LIGHT B10 - ............. OPEN
B11 ......- ....... OPEN
B12 ... _. . . . - OPEN
SM 8-10550 Issued 03-2001
SECTION 10002 61
Connector 40
Location: Cab Floor (Right Hand Console)
DI99A036
RIGHT HAND CONSOLE TO TRANSMISSION HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 543 LB MFD SOLENOID B+ 25 .. .. .. -- OPEN
2 233 Y FUEL LEVEL SENDER 26 .......... OPEN
3 507 R +8 V POSITION POTENTIOMETER 27 530 T TRAILER BRAKE SOLENOID
4 507 LB POSITION SIGNAL 28 .......... - OPEN
5 705 BR POSITION POTENTIOMETER LOW 29 ....... .. .. OPEN
6 .......... OPEN 30 .. .... _... OPEN
7 560 CLEAN GROUND HITCH CONTROL 31 240 Y TRAILER BRAKE PRESSURE
BRIW SWITCH
8 269 Y PARK BRAKE WARNING LIGHT 32 ............ OPEN
9 532 LB DIFF LOCK SOLENOID B+ 33 .......... OPEN
10 511 R HITCH SOLENOID B+ 34 624W PTO NEUTRAL START SWITCH OUT
11 513 LB HITCH RAISE SOLENOID 35 622W PTO NEUTRAL START SWITCH IN
12 514 R HITCH PIN +8V 36 563 T REVERSE POSITION SWITCH B+
13 ............ OPEN 37 563 T REVERSE POSITION SWITCH
SIGNAL
14 514 BR HITCH PIN LOW
514 LB HITCH PIN SIGNAL 38 735 LB DIFF LOCK WARNING LIGHT
15
16 .. - .. .. - OPEN
39 516T LOADER SOLENOID IN
40 515 T LOADER SOLENOID OUT
17 512 LB HITCH LOWER SOLENOID
GROUND 41 279 BR PARK BRAKE ALARM
18 215 Y WHEEL SPEED SIGNAL 42 ............ OPEN
19 .. .. - -- OPEN 43 215 R AXLE SPEED B+ (FROM
.......... JJE1015311)
20 OPEN
........... 44 ............ OPEN
21 OPEN
45 .. .......... OPEN
22 580 T POWERSHIFT SOLENOID
46 .... .. .... OPEN
23 .... - ..... OPEN
...... .... 47 ........... OPEN
24 OPEN
48 ...... .... OPEN
SM 8-10550 Issued 03-2001
62 SECTION 10002
Connector 52 Connector 59A
Location: Cab Floor (Rear Right Hand Console) Location: Right Hand Console
• .'.
6{ " 1
5i -'
• i
\
, -'
.7<
• 2
4j
• i
• '3
0 199A070
RIGHT HAND CONSOLE HARNESS TO
DI99A035 HITCH DROP SPEED AND UPPER HEIGHT POTENTIOMETERS
RIGHT HAND CONSOLE TO FENDER HARNESS Cavity Wire Circuit
No
Cavity Wire Circuit 1 502 R HITCH DROP SPEED
No POTENTIOMETER HIGH
A 756 P LH TURN SIGNAL 2 502 LB HITCH DROP SPEED
POTENTIOMETER SIGNAL
B 757 P RH TURN SIGNAL
3 502 BR HITCH DROP SPEED
C 563 LB IMPLEMENT DOWN SWITCH
POTENTIOMETER LOW
D 707 P LH TAIUPOSITION LIGHT
4 560 R HITCH UPPER HEIGHT
E 708 P LH TAIUPOSITION LIGHT POTENTIOMETER HIGH
F 785 V REAR FOG LIGHT (EUR) 5 560 LB HITCH UPPER HEIGHT
G 702 P BRAKE LIGHTS POTENTIOMETER SIGNAL
H 528 R HITCH REMOTE SWITCH B+ 6 560 BR HITCH UPPER HEIGHT
POTENTIOMETER LOW
J 528 LB HITCH RAISE
K 529 LB HITCH LOWER
Connector 59B
L 8350 FRONT WINDSCREEN WASHER
Location: Right Hand Console
M 8450 REAR WINDSCREEN WASHER
N 776 P ROTARY BEACON LIGHT (EUR)
1 133 R AUXILIARY POWER SWITCHED B+
2 784 P REAR FENDER WORK LIGHTS 6( • :. • ; 1
,
,
5( . )
, -'
\
,
• :2
'J ;,/
4l • , \
• ~3
DI99A070
RIGHT HAND CONSOLE HARNESS TO
HITCH TRAVEL POTENTIOMETER
Cavity Wire Circuit
No
1 503 R HITCH RESPONSE
POTENTIOMETER HIGH
2 503 LB HITCH RESPONSE
POTENTIOMETER SIGNAL
3 503 BR HITCH RESPONSE
POTENTIOMETER LOW
4 506 R HITCH TRAVEL POTENTIOMETER
HIGH
5 506 LB HITCH TRAVEL POTENTIOMETER
SIGNAL
6 506 BR HITCH TRAVEL POTENTIOMETER
LOW
SM 8-10550 Issued 03-2001
SECTION 10002 63
Connector 66 (J1, 16 Pin)
Location: Right Hand Console
D197J184
RIGHT HAND CONSOLE HARNESS
TO HITCH CONTROL MODULE
Cavity Wire No Circuit
1 560 BR/W CLEAN GROUND
2 509 LB DOWN SWITCH
3 561 LB RELAY ENABLE
4 508 LB HITCH ENABLE LIGHT
5 562 LB MOMENTARY SWITCH
6 ----- OPEN
7 511 R PWM DIODE CLAMP
8 ............. OPEN
9 528 LB REMOTE UP SWITCH
10 510 LB UP SWITCH
11 513 LB HITCH VALVE RAISE
OR
513 BR
12 ... - ...... OPEN
13 529 LB REMOTE DOWN SWITCH
14 500 R SWITCHED POWER B+
15 512 LB HITCH VALVE LOWER
OR
512 BR
16 ............. OPEN
SM 8-10550 Issued 03-2001
64 SECTION 10002
Connector 67 (J2, 37 Pin)
Location: Right Hand Console
DI97K094
RIGHT HAND CONSOLE HARNESS
TO HITCH CONTROL MODULE
Cavity Wire Circuit Cavity Wire Circuit
No No
1 504 R POSITION COMMAND HIGH 19 - - - .. - OPEN
2 507 LB HITCH POSITION SIGNAL 20 514 BR DRAFT SENSOR GROUND
(ROCKS HAFT) -- - ....
21 OPEN
3 502 LB DROP SPEED SIGNAL
22 ---- ~ OPEN
4 505 LB LOAD COMMAND SIGNAL
23 503 R RESPONSE HIGH
5 ----- OPEN
24 560 R UPPER LIMIT HIGH
6 504 BR POSITION COMMAND LOW
25 506 BR TRAVEL LOW
7 504 LB POSITION COMMAND SIGNAL
26 560 BR UPPER LIMIT LOW
8 503 LB RESPONSE SIGNAL
27 215 Y WHEEL SPEED
9 -- - - - OPEN .. -- --
28 OPEN
10 - .. - - - OPEN - - ..... -
29 OPEN
11 514 R DRAFT SENSOR +8V
30 - - .. -- OPEN
12 507 BR HITCH POSITION LOW
31 505 BR LOAD COMMAND LOW
(ROCKS HAFT)
13 506 LB TRAVEL SIGNAL
32 ----- OPEN
33 514 LB DRAFT SENSOR SIGNAL
14 560 LB UPPER LIMIT SIGNAL
34 507 R HITCH POSITION HIGH
15 - ... . p ..
OPEN
(ROCKS HAFT)
16 502 R DROP SPEED HIGH
35 502BR DROP SPEED LOW
17 505 R LOAD COMMAND HIGH
36 503 BR RESPONSE LOW
18 506 R TRAVEL HIGH
37 .. ---- OPEN
SM 8-10550 Issued 03-2001
SECTION 10002 65
Connector 68 (J3, 9 Pin)
Location: Cab Floor (Rear Right Hand Console)
DI99A035
RIGHT HAND CONSOLE TO FENDER HARNESS
Cavity Wire Circuit
No
1 BR DISPLAY SEGMENT '1 "
2 R DISPLAY SEGMENT '2"
3 0 DISPLAY SEGMENT '3"
4 Y DISPLAY SEGMENT '4"
5 LG DISPLAY SEGMENT '5"
6 LB DISPLAY SEGMENT '6"
7 V DISPLAY SEGMENT '7"
8 G DISPLAY SEGMENT '8"
9 W + VDC"
SM 8-10550 Issued 03-2001
Section
10002
HITCH/MFD/DIFFERENTIAL LOCK
CONTROLLER
Calibration, Error Codes,
Troubleshooting and Schematics
CX Series Tractors
(Equ ipped With Ride Control)
~ © 2001 McCormick Tractors International Limited .
McCORMICK 8M 8-10560 March 2001
2 SECTION 10002
TABLE OF CONTENTS
SPECIAL TOOLS ........ .......... .. .... ............ ............ .. ............................ .... .... ... .. ..... ... ...... ... ... ... ......... ... .......... ............. 4
TOOLS TO BE MADE .................... ....... ... ...... ... .. ....... ...... ................................. ................. .................................. .... 4
DELUXE HITCH CALIBRATION .......................................................................................... .............. ..... ......... ... ..... 5
Tire Size Calibration and Ride Control Enabling/Disabling .................................................................................. 8
GENERAL INFORMATION FOR HITCH ERROR CODES
Normal Operation ................... .... .......... .. .............................. ............. ... .......... .... ............ .. .................................... 9
No Error Codes Displayed But Hitch Is Not Working Correctly ........ .. ............ .. ............ .. ............................ .......... 9
Controller LED .............................................. ............ .... ....... ... ............................... .. ............................... .... ........ . 9
Failure Modes ......... ..... .. ... ....... .. ................... ... ............. ..... ......................................................................... .. ....... 9
General Notes ........ ..... ............ .. ............. .. .......... ..... .... .. ....... ....................................................................... .. ..... 10
Error Codes That Disable Hitch Motion .............. ......... ...... .. ... ................ ........ .. ............ .... ........ ... .... ........... .. ..... 10
Other Possible Error Indications ........................................ ... ....... .... .. ............. .. .......... ...... .......... ...... .......... ..... .. 10
Error Codes That Allow Hitch Operation .. ........... ............................................................................................... 11
Failures That Are Checked Once ......... .... ........... ...... ........ .... ............................. ............. ....... ................... .... ..... 11
Double Failures Involving The UP/DOWN Switch .............................................. ............ .. ........ ...... ........ ........... 11
CALIBRATION ERROR CODE CHART .... .. ...................... .. ... ..... ......... ... ....... .. ... .... ... ....... .... ................................ . 12
READING AND ERASING ERROR CODES ......................................................................................................... 14
HITCH SYSTEM PERFORMANCE CODE CHART ................... ........................... ... ........................... ............. ...... 15
CIRCUIT TESTING
General Information ............... ............................................................................................................................ 19
Hitch Operating Circuit
Test 1 - No Power to Controller (Power and Clean Ground) ...... ................................................................... 20
Test 2 - Circuit Shorted to Ground .... .... ........................ ............................................................................. .... 21
Test 3 - Hitch Up/Down Switch and Hitch Enable Lamp .............. ................. ............ .................................... 23
Test 4 - Hitch Up/Down Switch Circuit ............ ..... .......... ..... ........................... ................ ................................ 25
Test 5 - Hitch Solenoids Circuit .................................................................................... ............ .... .......... .. ..... 27
Test 6 - R/H Hitch Remote Switch ................................................................................................................. 29
Test 7 - LlH Hitch Remote Switch ............................................ .... ......................... ........ ........... ...... ............... 31
Hitch Position Control Circuit
Test 8 - Hitch Position Potentiometer ............................................................................................................ 33
Test 9 - Hitch Position Command Potentiometer .................................................. ........................................ 36
Test 10 - Hitch Drop Speed Potentiometer ..................... .. ......................... .................................................... 38
Test 11 - Hitch Upper Height Potentiometer .................. ... ........... .. ....... .......... ......................................... ...... 40
Hitch Load Control Circuit
Test 12 - Load Pin ............... .... ........... .... ....................................................................................................... 42
Test 13 - Hitch Load Command Potentiometer ............................................................................................. 44
Test 14 - Hitch Travel Potentiometer .... ......... ..... .... ..... .... ............. .. ................. .. ..... ...... ........ .... .............. ....... 46
Test 15 - Wheel Speed Sensor .. .. ..................... .................. ... ..................... ..... .... ..... ............... .. ...... ..... ........ 48
Slip Limit Control Circuit
Test 16 - Slip Control Switch ............ .............................................................. .. ....... ..... .......................... .. ..... 50
Test 17 - Slip Control Switch Circuit .... .. ........... ........... .......... ...... .................................... ....... ....................... 51
Test 18 - Radar .......... ... .. ... .... .. ..... ... ......... .. ........ .... .... ..... .............. ..... ..... ................. .. ................................... 52
Ride Control Circuit
Test 19 - Ride Control Switch ........................................ ... ............ .... ..... .. ... .... ............... .. ......... .............. ... .... 55
Differential Lock Circuit
Test 20 - Differential Lock Solenoid ............................................................................................................... 57
Test 21 - Differential Lock Switch, Auto Differential and Auto Indicator Lamp ....... ................ .. ............ .... ..... 59
Test 22 - Differential Lock Warning Lamp and Switch .................... ......... ................ .... ...... ............................ 61
MFD Circuit
8M 8-10560 Issued 03-2001
SECTION 10002 3
Test 23 - MFD Solenoid ......... .............. .... .. ....... ................................. ... .. ......... ... ......... .. ............................... . 62
Test 24 - MFD Switch and Auto MFD Circuit .... .. .. ...... ........ ... .......... ..... ..... ... ..... .. ........... .... ...... ..... .... .. .. ........ 64
Test 25 - MFD Relay Circuit .... .. .... ... ..... .. ..... .. ............ .. ... .. ..... ..... .. ..... .. ........ ....... ..... .................. ....... ... ..... .. ... 65
Test 26 - MFD Indicator Lamp .... .. .. .. ... .. .......... .. ....... ... ........ .. ........................... ....... ................... .. ......... ........ 67
Brake Switches
Test 27 .. ..... ... ................... ................ ... .... ........ ...... .... ......... .. ..... ........ ........... .... ... .... ........ .... ........................ ... 68
HARNESS LAYOUT, SCHEMATICS AND CONNECTORS
Instrument Panel Components ... .. ........................... .. .............................................................. .......... ..... ............ 71
Right Hand Console Harness Components ......... ................. ... .. ....... ..... ... ...... ... ... .... .. ... ....... .... ... .. ............ ... .... . 72
Transmission Harness and Fender Harness Components ...... ................. .............................. ......... .. .. .. ....... ..... 73
Hitch Control Schematic Circuit ... .... .......... .. ... ......... ... ............ .... ... .. ........... ......... ................ ... ............................ 74
Differential Lock and MFD Schematic Circuit ......... .................. .. ... .......... .. .. ... ............ ..... ........... .............. ......... . 76
Schematic Symbols .. ............. ........... .. .. ... .... ... .... ............. .. .... ...... .. ... ....... ......... ... ..... .. .. .. ... ....... .... ... .. ... .... .. ... 78
Schematic Legend ...................... ........... ................ .. ............ .................. .......... ............... ..... ......... .... ........... .. 79
Wire Colour Code ... ... ........................... ... ............. ......... .. .. .... .. ......... .... .. ... .... .... ......... ...... .... .......... .. ............. 79
Main Connectors ...... ... .. ...... .. .. ... .... .... ..... ... ....... .. ...... ... .... ... ........ ... ......... .... ....... ............... .. ..... .... ............. ... .. 80
TIRE RADIUS CONSTANT TABLE ... ... .. .. ... ... ........ ....... ..... ....... ..... .. .. ........ .......... ...... ..... ... ..... .. ... ........ .. ...... .. .. ...... 88
8M 8-10560 Issued 03-2001
4 SECTION 10002
SPECIAL TOOLS
DD98H120 DD99A051
MC2616 MULTIMETER KIT includes: MC2656 TEST PROBE KIT
MC2616-1 MULTIMETER ONLY
MC2616-2 TEST LEADS
MC2616-3 TEMPERATURE PROBE
DD97E383
MC31000A HARNESS REPAIR KIT
TOOLS TO BE MADE
353870A1
B A B A
C C
LOAD PIN AND POTENTIOMETER TEST HARNESS (VIEWED FROM WIRE INSERTION SIDE
PARTS REQUIRED
1. HARNESS (PI N 353870A1) 1 OFF 4. MC3 11 05 PI NIWI RE 3 OFF (FROM MC 31000-2)
2. CONNECTOR BLOCK (PIN 225 29 4C! ) 1 OFF 5 . MC31011 SPLICE 3 OFF (F ROM MC3 1000-2)
3. WEDGE (PI N 225297C1) OR EQUIVALENT
• Install wires MC31105 into connector block 225294C1 and secure with wedge 225297C1.
• Splice wires MC311 05 from connector 225294C 1 into the harness 353870A 1 approximately 10 cm from one
of the connectors. Make sure the wires from connector 225294C 1splice into harness 353870A 1 as follows :
Pin A of 225294C1 into wire 485A.
Pin B of 225294C1 into wire 485B
Pin C splices into the Brown wire.
SM 8-10560 Issued 03-2001
SECTION 10002 5
DELUXE HITCH CALIBRATION
Before starting the calibration procedure make sure:
1. 91 kg of weight is mounted on the lift arms.
2. Transmission oil temperature must be above
38 °C.
3. Remove the Auto Hitch lift rods (if equipped).
IMPORTANT: If an unexpected code appears on
the diagnostic display during any Step of
calibration there is an error in the electronic
hitch system. Error codes must be identified
and corrected before hitch calibration can
proceed. Refer to CALIBRATION ERROR CODE
CHART on page 12.
YES and NO are signaled by using the hitch up/down DROOH076
switch (5) as follows:
YES = Push hitch up/down switch into the DOWN
MOMENTARY position and release.
NO = Push hitch up/down switch into the UP position
then back to the DOWN (centre) position.
NOTE: The DOWN MOMENTARY position is
below the centre position and spring loaded to
return to the centre position when released.
DOWN and UP positions are detented.
The calibration procedure may be exited at any
time by toggling the hitch up/down switch UP
then DOWN except when answering a YES or DROOH077
NO question. 5. HITCH UP/DOWN SWITCH
AND HITCH ENABLE LAMP
6 . POSITION COMMAND KNOB
7. OUTER LOCKING RING
8. LOAD CONTROL
9 . SLIP CONTROL SWITCH (IF EQUIPPED)
10 . RIDE CONTROL SWITCH
STEP 1
NOTE: Push and hold the hitch up/down switch (5) in
the DOWN MOMENTARY position while starting the
engine. Release the hitch up/down switch when the
first character after the 8 appears in the diagnostic
display (1) of the hitch control panel. If the hitch up/
down switch is NOT released, the calibration
DP98G261
sequence will terminate.
1 . DIAGNOSTIC DISPLAY
2. UPPER LIMIT CONTROL
WARNING: Never operate the engine in a
A
3. TRAVEL CONTROL
4. HITCH DROP SPEED closed building. Proper ventilation is required
• under all circumstances. SM1 aaA
SM 8-10560 Issued 03-2001
6 SECTION 10002
STEP 2 STEP 9
The diagnostic display will read C, do you want to The diagnostic display will read 1, representing
calibrate the hitch or read error codes? current model code.
Answer YES to calibrate the hitch and continue to To select the correct model code answer YES until
STEP 3 or NO to display error codes, refer to the correct model code is shown in the diagnostic
Page 14. display. Enter and store the model code by answering
NO.
STEP 3 TRACTOR TYPE MODEL CODE
The diagnostic display will read c , do you want to No Booster Cylinders 1
continue calibration or enter tire size?
One Booster Cylinder 2
Answer YES to calibrate the hitch.
Answer NO to enter the tire size and enable ride Two Booster Cylinders 3
control Refer to "Tire Size Calibration and Ride
Control Enabling/Disabling" on page 8. STEP 10
The diagnostic display will read c, was the correct
STEP 4 model code selected?
The diagnostic display MAY read 9 if two load Answer YES for correct model code or NO to repeat
sensing hitch pins have not been detected. Does the STEP 9.
system have two load sensing hitch pins?
Answer NO and continue to STEP 5. STEP 11
If the diagnostic display DOES NOT read g, the The diagnostic MAY display F.
system will automatically continue to STEP 5.
Answer NO.
STEP 5 If the diagnostic display DOES NOT read F, the
system will automatically continue to STEP 12.
The diagnostic display will read II , does the tractor
have a true ground speed sensor (radar)?
STEP 12
Answer YES and continue to STEP 6.
The diagnostic display will read 2 , is the tractor
Answer NO and continue to STEP 7. European or North American?
Answer YES for North American tractors. Answer NO
STEP 6 for European tractors.
The diagnostic display will read 3, does the tractor
have a wheel slip limit control? STEP 13
Answer YES or NO. The diagnostic display will read d , do you want to
enter tire size?
STEP 7 Answer YES and continue to STEP 14.
The diagnostic display will read 4, does the tractor Answer NO to exit.
have a MFD?
Answer YES or NO. STEP 14
The diagnostic display will read 0, representing the
STEP 8 first digit of the Tire Code. Refer to the TIRE RADIUS
The diagnostic display will read 7 , do you want to CONSTANT TABLE on page 88 and select the
enter tractor model code? correct code for the rear tires installed on the tractor.
Answer YES and continue to STEP 9. NOTE: Tire Codes must a/ways be entered as
four digit numbers. If the Tire Code is less than
Answer NO to exit.
1000, use a zero (0) as the first digit.
To select the first digit of the tire code answer YES
until the correct digit is shown in the diagnostic
display. Enter the digit by answering NO.
8M 8-10560 Issued 03-2001
SECTION 10002 7
STEP 15 STEP 20
The diagnostic display will read 0, representing the The diagnostic display will read 6. Turn the outer
second digit of the Tire Code. locking ring (7) on the Position Command Knob to
position 5. Turn the Position Command Knob (6) fully
To select the second digit of the tire code answer
clockwise to the hitch raised position (by-passing the
YES until the correct digit is shown in the diagnostic
locking ring).
display. Enter the digit by answering NO.
IMPORTANT: DO NOT move the Position
STEP 16 Command Knob fully clockwise to the Transport
Position.
The diagnostic display will read 0, representing the Answer YES.
third digit of the Tire Code.
The hitch will begin calibrating. It may take several
To select the third digit of the tire code answer YES minutes before the hitch raises.
until the correct digit is shown in the diagnostic NOTE: If for any reason calibration must be
display. Enter the digit by answering NO. stopped at this point, place the hitch up/down
switch in the UP position. The digital display will
STEP 17 read 0 USER QUIT. If other codes appear on
The diagnostic display will read 0, representing the the display indicating errors, refer to
fourth digit of the Tire Code. CALIBRATION ERROR CODE CHART on page
12 or HITCH SYSTEM PERFORMANCE CODE
To select the fourth digit of the tire code answer YES CHART on page 15.
until the correct digit is shown in the diagnostic
display. Enter the digit by answering NO. STEP 21
The diagnostic display will repeat in sequence the When the hitch is fully raised the diagnostic display
four digit tire code entered in STEP 14 to STEP 17. will read 9. Turn the Position Command Knob (6) fully
counterclockwise to the hitch lowered position (by-
STEP 18 passing the locking ring).
The diagnostic display will read c, was your Tire Code Answer YES.
correct? The hitch will immediately lower for one second after
Answer YES and continue to STEP 19. which the hitch will begin calibrating. It may take
several minutes before the hitch lowers.
Answer NO to repeat STEP 14.
NOTE: If for any reason calibration must be
stopped at this point, place the hitch up/down
STEP 19 switch in the UP position. The digital display will
NOTE: During calibration, whenever current is read 0 USER QUIT. If other codes appear on
sent to a coil the dot on the digital display will the display indicating errors, refer to
flash. CALIBRATION ERROR CODE CHART on page
12 or HITCH SYSTEM PERFORMANCE CODE
The diagnostic display will read 8, do you want to CHART on page 15.
lower the hitch?
Answer YES holding the hitch UP/DOWN switch STEP 22
down in the DOWN MOMENTARY position until the When the hitch is lowered the diagnostic display will
hitch is fully lowered. read U, is the hitch fully lowered?
IMPORTANT: The hitch will continue to lower IMPORTANT: DO NOT answer YES until al/
while the hitch up/down switch is held in the hitch movement has stopped and the hitch is
DOWN MOMENTARY position. fully lowered or the hitch calibration procedure
will have to be repeated.
When the hitch is fully lowered answer YES.
STEP 23
Calibration is complete, the diagnostic display will
read the system normal code 0.
SM 8-10560 Issued 03-2001
8 SECTION 10002
Tire Size Calibration and Ride Control Enabling/Disabling
STEP 1 STEP 8
Refer to "DELUXE HITCH CALIBRATION" on page 5 The diagnostic display will read 0, representing the
and carry out STEP 1 to STEP 3. third digit of the Tire Code.
To select the third digit of the tire code answer YES
STEP 2 until the correct digit is shown in the diagnostic
When the diagnostic display reads c? display. Enter the digit by answering NO.
Answer No.
STEP 9
STEP 3 The diagnostic display will read 0, representing the
fourth digit of the Tire Code.
The diagnostic display will read r.
To select the fourth digit of the tire code answer YES
Answer YES to enable the ride control. until the correct digit is shown in the diagnostic
Answer NO to disable the ride control. display. Enter the digit by answering NO.
The diagnostic display will repeat in sequence the
STEP 4 four digit tire code entered in STEP 14 to STEP 17.
The diagnostic display will read S, do you want to
enter tire size? STEP 10
Answer YES and continue to STEP 5. The diagnostic display will read c, was your Tire Code
correct?
Answer NO to exit.
If the code is correct answer YES.
STEP 5 If the code is not correct answer NO to repeat
The diagnostic display will read d, do you want to STEP 6.
enter tire size code?
STEP 11
Answer YES.
Tire size calibration is complete, the diagnostic
STEP 6 display will read the system normal code O.
The diagnostic display will read 0, representing the
first digit of the Tire Code. Refer to the TIRE RADIUS
CONSTANT TABLE on page 88 and select the
correct code for the rear tires installed on the tractor.
NOTE: Tire Codes must always be entered as
four digit numbers. If the Tire Code is less than
1000, use a zero (0) as the first digit.
To select the first digit of the tire code answer YES
until the correct digit is shown in the diagnostic
display. Enter the digit by answering NO.
STEP 7
The diagnostic display will read 0, representing the
second digit of the Tire Code.
To select the second digit of the tire code answer
YES until the correct digit is shown in the diagnostic
display. Enter the digit by answering NO.
SM 8-10560 Issued 03-2001
SECT/ON 10002 9
GENERAL INFORMATION FOR HITCH ERROR CODES
Normal Operation
The diagnostic display shows error codes which assist in troubleshooting the Electronic Hitch Control System.
When the key switch is placed in the ON position the diagnostic display will self test showing 8 for 2 seconds. If '.'
appears on the diagnostic display the hitch position is above the upper limit setting, carry out the following :
1. Press and hold the hitch up/down switch in the DOWN MOMENTARY position to lower the hitch until the
upper limit is reached or,
2. Adjust the upper limit control (2) until the hitch position is matched.
The diagnostic display code for System Normal is 0 or O. There will be a dot. on the lower right hand side of the 0 if
the tractor is stationary or travelling at less then 0.5 mph (0.8 km/h). There will be no dot. for speeds of more than
0.5 mph (0.8 km/h). If no dot. appears below 0.5 mph (0 .8 km/h) check the wheel speed sensor, refer to Test 15 -
Wheel Speed Sensor on page 48 .
No Error Codes Displayed But Hitch Is Not Working Correctly
1. Potentiometer retaining nut loose. Check Hitch Position , Position Command, Load Control , Upper Limit
Control, Travel Control and Drop Speed Control potentiometers. Repeat calibration.
2. Hitch will not fully raise or fully lower. Potentiometer retaining nut loose. Check Hitch Position, Position
Command and Upper Limit Control potentiometers. Repeat calibration .
3. Hitch does not lower or drop rate is too slow for the application . Adjust Drop Speed Control (4) .
4. Hitch will not raise or lower. Possible contamination of hydraulic oil causing hitch valve spool to stick.
Attempt re-calibration before further investigation.
Controller LED
If the diagnostic display is blank and the hitch enable lamp does not illuminate when the key switch is in the ON
position , check the green LED positioned between the two 12 pin connectors on the controller. Position an item of
reflective material between the 12 pin connectors on the controller and observe the reflection from the green LED.
1. If the green LED is OFF there is no power to the controller or the LED is bad, refer to Test 1 - No Power to
Controller (Power and Clean Ground) on page 20.
2. If the green LED is ON (NOT FLASHING) the controller needs programming or replacing.
3. If the green LED is ON (FLASHING) the controller has power and is programmed, if a fault exists refer to
the hitch system performance code chart.
If the diagnostic display is blank, the hitch enable lamp is illuminated and the hitch operates normally, the diagnostic
display may be defective. Test the diagnostic display by disconnecting the tractor diagnostic display from the control
module and connecting a good secondary diagnostic display. If the diagnostic display still does not work disconnect
secondary diagnostic display and then replace the control module. Connect the original tractor diagnostic display to
the control module.
Failure Modes
1. HALT - Hitch is totally disabled and no electronic actuation is possible. The diagnostic display will flash H
and an error code. The hitch enable lamp will be illuminated.
2. LIMP - Hitch can only be actuated by repeated operation of the hitch up/down switch or the hitch remote
switch. The hitch will operate for 1.5 seconds. The tractor must be stationary. The hitch enable lamp will be
illuminated and an error code will be displayed.
3. DEGRADED 2 - Due to a failure, the draft control (if equipped) is not operational. The hitch enable lamp will
be illuminated and an error code will be displayed.
4. DEGRADED 1 - The hitch enable lamp is illuminated, hitch is operational and an error code will be
displayed. Default hitch settings have replaced the operators hitch settings due to component failure .
NOTE: Most DEGRADED 1 settings are intermittent and will clear. If errors continue corrective action
must be taken.
SM 8-10560 Issued 03-2001
10 SECTION 10002
General Notes
1. When an error code is displayed the hitch enable lamp must be illuminated . If the hitch enable lamp is not
illuminated, the lamp or lamp circuit may be damaged. Refer to Test 3 - Hitch Up/Down Switch and Hitch
Enable Lamp on page 23.
2. All error codes resulting in HALT or LIMP failure modes (including intermittent errors) are saved by the
controller memory. Restart the tractor and observe the diagnostic display for repeated error codes . Errors
must be corrected before normal hitch operation can continue.
3. When the hitch up/down switch error U is displayed the hitch up/down switch is disabled . Hitch operation
may continue using the Position Command Knob.
4. If the hitch raises or lowers momentarily then stops and the hitch enable lamp is not illuminated , check for
recorded error codes, refer to READING AND ERASING ERROR CODES on page 14.
EXAMPLE: If battery voltage is low and the Position Command Knob is used to raise or lower the hitch, the
current draw may momentarily lower battery voltage below 9.8 volts DC and cause a momentary LIMP
condition. The LIMP condition momentarily disables the Position Command Knob and stops the hitch. When
this occurs the voltage then increases above 9.8 volts cancelling the LIMP condition restoring normal hitch
operation. The error will be recorded as an A (low voltage). No error code will be displayed until all error codes
are recalled from the memory.
5. Before carrying out any further investigation, restart the tractor and observe the diagnostic display for error
codes. Errors can be intermittent and may be cleared at start up.
Error Codes That Disable Hitch Motion
Memory Failures
If there is a memory failure , the hitch will not be operational and the green LED (located on the bottom of the
controller box) will stay on. Refer to "Controller LED" on page 9.
HALT Conditions
When a HALT condition occurs the letter H will flash and alternate with the letter for the error code. Hitch motion will
be fully disabled. If failures are detected during calibration , the system will switch to the HALT failure mode and the
error code will be displayed. Refer to the CALIBRATION ERROR CODE CHART on page 12 and HITCH
SYSTEM PERFORMANCE CODE CHART on page 15.
Calibration Errors
All failures detected during calibration will be classed as HALT failure modes, although they may not be classified
as HALT failure modes in the HITCH SYSTEM PERFORMANCE CODE CHART on page 15.
Always re-calibrate the hitch if the controller, position command potentiometer, hitch position potentiometer, load
sensing hitch pin (if equipped) or the hitch valve are replaced.
Other Possible Error Indications
There are certain conditions that if detected may display an incorrect error code or fail to display an error code.
1. If battery voltage momentarily drops below 9.8 volts no error code will be displayed but the error will be
recorded . When errors are recalled , A (low battery voltage) will be displayed . Refer to HITCH SYSTEM
PERFORMANCE CODE CHART on page 15.
2. A shorted coil may also result in a combination of failures such as "A" and either "H", "2" or "H", "3" . The
hitch controller will show such a sequence. The reason is that if the coil is shorted to ground, the battery
voltage will drop momentarily.
3. The system may not detect a short or open circuit in the hitch enable lamp circuit because it is only tested
at start up.
8M 8-10560 Issued 03-2001
SECTION 10002 11
Error Codes That Allow Hitch Double Failures Involving The UPI
Operation DOWN Switch
The following failures are self healing operational When the hitch up/down switch and a second
failures (they do not necessarily indicate signal (shown below) have failed, the display will
component failure) which are NOT written to the flash the letter "F" and alternate with the code for
memory: the other failure. Hitch motion is available only
through the remote fender switches.
1. The hitch position is above the upper limit.
1. Position Sensor
2. A remote switch failure (on fender).
3. DOWN/MOMENTARY switch failure.
"F","H"337L96A
Refer to Test 8 - Hitch Position Potentiometer on
page 33.
The following are operational failures that are self
healing and ARE written to the memory: 2. Position Command
1. Low battery voltage . " F", "P " 337L96B
2. High battery voltage. Refer to Test 9 - Hitch Position Command
Potentiometer on page 36.
3. Drop rate. 3. High Battery Voltage
4. Travel " F", "E "337L96C
5. Draft pin errors. Refer to Section 4004, Battery Servicing and Testing.
4. Regulator failed - 5 Volt
NOTE: Most DEGRADED 1 failures (component
failures) occur intermittently during operation
and will be cleared at start up.
"F", "r " 337L96D
Hitch controller has failed.
Failures That Are Checked Once 5. Relay
The following failures are checked once at start up. "F", "F " 337L96E
Hitch controller has failed.
1. Relay contacts being welded closed.
6. Watchdog
2. Hitch switch lamp failure .
"F", "I: "
337L96F
3. Memory failure.
Hitch controller has failed.
4. Watchdog timer failure. 7. Low Battery Voltage
" F ", "A " 337L96G
Refer to Section 4004, Battery Servicing and Testing,
also check alternator output voltage.
SM 8-10560 Issued 03-2001
12 SECT/ON 10002
CALIBRATION ERROR CODE CHART
ERRORCOOEANOPROBLEM CAUSE CORRECTIVE ACTION
1. Position command knob is not at 1. Move position command knob to
"H"," r" 334 L96A
full raise.
2. Position command potentiometer
is defective or retaining nut is
full raise.
2. Go to Test 9 - Hitch Position
Command Potentiometer on
Position command is not at full loose. page 36.
raise.
1. Battery voltage is low. 1. Check battery condition, refer to
" H", " U " 2. No power to raise solenoid or
solenoid resistance is high.
3. Hitch valve raise spool is stuck
Section 4004 , Battery Servicing
and Testing.
2. Go to Test 5 - Hitch Solenoids
334 L96B
closed . Circuit on page 27 .
Current to raise hitch is above
3. Refer to Section 8009 Hitch
specified limits.
Valve and EDC Manifold.
1. Battery voltage is high. 1. Check battery condition, refer to
" H", " J" 2. Bad raise solenoid or solenoid
resistance is low.
Section 4004 , Battery Servicing
and Testing.
334L96C 2. Go to Test 5 - Hitch Solenoids
Current to raise hitch is below Circuit on page 27 .
specified limits.
" H", " r "
1. Battery voltage is high. 1. Check battery condition, refer to
Section 4004 , Battery Servicing
and Testing .
33 4L96D 2. Raise solenoid resistance is low. 2. Go to Test 5 - Hitch Solenoids
Circuit on page 27.
Full raise current detection out of
range (with position command
knob in the full raise position) .
" H", " a"
1. Hitch position potentiometer is 1. Go to Test 8 - Hitch Position
defective or retaining nut is Potentiometer on page 33.
loose.
334 L96E
Hitch position is not at maximum.
1. Position command knob is not at 1. Move position command knob to
"H"," 1" full lower.
2. Position command potentiometer
full lower.
2. Go to Test 9 - Hitch Position
334L96F is defective or retaining nut is Command Potentiometer on
loose. page 36.
Position command is not at full
lower.
8M 8-10560 Issued 03-2001
SECT/ON 10002 13
ERROB ~QDE AND PBQBLEM ~AU~E CQBRE~TIVE ACTIQN
H", --- "
1. Battery voltage is low. 1. Check battery condition, refer to
" " 2. No power to lower solenoid or Section 4004, Battery Servicing
solenoid resistance is high. and Testing.
334L96G 3. Hitch valve lower spool is stuck 2. Go to Test 5 - Hitch Solenoids
Current to lower hitch is above closed. Circuit on page 27.
specified limit. 3. Refer to Section 8009 Hitch
Valve and EDC Manifold.
1. Battery voltage is high. 1. Check battery condition, refer to
" H", " C"
334L96H
2. Bad LOWER solenoid or
solenoid resistance is low.
Section 4004, Battery Servicing
and Testing.
2. Go to Test 5 - Hitch Solenoids
Current to lower hitch is below Circuit on page 27.
specified limit.
" H", "d "
1. Operator did not acknowledge
when hitch was fully lowered and
the module was displaying U
1. Re-calibrate hitch.
Refer to DELUXE HITCH
CALIBRATION on page 5.
334L96J within six minutes.
Calibration time expired .
1. Position potentiometer is
" H", "
n " defective or retaining nut is
loose.
1. Go to Test 8 - Hitch Position
Potentiometer on page 33.
334L96K
Hitch position is not at minimum
1. Position potentiometer is 1. Go to Test 8 - Hitch Position
" H" n " "
334L96L
defective or retaining nut is
loose.
Potentiometer on page 33.
Hitch position range is out of limits.
1. Position command 1. Go to Test 8 - Hitch Position
" H", "- " potentiometer, hitch position
potentiometer or both are
Potentiometer on page 33 and
Test 9 - Hitch Position Command
334L96M defective or retaining nuts are Potentiometer on page 36.
loose.
Position command and hitch position
potentiometers are not aligned.
1. Defective load pin. 1. Go to Test 12 - Load Pin on page
" H", " I " DS99NOO8
42 .
Load pin 'no load' offset is
incorrect.
8M 8-10560 Issued 03-2001
14 SECTION 10002
READING AND ERASING ERROR CODES
YES and NO are signaled by using the hitch up/down STEP 2
switch as follows:
The diagnostic display will read C, do you want to
YES = Push hitch up/down switch into the DOWN calibrate the hitch?
MOMENTARY position and release.
Answer NO to display error codes.
NO =Push hitch up/down switch into the UP position
then back to the DOWN (centre) position. STEP 3
NOTE: The DOWN MOMENTARY position is If no error codes are recorded the diagnostic display
below the centre position and spring loaded to will read n. Answer NO and go to STEP 5.
return to the centre position when released.
DOWN and UP positions are detented. If error codes are recorded the first recorded error
code will be displayed (for example c).
Answer YES, the next recorded error code will be
displayed (for example r). Continue to answer YES to
display all recorded error codes.
STEP 4
When all recorded error codes have been displayed
the diagnostic display will read n, do you want to read
the error codes again?
Answer YES to repeat the error codes or NO to
continue.
STEP 5
DROOHon
The diagnostic display will read e, do you want to
ERASE error codes?
Answer YES to ERASE ERROR codes in the
controller memory.
Answer NO to KEEP ERROR codes in the controller
memory.
STEP 6
The diagnostic display will return the system normal
code O.
DP96G261
1. HITCH UPIDOWN SWITCH
AND HITCH ENABLE LAMP
2. DIAGNOSTIC DISPLAY
STEP 1
Push a nd hold the hitch up/down switch (1) in the
DOWN MOMENTARY position while turning the key
switch to the ON position. Release the hitch up/down
switch when the first character after the 8 appears in
the diagnostic display (2) of the hitch control panel. If
the hitch up/down switch is NOT released, the
calibration sequence will terminate.
SM 8-10560 Issued 03-2001
SECTION 10002 15
HITCH SYSTEM PERFORMANCE CODE CHART
These are error codes and corrective actions used in troubleshooting the electronic hitch system. The codes are
listed from the highest priority to the lowest priority. When more than one failure exists simultaneously the highest
priority failure will be displayed. All fa ilures are recorded in the controller memory and can be retrieved in order of
priority.
FAILURE
ERRQB CQDE CAU~E CQRRECTIVE ACTIQN
MODE
NO ERROR 1. Controller power DEGRADED 1. Go to Test 1 - No Power to Controller
(BLANK failure. 1 (Power and Clean Ground) on page 20.
DISPLAY) AND
2. Circuit has shorted to 2. Go to Test 2 - Circuit Shorted to Ground on
HITCH ENABLE
ground. page 21.
LAMP IS NOT
ILLUMINATED 3. Display circuit failure. 3. Replace display.
NOTE: If the fault remains reprogramme
the hitch controller, refer to Section
10010 and calibrate the hitch.
Open circuit or short to HALT Go to Test 5 - Hitch Solenoids Circuit on page
27.
" H", "2 " ground of lower solenoid
or lower solenoid circuit.
336L96A
Open circuit or short to 12 HALT Go to Test 5 - Hitch Solenoids Circuit on page
" H", "
U
" volts of lower solenoid or
lower solenoid circuit.
27 .
336L968
Open circuit or short to HALT Go to Test 5 - Hitch Solenoids Circuit on page
" H", "3 " ground of raise solenoid
or raise solenoid circuit.
27.
336L96C
Open circuit or short to HALT Go to Test 5 - Hitch Solenoids Circuit on page
ground of both raise and 27.
" H", "g " lower solenoids or both
336L96D raise and lower solenoid
circuits.
Controller memory HALT Re-calibrate the hitch, refer to DELUXE
., H", " P' failure. The system
cannot read cal ibration
HITCH CALIBRATION on page 5.
NOTE: If the fault remains reprogramme
DS98A1 33 values.
the hitch controller, refer to Section
OR 10010 and calibrate the hitch.
., H ~', " ~"
DS98A1 33
Short to 12 volts of the HALT Go to Test 5 - Hitch Solenoids Circuit on page
" H", "b " raise solenoid or raise
solenoid circuit failure.
27.
336L96F
Short to 12 volts of the HALT Internal short to 12 volts of hitch controller.
Reprogramme the hitch controller, refer to
" ", " " raise solenoid driver
H h336L96G
circuit. section 10010 and calibrate the hitch .
SM 8-10560 Issued 03-2001
16 SECTION 10002
FAILUR~
~BBQR ~QDE ~AUSE ~QRRE~TIVE A~TIQN
MODE
Short to 12 volts of the HALT Internal short to 12 volts of hitch controller.
" H", "J " lower solenoid driver
circuit.
Reprogramme the hitch controller, refer to
section 10010 and calibrate the hitch.
336L96H
Tractor has never been HALT Calibrate hitch, refer to DELUXE HITCH
calibrated . CALIBRATION on page 5.
" J" 338L96A
Open or shorted hitch LIMP Check Hitch Position Control Circuit, carry out
position circuit. the following:
" H" Test 8 - Hitch Position Potentiometer.
338L96B
Open or shorted position LIMP Check Hitch Position Control Circuit, carry out
command circuit. the following:
" P" Test 9 - Hitch Position Command
338L96C Potentiometer.
Loss of 5 volt regulator. LIMP Reprogramme the hitch controller, refer to
section 10010 and calibrate the hitch.
" r "
338L96D
Low battery voltage (less LIMP Refer to Section 4004 , Battery Servicing and
than 9.8 volts). Testing, also check alternator output voltage.
"
A" 338L96E
Short circuit of load pin
Go to Test 12 - Load Pin on page 42
causing momentary low
battery voltage
Watchdog circuit has LIMP Reprogramme the hitch controller, refer to
failed. section 10010 and calibrate the hitch.
" t: "
338L96G
High battery voltage LIMP Refer to Section 4004, Battery Servicing and
(greater than 18 volts) . Testing .
" E"
336L96H
Upper limit circuit failed. LIMP Go to Test 11 - Hitch Upper Height
Potentiometer on page 40.
" [ "
338L96J
Load control circuit has DEGRADED Check Hitch Load Control Circuit, carry
" " failed. 2 out the following:
L 338L96J
Test 12 - Load Pin on page 42,
Test 13 - Hitch Load Command
Potentiometer on page 44,
Test 14 - Hitch Travel Potentiometer on
page 46,
Test 15 - Wheel Speed Sensor on page 48.
8M 8-10560 Issued 03-2001
SECTION 10002 17
~QDE
FAlbURE
ERROB CAUSIi ~ORRE~IIVE ~TIQN
MQDE
load pin sensor has DEGRADED Go to Test 12 - Load Pin on page 42 .
failed . 2
" 5"
340L968
Hitch up/down switch has DEGRADED Go to Test 3 - Hitch Up/Down Switch and Hitch
" " failed . 1 Enable Lamp on page 23 .
U 338L96K
Hitch drop speed circuit DEGRADED Go to Test 10 - Hitch Drop Speed
has failed. 1 Potentiometer on page 38.
" 6"
338L96L
Hitch travel circuit has DEGRADED Go to Test 14 - Hitch Travel Potentiometer on
failed. 1 page 46 .
"g "
339L96D
Hitch enable lamp has DEGRADED Go to Test 3 - Hitch Up/Down Switch and Hitch
failed. 1 Enable Lamp on page 23 .
" ~"
335L96A
Hitch position is above DEGRADED Push and hold the hitch up/down switch in the
" -" 335L968
upper limit. 1 DOWN MOMENTARY position to lower the
hitch until the hitch upper limit is reached.
Hitch up/down switch has DEGRADED The error code will stop when switch is
" failed. 1 released from DOWN MOMENTARY position .
"
" 335L96D
If the fault remains go to Test 3 - Hitch Up/
Down Switch and Hitch Enable Lamp on page
23.
Fender remote switch(s) DEGRADED The error code will stop when remote switch is
has failed. 1
"
-- " 335L96C
released .
If the fault remains go to Test 6 - R/H Hitch
Remote Switch on page 29 and Test 7 - LlH
Hitch Remote Switch on page 31.
Slip switch has failed . DEGRADED Error code will stop when slip select is turned
" -- " 1 ON.
If the fault remains go to Test 16 - Slip Control
341 L96C
Switch on page 50 and Test 17 - Slip Control
Switch Circuit on page 51.
Slip lamp has failed . DEGRADED Go to Test 17 - Slip Control Switch Circuit on
1 page 51.
":"1 "
L.:
341 L96B
Radar is not detected. DEGRADED Go to Test 18 - Radar on page 52.
" 1
"r:
:J
341 L96A
SM 8-1 0560 Issued 03-2001
18 SECTION 10002
FAILUR!;
ERROR CODE ~A!JSE CQBBE~TIVE A~TIQN
.M.QQ£
MFD switch has failed . MFD Go to Test 24 - MFD Switch and Auto MFD
DISABLED Circuit on page 64.
[J
- RB96NOO5
Differential lock switch DIFF Go to Test 21 - Differential Lock Switch, Auto
has failed . DISABLED Differential and Auto Indicator Lamp on page
L 59.
- RB96NOO6
MFD driver circuit has MFD Check MFD Circuit, carry out the following:
failed. DISABLED Test 23 - MFD Solenoid.
C
- RB96NOO7
Differential lock driver DIFF Check Differential Lock Circuit, carry out the
circuit has failed. DISABLED following:
U Test 20 - Differential Lock Solenoid.
- RB96N008
., Auto differential lock
indicator lamp has failed .
LAMP IS
DISABLED
Go to Test 21 - Differential Lock Switch, Auto
Differential and Auto Indicator Lamp on page
59.
- RB96NOO9
8M 8-10560 Issued 03-2001
SECTION 10002 19
CIRCUIT TESTING
General Information
A WARNING: Never operate the engine in a closed building. Proper
~ ventilation is required under all circumstances.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with the parking
brake engaged and the engine OFF unless otherwise stated.
IMPORTANT: Put blocks in front of and behind the rear wheels.
IMPORTANT: The battery must be at full charge and all connections must be clean and tight before
testing. Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage to the
switches may occur.
IMPORTANT: Use test probe kit MC2656 when making electrical checks at connectors to avoid the risk
of shorting between the connector pins or terminals.
IMPORTANT: Follow the Error Code corrective action BEFORE replacing any components.
IMPORTANT: Replace the controller if the fault remains only after all necessary checks have been made
or reprogramming of the controller has been carried out.
NOTE: When measuring resistance values, always measure the resistance of the multimeter leads
before testing components. Subtract the resistance of the multimeter leads from the component
resistance to obtain a true resistance value.
NOTE: When testing diodes and diode modules use the multimeter diode test function.
NOTE: All components, wires and connectors disconnected during any electrical checks must be
connected when the checks are completed.
SM 8-10560 Issued 03-2001
20 SECTION 10002
Hitch Operating Circuit
Test 1 - No Power to Controller (Power and Clean Ground)
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information " on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Check fuse 33, if the fuse has blown refer to "Test 2 - Circuit Shorted to Ground" on page 21 .
NOTE: Turn the key to the ON position.
IMPLEMENT CONNECTOR HITCH UP/pOWN SWITCH
Check Point Reading Possible Cause of Bad Reading
Check 1: Implement switch connector 12 volts Bad circuit between switched power stud
terminal B for wire 528 Red to ground. and the implement switch connector. Go to
check 2.
NOTE: If the reading is correct go to Check 3.
NOTE: Remove the hitch up/down switch from the upper right hand console top cover. Do not
disconnect the switch from the harness.
Check 2: Hitch up/down switch connector 12 volts Bad circuit between switched power stud
terminal 5 for wire 500 Red to ground. and the hitch up/down switch . Also check
the switched power stud connections and
connector 26.
NOTE: Turn the key to the OFF position and disconnect connector 40 (right hand console harness to
transmission harness).
Check 3: Between connector 40 pin 7 Continuity Bad clean ground circuit. Check wire 500
(transmission harness side) for wire 500 Brown/White between connector 40 and
Brown/White to ground. the battery negative terminal.
NOTE: Connect connector 40 and remove the lower right hand console side cover. Disconnect
connector J2 (Green) from the hitch controller.
Check 4: Connector J2 (Green) pin 12 for Continuity Check wire 560 Brown/White or 500
wire 560 Brown/White or 500 Brown/White Brown/White between connector J2 and
to ground. connector 40 .
Also check connector 40.
continued ....
8M 8-10560 Issued 03-2001
SECTION 10002 21
NOTE: Turn the key to the ON position.
Check Point Reading Possible Cause of Bad Reading
Check 5: Connector J2 (Green) pin 1 for 12 volts Check wire 500 between the hitch up/down
wire 500 Red to ground. switch and the hitch controller.
NOTE: Check the operation of the hitch controller if the fault remains erase al/ error codes and reprogramme the
hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH CALIBRATION" on page 5.
Test 2 - Circuit Shorted to Ground
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information " on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position and remove fuse 33.
NOTE: Remove and disconnect the hitch up/down switch and the slip control switch (if equipped) from
the upper right hand console harness.
NOTE: Disconnect the implement (if connected) from the tractor harness.
HITCH UPIDOW'N SWITCH AND
SLIP CONTROL SWITCH
Check Point Reading Possible Cause of Bad Reading
Check 1: Hitch up/down switch connector No continuity Circuit shorted to ground.
terminal 5 for wire 500 Red to ground . Go to Check 2.
NOTE: If the reading at Check 1 is correct check the hitch up/down switch refer to "Test 3 - Hitch UpIDown Switch
and Hitch Enable Lamp" on page 23 and the slip control switch circuit refer to "Test 17 - Slip Control Switch
Circuit" on page 51.
NOTE: Disconnect connector 40 (transmission harness to right hand console harness).
Check 2: Hitch up/down switch connector No continuity Circuit shorted to ground.
terminal 5 for wire 500 Red to ground. Go to Check 3.
NOTE: If the reading at Check 2 is correct check the wheel speed sensor circuit, refer to 'Test 15 -
Wheel Speed Sensor" on page 48.
NOTE: Disconnect connector 52 (fender harness to right hand console harness) .
Check 3: Hitch up/down switch connector No continuity Circuit shorted to ground.
terminal 5 for wire 500 Red to ground. Go to Check 4.
NOTE: If the reading at Check 3 is correct go to Check 6.
continued ....
8M 8-10560 Issued 03-2001
22 SECTION 10002
NOTE: Remove the lower right hand console side cover and disconnect connector 26.
Check point Reading Possible Cause of Bad Reading
Check 4: Hitch up/down switch connector No continuity Check wires 500 between the following:
terminal 5 for wire 500 Red to ground. Connector 26 pin 0 and the hitch up/down
switch .
Hitch up/down switch and the splice.
Splice and hitch controller connector J2
(Green) pin 1.
Check wire 567 Red between the splice and
the slip control switch terminal block.
Check wire 500 Red or 528 Red between
splice and connector 52 .
Check 5: Connector 26 pin 0 (instrument No continuity Check wire 500 between connector 26 and
panel harness side) for wire 500 Red to fuse 33 .
ground.
Check 6: Connector 52 terminal H (fender No continuity Check the fender harness wire 528 Red
harness side) for wire 528 Red to ground. between connector 52 and the left and right
hand remote hitch switches. Also check the
implement switch connector wire 528 Red .
Check 7: Connector 52 terminal C (fender No continuity Check the fender harness wire between
harness side) for wire 563 Light Blue to connector 52 and the implement switch
ground . connector.
NOTE: If the readings at Check 6 and 7 are correct check the implement switch and harness. Then go
to Check 8.
NOTE: Disconnect the instrument cluster connector C2 from the harness.
CONNECTOR C2
Check 8: Instrument cluster connector C2 No continuity Circuit shorted to ground.
pin B-3 for wire 563 Light Blue to ground. Go to Check 9.
continued ....
8M 8-10560 Issued 03-2001
SECTION 10002 23
NOTE: Remove the lower right hand console side cover and disconnect connector 27.
Check Point Reading Possible Cause of Bad Reading
Check 9: Instrument cluster connector C2 No continuity Check wire 563 Light Blue between the
pin B-3 for wire 563 Light Blue to ground. instrument cluster connector C2 and
connector 27.
Check 10: Connector 27 pin 4 (right hand No continuity Check wire 563 Light Blue or 240 Yellow
console harness side) for wires 563 Light between connector 27 and connector 52
Blue or 240 Yellow to ground. and between connector 27 and the hitch
controller connector J 1 (Black) pin 31 .
Test 3 - Hitch Up/Down Switch and Hitch Enable Lamp
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Check fuse 33.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Remove the hitch switch from the upper right hand console top cover, do not disconnect the
switch from the harness. Check the hitch enable lamp bulb.
NOTE: Put the hitch up/down switch in the UP position and turn the key to the ON position.
HITCH UP/DOWN SWITCH
Check point Reading possible Cause of Bad Reading
Check 1: Hitch up/down switch connector 12 volts Bad circuit between switched power stud
terminal 5 for wire 500 Red to ground. and the hitch up/down switch. Also check
the switched power stud connections and
connector 26.
Check 2: Hitch up/down switch connector 12 volts Bad hitch up/down switch .
terminal 7 for wire 510 Light Blue to ground.
Check 3: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground .
Check 4: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 4 for wire 562 Light Blue to ground.
NOTE: When carrying out checks 3 and 4 a voltage of 0 to 0.04 mV may be detected.
continued ....
8M 8-10560 Issued 03-2001
24 SECTION 10002
NOTE: Put the hitch up/down switch in the DOWN position.
Check Point Reading Possible Cause of Bad Reading
Check 5: Hitch up/down switch connector 12 volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground.
Check 6: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 7 for wire 510 Light Blue to ground.
Check 7: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 4 for wire 562 Light Blue to ground.
NOTE: Hold the hitch up/down switch in the FAST DOWN (momentary) position.
Check 8: Hitch up/down switch connector o volts Bad hitch up/down switch.
terminal 7 for wire 510 Light Blue to ground.
Check 9: Hitch up/down switch connector 12 volts Bad hitch up/down switch.
terminal 2 for wire 509 Light Blue to ground.
Check 10: Hitch up/down switch connector 12 volts Bad hitch up/down switch .
terminal 4 for wire 562 Light Blue to ground.
Check 11: Hitch up/down switch connector o volts Bad circuit between the hitch up/down
terminal 9 for wire 508 Light Blue to switch and the hitch controller connector
ground. J2 (Green). Refer to "Test 4 - Hitch
Up/Down Switch Circuit" on page 25.
NOTE: If the readings are correct check the hitch up/down switch circuit, refer to 'Test 4 - Hitch
Up/Down Switch Circuit" on page 25.
8M 8-10560 Issued 03-2001
SECTION 10002 25
Test 4 - Hitch Up/Down Switch Circuit
NOTE: Before carrying out the fol/owing tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position. Remove the lower right hand console side cover and
disconnect connector J1 (Black) and J2 (Green) from the hitch controller.
NOTE: Remove the hitch up/down switch from the upper right hand console cover, disconnect the
switch from the harness.
HITCH UPIDOWN SWITCH CONNECTOR J1 (BLACK)
AND J2 (GREEN)
Check Point Reading Possible Cause of Bad Reading
Check 1: Hitch up/down switch connector No continuity Wire 510 shorted to ground. Check wire
terminal 7 for wire 510 Light Blue to ground. 510.
Check 2: Between the hitch up/down Continuity Check wire 510 between the hitch up/down
switch connector terminal 7 and connector switch and connector J 1 (Black) .
J 1 (Black) pin 38 for wire 510 Light Blue.
Check 3: Between the hitch up/down Continuity Check wire 562 between the hitch up/down
switch connector terminal 4 and connector switch and connector J 1 (Black).
J1 (Black) pin 40 for wire 562 Light Blue.
Check 4: Hitch up/down switch connector No continuity Wire 562 shorted to ground. Check wire
terminal 4 for wire 562 Light Blue to ground. 562.
continued ....
SM 8-10560 Issued 03-2001
26 SECTION 10002
NOTE: Disconnect connector 26 (instrument panel harness to right hand console harness).
Check point Reading Possible Cause of Bad Reading
Check 5: Hitch up/down switch connector No continuity Wire 509 shorted to ground . Check wire
terminal 2 for wire 509 Light Blue to ground. 509 between the hitch up/down switch and
connector 26 pin Z. Also check wire 509
between the hitch up/down switch and
connector J1 (Black) .
Check 6: Connector 26 (instrument panel No continuity Wire 509 shorted to ground . Check wire
harness side) pin Z for wire 509 Light Blue 509 between connector 26 pin Z and the
to ground. instrument cluster connector C2 pin B - 4.
Check 7: Between the hitch up/down Continuity Check wire 509 between the hitch up/down
switch connector terminal 2 and connector switch and connector J 1 (Black).
J 1 (Black) pin 39 for wire 509 Light Blue.
Check 8: Between hitch up/down switch Continuity Check wire 508 between the hitch up/down
connector terminal 9 and connector J2 switch and connector J2 (Green) .
(Green) pin 6 for wire 508 Light Blue to
ground.
Check 9: Hitch up/down switch connector Continuity Check wire 508 Brown and the chassis
terminal 10 for wire 508 Brown to ground. ground connection.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
SECTION 10002 27
Test 5 - Hitch Solenoids Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
IMPORTANT: Put blocks in front and behind the rear wheels.
NOTE: Disconnect the hitch raise and lower solenoids from the harness.
RAISE SOLENOiD CONNECTOR LOWER SOLENOID CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Between terminals 1 and 2 of the 5 to 12 Ohms Bad raise solenoid coil. Also check the
raise solenoid. solenoid harness.
Check 2: Between terminals 1 and 2 of the 5 to 12 Ohms Bad lower solenoid coil. Also check the
lower solenoid. solenoid harness.
NOTE: Disconnect connector 40 (transmission harness to right hand console harness). Disconnect
the raise and lower solenoids from the harness.
Check 3: Connector 40 pin 10 for wire 511 No continuity Wire 511 shorted to ground between
Red to ground. connector 40 and the Raise or Lower
solenoid connector.
Check 4: Between connector 40 pin 10 and Continuity Check wire 511 between connector 40
pin 1 of the lower solenoid connector for and the lower solenoid connector. Go to
wire 511 Red. check 5.
Check 5: Between connector 40 pin 10 and Continuity Check wire 511 between connector 40
pin 1 of the raise solenoid connector for wire and the raise solenoid connector.
511 Red.
NOTE: If one of the readings at checks 4 or 5 is correct, check wire 511 between the solenoid with the
bad reading and the splice.
NOTE: If both readings at checks 4 or 5 are not correct, first check wire 511 between connector 40
and the splice.
Check 6: Pin 2 of the raise solenoid No continuity Wire 513 shorted to ground between the
connector for wire 513 Light Blue to ground. splice and the raise solenoid connector.
Check 7: Pin 2 of the lower solenoid No continuity Wire 512 shorted to ground between the
connector for wire 512 Light Blue to ground. splice and the lower solenoid connector.
continued .....
SM 8-10560 Issued 03-2001
28 SECTION 10002
Check Point Reading Possible Cayse of Bad Reading
Check 8: Between pin 2 of the lower Continuity Check wire 513 between the lower
solenoid connector and pin 17 of connector solenoid connector and connector 40.
40 for wire 513 Light Blue.
Check 9: Between pin 2 of the raise Continuity Check wire 512 between the raise solenoid
solenoid connector and pin 11 of connector connector and connector 40.
40 for wire 512 Light Blue.
NOTE: Connect connector 40 (transmission harness to right hand console harness) .
NOTE: Remove the lower right hand console side cover and disconnect connector J2 (Green) from the
hitch controller.
CONNECTOR J2 (GREEN)
Check 10: Between hitch controller Continuity Check wire 511 between connector 40 and
connector J2 (Green) pin 2 and terminal 1 hitch controller connector J2 (Green). Also
of the raise or lower solenoid connector for check connector 40 .
wire 511 Red.
Check 11: Connector J2 (Green) pin 3 for No continuity Wire shorted to ground . Check the right
wire 513 Light Blue or 513 Brown to hand console harness for damage.
ground.
Check 12: Connector J2 (Green) pin 4 for No continuity Wire shorted to ground. Check the right
wire 512 Light Blue or 512 Brown to hand console harness for damage.
ground .
Check 13: Between connector J2 (Green) Continuity Check wire 512 between the hitch
pin 4 and the lower solenoid connector controller connector J2 and the raise
terminal 2 (harness side) for wire 512 Light solenoid connector.
Blue or 512 Brown. Also check connector 40 .
Check 14: Between connector J2 (Green) Continuity Check wire 513 between the hitch
pin 3 and the raise solenoid connector controller connector J2 and the raise
terminal 2 (harness side) for wire 513 Light solenoid connector.
Blue or 513 Brown. Also check connector 40.
8M 8-10560 Issued 03-2001
SECTION 10002 29
Test 6 - R/H Hitch Remote Switch
NOTE: Before carrying out the following tests , refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
IMPORTANT: Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage
to the hitch remote switches may occur.
NOTE: Turn the key to the OFF position and disconnect the R/H hitch remote switch from the harness.
Turn the key to the ON position.
R/H HITCH REMOTE SWITCH CONNECTOR
Check Point Reading possible Cause of Bad Reading
Check 1: Terminal B of the R/H hitch switch 12 volts Bad circuit between hitch up/down switch
connector for wire 528 Red to ground . and the R/H hitch switch connector. Go to
check 4.
NOTE: If the LlH hitch remote switch operates correctly check wire 528 Red between the R/H hitch
remote switch and the splice.
NOTE: Turn the key to the OFF position and hold the RIH hitch remote switch in the RAISE position.
Check 2: Between terminals Band C of the 3.9 Ohms Bad R/H hitch switch.
R/H hitch switch. approximately
NOTE: Hold the R/H hitch remote switch in the LOWER position.
Check 3: Between terminals B and A of the 3.9 Ohms Bad R/H hitch switch.
R/H hitch switch. approximately
NOTE: Disconnect connector 52 (fender harness to right hand console harness).
Check 4: Between connector 52 pin Hand Continuity Check wire 528 between connector 52 and
terminal B of the R/H hitch switch connector the R/H hitch switch connector.
for wire 528 Red.
NOTE: If the reading at check 4 is correct check wire 528 Red between the Hitch Up/Down switch and
connector 52. Also check the Hitch Up/Down switch.
continued ....
SM 8-10560 Issued 03-2001
30 SECTION 10002
Check Point Reading Possible Cause of Bad Reading
Check 5: Between connector 52 pin J and Continuity Check wire 528 between connector 52 and
terminal C of the R/H hitch switch connector the R/H hitch switch connector.
for wire 528 Light Blue.
NOTE: If the LlH hitch remote switch works correctly, check wire 528 Light Blue between the RIH
switch connector and the fender harness splice.
Check 6: Between connector 52 pin K and Continuity Check wire 529 between connector 52 and
terminal A of the R/H hitch switch connector the R/H hitch switch connector.
for wire 529 Light Blue.
NOTE: If the LlH hitch remote switch works correctly, check wire 529 Light Blue between the RIH
switch connector and the fender harness splice .
NOTE: Connect connector 52.
NOTE: Remove the lower right hand console side cover. Disconnect connector J1 from the hitch
controller.
CONNECTOR J1 (BLACK)
Check 7: Between connector J 1 (Black) pin Continuity Check wire 529 between the hitch
25 and the R/H hitch remote switch controller connector and connector 52.
connector terminal A for wire 529 Light Also check connector 52.
Blue.
Check 8: Between connector J 1 (Black) pin Continuity Check wire 528 between the hitch
24 and the R/H hitch remote switch controller connector and connector 52 .
connector terminal C for wire 528 Light Also check connector 52.
Blue.
SM 8-10560 Issued 03-2001
SECTION 10002 31
Test 7· L/H Hitch Remote Switch
NOTE: Before carrying out the fol/owing tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
IMPORTANT: Only use a HIGH IMPEDANCE multimeter fo r the tests. Do not use a test lamp or damage
to the hitch remote switches may occur.
NOTE: Turn the key to the OFF position and disconnect the LlH hitch remote switch from the harness.
Turn the key to the ON position. Turn the key to the ON position.
L1H HITCH REMOTE SWITCH CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal B of the LlH hitch switch 12 volts Bad circuit between hitch up/down switch
connector for wire 528 Red to ground . and the LlH hitch switch connector. Go to
check 4 .
NOTE: If the R/H hitch remote switch operates correctly check wire 528 Red between the LlH hitch
remote switch and the splice.
NOTE: Turn the key to the OFF position and hold the LlH hitch remote switch in the RAISE position.
Check 2: Between terminals Band C of the 3.9 Ohms Bad LlH hitch switch .
LlH hitch switch. approximately
NOTE: Hold the R/H hitch remote switch in the LOWER position.
Check 3: Between terminals B and A of the 3.9 Ohms Bad LlH hitch switch.
LlH hitch switch. approximately
NOTE: Disconnect connector 52 (fender harness to right hand console harness).
Check 4: Between connector 52 pin Hand Continuity Check wire 528 between connector 52 and
terminal B of the LlH hitch switch connector the LlH hitch switch connector .
for wire 528 Red.
NOTE: If the reading at check 4 is correct check wire 528 Red between the Hitch Up/Down switch and
connector 52. Also check the Hitch Up/Down switch.
continued ....
8M 8-10560 Issued 03-2001
32 SECTION 10002
Check Point Reading Possible Cause of Bad Reading
Check 5: Between connector 52 pin J and Continuity Check wire 528 between connector 52 and
terminal A of the LlH hitch switch connector the LlH hitch switch connector.
for wire 528 Light Blue.
NOTE: If the RIH hitch remote switch works correctly, check wire 528 Light Blue between the LlH
switch connector and the fender harness splice .
Check 6: Between connector 52 pin K and Continuity Check wire 529 between connector 52 and
terminal C of the LlH hitch switch connector the LlH hitch switch connector.
for wire 529 Light Blue.
NOTE: If the RIH hitch remote switch works correctly, check wire 529 Light Blue between the LlH
switch connector and the fender harness splice.
NOTE: Connect connector 52.
NOTE: Remove the lower right hand console side cover. Disconnect connector J1 from the hitch
controller.
CONNECTOR J1 (BLACK)
Check 7: Between connector J 1 (Black) pin Continuity Check wire 529 between the hitch
25 and the LlH hitch remote switch controller connector and connector 52.
connector terminal C for wire 529 Light Also check connector 52 .
Blue.
Check 8: Between connector J 1 (Black) pin Continuity Check wire 528 between the hitch
24 and the LlH hitch remote switch controller connector and connector 52.
connector terminal A for wire 528 Light Also check connector 52.
Blue.
SM 8-10560 Issued 03-2001
SECTION 10002 33
Hitch Position Control Circuit
Test 8 - Hitch Position Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Lower the rear three point hitch.
NOTE: Disconnect the hitch position potentiometer from the harness and connect the test harness,
refer to "TOOLS TO BE MADE" on page 4 between the potentiometer harness and transmission
harness.
NOTE: Turn the key to the ON position.
HARNESS SIDE POTENTIOMETER SIDE
DI98N034
HITCH POSITION POTENTIOMETER CONNECTOR PIN' IDENTIFICATION
CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Pin A of the open connector of 5 volts Bad feed circuit between hitch controller
the test harness to ground. approximately. connector J 1 (Black) and the potentiometer
connector. Go to check 5 and 6.
Check 2: Between pins A and C of the 5 volts Bad ground circuit between hitch controller
open connector of the test harness. approximately. connector J 1 (Black). and the potentiometer
connector. Go to check 5 and 6.
NOTE: Readings at checks 1 and 2 may not be of the same value.
NOTE: Turn the key to the OFF position. Disconnect the test harness from the transmission harness
connector.
Check 3: Between pins A and C of the 0.9 to 1.1K Ohms . Bad potentiometer.
open connector of the test harness.
NOTE: Start and run the engine at low idle , use the hitch remote switches when carrying out Check 4.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 4: Between pins Band C of the Steadily Make sure the potentiometer body tab is
open connector of the test harness. increasing Ohms correctly located into the housing and the
reading with no retaining nut is tight or replace the
intermittent potentiometer as necessary.
readings
continued ....
SM 8-10560 Issued 03-2001
34 SECTION 10002
NOTE: Stop the engine and turn the key to the OFF position. Connect the test harness to the
transmission harness and disconnect the test harness from the potentiometer connector.
NOTE: . Disconnect connector 40 (right hand console harness to transmission harness).
Check point Reading Possible Cause of Bad Reading
Check 5: Between pin A of the open Continuity Check wire 507 Red between connector 40
connector of the test harness and connector and the potentiometer connector.
40 pin 3 for wire 507 Red.
Check 6: Between pin B of the open Continuity Check wire 507 Light Blue between
connector of the test harness and connector connector 40 and the potentiometer
40 pin 4 for wire 507 Light Blue. connector.
Check 7: Between pin B of the open No continuity Wire 507 Light Blue shorted to ground
connector of the test harness to ground. between connector 40 and the
potentiometer.
Check 8: Between pin C of the open Continuity Check wire 507 Brown between connector
connector of the test harness and connector 40 and the potentiometer connector.
40 pin 5 for wire 507 Brown .
NOTE: Connect connector 40. Remove the lower right hand console side cover and disconnect
connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check 9: Between pin A of the test harness Continuity Check wire 507 Red between connector 40
and connector J2 pin 34 for wire 507 Red . and the hitch controller connector J 1
(Black).
continued .....
8M 8-10560 Issued 03-2001
SECTION 10002 35
Check point Reading Possible Cause of Bad Reading
Check 10: Between pin B of the open Continuity Check wire 507 Light Blue between
connector of the test harness and connector connector 40 and the hitch controller
J2 pin 2 for wire 507 Light Blue. connector J1 (Black).
Check 11: Between pin B of the open No continuity Wire 507 Light Blue shorted to ground
connector of the test harness to ground. between connector 40 and the hitch
controller connector J1 (Black).
Check 12: Between pin C of the open Continuity Check wire 507 Brown between connector
connector of the test harness and connector 40 and the hitch controller connector J 1
J2 pin 12 for wire 507 Brown. (Black).
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
'Test 9 - Hitch Position Command Potentiometer" on page 36.
"Test 10 - Hitch Drop Speed Potentiometer" on page 38.
"Test 11 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
SM 8-10560 Issued 03-2001
36 SECTION 10002
Test 9 - Hitch Position Command Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position. Make sure the hitch position command potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch position command potentiometer from the harness and connect the test
harness, refer to "TOOLS TO BE MADE" on page 4, between the potentiometer and right hand console
harness.
NOTE: Turn the key to the ON position.
HITCH COMMAND' POTENTIOMETER HITCH COMMAND' POTENTIOMETER
CONNECTOR
HARNESS SIDE POTENTIOMETER SIDE
DI98N034
CONNECTOR PIN' IDENTIFICATION
Check Point Reading Possible Cause of Bad Reading
Check 1: Pin A of the open connector of 5 volts Check wire 504 Red between hitch
the test harness to ground . approximately. controller connector J1 (Black) and the
potentiometer connector.
Check 2: Between pins A and C of the 5 volts Check wire 504 Brown between hitch
open connector of the test harness. approximately. controller connector J1 (Black) and the
potentiometer connector.
NOTE: Readings at checks 1 and 2 may not be of the same value.
continued .. ..
8M 8-10560 Issued 03-2001
SECTION 10002 37
NOTE: Turn the key to the OFF position. Disconnect the right hand console harness connector from the
test harness.
Check Point Reading Possible Cause of Bad Reading
Check 3: Between pins A and C of the 0.9 to 1.1K Ohms. Bad potentiometer.
open connector of the test harness.
NOTE: Turn the hitch position command control knob from fully counterclockwise to fully clockwise
when carrying out Check 4.
Check 4: Between pins Band C of the Steadily increasing Make sure the potentiometer body tab is
open connector of the test harness. Turn Ohms reading with correctly located into the housing and the
the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings. potentiometer as necessary.
NOTE: Remove the test harness and disconnect connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check 5: Between potentiometer connector Continuity Check wire 504 Red between the
pin A and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 16 for wire 504 Red. controller connector J 1 (Black) .
Check 6: Between potentiometer connector Continuity Check wire 504 Light Blue between the
pin B and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 17 for wire 504 Light Blue. controller connector J 1 (Black).
continued .. ..
8M 8-10560 Issued 03-2001
38 SECTION 10002
Check Point Reading Possible Cause of Bad Reading
Check 7: Pin B of the potentiometer No continuity Wire 504 shorted to ground between the
connector for wire 504 Light Blue to ground. hitch controller connector J1 (Black) and
the potentiometer.
Check 8: Between potentiometer connector Continuity Check wire 504 Brown between the
pin C and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 18 for wire 504 Brown. controller connector J 1 (Black) .
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
"Test 8 - Hitch Position Potentiometer" on page 33.
"Test 10 - Hitch Drop Speed Potentiometer" on page 38.
"Test 11 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
Test 10 - Hitch Drop Speed Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position . Make sure the hitch drop speed potentiometer body tab is correctly
located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch drop speed potentiometer from the harness. Turn the key to the ON
position.
HITCH DROP SPEED POTENTIOMETER'CONNECTOR 59A
POTENTIOMETER
Check point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59A 8 volts Check wire 502 Red between hitch
(right hand console harness side) pin 1 for approximately. controller conneCtor J 1 (Black) and the
wire 502 Red to ground. . potentiometer connector 59A.
continued ....
SM 8-10560 Issued 03-2001
SECT/ON 10002 39
NOTE: Turn the key to the OFF position.
Check Point Reading Possible Cause of Bad Reading
Check 2: Between potentiometer connector 9K to 11 K Bad potentiometer.
(potentiometer harness side) pins 1 and 3. Ohms
NOTE: Turn the hitch drop rate control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins 1 and 2. Ohms reading with correctly located into the housing and the
Turn the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings . potentiometer as necessary.
NOTE: Disconnect connector J1 (Black) from the hitch contr oller.
CONNECTOR J1 (BLACK)
Check 4: Between potentiometer connector Continuity Check wire 502 Red between the
pin 1 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 4 for wire 502 Red . hitch controller connector J 1 (Black).
Check 5: Between potentiometer connector Continuity Check wire 502 Light Blue between the
pin 2 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 5 for wire 502 Light Blue. hitch controller connector J 1 (Black).
Check 6: Between potentiometer connector Continuity Check wire 502 Brown between the
pin 3 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 6 for wire 502 Brown. hitch controller connector J 1 (Black).
NOTE: If the readings are correct check the hitch position control circu it, carry out the following :
"Test 8 - Hitch Position Potentiometer" on page 33.
'Test 9 - Hitch Position Command Potentiometer" on page 36 .
'Test 11 - Hitch Upper Height Potentiometer" on page 40.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch , refer to "DELUXE HITCH
CALIBRATION " on page 5.
SM 8-10560 Issued 03-2001
40 SECTION 10002
Test 11 - Hitch Upper Height Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "Genera/Information" on page 19.
NOTE: Turn the key to the OFF position. Make sure the hitch upper height potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the right hand console top cover.
NOTE: Disconnect the hitch upper height potentiometer from the harness. Turn the key to the ON
position.
HITCH UPP'ER HEIGHT POTENTIOMETER ' CONNECTOR 59A
POTENTIOMETER
Check Point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector 59A 8 volts Check wire 560 Red between hitch controller
(right hand console harness side) pin 4 for approximately. connector J 1 (Black) and the potentiometer
wire 560 Red to ground. connector 59A. Go to Check 4.
NOTE: Turn the key to the OFF position.
Check 2: Between potentiometer connector 9K to 11K Bad potentiometer.
(potentiometer harness side) pins 4 and 6. Ohms
NOTE: Turn the hitch upper height control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins 4 and 5. Ohms reading with correctly located into the housing and the
Turn the potentiometer slowly clockwise. no intermittent retaining nut is tight or replace the
readings. potentiometer as necessary.
continued ....
8M 8-10560 Issued 03-2001
SECTION 10002 41
NOTE: Disconnect connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 560 Red between the
pin 4 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 1 for wire 560 Red. hitch controller connector J 1 (Black).
Check 5: Between potentiometer connector Continuity Check wire 560 Light Blue between the
pin 5 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 2 for wire 560 Light Blue. hitch controller connector J 1 (Black).
Check 6: Between potentiometer connector Continuity Check wire 560 Brown between the
pin 6 and hitch controller connector J 1 potentiometer connector 59A and the
(Black) pin 3 for wire 560 Brown. hitch controller connector J1 (Black) .
NOTE: If the readings are correct check the hitch position control circuit, carry out the following:
"Test 8 - Hitch Position Potentiometer" on page 33.
'Test 9 - Hitch Position Command Potentiometer" on page 36.
"Test 10 - Hitch Drop Speed Potentiometer" on page 38.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
SM 8-10560 Issued 03-2001
42 SECTION 10002
Hitch Load Control Circuit
Test 12 - Load Pin
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position. Disconnect the load pin connector 49 from the harness.
HARNESS SIDE LOAD PIN SIDE
OI98N034
LOAD PIN CONNECTOR 49 CONNECTOR PIN' IPENTIFICATION
Check Point Reading Possible Cause of Bad Reading
Check 1: Between load pin connector 49 See Note Below Bad load pin .
(load pin harness side) pins A and B.
NOTE: Depending on the amplifier installed in the load pin a reading of approximately 203 K Ohms or
a reading of 80 to 90 K Ohms should be obtained at check 1.
Check 2: Between load pin connector 49 approximately Bad load pin.
(load pin harness side) pins A and C. 217 to
263 Ohms
NOTE: Connect the test harness. "TOOLS TO BE MADE" on page 4. between the load pin and the
transmission harness.
Check 3: Pin C of the open connector of 8 volts Bad feed circuit between the load pin
the test harness to ground . approximately connector 49 and hitch module connector
J1 (Black). Go to checks 9 and 10.
Check 4: Between pins C and A of the 8 volts Bad ground circuit between the load pin
open connector of the test harness. approximately connector 49 and hitch module connector
J 1 (Black). Go to checks 9 and 10.
NOTE: Readings at checks 3 and 4 may not be of the same value.
Check 5: Between pins C and B of the 3 volts Bad load pin.
open connector of the test harness. approximately
continued .....
8M 8-10560 Issued 03-2001
SECTION 10002 43
NOTE: Turn the key to the OFF position. Disconnect connector 40 (right hand console harness to
transmission harness) and remove the test harness .
Check Point Reading Possible Cayse of Bad Reading
Check 6: Between connector 40 pin 14 and Continuity Check wire 514 Brown between connector
connector 49 pin A for wires 514 Brown. 40 and connector 49.
Check 7: Between connector 40 pin 12 and Continuity Check wire 514 Red between connector 40
connector 49 pin C for wires 514 Red . and connector 49.
Check 8: Between connector 40 pin 15 and Continuity Check wire 514 between connector 40 and
the load pin connector 49 pin B for wire 514 the load pin connector 49.
Light Blue.
NOTE: Connect connector 40. Remove the lower right hand console side cover and disconnect
connector J2 from the hitch controller.
CONNECTOR J1 (BLACK)
Check 9: Between connector J1 (Black) pin Continuity Check wire 514 Black between connector
33 and pin A of the load pin for wires 514 40 and connector J 1 (Black).
Brown.
Check 10: Between connector J1 (Black) Continuity Check wire 514 Red between connector 40
pin 32 and pin C of the load pin for wire 514 and connector J1 (Black).
Red.
Check 11: Between connector J 1 (Black) Continuity Check wire 514 between LlH load pin
pin 35 and the load pin connector 49 pin B connector 49 and connector J1 (Black).
for wire 514 Light Blue.
SM 8-10560 Issued 03-2001
44 SECTION 10002
Test 13 - Hitch Load Command Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position. Make sure the hitch load command potentiometer body tab is
correctly located into the housing and the retaining nut is tight.
NOTE: Remove the upper right hand console cover.
NOTE: Disconnect the hitch load command potentiometer from the harness. Turn the key to the ON
position.
HITCH LOAD COMMANP HITCH LOAD POTENTIOMETER
POTENTIOMETER CONNECTOR
Check Point Reading Possible Cause of Bad Reading
Check 1: Potentiometer connector (right 8 volts Check wire 505 Red between hitch
hand console harness side) pin A for wire approximately. controller connector J 1 (Black) and the
505 Red to ground. potentiometer connector.
NOTE: Turn the key to the OFF position.
Check 2: Between potentiometer connector 990 to 1100 Bad potentiometer.
(potentiometer harness side) pins A and C. Ohms
NOTE: Turn the hitch load command control knob from fully counterclockwise to fully clockwise when
carrying out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
(potentiometer harness side) pins A and B. Ohms reading with correctly located into the housing and the
no intermittent retaining nut is tight or replace the
readings . potentiometer as necessary.
continued ....
8M 8-10560 Issued 03-2001
SECTION 10002 45
NOTE: Disconnect connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 505 Red between the
pin A and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 10 for wire 505 Red. controller connector J 1 (Black).
Check 5: Between potentiometer connector Continuity Check wire 505 Light Blue between the
pin B and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 11 for wire 505 Light Blue. controller connector J 1 (Black) .
Check 6: Between potentiometer connector Continuity Check wire 505 Brown between the
pin C and hitch controller connector J 1 potentiometer connector and the hitch
(Black) .pin 12 for wire 505 Brown. controller connector JJ1 (Black).
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
"Test 12 - Load Pin" on page 42.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
SM 8-10560 Issued 03-2001
46 SECTION 10002
Test 14 - Hitch Travel Potentiometer
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position. Make sure the hitch travel potentiometer body tab is correctly located
into the housing and the retaining nut is tight.
NOTE: Remove the lower right hand console top cover.
NOTE: Disconnect the hitch travel potentiometer from the harness. Turn the key to the ON position.
HITCH TRAVEL POTENTIOMETER POTENTIOMETER 'CONNECTOR 59B
Check point Reading Possible Cayse of Bad Readjng
Check 1: Potentiometer connector 598 8 volts Check wire 506 Red between hitch
(right hand console harness side) pin 4 for approximately. controller connector J 1 (Black) and the
wire 506 Red to ground. potentiometer connector. Go to check 4 .
NOTE: Turn the key to the OFF position.
Check 2: Between potentiometer 990 to 1100 Bad potentiometer.
connector 59B (potentiometer harness Ohms
side) pins 4 and 6.
NOTE: Turn the hitch travel control knob from fully counterclockwise to fully clockwise when carrying
out Check 3.
Check 3: Between potentiometer connector Steadily reducing Make sure the potentiometer body tab is
59B (potentiometer harness side) pins 4 Ohms reading with correctly located into the housing and the
and 5. Turn the potentiometer slowly no intermittent retaining nut is tight or replace the
clockwise. readings. potentiometer as necessary.
continued .. ..
SM 8-10560 Issued 03-2001
SECTION 10002 47
NOTE: Disconnect connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check Point Reading Possible Cause of Bad Reading
Check 4: Between potentiometer connector Continuity Check wire 506 Red between the
pin 4 and hitch controller connector J1 potentiometer connector and the hitch
(Black) pin 13 for wire 506 Red. controller connector J 1 (Black).
Check 5: Between potentiometer connector Continuity Check wire 506 Light Blue between the
pin 5 and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 14 for wire 506 Light Blue. controller connector J 1 (Black) .
Check 6: Between potentiometer connector Continuity Check wire 506 Brown between the
pin 6 and hitch controller connector J 1 potentiometer connector and the hitch
(Black) pin 15 for wire 506 Brown. controller connector J1 (Black).
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
'Test 12 - Load Pin" on page 42.
"Test 13 - Hitch Load Command Potentiometer" on page 44.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
48 SECTION 10002
Test 15 - Wheel Speed Sensor
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Turn the key to the OFF position and check fuse 33.
NOTE: If the instrument cluster is reading the wheel speed correctly (m.p.h. or Km/h) go to Check 7.
NOTE: Disconnect the wheel speed sensor from the transmission harness. Turn the key to the ON
position.
Check Point Reading possible Cause of Bad Reading
WHEEL SPEED SENsOR CONNECTOR CONNECTOR C2
Check 1: Terminal C of the wheel speed 12 Volts Bad circuit between the hitch up/down
sensor connector (transmission harness switch and the wheel speed sensor. Go to
side) for wire 215 Red to ground. check 2.
NOTE: If the reading is correct go to check 4.
NOTE: Turn the key to the OFF position and disconnect connector 40.
Check 2: Pin 43 of connector 40 for wire No continuity Check wire 215 Red between the wheel
215 Red to ground. speed sensor connector 40.
Check 3: Between terminal C of the wheel Continuity Check wire 215 Red between the wheel
speed sensor connector (harness side) and speed sensor connector 40.
pin 43 of connector 40 for wire 215 Red .
NOTE: If the reading at check 3 is correct, connect connector 40 and check the operation of the hitch
remote circuit. If the hitch remote switches operate correctly check wire 215 between connector 40
and the right hand console splice. If the remote switches do not operate correctly check the hitch
up/down switch circuit and the hi tch enable relay.
NOTE: Turn the key to the OFF position . If not already carried out, disconnect conn.ector 40.
Check 4: Between terminal B of the wheel Continuity Check wire 215 Brown/White between the
speed sensor connector (harness side) for wheel speed sensor connector and the
wire 215 Brown/white to ground. battery negative terminals. Also check the
battery negative terminal connections.
continued ... .
8M 8-10560 Issued 03-2001
SECTION 10002 49
NOTE: Disconnect connector 40 and disconnect the instrument cluster from the harness.
Check point Reading Possible Cause of Bad Reading
Check 5: Between terminal A of the wheel Continuity Check wire 215 Yellow between the wheel
speed sensor connector (harness side) and speed sensor and connector 40.
pin 18 of connector 40.
NOTE: Connect connector 40 and disconnect the instrument cluster from the harness.
Check 6: Between terminal A of the wheel Continuity Bad circuit between connector 40 and the
speed sensor connector (harness side) the instrument cluster connector C2 . Go to
instrument cluster connector C2 pin A-5. Check 6.
NOTE: Remove the lower right hand console side cover and disconnect connector 27.
Check 7: Between terminal A of the wheel Continuity Check wire 215 Yellow between the
speed sensor connector (harness side) and connectors 40 and 27. Also check
pin 7 of connector 27 (right hand console connector 40 .
harness side) for wire 215 Yellow.
Check 8: Between pin 7 of connector 27 Continuity Check wire 215 Yellow between connector
(instrument panel harness side) and 27 and the instrument cluster connector
instrument cluster connector C2 pin A-5 for C2.
wire 215 Yellow.
NOTE: If not already carried out, remove the lower right hand console side cover and disconnect
connector 27. Also connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check 9: Between pin 7 of connector 27 Continuity Check wire 215 Yellow between the splice
(right hand console harness side) and hitch and the hitch controller connector J 1
controller connector J1 (Black) pin 26 for (Black).
wire 215 Yellow.
NOTE: If the readings are correct check the hitch load control circuit, carry out the following:
'Test 12 - Load Pin" on page 42.
'Test 13 - Hitch Load Command Potentiometer" on page 44.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
SM 8-10560 Issued 03-2001
50 SECTION 10002
Slip Limit Control Circuit
Test 16 - Slip Control Switch
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Remove the slip control switch from the upper right hand console cover, do not disconnect the
switch from the harness.
NOTE: Put the slip control switch in the OFF position and turn the key to the ON position.
SLIP CONTROL SWITCH
Check point Reading possible Cause of Bad Reading
Check 1: Slip control switch connector 12 volts Check wires 500 Red and 567 Red between
terminal 5 for wire 567 Red to ground. the hitch up/down switch and the slip control
switch. Also check the splice and hitch
up/down switch circuit, refer to "Test 4 -
Hitch Up/Down Switch Circuit" on page 25.
Check 2: Slip control switch connector o volts Bad slip control switch .
terminal 2 for wire 567 Light Blue to ground .
Check 3: Slip control switch connector o volts Bad slip control switch .
terminal 4 for wire 568 Light Blue to ground.
NOTE: Put the slip control switch in the ON position.
Check 4: Slip control switch connector 12 volts Bad slip control switch .
terminal 2 for wire 567 Light Blue to ground.
Check 5: Slip control switch connector o volts Bad slip control switch .
terminal 4 for wire 568 Light Blue to ground.
NOTE: Hold the slip control switch in the SET (momentary) position .
Check 6: Slip control switch connector 12 volts Bad slip control switch.
terminal 2 for wire 567 Light Blue to ground.
Check 7: Slip control switch connector 12 volts Bad slip control switch.
terminal 4 for wire 568 Light Blue to ground.
NOTE: If the readings are correct check the following: 'Test 17 - Slip Control Switch Circuit" on page 51 .
"Test 18 - Radar" on page 52.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
SECTION 10002 51
Test 17 - Slip Control Switch Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Check the slip lamp bulb. Turn the key to the OFF position. Remove the lower right hand console
side cover and disconnect connector J1 (Black) and connector J2 (Green) from the hitch controller.
NOTE: Remove the slip control switch from the right hand console top cover, disconnect the switch from
the harness.
SLIP CONTROL SWITCH CONNECTOR J1 (BLACK) AND J2 (GREEN)
Check Point Reading Possible Cause of Bad Reading
Check 1: Slip control switch connector No continuity Wire 567 shorted to ground. Check wire
terminal 2 for wire 567 Light Blue to ground. 567 between the slip control switch and
connector J1 (Black).
Check 2: Between the slip control switch Continuity Check wire 567 between the slip control
connector terminal 2 and connector J1 switch and connector J 1 (Black) .
(Black) pin 23 for wire 567 Light Blue.
Check 3: Between the slip control switch Continuity Check wire 568 between the slip control
connector terminal 4 and connector J1 switch and connector J 1 (Black).
(Black) pin 22 for wire 568 Light Blue.
Check 4: Slip control switch connector No continuity Wire 568 shorted to ground. Check wire
terminal 4 for wire 568 Light Blue to ground. 567 between the slip control switch and
connector J1 (Black).
Check 5: Slip control switch connector No continuity Wire 570 shorted to ground. Check wire
terminal 9 for wire 570 Light Blue to ground . 570 between the slip control switch and
connector J1 (Black).
Check 6: Between the slip control switch Continuity Check wire 570 between the slip control
connector terminal 9 and connector J2 switch and connector J2 (Green) .
(Green) pin 9 for wire 570 Light Blue.
Check 7: Slip control switch connector Continuity Check wire 570 Brown and the chassis
terminal 10 for wire 570 Brown to ground. ground connections.
NOTE: If the readings are correct check the following: 'Test 16 - Slip Control Switch " on page 50. 'Test
18 - Radar" on page 52.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
52 SECTION 10002
Test 18 - Radar
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: If the wheel slip indicator and radar indicator on the instrument cluster are working correctly go
to Check 8.
NOTE: Turn the key to the OFF position. Disconnect the radar harness from the engine harness at
connector 20.
NOTE: Turn the key to the ON position.
CONNECTOR 20
Check pojnt Reading Possible Cause of Bad Reading
Check 1: Connector 20 terminal C (engine 12 Volts Bad circuit between the instrument cluster
harness side) for wire 280 Red to ground. connector C1 and connector 20.
Go to Check 2.
NOTE: Turn the key to the OFF position. Disconnect the instrument cluster from the harness. Remove
the cover from splice 5.
Check 2: Between instrument cluster Continuity Bad circuit between the instrument cluster
connector C1 pin A-3 and connector 20 connector C1 and connector 20. Also
terminal C (engine harness side) for wire check connector 10.
280 Red.
NOTE: If the reading at Check 2 is correct check the instrument cluster power supply.
Check 3: Between instrument cluster Continuity Bad circuit between the instrument cluster
connector C2 pin A-2 and connector 20 connector C2 and connector 20. Also
terminal A (engine harness side) for wire check connector 10.
280 Brown.
Check 4: Between instrument cluster Continuity Check wire 281 between the instrument
connector C2 pin A-10 and connector 20 cluster connector C2 and connector 20.
terminal B (engine harness side) for wire
281 Yellow.
continued ....
8M 8-10560 Issued 03-2001
SECTION 10002 53
Check Point Reading Possible Cause of Bad Reading
Check 5: Between instrument cluster Continuity Check wire 282 between the instrument
connector C2 pin B-2 and connector 20 cluster connector C2 and connector 20.
terminal 0 (engine harness side) for wire
282 Yellow.
CONNEC'TOR 20A
NOTE: Disconnect the radar harness from the radar at connector 20A.
Check 6: Between connector 20A and Continuity Bad radar harness.
connector 20 of the radar harness terminals
o for wire Light Green/Yellow.
Check 7: Between connector 20A and Continuity Bad radar harness.
connector 20 of the radar harness terminals
B for wire Light Green.
Check 8: Between connector 20A and Continuity Bad radar harness.
connector 20 of the radar harness terminals
A for wire Brown/Light Green.
Check 9: Between connector 20A and Continuity Bad radar harness.
connector 20 of the radar harness terminals
C for wire Light Green/Red .
NOTE: If the readings are correct replace the radar.
continued ....
SM 8-10560 Issued 03-2001
54 SECTION 10002
NOTE: If the instrument cluster is working correctly remove the lower right hand console side cover and
disconnect connector 26 (right hand console harness from the instrument panel harness) .
CONNECTOR J1 (BLACK)
Check Point Reading Possible Cause of Bad Reading
Check 10: Between instrument cluster Continuity Check wire 282 between the instrument
connector C2 pin B-2 and connector 26 pin cluster and connector 26.
N (instrument panel harness side) for wire
282 Yellow.
Check 11: Between instrument cluster Continuity Check wire 281 between the instrument
connector C2 pin A-1 0 and connector 26 pin cluster and connector 26.
V (instrument panel harness side) for wire
281 Yellow.
NOTE: Disconnect connector J1 (Black) from the hitch controller.
Check 12: Between hitch controller Continuity Check wire 282 between connector J1
connector J 1 (Black) pin 28 and connector (Black) and connector 26.
26 pin N (right hand console harness side)
for wire 282 Yellow.
Check 13: Between hitch controller Continuity Check wire 281 between connector J1
connector J1 (Black) pin 27 and connector (Black) and connector 26.
26 pin V (right hand console harness side)
for wire 281 Yellow.
NOTE: If the readings are correct check the following: "Test 16 - Slip Control Switch" on page 50. "Test
17 - Slip Control Switch Circuit" on page 51.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
SECTION 10002 55
Ride Control Circuit
Test 19 - Ride Control Switch
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 74 and 75.
NOTE: Check fuse 36.
NOTE: Turn the key to the OFF position. Remove the Ride Control switch from the lower right hand
console, do not disconnect the switch from the harness. Check the ride control indicator light bulb.
RIDE CONTROL SWITCH CONNECTOR J4 (GREY)
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal 10 of the ride control Continuity Check the Brown wire and the chassis
switch connector for the Brown wire to ground connection.
ground.
NOTE: Turn the key to the ON position.
Check 2: Terminal 5 of the ride control 12 Volts Bad circuit between fuse 36 and the ride
switch connector for wire 571 Red to control switch . Also check connector 26.
ground.
NOTE: For tractors equipped with Front PTa, if the reading at check 2 is not correct, check the
operation of the Front PTa. If the Front PTa works correctly, check wire 571 Red between the Front
PTa harness connector and the ride control switch .
NOTE: Put the ride control switch to the ON position.
Check 3: Terminal 2 of the ride control 12 Volts Bad ride control switch.
switch connector for wire 572 Light Blue to
ground.
Check 4: Terminal 9 of the ride control 12 Volts Check wire 752 Light Blue between
switch connector for wire 572 Light Blue to terminal 2 and 9 of the ride control switch .
ground .
NOTE: Hold the ride control switch in the OVERRIDE (momentary) position.
Check 5: Terminal 4 of the ride control 12 Volts Bad ride control switch.
switch connector for wire 573 Light Blue to
ground.
NOTE: Release the ride control switch and turn the key to the OFF position.
continued ....
SM 8-10560 Issued 03-2001
56 SECTION 10002
NOTE: Remove the lower right hand console side cover and disconnect connector J4 (Grey) from the
hitch controller.
Check Point Reading Possible Cause of Bad Reading
Check 6: Between terminal 2 of the ride Continuity Check wire 572 Light Blue between the
control switch connector and connector J4 ride control switch and connector J4.
pin 4 for wire 572 Light Blue.
Check 7: Between terminal 4 of the ride Continuity Check wire 573 Light Blue between the
control switch connector and connector J4 ride control switch and connector J4.
pin 6 for wire 573 Light Blue.
NOTE: Check the operation of the hitch controller if the fault remains erase all error codes and
reprogramme the hitch controller, refer to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH
CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
SECTION 10002 57
Differential Lock Circuit
IMPORTANT: If the AUTO differential mode is selected and the di fferential DOES NOT DISENGAGE
when the tractor speed is above 10 mph (16 kmlh) check the wheel speed sensor, refer to " Test 15 -
Wheel Speed Sensor" on page 48.
Test 20 - Differential Lock Solenoid
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information " on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Fully lower the rear three point hitch .
NOTE: Check fuse 26.
NOTE: Turn the key to the OFF position and disconnect the differential lock solenoid from the harness.
DIFFERENTIAL LOCK SOLENOID
Check Point Reading Possible Cause of Bad Reading
Check 1: Differential lock solenoid connector Continuity Check wire 539 Brown and the chassis
terminal 2 for wire 539 Brown to ground. ground connection.
Check 2: Between terminals 1 and 2 of the 8.7 to 9.5 Bad differential lock solenoid .
differential lock solenoid. Ohms
NOTE: Turn the key to the ON position and hold the Differential Lock switch in the ON (momentary)
position.
Check 3: Differential lock solenoid 12 volts Bad circuit between the differential lock
connector terminal 1 for wire 539 Light Blue switch (through the hitch controller) and
to ground. the differential lock solenoid. Check the
following :
Differential lock switch , refer to "Test 21 -
Differential Lock Switch, Auto Differential
and Auto Indicator Lamp" on page 59.
Auto differential circuit, refer to "Test 21 -
Differential Lock Switch , Auto Differential
and Auto Indicator Lamp" on page 59 .
NOTE: Release the differential lock switch to the ON (centre) position .
Check 4: Differential lock solenoid connector 12 volts Bad hitch controller.
terminal 1 for wire 539 Light Blue to ground.
continued .. ..
8M 8-10560 Issued 03-2001
58 SECTION 10002
NOTE: Hold both brake pedals DOWN.
Check Point Reading Possible Cause of Bad Reading
Check 5: Differential lock solenoid connector o volts Check the following:
terminal 1 for wire 539 Light Blue to ground. Brake circuits, refer to "Brake Switches" on
page 68.
Differential lock switch, refer to ''Test 21 -
Differential Lock Switch, Auto Differential
and Auto Indicator Lamp" on page 59.
NOTE: Release the brake pedals.
Check 6: Differential lock solenoid connector o volts Bad hitch controller.
terminal 1 for wire 539 Light Blue to ground.
NOTE: Put the Differential Lock switch in the AUTO position.
Check 7: Differential lock solenoid connector 12 volts Bad circuit between the differential lock
terminal 1 for wire 539 Light Blue to ground. switch (through the hitch controller) and
the differential lock solenoid. Check the
auto differential circuit, refer to ''Test 21 -
Differential Lock Switch, Auto Differential
and Auto Indicator Lamp" on page 59.
NOTE: Checks 8 and 9 should be carried out on the LlH and RIH brake pedal individually. Unlatch the
brake pedals and hold down the UH brake pedal.
Check 8: Differential lock solenoid connector o volts Check the brake circuits refer to "Brake
terminal 1 for wire 539 Light Blue to ground. Switches" on page 68.
NOTE: Release the UH brake pedal.
Check 9: Differential lock solenoid connector 12 volts Bad hitch controller.
terminal 1 for wire 539 Light Blue to ground.
NOTE: Repeat checks 8 and 9 using the RIH brake pedal.
NOTE: Put the differential lock switch in the OFF position. Start and run the engine at low idle, put the
differential lock switch in the AUTO position. Use the hitch remote switches to raise the hitch to the upper
third of the hitch travel when carrying out Check 10.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 10: Differential lock solenoid o volts Bad hitch controller.
connector terminal 1 for wire 539 Light
Blue to ground.
NOTE: Lower the hitch bellow the upper third of the hitch travel when carrying out Check 11.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 11: Differential lock solenoid 12 volts Bad hitch controller.
connector terminal 1 for wire 539 Light
Blue to ground.
SM 8-10560 Issued 03-2001
SECTION 10002 59
Test 21 - Differential Lock Switch, Auto Differential and Auto Indicator Lamp
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information " on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Fully lower the rear three point hitch.
NOTE: Turn the key to OFF position. Remove the differential lock switch from the upper right hand
console top cover, DO NOT disconnect the switch from the harness.
NOTE: Turn the key to the ON position and put the differential lock switch in the OFF position.
DIFFERENTIAL' LOCK SWITCH CONNECTOR J1 (BLACK),
J2 (GREEN) AND J4 (GREY)
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal 3 of the differential lock 12 volts Bad circuit between switched power stud
switch connector for wires 540 Red or 546 and the differential lock switch.
Red and 540 Red to ground, Also check the switched power stud
con,nections and connector 26.
Check 2: Terminal 1 of the differential lock o volts Bad differential lock switch.
switch connector for wire 532 Light Blue to
ground .
Check 3: Terminal 7 of the differential lock o volts Bad differential lock switch,
switch connector for wires 546 Light Blue to
ground.
NOTE: Hold the differential lock switch in the ON (momentary) position .
Check 4: Terminal 1 of the differential lock 12 volts Bad differential lock switch.
switch connector for wire 532 Light Blue to
ground .
Check 5: Terminal 7 of the differential lock o volts Bad differential lock switch .
switch connector for wires 546 Light Blue to
ground .
continued ....
8M 8-10560 Issued 03-2001
60 SECTION 10002
NOTE: Put the differential lock switch in the AUTO position.
Check point Reading Possible Cause of Bad Reading
Check 6: Terminal 7 of the differential lock 12 volts Bad differential lock switch.
switch connector for wires 546 Light Blue to
ground .
Check 7: Terminal 1 of the differential lock o volts Bad differential lock switch.
switch connector for wire 532 Light Blue to
ground.
Check 8: Terminal 9 of the differential lock 12 volts Bad circuit between the controller and the
switch connector for wire 539 Light Blue to differential lock switch indicator lamp. Go
ground . to Check 10.
NOTE: Turn the key to the OFF position.
Check 9: Terminal 10 of the differential lock Continuity Check the chassis ground wire and the
switch connector for Brown wire to ground . chassis ground connection .
NOTE: Remove the lower right hand console side cover. Disconnect connector J1 (Black), connector
J2 (Green) and connector J4 (Grey) from the hitch controller.
Check 10: Between terminal 9 of the Continuity Check wire 539.
differential lock switch connector and
connector J2 (Green) pin 5 for wire 539
Light Blue.
NOTE: Turn the key to the ON position and hold the differential switch in the ON (momentary) position.
Check 11: Connector J4 (Grey) pin 2 for 12 volts Check wire 532 between the differential
wire 532 Light Blue to ground. lock switch and connector J4.
NOTE: Put the differential switch in the AUTO position.
Check 12: Connector J1 (Black) pin 30 for 12 volts Check wire 546 between the differential
wire 546 Light Blue to ground. lock switch and connector J 1.
NOTE: Turn the key to the OFF position and disconnect the differential lock solenoid from the harness.
Check 13: Between connector J2 (Green) Continuity Check wire 539 between connector J2
pin 7 and differential lock solenoid (Green) and the differential lock solenoid.
connector terminal 1 for wire 539 Light Blue. Also check connector 40 and splice pack 9
(if equipped) or the R/H console harness
line splice.
NOTE: If the readings are correct check the brake circuits, refer to "Brake Switches" on page 68. If the
brake circuits are working correctly, erase all error codes and reprogramme the hitch controller, refer
to Section 10010. Calibrate the hitch, refer to "DELUXE HITCH CALIBRATION" on page 5.
8M 8-10560 Issued 03-2001
SECTION 10002 61
Test 22 - Differential Lock Warning Lamp and Switch
NOTE: Before carrying out the following tests, refer to Circuit Testing "Genera/Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Turn the key to the OFF position and check the differential lock warning lamp bulb.
NOTE: Disconnect the differential lock warning switch from the harness. Turn the key to the ON position and allow
the hitch controller to go through the self test procedure.
CONNECTOR C1 PIFFERENtlAL LOCK
WARNING SWITCH
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal A of the differential lock 12 volts Check wire 735 Light blue between the
warning switch (harness side) for wire 735 differential lock warning switch and the
Light Blue to ground. splice. Also check the hitch error codes and
hitch solenoid circuits.
NOTE: Turn the key to the OFF position and remove and disconnect the instrument cluster from the
harness.
Check 2: Between the instrument cluster Continuity Bad circuit between the differential lock
connector C 1 pin A-6 and terminal B of the warning switch and the instrument cluster.
differential lock warning switch (harness Go to check 3.
side) for wire 735 Light Blue.
NOTE: If the reading at checks 1 and 2 are correct replace or adjust the differential lock warning
switch as necessary, refer to Section 9001.
NOTE: Disconnect connector 40 (transmission harness to right hand console harness).
Check 3: Between the connector 40 pin 9 Continuity Check wire 735 Light Blue between
and terminal B of the differential lock connector 40 pin 9 and the differential lock
warning switch (transmission harness side) warning switch.
for wire 735 Light Blue.
NOTE: Connect connector 40 and remove the lower right hand console side cover. Disconnect
connector 26 (instrument panel harness to right hand console harness).
Check 4: Between terminal B of the Continuity Check right hand console harness wire 735
differential lock warning switch (transmission Light Blue between connectors 26 and 40.
harness side) and pin F of connector 26
(right hand console side) for wire 735 Light
Blue.
NOTE: If the readings are correct check the instrument panel harness wire 735 Light Blue between
instrument cluster connector C1 and connector 26.
8M 8-10560 Issued 03-2001
62 SECTION 10002
MFD Circuit
IMPORTANT: If the AUTO MFD mode is selected and the MFD DOES NOT DISENGAGE when the
tractor speed is above 10 mph (16 kmlh) check the wheel speed sensor, refer to "Test 15 - Wheel Speed
Sensor" on page 48.
IMPORTANT: When the AUTO MFD is selected the MFD must ENGAGE when the brakes are applied
when the tractor is travelling above 10 mph (16 kmlh). If the MFD does not engage when the brakes are
applied check the brake circuits, refer to "Brake Switches" on page 68.
Test 23 - MFD Solenoid
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Check fuse 26.
NOTE: Turn the key to the OFF position and disconnect the MFD solenoid harness connector from the
transmission harness.
MFD SOLENOID CONNECTOR MFD SOLENOID
Check point Reading Possible Cause of Bad Reading
Check 1: MFD solenoid harness connector approximately Bad MFD solenoid harness. Go to check 2.
for wire 543 Light blue to ground. 10 Ohms
NOTE: If the reading is correct go to check 4.
NOTE: Remove the cover plate and disconnect the MFD solenoid from the solenoid harness.
Check 2: Between the terminals of the Continuity Bad MFD solenoid harness.
MFD solenoid harness for wire 543 Light
Blue.
Check 3: MFD solenoid terminal to ground. approximately Bad MFD solenoid.
10 Ohms
NOTE: Turn the key to the ON position and put the MFD switch in the OFF position.
Check 4: MFD solenoid harness connector 12 volts Bad circuit between the MFD switch and
(transmission harness side) terminal for the MFD solenoid: Check the following:
wire 543 Light Blue to ground. MFD switch . refer to "Test 24 - MFD Switch
and Auto MFD Circuit" on page 64.
MFD relay, refer to "Test 25 - MFD Relay
Circuit" on page 65.
Also check connector 40.
continued ....
SM 8-10560 Issued 03-2001
SECTION 10002 63
NOTE: Hold both brake pedals DOWN.
Check Point Reading Possible Cayse of Bad Reading
Check 5: MFD solenoid harness connector o volts Check the brake circuit, refer to "Brake
(transmission harness side) terminal for Switches" on page 68 and MFD relay, refer
wire 543 Light Blue to ground . to "Test 25 - MFD Relay Circuit" on
page 65.
NOTE: Release the brake pedals and put the MFD switch in the ON position.
Check 6: MFD solenoid harness connector o volts Check MFD switch , refer to "Test 24 - MFD
(transmission harness side) terminal for Switch and Auto MFD Circuit" on page 64
wire 543 Light Blue to ground. and the MFD relay, refer to "Test 25 - MFD
Relay Circuit" on page 65 .
NOTE: Put the MFD switch in the AUTO position.
Check 7: MFD solenoid harness connector o volts Bad circuit between the MFD switch and
(transmission harness side) terminal for the MFD solenoid. Also check the
wire 543 Light Blue to ground . following:
MFD switch , refer to "Test 24 - MFD Switch
and Auto MFD Circuit" on page 64 .
NOTE: Start and run the engine at low idle, use the hitch remote switches to raise the hitch to the upper third
of the hitch travel when carrying out Check 8. Make sure the range and speed selector levers are in
NEUTRAL.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 8: MFD solenoid harness connector 12 volts Bad hitch controller.
(transmission harness side) terminal for
wire 543 Light Blue to ground.
NOTE: Lower the hitch bellow the upper third of the hitch travel when carrying out Check 9.
IMPORTANT: Watch for pinch points between the lower links and the tractor when the hitch is moved.
Check 9: MFD solenoid harness connector o volts Bad hitch controller.
(transmission harness side) terminal for
wire 543 Light Blue to ground.
SM 8-10560 Issued 03-2001
64 SECTION 10002
Test 24 - MFD Switch and Auto MFD Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information " on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Fully lower the rear three point hitch.
NOTE: Turn the key to OFF position. Remove the MFD switch from the upper right hand console top
cover, DO NOT disconnect the switch from the harness.
NOTE: Turn the key to the ON position and put the MFD switch in the OFF position.
MFD SWITCH CONNECTOR J1 (BLACK),
J2 (GREEN) AND J4 (GREY)
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal 5 of the MFD switch 12 volts Bad circuit between switched power stud
connector for wires 530 and 540 Red to and the MFD switch.
ground. Also check the switched power stud
connections, connector 26 and splice 9.
Check 2: Terminal 1 of the MFD switch o volts Bad MFD switch .
connector for wire 541 Light Blue to ground.
Check 3: Terminal 7 of the MFD switch o volts Bad MFD switch .
connector for wire 565 Light Blue to ground.
NOTE: Put the MFD switch in the ON position.
Check 4: Terminal 1 of the MFD switch 12 volts Bad MFD switch.
connector for wire 541 Light Blue to ground .
Check 5: For terminal 7 of the MFD switch o volts Bad MFD switch .
connector for wire 565 Light Blue to ground.
NOTE: Put the MFD switch in the AUTO position.
Check 6: Terminal 7 of the MFD switch 12 volts Bad MFD switch.
connector for wire 565 Light Blue to ground .
Check 7: Terminal 1 of the MFD switch o volts Bad MFD switch.
connector for wire 541 Light Blue to ground.
NOTE: Turn the key to the OFF position. Remove the lower right hand console side cover and disconnect
connector J1 (Black) and J4 (Grey) from the hitch controller. Turn the key to the ON position.
Check 8: Connector J1 (Black) pin 29 for 12 volts Check wire 565 Light Blue between the
wire 565 Light Blue to ground. MFD switch and connector J1 .
continued .. ..
8M 8-10560 Issued 03-2001
SECTION 10002 65
NOTE: Put the MFD switch in the ON position.
Check Point Reading possible Cause of Bad Reading
Check 9: Connector J4 (Grey) pin 5 for wire 12 volts Check wire 541 Light Blue between the
541 Light Blue to ground. MFD switch and connector J4.
NOTE: Turn the key to the OFF position. Remove relay 3 MFD and disconnect connector J2 (Green)
from the hitch controller.
Check 10: Between the MFD relay terminal Continuity Check wire 566 Light Blue between the
block terminal 2 and connector J2 (Green) MFD relay and connector J2.
pin 8 for wire 566 Light Blue.
NOTE: If the readings at checks 8, 9 and 10 are correct, check the MFD relay circuit on Page 65 and
the brake switches on Page 68. If the MFD relay circuit, MFD switch and brake switches are operating
correctly, erase all error codes and reprogramme the hitch controller, refer to Section 10010. Calibrate
the hitch.
Test 25 - MFD Relay Circuit
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Turn the key to the OFF position. Remove the lower right hand console side cover and remove the MFD relay.
DS98M197
RELAY MFD MFP RELAY CONNECTOR BLOCK
Check Point Reading possible Cause of Bad Reading
Check 1: Terminal 2 of the MFD relay Continuity Check the chassis ground wire and the
connector block for Brown wire to ground. chassis ground connection.
NOTE: Turn the key to the ON position.
Check 2: Terminal 3 of the MFD relay 12 volts Check wire 540 between the MFD switch
connector block for wires 540 Red to and the MFD relay. Also check the MFD
ground. switch, refer to "Test 24 - MFD Switch and
Auto MFD Circuit" on page 64.
continued .. ..
SM 8-10560 Issued 03-2001
66 SECTION 10002
NOTE: Turn the key to the OFF position. Disconnect connector J2 (Green) from the hitch controller.
MFD SOLENOID CONNECTOR CONNECTOR J2 (GREEN)
Check Point Reading Possible Cause of Bad Reading
Check 3: Between terminal 1 of the MFD Continuity Check wire 566 between the MFD relay and
relay connector block and connector J2 connectorJ2.
(Green) pin 8 for wire 566 Light Blue.
NOTE: Disconnect the MFD solenoid from the harness.
Check 4: Between terminal 4 of the MFD Continuity Check wire 543 between the relay and the
relay and terminal 1 of the MFD solenoid solenoid.
connector for wire 543 Light Blue. Also check connector 40.
Check 5: Between terminal 5 of the MFD Continuity Check wire 542 between the relay and
relay and terminal A of connector 26 connector 26.
(instrument panel harness side) for wire 542 Also check connector 26.
Light Blue.
NOTE: Install the MFD relay and turn the key to the ON position. Put the MFD switch in the ON
position.
Check 6: Terminal A of connector 26 (R/H 12 volts Bad relay. Also check wire 542 between the
console harness side) for wire 542 Light relay and connector 26, go to Check 9.
Blue to ground .
NOTE: Turn the MFD switch to the OFF position.
Check 7: Terminal A of connector 26 (R/H o volts Bad relay.
console harness side) for wire 542 Light
Blue to ground.
continued .. ..
SM 8-10560 Issued 03-2001
SECTION 10002 67
NOTE: Remove the instrument cluster, do not disconnect the instrument cluster from the harness.
CONNECTOR C1
Check Point Reading Possible Cause of Bad Reading
NOTE: Remove the instrument cluster, do not disconnect the instrument cluster from the harness.
Check 8: Between terminal A of connector Continuity Check wire 542 between the cluster and
26 (instrument panel harness side) and connector 26 .
instrument cluster connector C1 A-11 for
wire 542 Light Blue.
NOTE: If a new MFD relay has been installed when carrying out the MFD relay circuit test and the fault
remains check the MFD switch on Page 64 and brake switch circuits on Page 68. If the MFD switch
and the brake switches are operating correctly, erase all error codes and reprogramme the hitch
controller, refer to Section 10010. Calibrate the hitch.
Test 26 - MFD Indicator Lamp
NOTE: Before carrying out the following tests , refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Turn the key to the OFF position. Remove the instrument cluster from the instrument panel DO
NOT disconnect the instrument cluster from the harness.
NOTE: Turn the key to the ON position and put the MFD switch in the ON position.
CONNECTOR Cl
Check Point Reading Possible Cause of Bad Reading
Check 1: Instrument cluster connector C1 12 volts Bad circuit between the MFd relay and the
pin A-11 for wire 542 Light Blue to ground . approximately instrument cluster.
NOTE: If the readings at Check 1 are correct check the instrument cluster clean ground circuit.
8M 8-10560 Issued 03-2001
68 SECTION 10002
Brake Switches
Test 27
NOTE: Before carrying out the following tests, refer to Circuit Testing "General Information" on page 19.
NOTE: Refer to the Schematic Circuit on Page 76 and 77.
NOTE: Check fuse 26.
NOTE: Turn the key to the OFF position . Remove the instrument cluster from the instrument panel and
remove the two instrument panel retaining screws to gain access to the brake switches. Disconnect the
LlH and RIH brake switches from the harness. Turn the key to the ON position.
LlH AND R/H BRAKE SWITCHES INSTRUMENT PANEL
RETAINING SCREWS
Check Point Reading Possible Cause of Bad Reading
Check 1: Terminal A of the left hand brake 12 Volts Bad circuit between switched power stud
switch connector for wire 530 Red to and the left hand brake switch.
ground.
Check 2: Terminal A of the right hand brake 12 Volts Bad circuit between switched power stud
switch connector for wire 530 Red to and the right hand brake switch.
ground .
NOTE: If one of the reading at check 1 or check is correct and the reading at the other is incorrect,
check the wire 530 Red between the brake pedal switch with the bad reading and the splice.
NOTE: Turn the key to the OFF position.
Check 3: Between terminals A and B of the No continuity Adjust or replace the switch as necessary,
left hand brake switch. refer to Section 9001, Pedal Lever and
Switch Adjustments.
Check 4: Between terminals A and B of the No continuity Adjust or replace the switch as necessary,
right hand brake switch. refer to Section 9001, Pedal Lever and
Switch Adjustments .
NOTE: Hold both brake pedals DOWN.
Check 5: Between terminals A and B of the 3.9 Ohms Adjust or replace the switch as necessary,
left hand brake switch. approximately refer to Section 9001, Pedal Lever and
Switch Adjustments.
Check 6: Between terminals A and B of the 3.9 Ohms Adjust or replace the switch as necessary,
right hand brake switch . approximately refer to Section 9001, Pedal Lever and
Switch Adjustments .
8M 8-10560 Issued 03-2001
SECTION 10002 69
NOTE: Turn the key to the OFF position. Remove the lower right hand console side cover and remove
the brake relays.
241
DS98M197
LlH AND R/H B'RAKE RELAYS RELAY CONNECTOR
Check point Reading possible Cause of Bad Reading
Check 7: Between terminal 1 of brake relay Continuity Check wire 536 between the left hand
4 (left) and terminal B of the left hand brake brake switch and relay 4.
switch for wire 536 Light Blue. Also check connector 27.
Check 8: Between terminal 1 of brake relay Continuity Check wire 531 between the right hand
5 (right) and terminal B of the right hand brake switch and brake relay 5.
brake switch for wire 531 Light Blue. Also check connector 28.
NOTE: Disconnect connector J1 (Black) from the hitch controller.
CONNECTOR J1 (BLACK)
Check 9: Between terminal 1 of brake relay Continuity Check wire 536 between relay 4 and
4 (left) and connector J1 (Black) pin 36 for connector J 1 (Black).
wire 536 Light Blue.
Check 10: Between terminal 1 of brake Continuity Check wire 531 between relay 5 and
relay 5 (right) and connector J 1 (Black) pin connector J 1 (Black).
37 for wire 531 Light Blue.
SM 8-10560 Issued 03-2001
70 SECTION 10002
This Page Has Been Left Blank
SM 8-10560 Issued 03-2001
SECTION 10002 71
HARNESS LAYOUT, SCHEMATICS AND CONNECTORS
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1. CONNECTOR 1 (TO CAB HARNESS) 14. UPPER/LOWER HEADLIGHT SWITCH (EUROPE ONLY)
2. POWERSHIFT CLUTCH PEDAL POSITION SWITCH 15. KEY SWITCH
3. ROTARY LIGHT SWITCH 16 . CAB POWER RELAY
4. FUSE BLOCK 17. HEADLIGHT DIPPER RELAY
5. COLD START SWITCH 18 . FLASHER RELAY
6. INSTRUMENT CLUSTER CONNECTOR C2 19. BLOWER MOTOR CIRCUIT BREAKER
7. SWITCHED POWER STUD 20. LEFT HAND BRAKE PEDAL SWITCH
8. REAR WORK LIGHT RELAY 21 . RIGHT HAND BRAKE PEDAL SWITCH
9. FRONT WORK LIGHT RELAY 22 . 3 PIN ACCESSORY POWER CONNECTOR
10 . AC C ESSORY POWER RELAY 23. UNSWITCHED POWER STUD (BATTERY POWER)
11 . INSTRUMENT CLUSTER CONNECTOR C1 24 . CONNECTOR 71 (SELF CANCELLING TURN SIGNAL)
12. HAZARD WARNING SWITCH (EUROPE ONLY) 25 . CONNECTOR 32 (STALK SWITCH)
13 . WORK LIGHT SWITCH
G1. CHASSIS GROUND CONNECTION G1
SM 8-10560 Issued 03-2001
72 SECTION 10002
--- -------
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--;
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1. CONNECTOR #26 (TO INSTRUMENT PANEL) 14. RIDE CONTROL SWITCH
2. CONNECTOR #27 (TO INSTRUMENT PANEL) 15 . HITCH DROP SPEED POTENTIOMETER
3. CONNECTOR #29 (TO INSTRUMENT PANEL) 16. HITCH TRAVEL POTENTIOMETER
4. AUDIBLE ALARM RELAY 17. HITCH DIAGNOSTIC DIGITAL DISPLAY
5. MFD RELAY 18 . HITCH UPPER HEIGHT CONTROL POTENTIOMETER
6. BRAKE RELAY (RIGHT) 19. HITCH CONTROLLER
7. BRAKE RELAY (LEFT) 20 . CONNECTOR J1 (BLACK)
8. HITCH UPIDOWN SWITCH 21 . CONNECTOR J4 (GREY)
9. DIFFERENTIAL LOCK SWITCH 22. CONNECTOR J3 (BROWN)
10. MFD SWITCH 23 . CONNECTORJ2(GREEN
11 . SLIP LIMIT CONTROL SWITCH (IF EQUIPPED) 24 . PROGRAMMING CONNECTOR
12. POSITION COMMAND POTENTIOMETER 25 . CONNECTOR #40 (TO TRANSMISSION HARNESS)
13. LOAD COMMAND POTENTIOMETER 26 . CONNECTOR #52 (TO FENDER HARNESS)
G2 . CHASSIS GROUND CONNECTION G2
SM 8-10560 Issued 03-2001
SECTION 10002 73
DI97N013
1. CONNECTOR #40 (TO RIGHT HAND CONSOLE) 6. HITCH POSITION POTENTIOMETER
2. HITCH LOAD SENSING PIN CONNECTOR 7. HITCH LOAD SENSING PIN
3. HITCH LOWER SOLENOID 8. LEFT HAND HITCH REMOTE SWITCHES
4. HITCH RAISE SOLENOID 9. RIGHT HAND HITCH REMOTE SWITCHES
5. HITCH POSITION POTENTIOMETER CONNECTOR 10 . CONNECTOR #52 (TO RIGHT HAND CONSOLE)
SM 8-10560 Issued 03-2001
74 SECTION 10002
Hitch Control Schematic Circuit
WHEEL SPEED SENSOR, HITCH SOLENOIDS AND LOAD PIN INSTRUMENT CLUSTER HITCH POSITION POTENTIOMETER AND REMOTE SWITCHES RADAR, TRAILED IMPLEMENT SWITCH, HITCH UP/DOWN SWITCH AND SLIP CONTROL SWITCH
- - - - - BATTERY POWER ( B + ) - - - - - - INSTRUMENT CLUSTER
- - - - - SWITCHED POWER ---4ITI----- FUNCT ION PIN NO 281 Y 75 2 8 1 Y 7 5 ¥ 281Y75 2B1Y75--
RADAR SIGNAL 2·A·l0 r-: r-- . - - - - - - - 282Y75 N 282Y.75 - - - -- - - - - - - - - - - - - - - - - - - - -- -- - - -- - - - 282Y75 _
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281 Y 75 2B1Y 75
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a: RADAR PRESENT 2·6-2 r-: r-- 282Y 75 282Y.75 ~
...'" r-: 282Y.75 I 509LB.75 Z
26
509LB.75 509LB;z.75 562lB.75 -
509lB.75 _
FUSE
HITCH IMPLEMENT UP/ooWN SWITCH
RADAR GROUND
2·B-4
2-A·2
r:r 509lB 75
~f- 280BR.75
10"
-==-:- ~rb-------- 510lB75-
#33 RADAR POWER OLITPUT (12V) l ·A-3 r--
280R 75 '------282Y75-~'HH- 282Y75 0 LGIY75 0 -20A
R 83' ~_ f6'T'4l 2 7 ~ 50BlB 75 _
550Rl .0
7.SA
TRAILED IMPLEMENT UP/ooWN SWITCH
WHEEL SPEED SIGNAL
2·B-3
2-A·5
~r-- 563lB.75
~r-- 215Y 75 II ' - - - - - -- - - - - 281 Y 75 -
' - - - - - - - - - - - 280BR.75 -
L -_ __ _ _ _ _ _ _ _ _ 280R 75 -
~ i-;:F -
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281 Y 75
280SA 75
280R 75
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HITCH
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500Rl0 - - - - - - - - - -- -- - - - - - - - - - 500Rl 0 - - - + + + - - - - - + - - -- - SOOR1.0 ~ 500Rl0 <;I SWITCH
215Y 76 ~ 215Y.75 ] 215Y 75 ~ 5 1~
LEJ ~7 563lB.75 OR 240Y.75
L -_ _ _ __ _ _ _ ______ 563lB.75 4 563lB.75 OR 240Y.75 - - - - - - , 5 R
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AFS CONNECTOR 5
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281Y 75
282Y75 - - ----' 215R.75 II
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- - - - - --
r'- -- - - - -
- - - 215Y 75 - -- - - - - - -- - --
513lB.75 OR 513BRl 0 - - - --
- - - - - - - - - - - - -- -- - - -- -- _ + - + - - - + - - - 1 - - --
- - - -- - - - - - - - -- -- -- - - - - - -- -- + - + - - - + - + -- -
- - - - - - + - - -- - --- 215Y 75 - -
- - -- - --+- - 513lB 75 OR 513BRl 0 -
215Y 75 ----------W-TO-AR-DN-I~-~~-R-lE-I~-~-I~-~-0-~T-~-KH-- ~,,~ HII [ ~:::: - - - - - -- - - - - - - - - - - - -- - -- - -- - -- -- ----++---t--+- - - - - - -- --lf---____ ~:::~--~
. - - - -- - 511 Rl .0 - - - - -- ----, 0 0 507lB 75 - - - - - -- - - - - - - - - - - - -- - -- - - - - - - -- - -- -+-+- - + + - - - - - - -- -- + - - -_ _ _ 507lB.75 _
511Rl0
q~LOV)r.n
§~ ~ i~~ 507Rl 0 .---_ _ _ 529LB.75 _ K ~t- 529lB 75 - - _/ - / -_ _+-+-_ _ _ __ _ _ _ _+ -- - -- - 5~:l~\~ -=--_-
:n u; u::; ;;; u; ~ _ 528L875 - J ~~ 528LB 75 528LR75 _
RAISE LOWER
r- 528R.'75 - H ~I- 500R .75 ~R 528R 75 -+-+_ _---1
-r. '-----+ ----+- - -
SOLENOID
5 1012
OHMS
SOLENOID
510 12
OHMS
r--- C ~ 563lB 75 OR 240Y 75 -
563lB 75 OR 240Y 75 563lB.75 OR 240Y 75 -
'-- 508SA.7 5 -
~
L :!?:!?:!? I ..--- 568LB,75 ----+- 568lB 75 -
g5 :9 a: L - -_ _ _ 583LB.75 - _ _ ..., 567lB.75 567LB.75 -
511Rl 0 ~ ~ ~ .-------t- 570lB.75 -
HITCH
;~:: II POSITION TRAilED
SUP
iII r
POTENTIOMETER
513LB10 - - - - -- - - - - - - :
~ ~ ~ L{) L{)
IMPLEMENT
SWITCH
SEE NOTE 1
( II
6 SUP
~~a: co
~~ co CONTROL
L a
CCI
Q') OJ
:~: =lB :::~=;: ~
GROUND LOAD SWITCH
.
SPEED
SENSOR
PIN
SENSOR
R.75 C
49
1--- - -
514R 75 - - - - - - - '
571R75 R
l R
528R.75
~
i
on
.....
'--- - - - - - - - + - - - -- -- - - - - - - - -- -- - - - - - - - 550Rl 0 <1 lHHITCH
REMOTE SWITCH
WITH 390
A
B
528lB.75
528R.75
528LB.75
528R.75
C.
B
RHHITCH
REMOTE SWITCH
WITH 390
'"
":
gj
a:w
co
~~~I~~~~~ ~~~I~~~~~ ~
o
TO FRONT PTO SOLENOID <::J--- 551lBl0 3 C 529LB.75 529LB.75 A In
G2
551BR;:ONTCONNECTOR
~0:ARNESS 571R 75 -
~
____ _ _ _ _ _ _l _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _L_____
571R.75
_ _ _ _ _ _ __ __ _ _ _ _ _ ~ ~±---~±---
G2 571 R.75 -
-----CHASSISGROUND ----~----~~~~----------~~~---""~~----------------~""""------------------~"'"'"'"'~---------------------- CHASSISGROUND~G~
2 ~--~.-~-------
- - - CLEAN GROUND CLEAN GROUND _ _ _ _ _ _ _ _ _ _ __
DIOOH045
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur.
SM 8-10560 Issued 03-2001
SECTION 10002 75
RIDE CONTROL SWITCH HITCH CONTROLLER HITCH CONTROL AND HITCH COMMAND POTENTIOMETERS
HITCH CONTROLLER HITCH CONTROllER CONNECTOR IDENTIFICATION HITCH HITCH TRAVEL UPPER HEIGHT
- - 261 Y 75 - - - - - - - - - 261Y.75 _
~ Jl·27 RADAR SIGNAL Jl BLACK DROP SPEED
POTENTIOMETER
OJ" \ POTE NTiOMETER CONTROL
POTENTIOMETER
- - 262Y.75 - -- - -- -- - 262Y75 - ~ Jl·26 RADAR PRESENT J2 GREEN
562lB 75- ~ Jl·40 HITCH MOMENTARY SWITCH J3 BROWN HITCH
- - 562lB 75 - - - - -- - --
509lB.75 - ~ HITCH DOWN SWITCH J4 GREY DIAGNOSTICS
- - 509lB 75 - -- - - - - -- Jl·39
~
6
- - 510lB 75 - - - - - -- - - 510lB 75 - ~ Jl·36 HITCH UP SWITCH A SEGMENT 1 J3-1 ~I- BR _
- - 506lB 75 - - -- - - -- - 506lB.75 - ~ J2·6 HITCH ENABLE LAMP BSEGMENT 2 J3-2 r- r-- R_
~ J2·10 NOT USED CSEGMENT3 J3·3 r-- 0 -
J2·11 7 SEGMENT
~ NOT USED DSEGMENT 4 J3-4 r-- Y-
lED DISPLAY
~ E SEGMENT 5 J3·5 f-- l G _
~ F SEGMENT 6 J3·6 ~f--lB-
~ G SEGMENT 7 J3·7 ~ I-- V_
DIFFERENTIAL lOCK SWITCH <J 546lB.75 - ~ Jl·30 AUTO DIFFERENTIAL INPUT DECIMAL POINT 6 J3·6 ~r-- G-
AUTO DIFFERENTIAL lOCK LAMP <J 539lB.75 - ~ J2·5 AUTO DIFFERENTIAL ENABLE VCCSOURCE9 J3·9 ~ r-- W-
DIFFERENTIAL lOCK SOLENOID <J 539lBl0 - ~ J2·7 DIFFERENTIAL SOLENOID OUTPUT PROGRAM A J3-10
~ PROGRAM B J3-11
a:"'" <Ii a:"'" <Ii '"
U1 U1 U1 U1
" a:....'"
PROGRAM GROUND J3·12
" a:'"....
- - 500Rl 0 - - - - - - - - - 500Rl 0 - ~ J2·1 SWITCHEDB+ r--
~~
- - 215Y.75 - - - - - - -- -
" a:'" ci <Ii
215Y 75 - ~
~
Jl·26 WHEEL SPEED SIGNAL
'"
('oJ
0
...J
N
0
('oJ
0
U1 '"
<D
0 0
...J <D
<D 0
U1
'"
0
<D
...J
0
<D
g
- - 511Rl 0 - - - - - - -- -
- - 512lB.75 OR 512BRI 0 - - - - -
511Rl 0 -
512lB.75OR 512BR1 .0- ~
J2·2
J2·4
HITCH SOLENOID SUPPLY OUTPUT
HITCH VALVE lOWER
W U1 U1
'" '" '" '" '"
- - 513lB.75 OR 513BRI 0 - -- - - 513lB.75 OR 513BR1 .0- ~ J2·3 HITCH VALVE RAISE
1
d
- 514BR.75 - - - - - - - - - 514BR.75 - ~ Jl·33 DRAFT SENSING GROUND I
- - 514lB.75 - - - - -- - - - 514lB 75 - ~ Jl·35 DRAFT SENSOR SIGNAL "
a: '"~
- - 514R 75 - - - - - - -- - 514R.75 - ~ Jl·32 DRAFT SENSOR (+6 VOLTS) ~ ~
~ Jl·34 NOT USED ~ ~
- - 507BR 75 - - - - - - -- - 507BR.75 - ~ Jl·21 HITCH POSITION POTENTIOMETER lOW
~t;~ ~ 1;t;~ I~1
- - 507lB.75 - - - -- - - - - 507lB 75 - ~ Jl·20 HITCH POSITION POTENTIOMETER SIGNAL HITCH CONTROllER l 3l2jl j 615 1
- - 507Rl0 - - - - - - -- - 507Rl0 - ~ Jl·19 HITCH POSITION POTENTIOMETER HIGH PROGRAMING
CONNECTOR
- - 529lB.75 - - - -- - - - - 529lB.75 - ~ Jl·25 REMOTE DOWN SWITCH
- - 526lB.75 - - - - - - -- - 528lB.75 - ~ Jl·24 REMOTE UP SWITCH
MFD RELAY <:J-- 566lB 75 - ~ J2·6 MFD SOLENOID OUTPUT
- 563lB 75 OR 240Y 75 - - - -- - MFDSWITCH <:J-- 565lB.75 - ~ Jl·29 AUTO MFD INPUT HITCH DROP RATE POTENTIOMETER lOW Jl·6 .<- 502BR75 -
I 563lB.75 OR 240Y.75 ~ Jl·31 IMPLEMENT UP INPUT HITCH DROP RATE POTENTIOMETER SIGNAL Jl·5 . <- 502lB75
- - 5 6 6 l B . 7 & 6 - - - - -- - -- 566lB.75 - ~ Jl·22 SLIP SET HITCH DROP RATE POTENTIOMETER HIGH Jl·4 :<- 502R.75
--567LB.7 & 5 - - - - - -- -- 567lB.75 - ~ Jl·23 SLIP SELECTED (ON) HITCH UPPER LIMIT POTENTIOMETER lOW Jl·3 .<- 560BR.75
- - 5 1 O L B . 7 & 5 - - - - - -- -- 570lB 75 - ~ J2·9 SLIP lAMP HITCH UPPER LIMIT POTENTIOMETER SIGNAL Jl·2 - 560lB75
573lB.75 573lB 75- ~ J4·6 AUTO HITCH UP HITCH UPPER LIMIT POTENTIOMETER HIGH J1-1 - 560R75
2LB.75 572lB 75- ~ J4·4 RIDE CONTROL ON HITCH TRAVEL POTENTIOMETER lOW J1-15 - 506BR 75
RIDE J4·1 NOT USED
~ HITCH TRAVEL POTENTIOMETER SIGNAL Jl·14 - 506lB.75
~
CONTROL
SWITCH FROM BRAKE <J- 536lB.75 - ~ Jl·36 lEFT HAND BRAKE INPUT HITCH TRAVEL POTENTIOMETER HIGH Jl·13 - 506R75
RELAYS <J- 531LB.75- ~ Jl·37 RIGHT HAND BRAKE INPUT NOT USED Jl·9
II NOT USED
t;. ) ~ Jl·6 <
<J-
w
I@ DIFFERENTIAL
LOCK SWITCH
532lB 75 -
. ~
~
J4·2
J4-3
DIFFERENTIAL LOCK ENGAGE
NOT USED
NOT USED
HITCH POSITION COMMAND POTENTIOMETER HIGH
Jl-7
J1-16 - 504R75 A HITCH
o MFOSWITCH <J- 541LB1 .0 - ~ J4-5 MFDON HITCH POSITION COMMAND POTENTIOMETER SIGNAL Jl · 17 - 504lB75 8 POSITION COMMAND
iI' POTENTIOMETER
~
a:
w ~ HITCH POSITION COMMAND POTENTIOMETER lOW Jl·16 - 504BR.75 C
>
o ~ HITCH LOAD COMMAND POTENTIOMETER HIGH Jl-l0 <- 505R75 HITCH
....
U1
,.- 500BRWI 0 ~ 500BR1W1.0 OR _ H J2-12 CLEAN GROUND HITCH lOAD COMMAND POTENTIOMETER SIGNAL Jl-l1 f-- 505lB.75 lOAD COMMAND
cr' 560BRW1.0 POTENTIOMETER
40 ~ HITCH lOAD COMMAND POTENTIOMETER lOW J1-12 r- 505BR 75
- - - - - 571R 7 5 - - - - - - - - ' '" G2
1 54 551 57 1
~ CHASSIS GROUND _ __ _ _ _ _ _ _ _ __
---"1."'11.",>,,,,»,,,,,/),,»r--- CHASSIS GROUND /"I/If/If/ "lflllllll 1/11/1/11/1
- - - -- - - - - CLEAN GROUND ClEANGROUND-------- - - - -
DIOOH046
8M 8-10560 Issued 03-2001
76 SECTION 10002
Differential Lock and MFD Schematic Circuit
BRAKE RELAYS AND BRAKE SWITCHES DIFFERENTIAL LOCK AND MFD
--- BATTERYPOWER(B~------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- BATTERYPOWER(B~ -----------------
- - SWITCHED POWER SlMTCHED POWER - - - - - - - - -
536LB.75 - -- - - - - - - - - - - -- - -- - - - -- - - -- - - - - - - - - -- -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - -- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - -- - - - - - - - - - - - - - - - - - 5~LB7>___
531LB75 - - - - - - -- -- - - - - -- - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - 531LB75---
n~
C'!
..
N
Ir
540R1 .0 540R1 0 OR 546R1 .0 540R1 .0
U
i ' '
~ {'""
~ : :
~
l
530R 75 / " - - - - - - 540R1 .0
#26 LH BRAKE
530R 75
• 530R.75
RH BRAKE
>'
0:
~
Z
w
:2
MFD
SlMTCH
l!' 20 AMP 30 AMP SWITCH SWITCH o
.- 26 U N/C N/C ~u.~
~ 540R1 .0
(WITH 390HM 531R 75
(WITH 390HM
RESISTOR)
zu.:=J
o0 4; ,--.L.f--'-- - -.L.f--'--,-y....,
MFD RELAY
(DIODE SUPPRESSED)
RESISTOR)
~ q SEE NOTE1 SEE NOTE 1 DIFFERENTIAL ~ 0
0:
N LOCK ~+-~~--~
C>
r-. S ....nCH
5~LB. 75 - A
Ir
o
q ,.---- - - - - - - 536lB.75
c:
N ~ 531lB.7S - - - - - - - -- - - - -- -- - - - - - - - - - - - -
....o
'-_____+---, sa1t-B.7S , - - - - - - - - - 531LB.75 - - - - - -- - - - - - - - -- - 531LB.75
~--------- 702P1 0 OR 702R1 0
I L ~,"" 541 LB1 0
----------t-t-t- - ---------- 565LB.75
541 LB1 0
' - - - - - - - - - - -- - - - - - - - - - - - 539LB.7S 539LB 75
LEFT HAND
BRAI<ERELAY
RIGHT HAND
BRAKE RELAY
546LB.7S --+---- -------------- ------------ 546LB 75 ----------t-l--I-------------- 546LB 75
(DIODE SUPPRESSED) (DIODE SUPPRESSED) S32LB.7S -+- - -------------- ----------- 532LB.75 ---------1-1-1------------- 532LB.75
,------------- 539LB1 0
r------ BR.75 - - - - - - - - - - - - - - - '
- - - - - - - - 511R1 .0 - -
,--- - - - - BR.75 - - - - - - - - - -- - - -- - - -- - - - - - - - - -- -- -- - - - - BR75 q
~
tt:
L-~~--------------- BR75------------/ 549LB1 0 OR 349LBl 0
~ INSTRUMENT CLUSTER
'--~--------------- 702P1 0 -
' - - - - - - - - - - -- - - - 539LB1 0 -
----------'
- -------------'
' - j - - - - - - 702P1 0
MFD INDICATOR
DIFFERENTIAL LOCK WARNING UGHT
1·A·11
1·A-6
~ f--
~ f--
31
'--
542LB.75
735LB 75 ---w .
~542lB.75
735LB 75 OR 53SLB.75
543LB1 0 ~ 543LB10 - - - - - - - - - -- - -- - - - - 543LB1 .0
TO PNEUMATIC ,----- - - - 539lB1 0 - - -- - - - - - - - - - - - - - - 539LB1 .0
TRAILER BRAKE ~ ~
SOLENOID ri ri
CD CD
7 POLE DIFFERENTIAL LOCK
TRAILER WARNING LIGHT TO HITCH
SOCKET
MFD DIFFERENTIAL SWITCH
SOLENOID SOLENOIDS
LOCK N/O
~~
B+OFF
SOLENOID (WITH 3 9 OHM
RESISTOR)
SEE NOTE 1
735LB.75
G2 G5 G5 G5 G2 G2 G3
- - - - - - - - - - - - - -. .- - - - - - - - - -__~ CH~SSISGROUND --. .--~~~----------------. .~--------~""""~------------------------~----~----~--------------------. .~~~~------------ CHASSISGROUND ---------------------)"""""""""H~--------------------
- - - - - - - - - - - - - - -- - - -- - - -- - ---- CLE~IGROUND CLEAN GROUND - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
DlOOH052
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur.
SM 8-10560 Issued 03-2001
SECTION 10002 77
WHEEL SPEED SENSOR HITCH CONTROLER
------------ BATTERY POW£R (B+) ----------------------------------------- ---------------------------------------------------- BATTERYPOWER(B+) -----------------------
- - -- - - SIJIi1TCHED POW£R T SIJIi1TCHED POW£R - - - - - - - - - - - -
- - 536LB.7 5 TO 562LB.75 ~
INSTRUMENT
- - 531LB.75 '"
N
CLUSTER <:}- S09LB.75 ~ 509LB.75 ~ TO H
ITCH CONTROL MODULE
'"'"~ 510LB.75~
~ I'I),I~
508LB.75 ~
z
s:0
f
FUSE
#33 0 9
7,5 AMP tii TO SUP CON TROL TO HITCH REMOTE
« g a. I' '/1' I'n' " SlMTCH S'MTCHES
u.
o:p Ac?! I@
4 _,,1
A
HITCH CONTROLLER CONNECTOR IDENTIFICATION
0 c{ ....
0: HITCH '"ri J1 BLACK
0
....
~~
J2 GREEN
UP/DOWN
)F T
0
'" SIJIi1TCH ~ / OR528R75 J4 GREY
I ~ 500Rl0
215R 75
500Rl .0
215R.75 ~ 500Rl 0 154155 156
J2·l SIJIi1TCHEDB+
HITCH CONTROLLER
536LB 7 5 - b; Jl·36 LEFT BRAKE INPUT
531LB 75 - H J1·37 RIGHT BRAKE INPUT
- - 566LB7 5 566LB 7 5 - ~ J2·8 MFDCONTROL
- - 565LB.75 565LB 75 - J1·29 AUTOMFDIN
- - 541LB1 ,0 541LB1 0 - J4·S MFDON
- - 539LB75 539LB 75 - J2·" DIFFERENTIAL AUTO LAMP
- - 546LB7 5 546LB 75- ~ J1·30 AUTO DIFFERENTIAL INPUT
- - 532LB7 5 532LB 75 - H J4·2 DIFFERENTIAL ENGAGED
- - 539LB1 a 539LB1 0 - J2·7 DIFFERENTIAL CONTROL
- - 5l1Rl ,O 511Rl0 J2·2 HITCH SOLENOID SUPPLY OUTPUT
5OOBRlWl .0 OR S608RW1 .0 500BRIW1 a OR 560BRWl 0 - J2·l2 CLEAN GROUND
215Y.75 215Y75 Jl·26 WH EEL SPEED SIGNAL
....
'"
ri
....
'"
'"
N Ii
III
I <Xl
0
140 17 118 143 1 '" '"....
'J,.'
~
N
T L v:
27
~~J~~~~~~ECTOR as
I '"": ":'" 215Y75 I:>.:;! 7 f----4 ......- 2l5Y 75 ---{>
215Y.75 ----C> TO AFSCONNECTOR TERMINAL 4
- CHASSIS GROUND
- - - CLEAN GROUND
----'i-----...,~rm""'------------'i---------------------
G2
.. ----------------------------------..,,~rm.r_----- CHASSIS GROUND - - - - - - - - - - - - - - - - - - - - - - - - -
CLEAN GROUND - - - -- - - - -- - - - -
DIOOH053
8M 8-10560 Issued 03-2001
78 SECTION 10002
Schematic Symbols
ACTUATORS
T LEVER
T HAND
~
FOOT
~
TEMPERATURE
6
LIQUID LEVEL FLOAT
y
PRESSURE
~
COIL
-kJ--
DIODE
CONTACTS
i ~ @ A
0
MOMENTARY
MAINTAINED
VARIABLE RESISTOR RESISTOR MAGNETIC
HOUSINGS
G
VACUUM SWITCH
®
PRESSURE SWITCH
0
TEMPERATURE SWITCH
@
MOTOR
Q9
LIGHT
SWITCH CONTACT CONFIGURATION
~
/0 ~ ?o ~
o 0
S.PS.T. S.PD.T. D.P.S.T. D.P.D.T.
(SINGLE POLE SINGLE (SINGLE POLE DOUBLE (DOUBLE POLE SINGLE (DOUBLE POLE DOUBLE
THROW) THROW) THROW) THROW)
MISCELLANEOUS SYMBOLS
O\y c)Q
FUSE CIRCUIT BREAKER
NOTE: Schematic symbols shown with tractor parked and power OFF..
SM 8-10560 Issued 03-2001
SECTION 10002 79
Schematic Legend
- - - - - - 123 Y 1 . 0 - - - - - - CIRCUIT TAG IF REQUIRED
CIRCUIT NUMB~ r ~RECOLOUR
SIZE mm 2
CONNECTOR TERMINAL
"-..~(I
00
CONNECTOR TYPE
INDICATES INLINE CONNECTION WITH
TERMINALS
--------~()~-------- INDICATES CIRCUIT CONNECTION
INDICATES CIRCUIT CROSSING NOT
CONNECTED
INDICATES CHASSIS GROUND CONNECTIONS
Wire Colou r Code
R ......... ............ ... ............................ ... ............ ............. RED
T ..... .. ............ .. ........................ .. .. ... .. .. ......... ... .......... ... TAN
w........................................................................... WHITE
Y ................................... .. ............ ..... ............ .. .... YELLOW
B ...... .. .......................... .............. ..... ...................... BLACK
G .... ... ........... ...... ....... ........ .. ........... .... .... .. .............. GREY
0 .... .... .................. ........ ..... ......... ..... .................. ORANGE
P ....... .. ........... ............... .. ............ ..... ........... .... .......... PINK
V .... ... .. ..................... ..... .. ... .. .. ..... ........ VIOLET (PURPLE)
BR ... .. .......................... .. ............ .. .......... .. ... .. ...... BROWN
DB .. .... .......... ....... ..... .. .. ..... ........................... DARK BLUE
DG .... ............ ...... .......... .. ... .... ..... ... ............ DARK GREEN
LB ...... .. ....... ... .. ..... ...... .. .. ..... ......... ... ....... .... LIGHT BLUE
LG .. .... ............. .. .. ............ ............ ..... ........ LIGHT GREEN
SM 8-10560 Issued 03-2001
80 SECTION 10002
Main Connectors
Connector 10 Connector 26
Location: Cab Firewall Location: Right Hand Console
~
l
o
L......J
f- l- f.- r-
ENGINE TO INSTRUMENT PANEL HARNESS 478196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire Circuit
Cavity Wire Circuit
No
No
A 8020 AlC HIGH PRESSURE SWITCH
A 542 LB MFD INDICATOR LIGHT
B 624W B+ FROM STARTER
B 707 P LH TAIUPOSITION LIGHT
C 8040 AlC HIGH PRESSURE SWITCH
C 708 P RH TAIUPOSITION LIGHT
0 162 R UNSWITCHED 8+ (CLOCK)
0 500 R HITCH B+
E 200 INSTRUMENT CLUSTER CLEAN
E 622W NEUTRAL START
BRIW GROUND (BATTERY - TERMINAL)
F 735 LB DIFF LOCK INDICATOR LIGHT
F 80 3 0 AlC COMPRESSOR CLUTCH
_.......... G 784 V REAR FENDER WORK LIGHTS
G OPEN
H 810 R SEAT B+
H 551 LB FRONT PTO
J 546 R MFD AND DIFF LOCK B+
J 231Y COOLANT LEVEL
K 134 R AUXILIARY POWER CONNECTOR
K 216 Y ALTERNATOR 'W' TERMINAL,
SWITCHED B+
ENGINE RPM
235 Y ENGINE COOLANT TEMPERATURE L 757 P RH TURN SIGNAL
L
M 255 Y ENGINE OIL PRESSURE SWITCH M 756 P LH TURN SIGNAL
N 266 Y AIR FILTER RESTRICTION SWITCH N 282Y RADAR PRESENT
P 133 R AUXILIARY POWER
P 121 Y ALTERNATOR 0+ TERMINAL,
FENDER HARNESS CONNECTOR
WARNING LIGHT AND EXCITE
(EUR)
R ............ OPEN 7 PIN CONNECTOR (NAO)
S 890 R HORN FEED R 135 R RH CONSOLE AUXILIARY POWER
T 890 BR HORN GROUND UNSWITCHED B+
U - .. . . - ... OPEN S 817 R CIGAR LIGHTER
V 738 P RH HEADLIGHT (LOW BEAM) T 269Y PARK BRAKE WARNING LIGHT
W 741 P RH HEADLIGHT (HIGH BEAM) U 702 R BRAKE RELAY B+
AA ........... OPEN V 281 Y RADAR SIGNAL
BB 737 P LH HEADLIGHT (LOW BEAM) W 785 R REAR FOG LIGHTS (EUR)
CC 740 P LH HEADLIGHT (HIGH BEAM) X 622W NEUTRAL START
DO 606W FUEL SHUT-OFF Y 296Y 1000 RPM PTO SWITCH
EE 280 BR GROUND SPEED RADAR GROUND Z 509 LB HITCH DOWN SWITCH
FF 281 Y GROUND SPEED RADAR SIGNAL
GG 280 R GROUND SPEED RADAR B+
HH 282 Y GROUNDSPEED RADAR PRESENT
1 641 W ETHER STARTITHERMOSTART
2 .. .. ........ OPEN
3 784 V WORK LIGHTS (FROM JJE1 013119)
4 - .. ........ OPEN
SM 8-10560 Issued 03-2001'
SECTION 10002 81
Connector 27 Connector 29
Location: Right Hand Console Location: Right Hand Console
W
:c::: 0 DF:
IL
OD
:c::: 8B
482196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
480196
Cavity Wire Circuit
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS No
Cavity Wire Circuit A 8350 FRONT WINDSCREEN WASHER
No B 8450 REAR WINDSHIELD WASHER
1 240 Y AIR TRAILER BRAKE PRESSURE C 550 R FRONT PTO B+
SWITCH D 551 LB FRONT PTO SOLENOID
2 515 R LOADER CONTROLS B+ E 279 R AUDIBLE ALARM
3 563 T REV POSITION SWITCH F ..... . . . . . . OPEN
4 240 Y IMPLEMENT UP SWITCH G 776 P ROTARY BEACON LIGHT
5 536 LB LEFT BRAKE RELAY H 775 P ROTARY BEACON LIGHT B+
6 233 Y FUEL LEVEL SENDER
7 215 Y WHEEL SPEED SENSOR
8 ......... . . ... OPEN
9 - ........... OPEN
10 ... - -- - OPEN
11 531 RIGHT BRAKE RELAY
12 550 R POWERSHIFT RELAY B+
SM 8-10560 Issued 03-2001
82 SECTION 10002
Connector 30 Connector 31
Location: Instrument Cluster Location: Instrument Cluster
a:55i iI5i:ii
DO 00
DO 00
DO 00
00 DO
00 00
DO DO
00 00
DO 00
00 00
00 DO
00 DO
DO 00
&!lI &!l
483196 483196
INSTRUMENT CLUSTER CONNECTOR C1 INSTRUMENT CLUSTER CONNECTOR C2
Cavity Wire Circuit Cavity Wire Circuit
No No
Ai 770P 2ND TRAILER TURN SIGNAL Ai .......... - OPEN
A2 200 R SWITCHED POWER B+ A2 .............. OPEN
A3 280 R GROUND SPEED RADAR B+ OUT A3 ... - ........ OPEN
A4 ..... - ...... OPEN A4 216 Y ALTERNATOR 'W TERMINAL,
A5 769 P 1ST TRAILER TURN SIGNAL ENGINE RPM
DIFF LOCK WARNING LIGHT A5 215 Y WHEEL SPEED SIGNAL
A6 735 LB
TURN SIGNAL COMMON A6 266 Y AIR FILTER RESTRICTION
A7 720 BR
A8 - ........... OPEN A7 121 Y ALTERNATOR D+ TERMINAL,
WARNING LIGHT AND EXCITE
A9 202 R UNSWITCHED B+ (CLOCK)
A8 200 CLEAN GROUND
A10 768 P RH TURN SIGNAL WARNING LIGHT BR/W
A11 542 LB MFD A9 723 P HIGH BEAM WARNING LIGHT
A12 ............ - OPEN A10 281 Y GROUND SPEED RADAR SIGNAL
B1 240 Y AIR TRAILER BRAKE PRESSURE A11 255 Y ENGINE OIL PRESSURE
B2 ............ - OPEN A12 ...... _...... OPEN
B3 201 R ACCESSORY POWER B+ B1 726 P BACK LIGHTING
B4 235 Y ENGINE COOLANT TEMPERATURE B2 282 Y GROUND SPEED RADAR PRESENT
B5 269 Y PARK BRAKE WARNING LIGHT 83 563 LB TRAILED IMPLEMENT SWITCH
B6 ............... OPEN 84 509 LB HITCH IMPLEMENT SWITCH
B7 784 V LOWER WORK LIGHT WARNING B5 ............ OPEN
B8 231Y COOLANT LEVEL B6 ... ............ OPEN
B9 267 Y HYDRAULIC FILTER RESTRICTION B7 ...... . . ... . . OPEN
B10 296 Y 1000 PTO WARNING LIGHT B8 500 R REVERSE INDICATOR LAMP (+)
B11 233 Y FUEL LEVEL 89 569T POWERSHIFT SPEED INDICATOR
B12 706 P LH TURN SIGNAL WARNING LIGHT B10 570 T POWERSHIFT SPEED INDICATOR
B11 ...... - ..... OPEN
B12 ...... - ...... OPEN
SM 8-10560 Issued 03-2001
SECTION 10002 83
Connector 40
Location: Cab Floor (Right Hand Console)
RIGHT HAND CONSOLE TO TRANSMISSION HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 543 LB MFD SOLENOID B+ 25 ............. OPEN
2 233 Y FUEL LEVEL SENDER 26 ............. OPEN
3 507 R +8 V POSITION POTENTIOMETER 27 530 T TRAILER BRAKE SOLENOID
4 507 LB POSITION SIGNAL 28 ... _.. .... OPEN
5 707 BR POSITION POTENTIOMETER LOW 29 - .. .. .... OPEN
OR ..........
30 OPEN
707 B
31 240 Y TRAILER BRAKE PRESSURE
6 590 CLEAN GROUND PTO
SWITCH
BR/W CONTROLLER
32 ........... OPEN
7 500 CLEAN GROUND HITCH
BR/W CONTROLLER 33 .. .. ...... OPEN
8 269Y PARK BRAKE WARNING LIGHT 34 624 W PTO NEUTRAL START SWITCH OUT
9 532/539 DIFF LOCK SOLENOID B+ 35 622W PTO NEUTRAL START SWITCH IN
LB 36 563 T REVERSE POSITION SWITCH B+
10 511 R HITCH SOLENOID B+ 37 563 T REVERSE POSITION SWITCH
11 513 LB HITCH RAISE SOLENOID B+ SIGNAL
12 514 R HITCH PIN +8 VOLTS 38 735 LB DIFF LOCK WARNING LIGHT
13 515 LB LH HITCH PIN SIGNAL 39 516 T LOADER SOLENOID IN
14 514 BR HITCH PINS LOW 40 515 T LOADER SOLENOID OUT
OR 41 279 BR PARK BRAKE ALARM
514 B
42 ...... .... OPEN
15 514 LB RH HITCH PIN SIGNAL
43 215 R AXLE SPEED B+ (FROM
16 -
- ...... OPEN JJE1015311)
17 512 LB HITCH LOWER SOLENOID 44 - ......... OPEN
GROUND
45 ........... OPEN
18 215 Y WHEEL SPEED SIGNAL
46 ..... . . . .. OPEN
19 597 LB PTO SOLENOID B+
47 ............ OPEN
OR
597 R 48 ........... OPEN
20 597 LB PTO SOLENOID GROUND
OR
597 BR
21 267Y HYDRAULIC FILTER RESTRICTION
OR OR
267Y HYDRAULIC FILTER SIGNAL
22 5B2T POWERSHIFT SOLENOID S1
23 583 T POWERSHIFT SOLENOID S2
SM 8-10560 Issued 03-2001
84 SECTION 10002
Connector 52 (15 Pin Connector)
Location: Cab Floor Right Hand Console
DI99A035
RIGHT HAND CONSOLE TO FENDER HARNESS
Cavity Wire Circuit
No
A 765 P LH TURN SIGNAL
B 766 P RH TURN SIGNAL
C 563 LB IMPLEMENT DOWN SWITCH
D 707 P LH TAIUPOSITION LIGHT
E 708 P RH TAIUPOSITION LIGHT
F 789 V REAR FOG LIGHT (EUROPE)
G 702 P BRAKE LIGHTS
H 528 R HITCH REMOTE SWITCH B+
J 528 LB HITCH RAISE
K 529 LB HITCH LOWER
L 8350 FRONT WINDSCREEN WASHER
M 8450 REAR WINDSCREEN WASHER
N 776P ROTARY BEACON LIGHT (EUROPE)
1 133 R AUXILIARY POWER SWITCHED B+
2 784 P REAR FENDER WORK LIGHTS
SM 8-10560 Issued 03-2001
SECT/ON 10002 85
Connector 54 (J1 Black)
Location: Right Hand Console
r
... -
o
00000 00000
00000 00 00 a
00000 00 00 a
00000 00000
...
DI98M094
RIGHT HAND CONSOLE HARNESS TO HITCH CONTROLLER
Cavity Wire Circuit Cavity Wire Circuit
No No
J1-1 560 R HITCH UPPER LIMIT J1 -17 504 LB HITCH POSITION COMMAND
POTENTIOMETER (HIGH) POTENTIOMETER (SIGNAL)
J1-2 560 LB HITCH UPPER LIMIT J1-18 504 BR HITCH POSITION COMMAND
POTENTIOMETER (SIGNAL) POTENTIOMETER (LOW)
J1-3 560 BR HITCH UPPER LIMIT J1-19 507 R HITCH POSITION POTENTIOMETER
POTENTIOMETER (LOW) (HIGH)
J1-4 502 R HITCH DROP RATE J1-20 507 LB HITCH POSITION POTENTIOMETER
POTENTIOMETER (HIGH) (SIGNAL)
J1-5 502 LB HITCH DROP RATE J1-21 507 BR HITCH POSITION POTENTIOMETER
POTENTIOMETER (SIGNAL) (LOW)
J1-6 502 BR HITCH DROP RATE J1-22 567 LB SLIP SET
POTENTIOMETER (LOW) J1-23 568 LB SLIP SELECTED
J1-7 503 R HITCH RESPONSE
J2-24 528 LB REMOTE UP SWITCH
POTENTIOMETER (HIGH)
J1-25 529 LB REMOTE DOWN SWITCH
J1-8 503 LB HITCH RESPONSES
POTENTIOMETER (SIGNAL) J1-26 215 Y WHEEL SPEED SIGNAL
J1-9 503 BR HITCH RESPONSE J1-27 281 Y RADAR SIGNAL
POTENTIOMETER (LOW) J1-28 282 Y RADAR PRESENT
J1-10 505 R HITCH LOAD COMMAND J1-29 565 LB AUTO MFD INPUT
POTENTIOMETER (HIGH)
J1 - 30 546 LB AUTO DIFFERENTIAL INPUT
J1-11 505 LB HITCH LOAD COMMAND
J1-31 563 LB IMPLEMENT UP INPUT
POTENTIOMETER (SIGNAL)
J1-32 514 R DRAFT SENSOR (+8 VOLTS)
J1-12 505 BR HITCH LOAD COMMAND
POTENTIOMETER (LOW) J1-33 514 B DRAFT SENSING GROUND
J1-13 506 R HITCH TRAVEL POTENTIOMETER J1 - 34 515 LB LEFT DRAFT SENSOR SIGNAL
(HIGH) J1-35 514 LB RIGHT DRAFT SENSOR SIGNAL
J1-14 506 LB HITCH TRAVEL POTENTIOMETER
J1 - 36 536 LB LEFT HAND BRAKE INPUT
(SIGNAL)
J1-37 531 LB RIGHT HAND BRAKE INPUT
J1-15 506 BR HITCH TRAVEL COMMAND
POTENTIOMETER (LOW) J1-38 510 LB HITCH UP SWITCH
J1-16 504 R HITCH POSITION COMMAND J1-39 509 LB HITCH DOWN SWITCH
POTENTIOMETER (HIGH) J1-40 562 LB HITCH MOMENTARY SWITCH
SM 8-10560 Issued 03-2001
86 SECTION 10002
Connector 55 (J2 Green) Connector 56 (J3 Brown)
Location: Right Hand Console Location: Right Hand Console
DI98M096 DI98M096
RIGHT HAND CONSOLE HARNESS TO RIGHT HAND CONSOLE HARNESS TO
HITCH CONTROLLER HITCH CONTROLLER
Cavity Wire Circuit Cavity Wire Circuit
No No
J2-1 500 R SWITCHED B+ J3-1 BR A SEGMENT 1
J2-2 511 R HITCH SOLENOID SUPPLY J3-2 R B SEGMENT 2
OUTPUT J3-3 0 CSEGMENT 3
J2-3 513 LB HITCH VALVE RAISE
J3-4 Y D SEGMENT 4
J2-4 512 LB HITCH VALVE LOWER
J3-5 LG E SEGMENT 5
J2-5 539 LB AUTO DIFFERENTIAL ENABLE J3-6 LB F SEGMENT 6
J2-6 508 LB HITCH ENABLE LAMP
J3-7 V G SEGMENT 7
J2-7 539 LB DIFFERENTIAL SOLENOID
J3-8 G DECIMAL POINT 8
OUTPUT
J3-9 W VCCSOURCE 9
J2-8 566 LB MFD SOLENOID OUTPUT
J3-10 W PROGRAM A
J2-9 570 LB SLIP LAMP
J3-11 W PROGRAM B
J2-10 -- -- - OPEN
J3-12 BR PROGRAM GROUND
J2-11 - . -- .. OPEN
J2-12 500 BR/W CLEAN GROUND
Connector 57 (J4 Grey)
Location: Right Hand Console
6( _ )
.,...,.
s( _ :
~ <
4( _ ;
"--
DIGGA070
RIGHT HAND CONSOLE HARNESS TO
HITCH CONTROLLER
Cavity Wire . Circuit
No
J4-1 -- - - - OPEN
J4-2 532 LB DIFFERENTIAL ENGAGED
J4-3 .. --- .. OPEN
J4-4 572 LB RIDE CONTROL ON
J4-5 541 LB MFDON
J4-6 573 LB AUTO HITCH
SM 8-10560 Issued 03-2001
SECTION 10002 87
Connector 59A Connector 59B
Location: Right Hand Console Location: Right Hand Console
6r '"
•) { . ', 1 6 / . ',
\
-
I ( • '1
-,
~.
5( • ~ \ • j2 5( • l • "2
;-
~ --
41 . ) ( . )3 4 t• ; \ • '3
DI99A070 DI99A070
RIGHT HAND CONSOLE HARNESS TO RIGHT HAND CONSOLE HARNESS TO
HITCH DROP SPEED AND UPPER HEIGHT POTENTIOMETERS HITCH TRAVEL POTENTIOMETER
Cavity Wire Circuit Cavity Wire Circuit
No No
1 502 R HITCH DROP SPEED 1 ..... - - - OPEN
POTENTIOMETER HIGH ............. -
2 OPEN
2 502 LB HITCH DROP SPEED
POTENTIOMETER SIGNAL
3 --- -- OPEN
4 506 R HITCH TRAVEL POTENTIOMETER
3 502 BR HITCH DROP SPEED
HIGH
POTENTIOMETER LOW
5 506 LB HITCH TRAVEL POTENTIOMETER
4 560 R HITCH UPPER HEIGHT
SIGNAL
POTENTIOMETER HIGH
6 506 BR HITCH TRAVEL POTENTIOMETER
5 560 LB HITCH UPPER HEIGHT
LOW
POTENTIOMETER SIGNAL
6 560 BR HITCH UPPER HEIGHT
POTENTIOMETER LOW
SM 8-10560 Issued 03-2001
88 SECT/ON 10002
TIRE RADIUS CONSTANT TABLE
NOTE: Tire Codes must always be entered as four digit numbers. If the Tire Code is less than 1000, use
zero (0) as the first digit.
Rear Tire Size Constant Rear Tire Size Constant
8.3 - 24 0470 16.9 - 24 0620
8.3 - 32 0570 16.9 - 24 IND 0610
8.3 - 36 0620 16.9 - 26 0645
8.3 - 38 0645 16.9-28 0670
8.3 - 44 0720 16.9 - 28 IND 0660
9.5 - 20 0455 16.9 - 30 0695
9.5 - 24 0495 16.9 - 34 0745
9.5 - 28 0545 16.9 - 341ND 0730
9.5 - 36 0645 16.9 - 38 0795
9.5 - 38 0670 16.9 - 42 0845
9.5 - 44 0745 17.5 L-24IND 0580
9.5 - 48 0795 18.4 - 24 IND 0635
11.2 - 20 0465 18.4 - 26 0670
11.2 - 24 0515 18.4 - 26 IND 0665
11 .2 - 28 0565 18.4 - 28 IND 0685
11.2 - 36 0665 18.4 - 30 0720
11.2 - 38 0690 18.4 - 30 IND 0715
12.4 - 20 0490 18.4 - 34 0770
12.4 - 24 0540 18.4-38 0837
12.4-28 0590 18.4 R - 42 (R1 TREAD) 0883
12.4 - 32 0640 18.4 - 42 (R1 TREAD) 0889
12.4-36 0690 18.4 R - 42 (R2 TREAD) 0903
12.4 - 38 0720 18.4 R - 46 (R1 TREAD) 0936
12.4 - 42 0796 18.4 - 46 0930
12.4 - 46 0820 19.5 L - 24 IND 0610
12.4 - 54 0942 20.8 - 34 0805
13.6-24 0560 20.8 - 38 (R2 TREAD) 0873
13.6 - 28 0610 20.8 R - 38 (R1 TREAD) 0872
13.6 - 36 0715 20.4 R - 38 (R1W TREAD) 0869
13.6-38 0740 20.4 R - 38 (R2 TREAD) 0885
13.6 - 46 0845 20.4 - 42 (R1 TREAD) 0918
14.9-24 0590 20.4 R - 42 (R1W TREAD) 0919
14.9 - 241ND 0580 20.4 R - 42 (R1 TREAD) 0926
14.9-26 0615 21 L - 24 IND 0635
14.9-28 0640 21 L - 30 0720
14.9 - 281ND 0630 21 .3 - 26 0760
14.9-30 0665 21 .3 - 261ND 0750
14.9 - 38 0765 21 .3 - 30 0810
14.9 R - 46 0882 21 .3 - 34 0860
15.5 - 38 0745
SM 8-10560 Issued 03-2001
SECTION 10002 89
Rear Tire Size Constant Rear Tire Size Constant
24.5 - 32 0848 420/80 R 46 (R1 TREAD) 0886
24.5 R - 32 0851 460/70 R24 0590
28 L - 26 0720 480/70 R24 0620
30.5 L R32 0863 480/70 R26 0645
800/60 R32 0820 480/70 R28 0670
440/65 R24 0560 480/70 R30 0695
440/65 R28 0610 480/70 R34 0745
480/65 R24 0590 480/70 R38 0795
480/65 R28 0640 500/70 R34 0745
540/65 R24 0620 520/70 R26 0650
540/65 R26 0645 520/70 R30 0720
540/65 R28 0670 520/70 R34 0770
540/65 R30 0695 520/70 R38 0820
540/65 R34 0745 540/70 R34 0770
540/65 R38 0795 580170 R26 0670
600/65 R28 0695 580/70 R38 0875
600/65 R34 0770 580/70 R42 0905
600/65 R38 0820 600/70 R30 0745
650/65 R38 0855 620/70 R26 0720
750/65 R26 0770 620/70 R38 0855
800/65 R32 0870 620/70 R42 0905
260/70 R16 0360 650/70 R26 0745
260/70 R18 0390 650/70 R30 0795
260/70 R20 0415 680/70 R32 0820
300/70 R16 0375 680/70 R34 0855
300/70 R18 0405 710/70 R 38 (R1W TREAD) 0920
300/70 R20 0445 340/75 R20 0480
300/95 R46 (R1 TREAD) 0831 380/75 R26 0500
320/70 R20 0465 620/75 R26 0760
320/70 R24 0515 620/75 R30 0810
320/70 R28 0565 620/75 R34 0860
360/70 R20 0490 650/75 R32 0835
360/70 R24 0540 650/75 R34 (R 1W TREAD) 0881
360/70 R28 0590 680/75 R32 0870
380/70 R20 0510 710/75 R34 0905
380/70 R24 0560 210/80 R16 0345
380/70 R28 0610 520/85 R46 (R1W TREAD) 0979
400/70 R24 0560
420/70 R24 0590 IMPORTANT: If the size of tire installed on the
420/70 R28 0640
tractor is not listed, refer to the tire
manufactures specification for the rolling
420/70 R30 0665
circumference. Divide the specified rolling
circumference by 6.28 to give the correct
ground speed Tire Radius Constant.
8M 8-10560 Issued 03-2001
Section
10006
TRANSMISSION CONTROLLER,
F/N/R AND POWERSHIFT
Calibration, Error Codes
Troubleshooting and Schematics
CX Series XtraShift Tractors
~ © 2004 McCormick Tractors International Limited.
McCORMICK SM 8-12101 September 2004
2 SECTION 10006
TABLE OF CONTENTS
SPECIAL TOOLS ...................... .......... ............ .. .... ..... ... ... ... ...... .. ... .... .... ......................... .. .... ........ ...... ..... ....... ....... .. 4
ELECTRONIC TRANSMISSION CONTROL
Transmission Control Functions ......................................... ... ........ .. ... ............. .. ........ .. .... ... ............. .. ..... .. .. ... ...... 5
Controller LED 's ............... ..... .. ................. .. ........ ... .. .......... .. .. ............ ... .. ..... .. ....... ............................ .. ..... .. ....... .... 5
Error Codes .. ............. .... ...................... .... .. ......................................... .... ............ .... .... .... .... ........ .... ... .......... ......... 5
Operators Seat Switch Monitor, Park Brake and Alarm .... ...... ........ .. .. .. ............ .. .... .. ........................... ................ 5
CALIBRATION .. .. ....... .. ....... .. ...... .. .... .. ... .. ... .. .. ..... ..... .. .. .. .. .......... .. ......... ............ ................. ........... ........ ......... ... .... .. 6
Calibration Procedure - Method 1 (New Controller) .................................. .. ............... .... ...... .. .......... ..... ............... 6
Calibration Procedure - Method 2 (Existing Controller Recalibration) ............ .... .......... .... ....... ........ .................... 8
Tyre Radius Constant Table .... .. .... ..... ... .. ..... .. ............ ... ..... ... ............ .. .... ........ .. ..... .... ... .. .. ......... .... ...... ...... ..... .. 12
INCHING PEDAL POTENTIOMETER ADJUSTMENT .... ............ .. ....... ..... ... ........ ... .. ............ .. .. ...... ...................... 13
ERROR CODES
General Information ......... ... .... ....... ... ... .. .. .. ....... .......... .......... .................................... .. .. ..... .. .... ..... ............. .. ...... 14
Retrieving and Identifying Error Codes ...... ........ .. .. .... .... .. .... .. .......... .. .. ............ .. ............ .. ............ .. .. .. ............ .... 14
Error Code Quick Reference Guide ...... ..... ........ .. .. .. ...... ...... ........ .. .. .. ... ......... ...... ............ .. ... .. ..... .. ......... .... .... ... 15
TROUBLESHOOTING GUIDE
Circuit Testing General Information ....... .. ..... .. ................... .. .. ........ .... ... ....... .. ....... ...... ...... .............. ................... 21
Error Code 20/19 . .................................. .. ............ .. .............. ... ....... .. .. ... .. ..... ...... ........... .. ... ........... .. ........... ........ 22
Error Code 22/12 . ... ............................. .. ....... .... .......... .. ..... ... ...... ....... ... ..................... ... .. ... .. .. .. .. .... .... .... .. .... ...... 24
Error Code 22/15 . .................... .. ............ .. ......................... ............... ..... ....... ....... ............ ... ........... ............. .... .... 26
Error Code 24/12 . ... .. ............... .. .......... .. .. .. ......... ..... .......... .. ... ......... .. ............ ... ............ .... .............. ... ................ 28
Error Code 24/15 . ... .... ............... .... ........ .. .. .......... .... ............ ... ........... ... .......... .. ................... .. ...................... ...... 30
Error Code 25/11 & 12. .. .. ....... ... .... ..... ..... ... ........... .. .. ........ .. ........ ........... ... .. ....... .. ............ ..... .. ... .. ... .... ... .. ...... ... 32
Error Code 25/15 & 16 . ......... .. ............ ..... ............ .. .. .......... .. ..... ......... ... ... .. ..... .. ..... .. .. ....... ..... ... .... .. ............. .. .... 34
Error Code 26/12 ....... ... .......... .... ..... .. .... ... .......... ... .. ...... .. ... .. ............ ............... .. .............................. ... ............... 36
Error Code 26/15 ... ................ ... ..... ...... ......... ...... .... ....... ..... ..... ..... ....... .... ... .. .... ... ....... ................... ........ .......... .. 38
Error Code 28/12 ..... ..... ........................ ............ ........ ..... ..... .. ..... .. ...... .. .... .. .......... ............ ..... ......... ..... .......... ... .. 40
Error Code 28/15 ... .. .. ... .. ..... .. .. .......... .. ..... .......... .. .. .......... .... ...... .. .... ... .... ... ... .. .. .. .......... .. .. .......... .. .... .. ...... .. ... ... 42
Error Code 37/23 ... ............ .... ..... .. ... .... ... .... .. ... .. ........ .. ..... .... ................... .. ... ..... .. .... ..... ....... .......... ... ........... ...... 44
Error Code 37/24 ....... ... ..... .. ...... ..... ...... .. ............................... ..... .... .... ....... ... ..... ..... .. ..... .... ................... ... .. .... .... 46
Error Code 37/25 ........ .............. ........... ... ............ .. .............. .. ......................................... .. .. ............ ................. ... 48
Multi Error Codes 22/12 , 24/12 and 25/11 & 12 .. ........ .. .... .............. .... ............ .... ............ ............... .. .. ................ 50
Multi Error Codes 22/15 , 24/15 and 25/15 & 16 .. ................................... .............. ........ ........................ .............. 52
No Error Code
Controller LED'S not Illuminated ....... ....................... ... .. ....... .. ......... .... ................... .. ............... ......... .. ........... 54
No Error Code
No Forward Drive....... .. ........ ......... .. .. ................................ .. ...... ............... ........ ......... .... ............ .................... 58
No Error Code
No Reverse Drive ... .......................... .... .. ............................. .......... .. ................ .. ........ .. .............. ........ ..... ... .... 58
No Error Code
No Forward or Reverse Drive............ .. .. ..... ... ................... .. ........... ............... .... ........ ... .... .. ....... .. ............ ... .... 60
No Error Code
Return to Neutral Light on when Forward or Reverse Selected .... .. ..... ................................. .............. .. .. ...... 62
No Error Code
No Drive in 1st Speed Powershift .. .... .................... ...... ........... ....... .... ............... ...... :............. .. .. .. .. ................. 64
No Error Code
No Drive in 2nd Speed Powershift .. .... .... .. .. .. .. ...... .. .. .. ................ .... ...... .. .... ................................ ............. .... .. 66
No Error Code
No Drive in 3rd Speed Powershift .. ....... .... ............................. ....... ................ .... ...... ....... .. ............................. 68
No Error Code
No Drive in 1st, 2nd or 3rd Speed Powershift ..... ...... .. ........... ........ ... ......... .. ............... ............. ... .. ..... ... .. .... .. 70
No Error Code
Defaults to 1st Speed Powershift 1 when 2nd Speed Powershift Selected ............ ...... .. ..... ...... .. ..... ............ . 72
No Error Code
Defaults to 3rd Speed Powershift 3 when 1st and 2nd Speed
Powershift Selected ........... ... ................ ........... .. ............ .. ............................... ........................... .. ............. .. ... 74
8M 8·1 2101 Issued 09-2004
SECTION 10006 3
HARNESS LAYOUT AND CHASSIS GROUND LOCATION
Instrument Panel Harness Components - Tractors Without Ride Control... ..... ........................ ......... ............ .. ... 77
Instrument Panel Harness Components - Tractors With Ride Control .......................... .......... .. ........ .. ............... 78
Right Hand Console Harness Components
- Tractors Without Ride Control ..... ......... ........ .... .......... ............................................ .......... .. ........ .. ............... 79
Right Hand Console Harness Components
- Tractors With Ride Control .. .. .......... .... ....... .. ................................................................... .. ......... .. ............... 80
Transmission Harness Components .......... ................................ ........................ .. ......... .......... .. ......................... 81
SCHEMATIC CIRCUIT ..... .. ................ .. .... .................... .. ....................... .... .. .......... .. ................................ ............... 82
MAIN CONNECTORS ... ..... ....... .. ....... .. ... ...... ... ..... ... .. ......... ............ ............ ...................... ... ....... .. ......................... 85
8M 8-12101 Issued 09-2004
4 SECTION 10006
SPECIAL TOOLS
DD98H120 MI03E142
MC2616 MULTIMETER KIT includes: 1012T1 POTENTIOMETER TEST HARNESS
MC2616-1 MULTIMETER ONLY
MC2616-2 TEST LEADS
MC2616-3 TEMPERATURE PROBE
MDOJF063
1015T1 SOLENOID CALIBRATION HARNESS
D099A051
MC2656 TEST PROBE KIT
OD97E383
MC31000B HARNESS REPAIR KIT (EUROPE)
8M 8-12101 Issued 09-2004
SECT/ON 10006 5
ELECTRONIC TRANSMISSION CONTROL
Transmission Control Functions
The function of the transmission controller is to provide electro-hydraulic control of the transmission powershift and
forward/reverse clutches by the following :
A. Pulse Width Modulation (PWM) of the electro-hydraulic Powershift solenoids for controlled Powershift
clutch engagement.
B. Pulse Width Modulation (PWM) of the electro-hydraulic Forward and Reverse solenoids for controlled
Forward and Reverse clutch engagement.
C. Monitor the transmission clutch output speeds.
D. Monitor engine speed (flywheel speed) and compare with clutch output speed to determine clutch
slippage.
E. Monitor wheel speed to determine tractor motion.
F. Monitor the time elapsed in the operator seat switch state.
G. Monitor powershift and forward/neutral/reverse operator control switch states, park brake engagement
and range selection .
H. Control the audible alarm and F/N/R and powershift speed indicators.
IMPORTANT: The transmission controller factory installed software for early production tractors does
not display tyre constants .
Controller LED's
The electronic transmission controller will display two Green LED's when the key switch is in the ON position a
power LED and a system LED. Also the controller will display two further LED's a Red Status LED and a Yellow
Mode LED. When the controller is operating correctly the Red Status LED will not be illuminated and the Yellow
Mode LED will flash every 2 seconds.
If an error occurs both the Red Status LED and the Yellow Mode LED will flash quickly approximately fifteen times
followed by a sequence of flashes to indicate the detected error, refer to "Error Code Quick Reference Guide" on
page 15.
Error Codes
Transmission control system error codes will only be displayed while faults (errors) are active. Error codes are
identified by a sequence of flashes from the transmission controller Status and Mode LED's, refer to "Retrieving
and Identifying Error Codes" on page 14. When all faults have been corrected the Red Status LED will be OFF and
the Yellow Mode LED will flash every 2 seconds.
IMPORTANT: Faults relating to the flywheel and clutch speed sensors will result in an erratic shuttle
change. Error codes for the flywheel sensor can only be read with the engine running . Error codes for
the clutch sensors can only be read with the engine running and the FINIR lever in Forward or Reverse
(Range and Speed levers in NEUTRAL).
Operators Seat Switch Monitor, Park Brake and Alarm
If the transmission controller is switched ON for 25 hours and the controller does not detect a seat switch change of
state (from contacts closed to open) controller will assume the seat switch is faulty. The audible alarm will sound
and the return to neutral light will illuminate when forward or reverse is selected.
If Forward or Reverse is selected and the park brake is engaged the audible alarm will sound intermittently until the
park brake is disengaged.
SM 8-12101 Issued 09-2004
6 SECTION 10006
CALIBRATION
The transmission controller is calibrated on leaving the factory, if any of the following components :
transmission controller, inching pedal potentiometer, forward solenoid coil and reverse solenoid coil are replaced
or the rear tyre size is changed the calibration procedure MUST be carried out in order for the transmission
control system to operate correctly.
In addition it will also be necessary to calibrate the transmission controller if the clutch packs or the main and
transfer hydraulic pumps have been serviced or replaced.
There are two methods of calibrating the transmission control system, method 1 is for calibrating a new controller
and method 2 is for recalibrating an existing controller.
The tyre size code is a two digit number and is identified by a sequence of flashers at a rate of two flasher per
second of the instrument cluster return to neutral light. The sequence begins with neutral light ON for 1 second
then a pause of 1 second. The light will then flash a series of flashes, the first series of flashes represents the first
digit of the code and the second series of flashes the second digit.
Example: FLASH (1 second) - 1 second Pause - FLASH - FLASH - 1 second Pause - FLASH- FLASH- FLASH .
This series of flashes represents a tyre constant of 23.
IMPORTANT: The transmission controller factory installed software for early production tractors does
not display tyre constants.
Calibration Procedure - Method 1 STEP 3
(New Controller) After the inching pedal calibration has been carried
out the controller will automatically go into the tyre
NOTE: Before carrying out the calibration constant mode. Refer to the Tyre Radius Constant
procedure check the inching pedal potentiometer Table on page 12 for the correct tyre constant.
adjustment. Refer to INCHING PEDAL
POTENTIOMETER ADJUSTMENT on page 13. STEP 4
IMPORTANT: During calibration the tractor will Move the F/N/R lever from neutral to forward , tyre
move slightly, MAKE SURE the calibration constant 11 will now be selected. Count the number
procedure is carried out in a clear area free of of flashes of the neutral light and check the tyre
any obstructions. constant selected , refer to example above.
NOTE: Every time the FINIR lever is moved from
STEP 1 neutral to forward the next constant will be
Park the tractor on hard level ground clear of selected.
obstructions and APPLY the parking brake . Put the
F/N/R, speed and range selector levers in Neural STEP 5
and turn the key to the OFF position .
If tyre constant '11' is not the required constant
continue to move the F/N/R lever from neutral to
STEP 2 forward and back to neutral until the correct constant
Sit on the seat and turn the key to the ON position, is selected .
DO NOT start the engine. Hold the inching pedal NOTE: Moving the FINIR lever into forward will
down for approximately 5 seconds then fully release move up to the next tyre constant e.g. 11 - 12 -13
the pedal. etc. and moving the FINIR lever into reverse will
During the inching pedal calibration the return to move down to the previous tyre constant e.g. 13 -
neutral light will flash at a rate of 1Hz (one flash per 12 -11 etc.
second) and the audible alarm will sound at a rate of
1Hz (one beep per second).
When the audible alarm stops sounding the inching
pedal calibration is complete.
8M 8-12101 Issued 09-2004
SECTION 10006 7
STEP 6 STEP 8
When the required tyre constant has been selected Hold the inching pedal down and select Low Range
lift the F/N/R lever out of the neutral slot three times and 1st Speed/1 st Powershift. Release the inching
in succession to store the constant in the controller. pedal, disengage the park brake move the F/N/R
Make sure the lever does not go into forward or lever into Forward. After a short delay the tractor will
reverse. If the tyre constant has been accepted the move slightly then stop.
audible alarm will sound. During the forward clutch solenoid coil calibration the
return to neutral light and reverse light will flash at a
NOTE: If the wrong tyre constant is stored into the
rate of 2Hz (two flashes per second) and the audible
controller continue with Steps 7 to 9 then refer to
alarm will sound at a rate of 2Hz (two beeps per
Inching Pedal Calibration and Tyre Constant on
second).
page 8.
STEP 7 WARNING: Keep everybody clear of the
~ tractor when carrying out the transmission
Make sure the F/N/R, speed and range selector control calibration procedure.
levers are in Neural. Start and run the engine at LOW
idle.
STEP 9
WARNING: Never operate the engine in a Move the F/N/R lever into Reverse, after a short
~ closed building, proper ventilation is delay the tractor will move slightly and stop. The
required under all circumstances. calibration procedure is now complete and the return
to Neutral light be on steady. Move the F/N/R lever to
neutral then check the operation of the transmission
control system.
During the reverse clutch solenoid coil calibration the
return to neutral light will flash at a rate of 2Hz (two
flashes per second) and the audible alarm will sound
at a rate of 2Hz (two beeps per second). The reverse
light will be on (not flashing).
8M 8-12101 Issued 09-2004
8 SECTION 10006
Calibration Procedure· Method 2 STEP 4
(Existing Controller Recalibration) After the inching pedal calibration has been carried
out the controller will automatically go into the tyre
NOTE: Before carrying out the calibration procedure constant mode. Refer to the Tyre Radius Constant
check the inching pedal potentiometer adjustment. Table on page 12 for the correct tyre constant.
Refer to INCHING PEDAL POTENTIOMETER IMPORTANT: The transmission controller
ADJUSTMENT on page 13. factory installed software for early production
IMPORTANT: During calibration of the forward or tractors does not display tyre constants.
reverse clutch solenoid coils the tractor will move IMPORTANT: DO NOT turn the key OFF if the
slightly, MAKE SURE the calibration procedure is tyre constant is to be changed.
carried out in a clear area free of any obstructions.
NOTE: If the tyre constant is NOT to be changed,
Inching Pedal Calibration and Tyre turn the key OFF and go to Forward Solenoid Coil
Constant Calibration on page 9.
NOTE: To change the tyre constant the inching NOTE: If the tyre constant is to be changed and
pedal calibration must be carried out to enable the the key turned OFF before the constant has been
controller to enter the tyre constant mode. stored, repeat Steps 1 to 3 to re-enter the tyre
constant mode.
STEP 1
STEP 5
Park the tractor on hard level ground clear of
obstructions and APPLY the parking brake. Put the Move the F/N/R lever from neutral to forward and
F/N/R, speed and range selector levers in read the displayed tyre code by counting the number
NEUTRAL and turn the key to the OFF position. of flashes of the return to neutral light, refer to
"CALIBRATION" on page 6.
STEP 2 NOTE: No tyre codes will be displayed until the
FINIR lever is moved into Forward or Reverse.
Remove the instrument panel left hand cover and
turn the key to the ON position, wait for the
instrument cluster to carry out the self test procedure STEP 6
then disconnect inching pedal potentiometer If the tyre constant displayed is BELOW the required
connector. constant move the F/N/R lever from neutral to
forward until the required constant is displayed.
STEP 3 If the tyre constant displayed is ABOVE the required
constant move the F/N/R lever from neutral to
Wait approximately 3 seconds then reconnect the
reverse until the required constant is displayed .
inching pedal potentiometer connector, when the
return to neutral light begins to flash at a rate of 1Hz NOTE: Moving the FINIR lever into forward will
(one flash per second) and the audible alarm sounds move up to the next tyre constant e.g. 11 - 12 -13
at a rate of 1Hz (one beep per second), hold the etc. and moving the FINIR lever into reverse will
inching pedal down. When the return to neutral light move down to the previous tyre constant e.g. 13-
goes off and the alarm stops, fully release the pedal. 12 -11 etc.
The inching pedal calibration is now complete.
SM 8-12101 Issued 09-2004
SECTION 10006 9
STEP 7 Forward Solenoid Coil Calibration
When the required tyre constant has been selected IMPORTANT: The forward and reverse solenoids
lift the FIN/R lever out of the neutral slot three times can not be calibrated at the same time, they must be
in succession to store the constant in the controller. calibrated separately.
Make sure the lever does not go into forward or
reverse. If the tyre constant has been accepted the STEP 9
audible alarm will sound .
Make sure the tractor is parked on hard level ground
NOTE: If return to neutral light begins to flash and clear of obstructions and the parking brake is
the reverse indicator light illuminates, turn the key APPLIED. Put the F/N/R, speed and range selector
to the OFF position. levers in NEUTRAL and turn the key to the OFF
IMPORTANT: If the wrong tyre constant is stored position.
into the controller turn the key OFF and repeat the
inching pedal calibration and tyre constant STEP 10
procedure.
STEP 8
Turn the key OFF and continue to the Forward
solenoid coil calibration .
MI03E143
Disconnect the forward clutch solenoid (A) and
connect the calibration harness 1015T1 between the
transmission harness and the forward solenoid.
STEP 11
Sit on the seat and turn the key to the ON position.
Wait for the instrument cluster to carry out the self
test procedure then press and hold the calibration
harness 1015T1 switch button in for 5 seconds then
release. Start and run the engine at low idle within 5
seconds of releasing the switch.
WARNING: Never operate the engine in a
& closed building, proper ventilation is
required under all circumstances.
A WARNING: Keep everybody clear of the
tractor when carrying out the transmission
control calibration procedure.
8M 8-12101 Issued 09-2004
10 SECTION 10006
STEP 12 Reverse Solenoid Coil Calibration
When the forward solenoid calibration mode has IMPORTANT: The forward and reverse solenoids
been entered the return to neutral light and reverse can not be calibrated at the same time, they must be
light will flash at a rate of 2Hz (two flashes per calibrated separately.
second) and the audible alarm will sound at a rate of
2Hz (two beeps per second). STEP 15
IMPORTANT: If the engine is started after the Make sure the tractor is parked on hard level ground
neutral light and reverse light begin to flash and clear of obstructions and the parking brake is
the audible alarm starts to sound, STOP the APPLIED. Put the F/N/R, speed and range selector
engine and repeat Steps 9 to 12. levers in NEUTRAL and turn the key to the OFF
position.
STEP 13
Hold the inching pedal down and select Low Range STEP 16
and 1st Speed/1 st Powershift. Release the inching
pedal, disengage the parking brake move the F/N/R
lever into Forward. After a short delay the tractor will
move slightly then stop.
The calibration procedure is now complete for the
forward clutch solenoid coil.
The reverse light and the audible alarm will turn off
and the return to neutral light will remain on (not
flashing).
WARNING: Keep everybody clear of the
~ tractor when carrying out the transmission
control calibration procedure.
MI03E143
NOTE: If the return to neutral light continues to flash Disconnect the reverse clutch solenoid (8) and
and the audible alarm continues to sound, turn the connect the calibration harness 1015T1 between the
key to the OFF position and APPLY the parking transmission harness and the reverse solenoid .
brake. Put the FINIR, speed and range levers in
NEUTRAL and repeat Steps 11 to 13. STEP 17
STEP 14 Sit on the seat and turn the key to the ON position.
Wait for the instrument cluster to carry out the self
Put the F/N/R, speed and range selector levers into test procedure then press and hold the calibration
NEUTRAL and APPLY the parking brake. Turn the harness 1015T1 switch button in for 5 seconds then
key OFF and remove the calibration harness 1015T1, release. Start and run the engine at low idle.
connect the forward solenoid to the transmission
harness then continue to the reverse clutch coil WARNING: Never operate the engine in a
calibration. ~ closed building, proper ventilation is
required under al/ circumstances.
WARNING: Keep everybody clear of the
~ tractor when carrying out the transmission
control calibration procedure.
8M 8-12101 Issued 09-2004
SECTION 10006 11
STEP 18 STEP 20
When the reverse solenoid calibration mode has Put the F/N/R, speed and range selector levers into
been entered the return to neutral light will flash at a NEUTRAL and APPLY the parking brake. Turn the
rate of 2Hz (two flashes per second) and the audible key OFF and remove the calibration harness 1015T1,
alarm will sound at a rate of 2Hz (two beeps per connect the reverse solenoid to the transmission.
second). The reverse indicator light will remain on
(not flashing) STEP 21
IMPORTANT: If the engine is started after the Check the operation of the transmission control
neutral light and reverse light begin to flash and system.
the audible alarm starts to sound, STOP the
engine and repeat Steps 15 to 18.
STEP 19
Hold the inching pedal down and select Low Range
and 1st Speed/1 st Powershift. Release the inching
pedal , disengage the park brake move the F/N/R
lever into Reverse. After a short delay the tractor will
move slightly then stop.
The calibration procedure is now complete for the
reverse clutch solenoid coil.
The alarm will turn off and the return to neutral light
will remain on (not flashing).
A WARNING: Keep everybody clear of the
tractor when carrying out the transmission
control calibration procedure.
NOTE: If the return to neutral light continues to flash
and the audible alarm continues to sound, turn the
key to the OFF position and APPLY the parking
brake. Put the FINIR, speed and range levers in
NEUTRAL and repeat Steps 17 to 19.
8M 8-12101 Issued 09-2004
12 SECTION 10006
Tyre Radius Constant Table
Etrto*
Constant Rear Tyre Size
Rolling Radius (mm)
1 New Controller Default -
11 13.6 R28 610
12 14.9 R28 640
13 16.9 R28 670
14 16.9 R28(IND) 660
15 14.9 R30 665
16 16.9 R30 695
17 18.4 R30 720
18 18.4 R30(IND) 715
19 480/70 R30 695
21 12.4 R32 640
22 16.9 R34 745
23 18.4 R34 770
24 480/70 R34 745
25 520/70 R34 770
26 540/70 R34 770
27 540/65 R34 745
28 12.4 R36 690
29 13.6 R36 715
31 13.6 R38 740
32 15.5 - 38 745
• ETRTO = EUROPEAN TYRE & RIM TECHNICAL ORGANISATION
NOTE: If the tyre size installed is not shown in the table above, refer to the tyre manufactures specification for
the rolling radius. Select a tyre constant that matches or is nearest to the rolling radius shown in the table.
SM 8-12101 Issued 09-2004
SECTION 10006 13
INCHING PEDAL POTENTIOMETER ADJUSTMENT
STEP 1 STEP 4
Park the tractor hard level ground clear of
obstructions and APPLY the parking brake. Put the
F/N/R , speed and range selector levers in
NEUTRAL and turn the key to the OFF position.
STEP 2
MI03E145
Hold the inching pedal fully down and make a note of
the multimeter reading . If the reading is BELOW 0.5
volts, loosen the retaining screws (1) and turn the
potentiometer clockwise until a reading of
approximately 0.6 volts is obtained. Tighten the
retaining screws (1).
MI03E143
Remove the instrument panel left hand cover and STEP 5
disconnect the inching pedal potentiometer from the
harness . Connect the potentiometer test harness Release the inching pedal and check the
(A) , 10 12T1 between the potentiometer and the multimeter reading . If the reading is incorrect
harness. repeat Steps 3 and 4.
IMPORTANT: The multimeter readings MUST be
STEP 3 between a minimum of 0.5 volts (pedal fully
down) and a minimum of 3.9 volts (pedal fully
released) .
STEP 6
When the readings are correct turn the key to the
OFF position, remove the test harness and calibrate
the transmission controller.
MI03E144
Connect the multimeter MC2616 to the test harness.
Turn the key to the ON position and make a note of
the multimeter reading. If the reading is BELOW 3.9
volts, loosen the retaining screws (1) and turn the
potentiometer clockwise until a reading of
approximately 4 volts is obtained . Tighten the
retaining screws (1) .
SM 8-12101 Issued 09-2004
14 SECTION 10006
ERROR CODES
General Information
IMPORTANT: Before carrying out any troubleshooting procedures it is necessary to read, identify,
record all active error codes following the procedures below.
If an error occurs which stops the transmission from operating the audible alarm will sound continuously. If an
error occurs which does not allow a Powershift change to be made but allows the transmission to operate the
audible alarm will sound briefly each time a Forward or Reverse selection is made.
If an error occurs both the Red Status LED and the Yellow Mode LED on the transmission controller will flash
quickly approximately fifteen times, the Yellow Mode LED will then remain illuminated and the Red Status LED will
the flash a sequence of flashes to indicate the component or circuit where the fault has occurred.
The Red Status LED will then remain illuminated and the Yellow Mode LED will the flash a sequence of flashes to
indicate the type of fault that has occurred. When each component and error type code has been displayed the
controller will then proceed to display any further active error codes.
Retrieving and Identifying Error Codes
1. Put key switch in OFF position.
2. Remove the right hand console top cover.
3. Turn the key switch to the ON position . DO NOT START THE ENGINE.
4. Both the Red Status LED and the Yellow Mode LED on the transmission controller will flash quickly
approximately fifteen times indicating the presence of active error codes followed by the component error code
then the fault type error code.
5. An error code is a 2 digit number. Each digit of an error code number is represented by a series of flashes
from the transmission controller LED's .
6. To identify the component error code wait until both the Yellow Mode and RED status LED flash quickly
approximately fifteen times. Then count the number of flashes on the Red Status LED with the Yellow Mode
LED illuminated continuously. A series of flashes will be displayed followed by a pause and a second series of
flashes.
7. The first series of flashes represent the first digit of the error code, the second series of flashes the second
digit of the error code.
Example: FLASH - FLASH ---- Pause ---- FLASH- FLASH- FLASH-FLASH
This series of flashes represents component code 24.
8. With the Red Status LED illuminated continuously count the number of flashes on the Yellow Mode LED.
9. The first series of flashes represent the first digit of the error code, the second series of flashes the second
digit of the error code.
Example: FLASH ---- Pause ---- FLASH- FLASH- FLASH-FLASH-FLASH
This series of flashes represents error type code 15.
10.lffurther error codes are present the next error code will be displayed by repeating steps 6 to 9.
11 .lf no further error codes are present both the Red Status LED and the Yellow Mode LED on the transmission
controller will flash quickly approximately fifteen times and the error codes will be repeated.
NOTE: Turning the key to the OFF position then back to the ON position will restart the error code retrieval
procedure.
NOTE: Every time the key is turned to the ON position (engine not running) the controller will display component
code 20119 (Flywheel Sensor out of range, low). If the flywheel sensor is not faulty the error code will disappear
when the engine is started.
SM 8-12101 Issued 09-2004
SECTION 10006 15
Error Code Quick Reference Guide
This chart enables you to quickly identify error codes and corrective actions used in troubleshooting the electronic
Transmission Control system . For a detailed troubleshooting guide, refer to "TROUBLESHOOTING GUIDE" on
page 21.
NOTE: Faults relating to the flywheel and clutch speed sensors will result in an erratic shuttle change. Error codes
for the flywheel sensor can only be read with the engine running. Error codes for the clutch sensors can only be
read with the engine running and the F/N/R lever in Forward or Reverse (Range and Speed levers in NEUTRAL
and the Parking Brake ENGAGED).
~
*- WARNING: Never operate the engine in a closed building. Proper
ventilation is required under all circumstances.
COMPQNENT ERROB TYPE
PQSSIBLE ~AUSE AND CORRE~TIVE ACTION S~EPAG!;
~ CQDE
16 23 &24 1. Turn the key switch OFF then ON, if error remains replace --
the Controller.
20 19 Flywheel Sensor Not Within Range (Low) 22
1. Check the Flywheel Sensor and Flywheel Sensor circuit.
See Note Above
NOTE: Every time the key is turned to the ON position
(engine not running) the controller will display component
code 20/19 (Flywheel Sensor out of range, low). If the
flywheel sensor is not faulty the error code will disappear
when the engine is started.
22 12 Controller Powershift Selector Input Voltage too High. 24
1. Check the circuit between Powershift Resistor Pack and
controller connector 32 not shorted to voltage above 5
volts.
2. Check the Powershift Resistor Pack and Powershift
Selector Switch circuits not shorted to voltage above 5
volts.
22 15 Controller Powershift Selector Input Voltage too Low. 26
1. Check the circuit between Powershift Resistor Pack and
Controller Connector pin 32 for continuity and not shorted
to ground.
2. Check the Powershift Resistor Pack and Powershift
Selector Switch circuits for continuity and not shorted to
ground.
3. Check the Powershift Resistor Pack.
4. Check the Powershift Speed Selector Switch.
24 12 Controller Forward/Neutral/Reverse Input Voltage too High. 28
1. Check the circuit between Forward/Neutral/Reverse
Resistor Pack and Controller Connector pin 34 not shorted
to voltage above 5 volts.
2. Check Forward/Neutral/Reverse Resistor Pack and
Forward/Neutral/Reverse Selector Switch circuits not
shorted to voltage above 5 volts.
SM 8-12101 Issued 09-2004
16 SECTION 10006
COMPONENT ERROR TYPE
E!QSSIBLE CAUSE A~I:! CQRRECII~E ACTIQN SEEPAGE
~ .c.QQ&
24 15 Controller Forward/Neutral/Reverse Selector Input Voltage 30
too Low.
1. Check for 5 volts at pin 3 of Forward/Neutral/Reverse
Resistor Pack.
2. Check for 5 volts at pin 2 of Forward/Neutral/Reverse
switch connector.
3. Check Forward/Neutral/Reverse Resistor Pack and
Forward/Neutral/Reverse Selector Switch circuits for
continuity and not shorted to ground.
4. Check circuit between Forward/Neutral/Reverse Resistor
Pack and Controller Connector pin 34 for continuity and not
shorted to ground.
5. Check Forward/Neutral/Reverse Resistor Pack.
6. Check Forward/Neutral/Reverse Speed Selector Switch .
25 11 & 12 Controller Inching Pedal Switch Input Voltage too High. 32
1. Check Inching Pedal Switch circuits not shorted to voltage
above 5 volts.
Calibrate the transmission controller when the fault has been
corrected, refer to "CALIBRATION" on page 6 ..
25 15 & 16 Controller Inching Pedal Switch Input Voltage too Low. 34
1. Check for 5 volts at pin 2 of the Inching Pedal Switch
connector.
2. Check the Inching Pedal Switch circuits between the
Inching Pedal Switch and the controller for continuity and
not shorted to ground.
Calibrate the transmission controller when the fault has been
corrected, refer to "CALIBRATION" on page 6 ..
26 12 Forward Clutch Solenoid Resistance too High. 36
1. Check the forward solenoid circuits for continuity.
2. Check the forward solenoid circuits have not shorted to
ground.
Calibrate the transmission controller when the fault has been
corrected, refer to "CALIBRATION" on page 6 ..
26 15 Forward Clutch Solenoid Resistance too Low. 38
1. Check for short circuit across the Forward Solenoid valve.
2. Check the Forward Solenoid circuit between the controller
connector pin 6 and the Froward Solenoid terminal A has
not shorted any other circuit.
3. Check the Forward Solenoid circuit between the controller
connector pin 8 and the Froward Solenoid terminal B has
not shorted any other circuit.
Calibrate the transmission controller when the fault has been
corrected, refer to "CALIBRATION" on page 6 ..
28 12 Reverse Clutch Solenoid Resistance too High. 40
1. Check the Reverse Solenoid circuits for continuity.
2. Check the Reverse Solenoid circuits have not shorted to
ground.
Calibrate the transmission controller when the fault has been
corrected, refer to "CALIBRATION" on page 6 ..
SM 8-12101 Issued 09-2004
SECTION 10006 17
COMPQNENT ERBQB TYeE
PQSSIBLE CAUSE AND CQBRECTIVE ACTIQN SEEPA~E
~ ~
28 15 Reverse Clutch Solenoid Resistance too Low. 42
1. Check for short circuit across the Reverse Solenoid valve.
2. Check the Reverse Solenoid circuit between the controller
connector pin 7 and the Reverse Solenoid terminal A has
not shorted any other circuit.
3. Check the Reverse Solenoid circuit between the controller
connector pin 9 and the Reverse Solenoid terminal B has
not shorted any other circuit.
Calibrate the transmission controller when the fault has been
corrected , refer to "CALIBRATION" on page 6.
36 23 Tyre Size not Calibrated. -
1. Carry out the Calibration Procedure, refer to
"CALIBRATION " on page 6.
36 24 Inching Pedal not Calibrated . -
1. Carry out the calibration procedure, refer to
"CALIBRATION" on page 6 .
36 25 Forward Clutch not Calibrated. --
1. Carry out the Calibration Procedure, refer to
"CALIBRATION" on page 6.
36 26 Reverse Clutch not Calibrated. --
1. Carry out the Calibration Procedure, refer to
"CALIBRATION" on page 6.
37 23 Clutch Speed Sensor A Signal Is 0 Hz when the Clutch Speed 44
Sensor B Signal is Above 10Hz.
See Note on 1. Check the Clutch Speed Sensor A clean ground circuit for
Page 15. continuity.
2. Check for 12 volts at terminal B of the Clutch Speed
Sensor A.
3. Check the circu it between the Clutch Speed Sensor A and
the Controller, Connector 48 pin 17 for continuity and for
shorting to ground.
4. Check the installation and adjustment of the Clutch Speed
Sensor A.
5. Replace the clutch speed sensor A as necessary.
IMPORTANT: When installing the speed sensor make
sure the existing shim thickness is maintained and the
threads of the sensor are sealed with thread tape.
Tightened the sensor to a torque of 30 Nm , DO NOT
overtighten the sensor.
SM 8-121 01 Issued 09-2004
18 SECTION 10006
COMPQNENT EBBQRTYPE
PQ~SIBLE CA!J~E A~D ~QRRE~IIVE A~TIQ~ ~EE~AG!;
~ ~
37 24 Clutch Speed Sensor B Signal Is 0 Hz when the Clutch Speed 46
Sensor A Signal is Above 10Hz.
See Note on 1. Check the Clutch Speed Sensor B clean ground circuit for
Page 15. continuity.
2. Check for 12 volts at terminal B of the Clutch Speed
Sensor B.
3. Check the circuit between the Clutch Speed Sensor Band
the Controller, Connector 48 pin 18 for continuity and for
shorting to ground .
4. Check the installation and adjustment of the Clutch Speed
Sensor B.
5. Replace the clutch speed sensor B as necessary.
IMPORTANT: When installing the speed sensor make
sure the existing shim thickness is maintained and the
threads of the sensor are sealed with thread tape .
Tightened the sensor to a torque of 30 Nm, DO NOT
overtighten the sensor.
37 25 Clutch Speed Sensor A and Clutch Sensor B Signals out of
Phase.
1. Check the clutch speed sensors for damage and replace as
necessary.
IMPORTANT: When installing the speed sensor make
sure the existing shim thickness is maintained and the
threads of the sensor are sealed with thread tape .
Tightened the sensor to a torque of 30 Nm , DO NOT
overtighten the sensor.
38 23 . Excessive Clutch Pack Slippage. -
1. Service the Transmission Powershift Clutch Packs. refer to
Section 6009.
No Code No Code No Power To Controller. 54
1. - Check controller power circuit.
No F/N/R or Powershift
Selection
- Tractor Remains in Neutral
No Code No Code No signal from the F/N/R switch. 58
1. - Check the F/N/R switch and resistor pack circuits .
No Forward Drive.
No Code No Code No Signal from the F/N/R switch. 58
1. - Check the F/N/R switch and resistor pack circuits.
No Reverse Drive.
No Code No Code No signal from the F/N/R switch. 60
1. - Check the F/N/R switch . .
No Forward or Reverse Drive.
No Code No Code Operator Presence switch circuit failed. 62
1. - Check the Operator Presence switch circuit.
Return to Neutral Light On
When Forward or Reverse
Selected.
SM 8-12101 Issued 09-2004
SECTION 10006 19
COMPQ~ENT EBBQB n:~ E
PQSSIBLE ~AUSE AND CORR~CTIVfli ACTION SEEPAGE
~ ~
No Code No Code 1st Speed Powershift solenoid circuit failed. 64
1. - Check the 1st Speed Powershift solenoid circu it.
No Drive in 1st Speed
Powershift.
No Code No Code 2nd Speed Powershift solenoid circuit failed. 66
1. - Check the 2nd Speed Powershift solenoid circuit.
No Drive in 2nd Speed
Powershift.
No Code No Code 3rd Speed Powershift solenoid circuit failed. 68
1. - Check the 3rd Speed Powershift solenoid circuit.
No Drive in 3rd Speed
Powershift.
No Code No Code Powershift solenoid return circuit failed. 70
1. - Check Powershift solenoid return circuit between
No Drive in 1st, 2nd or 3rd connector 48 and splice SP8. Also check connector 40.
Speed Powershift.
No Code No Code Powershift selector switch circuit failed . 72
1. - Check the Speed Powershift selector switch circuit.
Defaults to 1st Speed
Powershift When 2nd Speed
Powershift Selected.
No Code No Code Powershift selector switch circuit failed . 74
1. - Check the Speed Powershift selector switch circuit.
Defaults to 3rd Speed 2. - Check the Powershift resistor circuit.
Powershift When 1st or 2nd
Speed Powershift Selected.
8M 8-121 01 Issued 09-2004
20 SECTION 10006
This Page Has Been Left Blank
SM 8-12101 Issued 09-2004
SECTION 10006 21
TROUBLESHOOTING GUIDE
Circuit Testing General Information
A WARNING: Never operate the engine in a closed building. Proper
~ ventilation is required under all circumstances.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with the
parking brake engaged and the engine OFF unless otherwise stated.
IMPORTANT: Put blocks in front of and behind the rear wheels .
IMPORTANT: The battery must be at full charge and all connections must be clean and tight before
testing. Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage to the
switches may occur.
IMPORTANT: Use MC2656 test probe kit when making electrical checks at connectors to avoid the risk
of shorting between the connector pins or terminals.
IMPORTANT: Replace the controller if the fault remains only after all necessary checks have been
made.
IMPORTANT: When disconnecting harness connector, always check the connector pins and terminals
for damage and alignment.
NOTE: Faults relating to the flywheel and clutch speed sensors will result in an erratic shuttle change.
Error codes for the flywheel sensor can only be read with the engine running. Error codes for the clutch
sensors can only be read with the engine running and the FINIR lever in Forward or Reverse (Range
and Speed levers in NEUTRAL and the Parking Brake ENGAGED) .
NOTE: When measuring resistance values, always measure the resistance of the multimeter leads
before testing components. Subtract the resistance of the multi meter leads from the component
resistance to obtain a true resistance value.
NOTE: When testing diodes and diode modules use the multimeter diode test function.
NOTE: All components, wires and connectors disconnected during any electrical checks must be
connected when the checks are completed.
8M 8-12101 Issued 09-2004
22 SECTION 10006
Error Code 20/19.
NOTE: Every time the key is turned to the ON position (engine not running) the controller will display
component code 20119 (Flywheel Sensor out of range, low). If the flywheel sensor is not faulty the error
code will disappear when the engine is started.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-16 from the flywheel sensor is too low
(below the specified limit).
System Response.
- Audible alarms does not sound when Forward or Reverse is selected and the park brake is applied .
- Bad shuttle change modulation.
Possible Cause.
1. Bad circuit between splice SP1 and the flywheel sensor.
2. Bad clean ground circuit between the flywheel sensor and the battery negative terminal.
3. Bad signal circuit between the flywheel sensor and the transmission controller (CN-16).
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information " on page 21 .
STEP 1
Turn the key OFF and disconnect the flywheel sensor. Turn the key ON and check for 12 volts at terminal B of
the transmission harness sensor connector.
- If 12 volts is not detected check the wire 910 Red between splice SP1 and the flywheel sensor connector.
Also check connector 40.
STEP 2
Check for continuity between terminal C of the flywheel sensor connector and chassis ground .
- If continuity is not detected check the wire 910 Brown between the flywheel sensor connector and the
battery negative terminal.
STEP 3
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between terminal A of the flywheel sensor connector and connector 40 pin 19.
- If continuity is not detected check the wire 910 Yellow between the flywheel sensor connector 40.
STEP 4
Connect connector 40 and disconnect the transmission controller from the harness. Check for continuity
between terminal A of the flywheel sensor connector and connector 48 pin CN-16.
- If continuity is not detected check the wire 910 Yellow between connector 40 and connector 48. Also check
connector 40.
- If continuity is detected check connector 48.
8M 8-12101 Issued 09-2004
SECTION 10006 23
- - - - - - - - - - - - - - - - - - - - - BATTERY POWER (B+) - - - - - - - - - - - - - - - - - - - - - -
----~91------------------- SIJIi1TCHED POWER - - -- - -- - - - - - -- -- - -- - - - - -
~ r---~~R1 0~~R10------, r -- --5(IOR1 0 - - - { > TO DEClUTCH SWITCH
r----jIl<:::-- - - -- :279R1 0 -----~C> TO AUDIBLE ALARM
FUSE SP1
-----300R1 0 48 TRANSMISSION CONTROLLER
28
15A CN-28 12V SWITCHED POWER
SOOR1.0 CN-42 12V SWITCHED POWER
.----t--- - - - - -- 303T 75 CN-4 SEAT SWITCH
OPERATOR ,.-- - - -- - - 910Y 75 CN-16 FLYVV1H EEL SPEED SENSOR SIGNAL
SEAT , . - - - - -- - 917lB1 .0 CLUTCH SPEED SENSOR B SIGNAL
SIJIi1TCH
(CLOSED ,.------ ~OY75 CN-3 HIGHILOW RANGE SVv1TCH
W/OPER CN-18 CLUTCH SPEED SENSOR A SIGNAL
IN SEAT) 918LB.75 (#917LBrJ_5~)-i~~~tt~~~~~~~===========j
CN-15 CHASSIS GROUND
CN-29 CHASSIS GROUND
500BR1.0 - - - - - - - - - - - 500BR1.0~
'----- - - 500BR 1.0 500BR 1.0
I ""'' 11
SP2
------~
------R-1-.0--~'"~"
21LB
580y.7: 75
o
;:
o
a;
I
tJjSi
HIGH/LOW .., an
~ RANGE is "-
~ SWITCH :g ~
10R1 .0 - -,
- ,
...- --+-fi,80R1 .0 - -- -- -- - - -...J-
"'r 3.:g~
RESISTOR A
/ "--1---- - 921 R 75 - - - - -,
SPS 580Y 75
r - - - - -- 921LB 75
q q
c;:
o
1.2KOHMS 12KOHMS
FLYWHEEL
SPEED
SENSOR
--+-~""'''"'"''''--------------+_-- CHASSIS GROUND ---~r--~""''''''",..-------~G!to1-~
---e--------------------------------------e------ CLEANGROUND --------e-------------------------~----
# Early Production Tractors Only.
SM 8-12101 Issued 09-2004
24 SECTION 10006
Error Code 22/12.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-32 from the powershift speed selector is
too high (above the specified limit).
System Response.
- Tractor remains in 1st Speed Powershift.
- Audible alarm sounds when F/N/R lever moves out of neutral.
Possible Cause.
1. Bad powershift resistor pack and powershift selector switch, sensor (-) circuit.
2. Bad powershift resistor pack.
3. Bad powershift selector switch .
4. Powershift signal circuit shorted to another circuit.
Circuit Checks.
IMPORTANT: Before carrying out the following tests. refer to Circuit Testing "Circuit Testing General
Information " on page 21.
Check for the following error codes :
A. Component error code 24/12.
B. Component error code 25/11 & 12 .
• A and B Present (see above) refer to "Multi Error Codes 22/12, 24/12 and 25/11 & 12." on page 50 .
• A and B Not Present (see above).
STEP 1
Turn the key OFF and disconnect the powershift resistor pack. Check the resistance readings between the
following resistor pack connector terminals. If any of the readings are incorrect replace the resistor pack.
- Terminals 1 and 4 = 3.3 K ohms.
- Terminals 2 and 4 =5.6 K ohms
- Terminals 3 and 4 = 33.0 K ohms
- Terminals 5 and 4 = 3.3 K ohms
STEP 2
Disconnect the transmission controller and check for continuity between terminal 3 of the powershift resistor
pack connector and connector 48 pin CN- 1.
- If continuity not detected check wire 923 Brown between the powershift resistor pack connector and splice SP7.
STEP 3
Disconnect powershift speed selector switch and check for continuity between terminal A of the powershift
speed selector switch connector and connector 48 pin CN-1 .
- If continuity not detected check wire 923 Brown between the powershift speed selector switch connector
and splice SP7.
STEP 4
Check the resistance readings between the following powershift speed selector switch connector terminals. If
any of the readings are incorrect replace the speed selector switch.
1ST SPEED 2ND SPEED 3RDSPEED
TERMINALS
SELECTED SELECTED SELECTED
Aand B Approximately Approximately No Continuity
3.9 ohms 3.9 ohms
Aand C No Continuity Approximately Approximately
3.9 ohms 3.9 ohms
STEP 5
Check for continuity between connector 48 pin CN-32 and the remain ing pins of connector 48.
- If continuity is detected check connector 48 and wire 927 Yellow between connector 48 and the powershift
resistor for shorting to other circuits .
SM 8-12101 Issued 09-2004
SECTION 10006 25
BATTERYPOW£R(B+) ------__________________________________________
------------- - - -- -- -- -- - - -- - - -- - - -- - - - - -- - - -- - - - S~TCHEDPOWER -------- _________________________________________
,......
TRANSMISSION CONTROLLER 48 POWERSHIFT
[:PO: ~; ~S!HiIFT~S:E~LE~CT~O:R: S;IG~N;A;L::~~::::~~~CiN~.3~2~~~~~927Y75
RESISTOR
--- - - - -- -- - 927Y 75 PACK
SENSOR RETURN (.) CN·l 923BR 75 --- - - - - - - - - - - -- - - ------,
R1=33KOHMS
I
d
SENSOR 5 VOLT SUPPLY(+) CN·14 921R101--- - - - - - -- ---,
INCHING PEDAL POSITION SIGNAL CN·31 924Y 75 --- -- - - -------, I R2=56KOHMS
R3 = 33.0 K OHMS
75~ ....~I
R4 = 3 3 KOHMS
FORWAROINEUTRAUREVERSE SELECTOR SIGNAL CN·34 922Y
TO PTO NEUTRAL .. "'
START SWITCH FORWARD/NEUTRAL! ,:
REVERSE RESISTOR ~ Si
PACK ,:
R1 = 15KOHMS l:::
R2 = 2 2 K OHMS a>
FROM KEY R3= 27 KOHMS
SWITCH R4 = 1 0 KOHMS ....
""
TERMINAL 2 >-
....
N
'"
FORWARD/NEUTRAL
N
m
ft>
!D "
!D /REVERSE '"r: "''''
~ ~ ...'"
~ ...
II>
Ii
28
~r: ci
SHUTTLE
S~TCH
M
0 ...
00 '" N '"
M
922Y 75
'" '" '" Ol
ljj 924Y 75
~
IfJ
~
N
'"
,-"
~----_'992'RlO_----~
..--...
"'--' 2
,
3
PO~SHIFT
3 POSITION
S'MTCH
ci 505T,75
N
Ol
II>
....
~21R7~5---------------------
SP3
GEAR SVIIITCH LOGIC
~
1 ,
51 S2
,
a '" ~
*
2 21R.7 2 1
3 924Y75 ---------------~----_r~ 3 0 1
, 923BR 75 --------------+--------4 51 82
INCHING PEDAL
POTENTIOMETER
SP4
SP7
-----+--t~-- 923BR.75 - - - - - - - -- - - 923BR 75
1-----_'921 R 7'5---------~~--s 5-- -- -- - - -- -- - - -- - - - -- -- - - - - - - ---S921R.7
- CHASSIS GROUND --)."It~'''/J'';;.,,7~.,,;,....--------------------------l"'f"'';''';'';;'''f~tI'''''- CHASSIS GROUND - - - - - - - - - - -
- - - - - CLEAN GROUND CLEAN GROUND - - - - - - -
SM 8-12101 Issued 09-2004
26 SECTION 10006
Error Code 22/15.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-32 from the powershift speed selector is
too low (below the specified limit).
System Response.
- Tractor remains in 1st Speed Powershift.
- Audible alarm sounds when F/N/R lever moves out of neutral.
Possible Cause.
1. Power supply to the powershift resistor pack circuit failed.
2. Bad powershift resistor pack.
3. Circuit between the transmission controller and powershift resistor pack failed.
Circuit Checks.
, IMPORTANT: Before carrying out the following tests, refe r to Circuit Testing "Circuit Testing General
Information" on page 21 .
Check for the following error codes :
A. Error code 24/15 .
B. Error code 25/15 &16 .
- A and B Present (see above) refer to "Multi Error Codes 22/15, 24/15 and 25/15 & 16." on page 52.
- A and B Not Present (see above).
STEP 1
Turn the key OFF and disconnect powershift resistor pack. Turn the key ON and check for 5 volts at powershift
resistor pack connector terminal 5.
- If 5 volts is not detected check wire 921 between the powershift resistor pack connector and splice SP6.
STEP 2
Turn the key OFF and check the resistance readings between the following resistor pack connector terminals.
If any of the readings are incorrect replace the resistor pack.
- Terminals 1 and 4 =3.3 K ohms .
- Terminals 2 and 4 =5.6 K ohms
- Terminals 3 and 4 = 33.0 K ohms
- Terminals 5 and 4 = 3.3 K ohms
STEP 3
Disconnect the transmission controller and check for continuity between connector 48 pin CN-32 and the right
powershift resistor pack connector terminal 4.
- If continuity is not detected check wire 927 Yellow for damage.
- Also check connector 48 .
8M 8-12101 Issued 09-2004
SECTION 10006 27
BATTERY POWER (B+)
SV\i1TCHED POWER
TRANSMISSION CONTROLLER
-4B POWERSHIFT
RESISTOR
POWERSHIFT SELECTOR SIGNAL CN-32 927Y 75 927Y.75 PACK
SENSOR RETURN (-) CN-l 923BR 75
Rl = 3.3 K OHMS
SENSOR 5 VOLT SUPPLY (+) CN-14 921Rl 0 R2 = 5.6 K OHMS
INCHING PEDAL POSITION SIGNAL CN-3l 924Y 75 R3 = 33_0 K OHMS
11
R4 = 3_3 K OHMS
FORWARD/NEUTRAUREVERSE SELECTOR SIGNAL CN-34
""'"~ I .... co
~ ~
M
TO PTO NEUTRAL ... '" on
START SWITCH
.
FORWARD/NEUTRAL!
REVERSE RESISTOR
PACK
I()
":
>-
~
N
C>
N
R1=15KOHMS N
R2 = 2 2 K OHMS '"
FROM KEY
SWITCH
R3=27KOHMS
R4 = 10 KOHMS .....,>=
TERMINAL 2
...
N
'" l-
ei
FORWARD/NEUTRAL
.... ...
N
N
!"
1t>
!" '"
!" /REVERSE
SHUTTLE
...
II>
~
M
II> '"
""': ' "
ttl; $
...
It>
ei
m 922Y 75
28
SV\i1TCH 0 gg N M
U)
'" N
a> 924Y.75
----,
..---.. 2
POWERSHIFT
3 POSITION
:e
ci
N ~5T7~
1-1J 3
S'MTCH
'" SP3 ....
'"
GEAR SVIIITCH LOGIC >=
L 2 1 R 75-S--- - -- - - - ---- 921R 75 S1 82 '"
N
II>
1 1 0 '"
*
2 21R7 2 1 1
3 924Y 76 - ---- - - - - - 1 1 - ---+-' 3 0 1 ...
- 1 923BR.75 ---------+-----. S1 52 ei
N
INCHING PEDAL
POTENTIOMETER
21R.75-- - - - - - . J SP4
SP7
1 - -- 923BR.75 ---- --+-....'--- 9236R.75
L......_ _ _ _~~ 5 2 1R.75- - - - -__-=:----9: 921R.7
CHASSIS GROUND -~j"»."/~'7lZ,,»,,»."'--------------------------~-"",,..- CHASSIS GROUND
- hllllI/IJI
- - - CLEAN GROUND - - - - - - -- -- - - - - - - -- - - -- - - - - - - - - - - -- -- - - - - - - -- - - - CLEAN GROUND
SM 8-12101 Issued 09-2004
28 SECTION 10006
Error Code 24/12.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-34 from the forward/neutral/reverse
selector is too high (above the specified limit).
System Response.
- Tractor remains in neutral
- Return to neutral light illuminates.
Possible Cause.
1. Bad Forward/Neutral/Reverse resistor pack, sensor (-) circuit.
2. Bad Forward/Neutral/Reverse resistor pack .
3. Forward/Neutral/Reverse signal circuit shorted to another circuit.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing Genera/
Information" on page 21 .
Check for the following error codes:
A. Error code 25/12.
B. Error code 22/12
- A and B Present (see above) refer to "Multi Error Codes 22/12, 24/12 and 25/11 & 12." on page 50.
- A Present.
STEP 1
Turn the key OFF and disconnect the transmission controller and the inching pedal potentiometer. Check for
continuity between connector 48 pin CN-1 and the inching pedal potentiometer connector terminal 1.
- If continuity is not detected check the following :
- Wire 923 Brown between splice SP4 and connector 28 pin 1.
- Wire 923 Brown between connector 28 pin 1 and splice SP7.
- A and B Not Present (see above).
STEP 1
Turn the key OFF and disconnect the forward/neutral/reverse resistor pack. Check the resistance readings
between the following resistor pack connector terminals . If any of the readings are incorrect replace the resistor
pack.
- Terminals 2 and 1 = 1.5 K ohms.
- Terminals 2 and 3 =4 .9 K ohms
- Terminals 2 and 5 = 1.0 K ohms
- Terminals 2 and 6 = Continuity
STEP 2
Disconnect the inching pedal potentiometer and check for continuity between the inching pedal potentiometer
connector terminal 1 and the forward/neutral/reverse resistor connector terminal 1.
- If continuity is not detected check wire 923 Brown between splice SP4 and forward/neutral/reverse resistor
connector for damage.
STEP 3
Disconnect the transmission controller and check for continuity between connector 48 pin CN-1 and the forward/
neutral/reverse resistor connector terminal 1.
- If continuity is not detected check the following:
- Connector 28
- Wire 923 Brown between splice SP4 and connector 28.
- Wire 923 Brown between connector 28 and splice SP7.
8M 8-12101 Issued 09-2004
SECT/ON 10006 29
--___________________________________________ BATTERYPO~R(B~ - - - - - - - - - -____________________________________
--------------------------------------------- S~TCHEDPO~R -----------------------------------------------
r--
TRANSMISSION CONTROLLER 48 POWERSHIFT
~I~~~~~::EVD~L:p~;~I~N(~IGNAL
iPOiWERi~S~H~IFTis:E~L~EC~T~OiR~SiIG;N;A~L~~~~~~~~C:N:.3:2~1~~~927Y
RESISTOR
PACK
SENSOR RETURN (.) CN·1 923BR 75-- - - -- -- -- - - -- ---------,
~~:~~ 9 2 2421Y R~75 0 ~ I _l.~~f!<'
Rl=33KOHMS
75 --- -- -------- 927Y 75 R2 = 56 K OHMS
R3 = 33.0 K OHMS
R4 = 3 3 K OHMS
FORWARD/NEUTRAl/REVERSE SELECTOR SIGNAL CN·34 ; ;
TO PTO NEUTRAL r;=4~====:;-1 :!: N
START SWITCH FORWARD/NEUTRALI >
REVERSE RESISTOR :!: ~
PACK ~
Rl=I .5KOHMS ~
R2 = 2 2 K OHM S '"
FROM KEY R3=27 KOHMS
SWITCH R4 = 1.0 K OHMS
TERMINAL 2
FORWARD/NEUTRAL
IREVERSE 28
SHUTILE 922Y15 ---~
SVu1TCH
924Y75 ---~
~~1.----r---
--~:::~·~75--------~
N I
---- , POWERSHIFT
3 POSITION
~
:!:
Sl
505T,75 1-fJ .---.. 2
3
S~TCH
II)
.....
L~R.75_5-----------------
SPJ
GEAR S~ TC H LOG IC ;,:
<0
N
S1 S2
921R .7 0>
"'
~~
\I)
1 1 .....
*
2 21R7 2 1 ai
3 924Y,75 ------ -------+------11--1 3 0 ""C>
!:l ...a:
- 1 923BR ,75 ---------- ---1------.... S1
N
INCHING PEDAL
POTENTIOMETER
21 R.7'5-- - - - - -- - -...J SP4
3BR .75 SP7
C 28
1 - - 923BR 75 ----------If-~J_- 92JBR.76 - - -- - - - - -- - - - - - - - - 923BR 75
'-------~ 5 f-----Q 21R . 7'5--------4I~-9 '5-------------------------------~921R7
- CHASSIS GROUND --,,»,,»"11","/ //."",---------------------------------------------.....,;""11""»""»""»""11""'- CHASSIS GROUND - - - - - - - - - - -
- - - - CLEAN GROUND CLEAN GROUND - - - - - - - - - - -
STEP 4
Check for continuity between connector 48 pin CN -34 and the remaining pins of connector 48.
- If continuity is detected check the following :
- Connectors 48 and 28
- Wire 922 Yellow for shorting to other circuits between connector 48 and connector 28.
- Wire 922 Yellow for shorting to other circuits between connector 28 and the forward/neutral/reverse resistor
connector.
SM 8-12101 Issued 09-2004
30 SECTION 10006
Error Code 24/15.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-34 from the forward/neutral/reverse
selector is too low (below the specified limit).
System Response.
- Tractor remains in neutral
- Return to neutral light illuminates.
Possible Cause.
1. Bad circuit between the transmission controller and forward/neutral/reverse resistor.
2. Bad forward/neutral/reverse resistor pack.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing Genera/
Information" on page 21.
Check for the following error codes:
A. Component error code 25/16.
B. Component error code 22/15.
- A and B Present (see above) refer to "Multi Error Codes 22/15, 24/15 and 25/15 & 16." on page 52.
- A Present (see above).
STEP 1
Turn the key OFF and disconnect the transmission controller and the inching pedal potentiometer. Check for
continuity between connector 48 pin CN-14 and the inching pedal potentiometer connector terminal 2.
- If continuity is not detected check
- Wire 921 Red between splice SP3 and connector 28 pin 5.
- Wire 921 Red between connector 28 pin 5 and splice SP6.
- A and B Not Present (see above).
STEP 1
Turn the key OFF and disconnect the forward/neutral/reverse resistor pack. Turn the key ON and check for 5
volts at the forward/neutral/reverse resistor connector terminal 3.
- If 5 volts is not detected check wire 921 Red between splice SP3 and the forward/neutral/reverse resistor
connector for damage.
STEP 2
Disconnect the transmission controller and check for continuity between connector 48 pin CN-34 and the
forward/neutral/reverse resistor connector terminal 6.
- If continuity is not detected check the following :
- Connector 28 pin 4.
- Wire 922 Yellow between the connector 28 pin 4 and the forward/neutral/reverse resistor connector for
damage.
- Wire 922 Yellow between the connector 28 pin 4 and connector 48 for damage.
- Connector 48.
STEP 3
Check the resistance readings between the following resistor pack connector terminals. If any of the readings
are incorrect replace the resistor pack.
- Terminals 1 and 4 = 1.5 K ohms.
- Terminals 2 and 4 =2.2 K ohms
- Terminals 3 and 4 =4.9 K ohms
- Terminals 5 and 4 = 1.0 K ohms
- Terminals 6 and 4 = Continuity
- Terminals 2 and 3 = 2.7 K ohms
8M 8-12101 Issued 09-2004
SECTION 10006 31
6ATIERY POI/IIER (6+)
SWTCHED POWER
T RANSMISSION CONTROLLER
.---
48 POWERSHIFT
RESISTOR
POWERSHIFT SELECTOR SIGNAL CN-32 927Y 75 927Y 75 PACK
SENSOR RETURN (-J CN-, 923BR 75
R1 = 3.3 K OHMS
SENSOR 5 VOLT SUPPLY (+) CN·14 - ~21 R1 0 R2 = 5 .6 K OHMS
INCHING PEDAL POSITION SIGNAL CN·31 924Y 75 R3 =33_0 K OHMS
R4 = 33 KOHMS
FORWARD/NEUTRAl/REVERSE SELECTOR SIGNAL CN-34
"~"~
I
11
~ ~
cr
~
N
N
'"
TO PTO NEUTRAL I()
I-
START SWITCH FORWARD/NEUTRAL! ,.:
REVERSE RESISTOR
PACK
I()
....
>-
'"
~
R1=15KOHMS ::l
FROM KEY
R2 = 2 2 K OHMS
R3 = 2 7 KOHMS
'"
SWITCH
TERMINAL 2
R4 = 1 0 KOHMS '"
.....
,.:
l-
S!
FORWARD/NEUTRAL
N
po
In
po 'po" /REVERSE
SHUITLE
on on
.... ........
r: r:...:
Ul
'"....
Ii
....'"
Ii
28
m 922Y 75
SWTCH '" on....o onon
0
on
0 N
m '"
N
m 924'1' 75
921Rl .
'"'-;e- ........
"''''
~r:
~ ~ '-; "'
I
'"....
Ii
i 923BR75
Ii Ii ~
C'l
0 o '"
.... 0
N
m N N
~
C'l
'" on '" m N
0)
0)
Ii --------, POI/IIERSHIFT
3 POSITION
on
'-'
0::
N
5OST75
1-fJ m
C'l
N
0)
-------- 2
3
SVV1TCH
'" on
~21R75~----------------------
SP3 r-;
GEAR SVV1TCH lOGIC >-
S1 52 ~ on
921R 7
'"
~J
1 1 0
*
2
3
21R.7
924'1' 75
2
3
1
0 ,
1
I-
------ 1 923BR75 ---------------r----~
SI S2 Ii
N
INCHING PEDAL
POTENTIOMETER
921 IU5_- -- - - - - - - ' SP4
r-:
cr SP7
N
923BR.75 923BR 75
21R 7 , R.75 921R 7
SP6
- CHASSIS GROUND -~j"II."II."h."Z"IZ";---------------------------."."-.,,..- CHASSIS GROUND mmm»
- - - - - CLEAN GROUND - - - -- - - - - ------------ - - ------------------------ -- - - ---------------------- CLEAN GROUND
SM 8-12101 Issued 09-2004
32 SECTION 10006
Error Code 25/11 & 12.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-31 from the inching pedal potentiometer
is too high (above the specified limit).
System Response.
- Tractor remains in neutral.
- Return to neutral light illuminated.
- Audible alarm sounds when F/N/R lever moves into of neutral.
Possible Cause.
1. Inching pedal potentiometer out of adjustment.
2. Bad inching pedal sensor (-) circuit.
3. Signal circuit between the transmission controller and the inching pedal potentiometer shorted to
another circuit.
4. Bad inching pedal potentiometer.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information " on page 21 .
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibrafion)" on page 8.
Check for the following error codes:
A. Component error code 24/12.
B. Component error code 22/12
• A and B Present (see above) refer to "Multi Error Codes 22/12, 24/12 and 25/11 & 12." on page 50.
• A Present.
STEP 1
Turn the key OFF and disconnect the transmission controller and the inching pedal potentiometer. Check for
continuity between connector 48 pin CN-1 and the inching pedal potentiometer connector terminal 1.
- If continuity is not detected check the following:
- Connector 28.
- Wire 923 Brown between splice SP4 and connector 28 pin 1.
- Wire 923 Brown between connector 28 pin 1 and splice SP7.
• A and B Not Present (see above).
STEP 1
Check and adjust the inching pedal potentiometer, refer to "INCHING PEDAL POTENTIOMETER ADJUSTMENT"
on page 13.
STEP 2
Turn the key OFF and disconnect the transmission controller and inching pedal potentiometer check for
continuity between connector 48 pin CN-31 and the remaining pins of connector 48.
- If continuity is detected check the following:
- Connector 28
- Wire 924 Yellow for shorting to other circuits between connector 48 and connector 28.
- Wire 924 Yellow for shorting to other circuits between connector 28 inching pedal potentiometer connector.
- Connector 48.
STEP 3
Check resistance between the following terminals of the inching pedal potentiometer:
- Terminals 1 to 3.
- Terminals 2 to 3.
- If a reading of 0 Ohms is detected replace the inching pedal potentiometer.
SM 8-12101 Issued 09-2004
SECT/ON 10006 33
--------------------------------------------- BATTERyPOWER(B+) ----__________________________________________
------- ---------- ------------------------------ - SWTCHEDPOWER ----------------------------------------------___
TRANSMISSION CO NTROLLER '48 POWERSHIFT
t~I~~~~:
P:O~W~E;RiS~:EVD~L:
HiIFTiS~E:P~~~I~N(~IGNAL
L~E~C~T~O;R~S;IG~N:A;L:~:::t~~~C~~::~
iN~_3:2~~~~~927Y9 92 2421Y R~75 0~
RESISTOR
PACK
SENSOR RETURN (-) CN-l 923BR 75 --------------------------,
--------------------"'!---,:SlI
~ ". ~!Il:.N
R1 = 3.3 K OHMS
75 ------------- 927YJ5 R2 = 5.6 K OHMS
R3 = 33.0 K OHMS
R4 = 3.3 K OHMS
FORWARD/NEUTRAL/REVERSE SELECTOR SIGNAL CN-34 =:
TO PTO NEUTRAL
START SWITCH FORWARD/NEUTRALI >'
REVERSE RESISTOR i!: Si
PACK >'
R1 = 1.5 KOHMS gj
R2 = 2 2 K OHMS Ol
FROM KEY R3=27KOHMS
SWITCH R4 = 10K OHMS
TERMINAL 2
FORWARD/NEUTRAL
/REVERSE "'t--
ci
SHUITLE III 922Y 75 ----~~
SWTCH M
N
0) 924Y.75 ----~~
921R1
.1
I~
i 923BR75
ci
N ~
"-""'1 POVVERSHIFT
ci ,.-..... 2 3 POSITION
CD
ro
C> 3
SM1TCH
SP3
GEAR SM1TCH LOGIC
....
10
>-
<D
N
Sl 52 Ol 10
1 1 0
*
2 21R.7 2 1 1
3 924y75 --------------~~----~~ 3 0 1 "-
1 923BR.75 ---------------+-----__ Sl 52 ci
N
0>
INCHING PEDAL
POTENTIOMETER
21 R.7'5--------------' SP4
23BR.75 SP7
C
I-------~~
28
1 - - - --
5
923BR 75 ----------+---41"--
21R 7'S---------~.,.._9
923BR 75 923BR 75
92 1R.7
----- CHASSISGROUND --->"»"k~)~»"»"I----------------------------------------------------~~""~-- CHASSIS GROUND
)/hI»»»
- - - - - CLEAN GROUND ------------------------------------------------------------------------- CLEAN GROUND
8M 8-12101 Issued 09-2004
34 SECTION 10006
Error Code 25/15 & 16.
Fault Description.
The signal voltage detected by the transmission controller at pin CN-31 from the inching pedal potentiometer
is too low (below the specified limit)
System Response.
- Tractor remains in neutral.
- Return to neutral light illuminated.
- Audible alarm sounds when F/N/R lever moves out of neutral.
Possible Cause.
1. Inching pedal potentiometer out of adjustment.
2. Inching pedal potentiometer linkage loose.
3. Bad inching pedal, sensor (+) circuit.
4 . Bad inching pedal, sensor (-) circuit
5. Bad circuit between the transmission controller and the inching pedal potentiometer.
6. Bad inching pedal potentiometer.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
Check for the following error code:
A. Component error code 24, error type code 15.
B. Component error code 22 , error type code 15
- A and B Present (see above) refer to "Multi Error Codes 22/15, 24/15 and 25/15 & 16." on page 52.
- A Present (see above).
STEP 1
Turn the key OFF and disconnect the inching pedal potentiometer. Turn the key ON and check for 5 volts at
terminal 2 inching pedal potentiometer connector.
- If 5 volts is not detected check the following :
- Connector 28 pin 5.
- Wire 921 Red between the connector 28 pin 5 and splice SP3 for damage.
- Wire 921 Red between the connector 28 pin 5 and the splice SP6 for damage.
- A and B Not Present (see above).
STEP 1
Check and adjust the inching pedal potentiometer, refer to "INCHING PEDAL POTENTIOMETER ADJUSTMENT"
on page 13.
STEP 2
Turn the key OFF and disconnect the inching pedal potentiometer. Check the potentiometer link arm is secure,
tighten then retaining screw as necessary. Turn the key ON and check for 5 volts at terminal 2 of the inching
pedal potentiometer connector.
- If 5 volts is not detected check wire 921 Red between splice SP3 and the inching pedal potentiometer
connector.
STEP 3
Turn the key OFF and disconnect the transmission controller and check for continuity between connector 48 pin
CN-1 and terminal 1 of the inching pedal potentiometer connector.
- If continuity is not detected check wire 923 Brown between the splice SP4 and the inching pedal
potentiometer connector.
SM 8-12101 Issued 09-2004
SECTION 10006 35
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -_______ BATTERyPOWER(8+) - - - - - -________________________________________
- - - -- - - - - - - - - -- -- - - - - -- - - -- - - - - - - - - - - -- -- ----- SWTCHEDPOWER - -- -__________________________________- - - - - - - - -
TRANSMISSION CONTROUER 4e POWERSHIFT
~iPOIW~ER~S~Hrl;~;S~E~L~E:CT:OiR~S~IGiN~AiL~~~~~~~~C~N~.3~2;1J1~~~927Y757~
RESISTOR
- - - - - - - -- - - -- 927Y 75 PACK
SENSOR RETURN (.) CN·l 923BR 75
I R133KOHMS
SENSOR 5 VOLT SUPPLY(+)
INCHING PEDAL POSITION SIGNAL
CN·14
CN-31
1Rl 0- ----------------------,
924Y
922Y 75 ~
I I :. R2 56 K OHMS
R3 33.0 K OHMS
R4 33 K OHMS
;
FORWARD/NEUTRAUREVERSE SELECTOR SIGNAL CN-34 :::
r---------------~
~_ ~
TO PTO NEUTRAL It) N
START SWITCH FORWARD/NEUTRAL! It)
;:
..,.
REVERSE RESISTOR
PACK
Rl = 1.5 KOHMS ~ III
R2= 22 KOHMS
FROM KEY R3 = 2 7 KOHMS
SWITCH R4 = 10K OHMS
TERMINAL 2
FORWARD/NEUTRAL
/REVERSE 28
SHUTILE 922Y75 --~
SWTCH
924Y75 --~
921Rl .
In
....
I
....
'"
1 923BR .7~
Ii
~
N N
~ ....
II>
--- 1 POWERSHIFT
Ii 3 POSITION
...,
<Xl --- 2
'+J
SWTCH
i!! ~ :3
Ii 5051.75
iii In
L21
SP3 ";
GEAR SWTCH LOGIC >-
CD
N
R.755-- -- ---------- - - -- -- Sl S2 (J) In
~~
1 1 ....
In
*
2 21 R.7 2 1 Ii
3 924Y75---------------r-----;~ 3 0
SI
'"
M
N ...
~
(J)
1 923BR .75 - - - - - - -- - - - - - + - - - - -. .
N
<1>
INCHING PEDAL
POTENTIOMETER
21R.75-- ----------' SP 4
SP7
923BR 75 ----------t--~J__-- 923BR.75 - - - - - - - - - - - - - - - - - ---- 923BR .75
f - - ----9:Z1 R.7 921R 75
- CHASSIS GROUND --.,/~"'It,"'It,"'N"',)/."'I----------------------------------------------.....,1"'JI"'tJ"'IJ"'h"'fI--- CHASSIS GROUND - - - - - - - - - - -
- - - - CLEAN GROUND CLEAN GROUND - - - - - -- - - -- -
STEP 4
Check for continuity between connector 48 pin CN-31 and the inching pedal potentiometer connector terminal 3.
- If continuity is not detected check the following:
- Connector 28 pin 9.
- Wire 924 Yellow between the connector 28 pin 9 and the inching pedal potentiometer connector for damage.
- Wire 924 Yellow between the connector 28 pin 9 and connector 48 for damage.
STEP 5
Check resistance between the following terminals of the inching pedal potentiometer:
- Terminals 1 to 3.
- Terminals 2 to 3.
- If a reading of 0 Ohms is detected replace the inching pedal potentiometer.
8M 8-12101 Issued 09-2004
36 SECTION 10006
Error Code 26/12
Fault Description.
The forward solenoid circuit resistance is too high.
System Response.
- Tractor will not drive in forward.
- Return to neutral light will illuminate when F/N/R lever is moved into forward.
- Tractor will drive in reverse.
Possible Cause.
1. Bad forward solenoid .
2. Bad circuit between the transmission controller and the forward solenoid.
3. Circuit between the transmission controller and the forward solenoid shorted to ground.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
STEP 1
Turn the key OFF and disconnect the forward solenoid, check the resistance between terminals 1 and 2 of the
forward solenoid.
- The resistance reading should be approximately 3.7 ohms at 20 0 C (68 0 F) replace the forward solenoid
coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between terminals 1 and 2 of the forward solenoid connector in turn to ground.
- If continuity is detected on terminal 1 check wire 915 Red between the forward solenoid connector and
connector 40 for damage.
- If the continuity is detected on terminal 2 check wire 915 Yellow between the forward solenoid connector
and connector 40 for damage.
STEP 3
Check for continuity between terminal 1 of the forward solenoid connector and connector 40, pin 25.
- If continuity is not detected on terminal 1 check wire 915 Red between the forward solenoid connector and
connector 40 for damage.
STEP 4
Check for continuity between terminal 2 of the forward solenoid connector and connector 40 pin 26.
- If the continuity is not detected on terminal 2 check wire 915 Yellow between the forward solenoid connector
and connector 40 for damage.
STEP 5
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between terminals 1 and 2 of the forward solenoid connector in turn to ground.
- If continuity is detected on terminal 1 check wire 915 Red between connector 48 and connector 40 for
damage.
- If continuity is detected on terminal 2 check wire 915 Yellow between connector 48 and connector 40 for
damage.
STEP 6
Check for continuity between terminal 1 of the forward solenoid connector and connector 48 pin CN-6.
- If continuity is not detected on terminal 1 check wire 915 Red between connector 48 and connector 40 for
damage. Also check connector 40.
- If continuity is detected on terminal 1 check connector 48.
8M 8-12101 Issued 09-2004
SECTION 10006 37
- - - - - - - - - - - - - - - - - - - - BATTERY POWER (B+) - -_ _ _ _ _ _ _ _ _ _ __ __ _ _ _ __
- - - - - -- - - - - - - - - - - - - -- -- - - - - - - -- ----------SWTCHEDPOWER----- -- -- - - - - -- - - - - -- -- - - -- -- -- - - -_________
=;-l
916Rl0
91 5Rl 0 II
916Rl .0
REVERSE FORWARD
SOLENOID SOLENOID
2 2
915Yl0 Cl 0
916Yl0 - - -- - - - - - 916Yl 0
C!C!~~
>= >=
<D
C(
LO lO
rr
(0
a; 0) 0; 0;
m"~=ON rom~~,. 70 I III
~RIE;VIERISIE~SIOiLEINIOI D~R~ET~UR~N~~~~~~~~lciN,19ji~~
FORWARD SOLENOID RETURN CN.S 915Yl ,0
916Yl 0
FORWARD SOLENOID eN.6 915Rl0
REVERSE SOLENOID CN·7 916Rl 0
- - CHASSIS GROUND -"T,)/;"'))"'IIJ.'1J))'?1.iJ,..------------------- --.....,j)'11j)'1J)j'?1.j)"'j)'1",- CHASSIS GROUND - - - - -
- - - - CLEAN GROUND CLEAN GROUND - -- - - -- -- - -
STEP 7
Check for continuity between terminal 2 of the forward solenoid connector and the controller connector pin eN-8.
- If continuity is not detected on terminal 2 check wire 915 Yellow between connector 48 and connector 40
for damage. Also check connector 40 .
- If continuity is detected on terminal 1 check connector 48.
SM 8-12101 Issued 09-2004
38 SECTION 10006
Error Code 26/15
Fault Description.
The forward solenoid circuit resistance is too low.
System Response.
- Tractor will not drive in forward.
- Return to neutral light will illuminate when F/N/R lever is moved into forward .
- Tractor may possibly drive in reverse.
Possible Cause.
1. Bad forward solenoid .
2. Circuit between the transmission controller and the forward solenoid shorted to another circuit.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
STEP 1
Turn the key OFF and disconnect the forward solenoid, check the resistance between terminals 1 and 2 of the
forward solenoid.
- The resistance reading should be approximately 3.7 ohms at 20 0 C (68 0 F) replace the forward solenoid
coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between connector 40 pin 25 and the remaining pins of connector 40 .
- If continuity is detected check wire 915 Red between the forward solenoid connector and connector 40 for
damage.
STEP 3
Check for continuity between connector 40 pin 26 and the remaining pins of connector 40.
- If continuity is detected check wire 915 Yellow between the forward solenoid connector and connector 40
for damage.
STEP 4
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48 pin CN-6 and the remaining pins of connector 48 .
- If continuity is detected check wire 915 Red between connector 40 and connector 48 for damage.
- Also check connectors 40 and 48.
STEP 5
Check for continuity between connector 48 pin CN-8 and the remaining pins of the connector 48.
- If continuity is detected check wire 915 Yellow between the connector 40 and connector 48 for damage.
- Also check connectors 40 and 48.
8M 8-12101 Issued 09-2004
SECTION 10006 39
------------------------------------------ BATTERYPO~R~~ - - - - - - - - - - - -________________________________
---------------------------------------------SWTCHEDPO~R---------- ______________________________- -_____
916R10
915Rl .0 II
916Rl .0 ~
REVERSE FORWARD
SOLENOID SOLENOID
915Yl0
916Y10 - -- -- - - - - - - - - 916Yl 0
~ ~ c::'! ~
>= 10
>= ~ ct:
'"c;; c;; 10
0) 0)
'"
~
TRANSMISSION CONTROLLER '4ii
REVERSE SOLENOID RETURN CN-S 916Yl0
FORWARD SOLENOID RETURN CN·8 915Yl0
FORWARD SOLENOID CN·S 915Rl0
REVERSE SOLENOID CN-7 916Rl.0
- CHASSIS GROUND
- - - CLEAN GROUND
-.,»""""""""",---------------------------------------------.. ., , , , ,;, ,;,7, 1"1--- CHASSIS GROUND - - - - - - - - - - -
CLEAN GROUND - - - - - -- -
SM 8-12101 Issued 09-2004
40 SECTION 10006
Error Code 28/12
Fault Description.
The reverse solenoid circuit resistance is too high.
System Response.
- Tractor will not drive in reverse.
- Return to neutral light will illuminate when F/N/R lever is moved into reverse.
- Tractor may possibly drive forward.
Possible Cause.
1. Bad reverse solenoid.
2. Bad circuit between the transmission controller and the reverse solenoid .
3. Circuit between the transmission controller and the reverse solenoid shorted to ground.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
STEP 1
Turn the key OFF and disconnect the reverse solenoid, check the resistance between terminals 1 and 2 of the
reverse solenoid.
- The resistance reading should be approximately 3.7 ohms at 20 0 C (68 0 F) replace the reverse solenoid
coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between terminals 1 and 2 of the reverse solenoid connector in turn to ground.
- If continuity is detected on terminal 1 check wire 916 Red between the reverse solenoid connector and
connector 40 for damage.
- If continuity is detected on terminal 2 check wire 916 Yellow between the reverse solenoid connector and
connector 40 for damage.
STEP 3
Check for continuity between terminal 1 of the reverse solenoid connector and connector 40 pin 28.
- If continuity is not detected on terminal 1 check wire 916 Red between the reverse solenoid connector and
connector 40 for damage.
STEP 4
Check for continuity between terminal 2 of the reverse solenoid connector and connector 40 pin 29.
- If continuity is not detected on terminal 2 check wire 916 Yellow between the reverse solenoid connector
and connector 40 for damage.
STEP 5
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between terminals 1 and 2 of the reverse solenoid connector in turn to ground.
- If the continuity is detected on terminal 1 check wire 916 Red between connector 48 and connector 40 for
damage.
- If continuity is not detected on terminal 2 check wire 916 Yellow between connector 48 and connector 40
for damage.
STEP 6
Check for continuity between terminal 1 of the reverse solenoid connector and connector 48, pin CN-7 .
- If continuity is not detected on terminal 1 check wire 916 Red between connector 48 and connector 40 for
damage.
- If continuity is detected on terminal 1 check connector 48 .
SM 8-12101 Issued 09-2004
SECTION 10006 41
- -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 8ATTERYPOWER (8+) - -_ _ _ _ _ _ _ __ _ _ __ _ _ _ _ __
----- -- -------------- - - ---------- -- -- -- - - SWTCHEDPOWER ------- - - -- - - - - -- - - -------------- - - -- - - -- - -
916Rl 0
915Rl0 II
916Rl .0 ~
REVERSE FORWARD
SOLENOID SOLENOID
9t5YLO
916Yl ,0 - -- -- - - - - - - 916Yl .0
~ q ~ I::!
;: ;:
to LO
~ ~
lfl (0
0;0;0;0;
ffi~'M'$'O' =~'O"~ r" I III
~RIE;VE;RIS;E;soiLEIN~O;ID~R~ET~U~R~N~j~~~~~JICIN.19ji~~
FORWARD SOLENOID RETURN eN-8 915Yl 0
916Yl 0
FORWARD SOLENOID eN.6 915Rl 0
REVERSE SOLENOID eN.7 916Rl 0
- CHASSIS GROUND -"l'l)}"'})I.'T1jJ.'T1jJ."-jjr---------------------.....,;;'11JZ"-"""»"'»"'(- CHASSIS GROUND - - - - -
- - - CLEAN GROUND CLEAN GROUND - - - - - - - - - - -
STEP 7
Check for continuity between terminal 2 of the forward solenoid connector and the controller connector pin CN-9.
- If continuity is not detected on terminal 2 check wire 916 Yellow between connector 48 and connector 40
for damage.
- If continuity is detected on terminal 1 check connector 48.
SM 8-12101 Issued 09-2004
42 SECTION 10006
Error Code 28/15
Fault Description.
The reverse solenoid circuit resistance is too low.
System Response.
- Tractor will not drive in reverse.
- Return to neutral light will illuminate when F/N/R lever is moved into reverse.
- Tractor will drive forward .
Possible Cause.
1. Bad reverse solenoid.
2. Circuit between the transmission controller and the reverse solenoid shorted to another circuit.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
STEP 1
Turn the key OFF and disconnect the reverse solenoid, check the resistance between terminals 1 and 2 of the
reverse solenoid .
- The resistance reading should be approximately 3.7 ohms at 20 0 C (68 0 F) replace the reverse solenoid
coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between connector 40 pin 28 and the remaining pins of connector 40.
- If continuity is detected check wire 916 Red between the reverse solenoid connector and connector 40 for
damage.
STEP 3
Check for continuity between connector 40 pin 29 and the remaining pins of connector 40 .
- If continuity is detected check wire 916 Yellow between the reverse solenoid connector and connector 40
for damage.
STEP 4
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48 pin CN-7 and the remaining pins of connector 48.
- If continuity is detected check wire 916 Red between the connector 40 and connector 48 for damage.
- Also check connectors 40 and 48.
STEP 5
Check for continuity between connector 48 pin CN-9 and the remaining pins of connector 48.
- If continuity is detected check wire 916 Yellow between the connector 40 and connector 48 for damage.
- Also check connectors 40 and 48.
SM 8-12101 Issued 09-2004
SECTION 10006 43
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -______ BATTERYPOWER(B~ ______________________________________________
- - - - - - - - - - - - - - - -- -- - - - - - - - - - - -- - - -- - - - - - - - - - - SWTCHEDPOWER - - - - - - - - - - - - - - - - - - - - - -- - - - - -- - - - - - - - - - - - - -_____
916R10
915Rl 0 II
916R1 .0 ~
REVERSE FORWARD
SOLENOID SOLENOID
9 15Yl .0
916Y1 .0 ----- -- -- - - - - 916Yl 0
q q q q
>= Il)
>= ~ ~
Il)
CD CD
a; a; a; a;
~
TRANSMISSION CONTROLLER 4a
REVERSE SOLENOID RETURN CN·9 916Yl0
FORWARD SOLENOID RETU RN CN-8 91SY1.0
FORWARD SOLENOID CN-6 915Rl .0
REVERSE SOLENOID CN-7 916Rl .0
- CHASSIS GROUND --.,»"»"ff"f!,"""I-----------------------------------------------h."h."/~.",~"'I"'rI-- CHASSIS GROUND - - - - - - - - - - - -
- - CLEAN GROUND CLEAN GROUND - - - - - - - - - - - -
8M 8-12101 Issued 09-2004
44 SECTION 10006
Error Code 37/23
Fault Description.
Output from the clutch speed sensor A is 0 Hz when the output from sensor B is above 10Hz.
System Response.
- Bad shuttle change modulation.
Possible Cause.
1. Bad speed sensor A (top sensor) .
2. Bad circuit between the transmission controller and speed sensor A.
Circuit Checks.
IMPORTANT: Before carrying out the following tests , refer to Circuit Testing "Circuit Testing General
Information" on page 21 .
NOTE: When the fault has been corrected calibrate the transmission controller, refer to "Calibration
Procedure - Method 2 (Existing Controller Recalibration)" on page 8.
STEP 1
Turn the key OFF and disconnect speed sensor A from the transmission harness (or adapter harness for early
production tractors). Turn the key ON and check for 12 volts at terminal 3 of the harness connector.
- If 12 volts is not detected check the following:
- Resistor adaptor harness wire 921 Red (early production tractors only).
- Wire 921 Red between the transmission harness connector and splice SP5.
STEP 2
Check for continuity between terminal 2 of the speed sensor A connector and ground.
- If continuity is not detected check the following:
- Resistor adaptor harness wire 921 Brown (early production tractors only).
- Wire 921 Brown between the transmission harness connector and the battery negative terminal.
STEP 3
Check for continuity between the following terminals of the speed sensor:
- Terminals 1 to 2.
- Terminals 1 to 3.
- Terminals 2 to 3.
- If continuity is detected check replace the sensor.
IMPORTANT: When installing the speed sensor make sure the existing shim thickness is maintained
and the threads of the sensor are sealed with thread tape. Tightened the sensor to a torque of 30 Nm,
DO NOT overtighten the sensor.
STEP 4
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between connector 40 pin 32 and terminal 1 of the adaptor harness connector.
- If continuity is not detected check the following:
- Resistor adaptor harness wire 921 Light Blue.
- Wire 921 Light Blue between connector 40 and resistor adaptor harness connector for damage.
STEP 5
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48 pin CN-18 and terminal 1 of the resistor adaptor harness
connector.
- If continuity is not detected check wires 918 Light Blue (917 Light Blue early tractors) between the connector
48 and connector 40 for damage.
STEP 6
Check for continuity between connector 48 pin CN-18 and the remaining pins of the connector 48.
- If continuity is detected check wire 918 Light Blue (917 Light Blue early tractors) between the connector 48
and connector 40 for damage.
SM 8-12101 Issued 09-2004
SECTION 10006 45
-------------------------------------------- BATTERYPOWER(B~ ------------------------------------------_____
------1'?f------------------- SV'v1TCHED POWER - - - - - - - -- - - - -- - - - - - - - - - -
,...----5C)ORl O~500Rl.0 ---"" ~--5(lO,Rl 0 - t : > TO DECLUTCH SWITCH
. - - - - ; I k : - - - - - - - -:279R1 a ------It> TO AUDIBLE ALARM
FUSE SP1
-----300R1 0
28
15A
5DDR1.0
.---- - 1 - - - - -- - - - 303T 75
OPERATOR , - - - -- - - - 910Y 75
SEAT , - - - - - - - 917LB1.0
SV'v1TCH
(CLOSED , . . - - - - - - 58DY 75
W/OPER 9l8LB 75 (#917LB.75)
~~~~=======l
IN SEAT)
5 0 0 B R 1 . 0 - - - - - - - - - - 500BR1.0;;r
L---_ _ _ 500BR 1.0 500BR 1.0
580Y.7:21LB75 ------~-----80-R-,-0-- ~'"~~
SP2
11
I ~
tJjSi
HIGH/LOW IJ)
;! RANGE 0 '"
~ ~ ~
r
SWITCH
10Rl.a - -, , -...- - t- '580Rl .0 - - - - - - - -- -...J
3.~cJ~M
RESISTOR
/ '--1-- -- 921R.75 A
SP6 580Y 75
, - - - - - - 921LB.75
1.2KOHMS 12K OHMS
FLYVvI-i EEL C!
SPEED cr
~
!
SENSOR
r?l
--~----~»""""""")~n~----------------------------~----- CHASSISGRO UN D --------~----~""""----------------4
G~,--~
--4-~-------------------~--- CLEANGRO UND----~-------------~~---
# Early Production Tractors Only.
8M 8-12101 Issued 09-2004
46 SECTION 10006
Error Code 37/24
Fault Description.
Output from the clutch speed sensor B is 0 Hz when the output from sensor A is above 10Hz.
System Response.
- Bad shuttle change modulation.
Possible Cause.
1. Bad speed sensor B (bottom sensor).
2. Bad circuit between the transmission controller and speed sensor B.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
IMPORTANT: When the fault has been corrected calibrate the transmission controller, refer to
"Calibration Procedure - Method 2 (Existing Controller Recalibrafion)" on page 8.
STEP 1
Turn the key OFF and disconnect speed sensor B from the resistor adaptor harness. Turn the key ON and check
for 12 volts at terminal 3 of the adaptor harness connector.
- If 12 volts is not detected check the following :
- Resistor adaptor harness wire 917 Red .
- Wire 917 Red between the transmission harness to resistor adaptor harness connector and splice SP5.
STEP 2
Turn the key OFF and check for continuity between terminal 2 of the adaptor harness connector and ground.
- If continuity is not detected check the following :
- Resistor adaptor harness wire 917 Brown.
- Wire 917 Brown between the transmission harness to resistor adaptor harness connector and the battery
negative terminal.
STEP 3
Check for continuity between the following terminals of the speed sensor :
- Terminals 1 to 2.
- Terminals 1 to 3.
- Terminals 2 to 3.
- If continuity is detected check replace the sensor.
IMPORTANT: When installing the speed sensor make sure the existing shim thickness is maintained
and the threads of the sensor are sealed with thread tape. Tightened the sensor to a torque of 30 Nm,
DO NOT overtighten the sensor.
STEP 4
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity
between connector 40 pin 30 and terminal 1 of the adaptor harness connector.
- If continuity is not detected check the following:
- Resistor adaptor harness wire 917 Light Blue.
- Wire 917 Light Blue between connector 40 and resistor adaptor harness connector for damage.
STEP 5
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48 pin CN-11 and terminal 1 of the resistor adaptor harness
connector.
- If continuity is not detected check wires 917 Light Blue between the connector 48 and connector 40 for
damage.
STEP 6
Check for continuity between connector 48 pin CN-17 and the remaining pins of the connector 48.
- If continuity is detected check wire 917 Light Blue between the connector 48 and connector 40 for damage.
SM 8-12101 Issued 09-2004
SECTION 10006 47
------------------------------------------___ BATTERYPOW£R(B+) -----------------------------------------------
r------------------------------------ S~TCHEDPOWER - - - -- ------------------------------------------
~---5()()IR1 0 ~ TO DECLUTCH SWITCH
.-----....,,----------:279R1 0 -----1[::> TO AUDI BlE ALARM
FUSE SP1
28 300Rl,O -------~300Rl . 0
15A
500R1.0
.-----+---------------- 303T 75
OPERATOR .---------------- 910Y 75
SEAT
.-------------- 917LB1.0
S~TCH
(CLOSED .------------ 580Y 75
W/OPER 918lB.75 (#917lB 75)
~~~~======1
IN SEAT)
500BR1.0 - - - - - - - - - - - - - - - - - - -
'--- - - _ 500BR1.0 __________________
' - - - - 921 lB 75 - - - -- - - -- - - - - - - - - - - - - - - - - - -
I.:
o HIGH/LOW
R
10
..: RANGE
....
In
a:i
[5 ~TCH
10R10 -----~---r~mR10 ---------------~
r'" WITH
390HM
RESSTOR
. / "--i------- 921 R 75
SP5
.---------- - 921lB,75
1.2KOHMS 12K OHMS
FL~EEL ~
SPEED ~
~
!
SENSOR
g
--~~--~»"»"»"~";"»~----------------------------~----- CHASSISGROUND --------t-----~""""----------------~
G~l ~~
--4-~--------------------------------------~------ClEANGROUND-------~--------------------------~~-
# Early Production Tractors Only.
SM 8-12101 Issued 09-2004
48 SECTION 10006
Error Code 37/25
Fault Description.
Output from the clutch speed sensors A and B out of phase.
System Response.
- Bad shuttle change modulation.
Possible Cause.
1. Bad speed sensor(s) - Remove the sensors in turn and check for damage, replace as necessary.
IMPORTANT: When installing the speed sensor make sure the existing shim thickness is maintained
and the threads of the sensor are sealed with thread tape. Tightened the sensor to a torque of 30 Nm,
DO NOT overtighten the sensor.
8M 8-12101 Issued 09-2004
SECTION 10006 49
--------------------------------------_______ BATTERYPOWER(B~ - - - - - -_________________________________________
~----------------------------------- S~TC HEDPOWER - - - - - -- -- -- -- - - - - - - - - - - - - - - - - -- - - -- -- -- - - -______
___- --5I:JOR10--c> TO DECLUTCH SWITCH
r--___,jI.;;:----------279R 1 0 ------1[::> TO AUDIBLE ALARM
FUSE SP1
28
3OOR1 ,0 - - -- - - - -300R1 0
15A
500R1 .0
r - - - - - t - - -- -- - - - -- --- 303T75
OPERATOR ,..-- -- - - - - - - - - - - 910Y 75
SEAT r-- - -- - - - - -- 917LB1.0
S~TCH
(CLOSED ,.---- - - -- - - 580Y 75
r -i~~~tt~~~~~~~===========j
W/OPER l
IN SEATl 918LB.75 (#917LB ·7_5:..
500BR 1.0 - - - - - - - - - - - - - - - - - 500BR 1 O~
' - - - - - - 500BR 1.0 500BR 1.0
SP2
~
L - - - - 921 LR75 - - - - - - - - - - - - - - - - - - - -- -- -----
I:
~
580Y 75 - - - -- - - - - - - - - - - - - - - - - - - - - - -- - - - - -- - - en
OOR 1&
1'O
o HIGHILOW
.; RANGE
n: SWITCH
~ ~TH
I 3.9 OHM
10R1 0 - -~---,. .- + -ssOR1 .0 - - -- -- - - - ----------' RESISTO R
/ '--+-- -- 921 R 75 - - - - - - - ,
SP5
,..-- -- - -- -- - 921LB.75
1.2KOHMS 1.2KOHMS
FLYWHEEL
SPEED
SENSOR
--~----~""""------------------------------~----- CHASSISGROUND --------~----~""""----------------~
G~l --~
--t~------------------------------------- ..----- CLEAN GROUND - - - - - - -. .- -- - - -----------------------""'---
# Early Production Tractors Only.
8M 8-12101 Issued 09-2004
50 SECTION 10006
Multi Error Codes 22/12, 24/12 and 25/11 & 12.
Fault Description.
The signal voltage from the transmission controller pin CN-14 is too high.
System Response.
- Tractor will not operate when forward or reverse is selected.
- Return to neutral light illuminates.
- Tractor defaults to Powershift 1.
Possible Cause.
1. Bad controller sensor (-) circuit.
2. Controller sensor (+) shorted to voltage above 5 volts .
3. Bad controller.
Circuit Checks.
IMPORTANT: Before carrying out the fol/owing tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
STEP 1
Turn the key OFF and disconnect the transmission controller and inching pedal potentiometer, check for
continuity between connector 48 pin CN-14 and terminal 1 of the inching pedal potentiometer connector.
- If continuity is not detected, check wire 923 Brown between the transmission controller and splice Spy for
damage.
STEP 2
Connect the transmission controller and disconnect the forward/neutral/reverse resistor pack, connector 32
(instrument panel harness to F/N/R switch) and powershift resistor pack. Turn the key ON and check for voltage at
terminal 3 of the inching pedal connector.
- If the voltage reading is above 5 Volts, check the following :
- Connectors 28 and 48.
- Wire 921 Red between splice SP6 and the controller connector pin CN-14 for damage (shorting to another
circuit) .
- Wire 921 Red between splice SP6 and the powershift resistor for damage (shorting to another circuit) .
- Wire 921 Red between splice SP6 and connector 28 pin 5 for damage (shorting to another circuit).
- Wire 921 Red between connector 28 pin 5 and splice SP3 for damage (shorting to another circuit).
- Wire 921 Red between splice SP3 and connector 32 (instrument panel harness to F/N/R switch) for
damage (shorting to another circuit) .
- Wire 921 Red between splice SP3 and the inching pedal potentiometer connector for damag~ (shorting to
another circuit).
- Wire 921 Red between splice SP3 and the forward/neutral/reverse resistor pack connector for damage
(shorting to another circuit) .
8M 8-12101 Issued 09-2004
SECTION 10006 51
921Rl .
I
:e
i 9238R76
Ii
N
"'....
Ii
--..., POWERSHIFT
3 POSITION
'"..,
a:
N
I-JJ
505T 75
m
l:l
0>
~ 2
3
S1MTCH
'" SP3
GEAR SWITCH '""">'
LOGIC
<D
N
L 21R.7&5--- - - -- - -- - - 921R.75 SI S2 0> III
1 1 0
*
2 21R..7 2 1 1
3 924Y 75 - - -- - - - - / ---+-' 3 0 1 ~
----- 1 ~38R75 -------+--~ SI S2 Ii
N
INCHING PEDAL
POTENTIOMETER
21R7&---- - - - - ' SP4
SP7
-----/-~~--- ~3BR7S ------------ 9238R 75
1----~21R.75_----...."....._9 &----------------~921R7
- CHASSIS GROUND -~J."»"""~'l':»""I..,,I--------------------------~J.,,1/,"1/".''''';''''»";-- CHASSIS GROUND - - - - - -
- - - CLEAN GROUND CLEAN GROUND - - - - - - -
SM 8-12101 Issued 09-2004
52 SECTION 10006
Multi Error Codes 22/15, 24/15 and 25/15 & 16.
Fault Description.
The signal voltage from the transmission controller pin CN-14 is too low.
System Response.
- Tractor will not operate when forward or reverse is selected.
- Return to neutral light illuminates.
- Tractor defaults to Powershift 1.
Possible Cause.
1. Bad controller sensor (+) circuit.
2. Bad controller.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
STEP 1
Turn the key OFF and disconnect the inching pedal potentiometer. Turn the key ON and check the voltage at
terminal 2 of the inching pedal potentiometer connector.
- If voltage is not detected check wire 921 Red between the transmission controller and splice SP6.
SM8-12101 Issued 09-2004
SECTION 10006 53
BATTERY POWER (B+)
SWITCHED POWER
.-- POWERSHIFT
TRANSMISSION CONTROLLER 48
RESISTOR
POWERSHIFT SELECTOR SIGNAL CN-32 927Y 75 927Y75 PACK
SENSOR RETURN (-) CN-1 923BR 75
!
Rl;33KOHMS
SENSOR 5 VOLT SUPPLY (+) CN-14 921R1 0 R2; 5.6 K OHMS
INCHING PEDAL POSITION SIGNAL CN-31 ~4Y75
R3 ; 33.0 K OHMS
I
R4 ; 3.3 K OHMS
FORWARD/NEUTRAUREVERSE SELECTOR SIGNAL CN-34
~~"~ "' '"
I
...
":
'~
"
M
N
<J)
..
N
TO PTO NEUTRAL
START SWITCH FORWARD/NEUTRAL!
'"
>
0)
\I')
REVERSE RESISTOR ..... N
PACK
Rl;15KOHMS ~ '"
FROM KEY
R2; 22 K OHMS '"
'"
R3; 2 7 K OHMS II)
SWITCH R4; 1 0 KOHMS ":
TERMINAL 2 ftN
'"
...Ii
FORWARD/NEUTRAL
'SO" to
!" ~ /REVERSE ...,.:
I()
'"~~'"
...... :eri :e
ci
28
N
SHUTTLE
SIMTCH
M
0 ...
00 '" N ...,
m ~2Y . 75
'" "' '"
(»
'" 0> 92 4Y.75
~21Rl
~ 1 ~3BR75
N .,
IfJ
POVVlERSHIFT
~ "--" 1
3 POSITION
:!l --- 2 SWITCH
'"
"- :;: :\
ci 505T75
N
0)
SP3
GEAR SWITCH LOGIC "'":>-
S1 S2 '"
N II)
L 21R.75-5- - - - - - - - -- -- 92 1R.75
1 1 0 '"
*
2 21R7 2 1 1
3 ~4 Y75 -----------~~----~~ 3 0 1 ~
1 923BR . 75 -------~~--.... S1 S2 Ii
N
INCHING PEDAL
POTENTIOMETER
21 R.75-- - - -- -- -------I SP4
SP7
923BR 75 - - - - - - - - - - - - - - -- - - --
21R.75--------~~,::-
.g 2' R 75 921R.7
SP!;
CHASSIS GROUND
---- CHASSISGROUND --~;"""h";~»~»"'----------------------------------------------------~""~~--
jllJjf/l/}1
- - - - - CLEAN GROUND - - - - - -- - - - - - - - -- - - - - - - - - - - -- - -- - - - - - - - - CLEAN GROUND
8M 8-12101 Issued 09-2004
54 SECTION 10006
No Error Code
Controller LED'S not Illuminated
Fault Description.
Controller fails to power up when the key is turned ON.
System Response.
The tractor will not operate - transmission controller LED 's not illuminated.
NOTE: If the audible alarm sounds continually go to Step 2.
Possible Cause.
1. Bad fuse 28 - circuit shorted to ground.
2. Bad circuit between the switched power stud and the transmission controller
3. Bad chassis ground circuit between the transmission controller and chassis ground connection G1 .
NOTE: The controller also grounds directly through the controller body to the cab frame.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information " on page 21.
Check fuse 28.
- If the fuse is OK go to Step 1.
- If the fuse has blown, replace fuse and turn the key to the ON position.
- If the fuse blows turn the key OFF and go to Step 4 .
. Fuse OK
STEP 1
Turn the key ON and check for 12 volts at fuse 28.
- If 12 volts is not detected check the circuit between the switched power stud and fuse 28.
STEP 2
Turn the key OFF and disconnect the transmission controller from the harness . Turn the key ON and check for
12 volts at pins 28 and 42 of connector 48 .
- If 12 volts is not detected at both pin 28 and 42 check the following:
Connector 28 pin 2.
Wire 500 Red between fuse 28 and connector 28.
Wire 500 Red between connector 28 and splice SP1.
- If 12 volts is not detected at one of the pins check the following:
For pin 28 - wire 500 Red between splice SP1 and the controller connector pin 28.
For pin 42 - wire 500 Red between splice SP1 and the controller connector pin 42.
STEP 3
Turn the key OFF and check for continuity between connector 48 pins 15 and pin 29 and chassis ground.
- If continuity is not detected at both pin 15 and 29 check the following:
The chassis ground connection G1 (instrument panel).
Connector 28 pin 3.
Wire 500 Brown between connector 28 and the chassis ground connection G1.
Wire 500 Brown between connector 28 and the splice SP2.
- If continuity is not detected at one of the pins check the following :
For pin 15 - wire 500 Brown between splice SP2 and the connector 48 pin 15.
For pin 29 - wire 500 Brown between splice SP2 and the connector 48 pin 29.
SM 8-12101 Issued 09-2004
SECTION 10006 55
_____________________________________________ BATTERVpoW£R(B+) _______________________________________________
r------------------------------------ S~TCHEDPOW£R -----------------------------------------------
OOR1 .0 ---C> TO DECLUTCH SWITCH
,-----j..,::---------- 279R1 .0 --------1[:> TO AUDIBLE ALARM
FUSE
28
300R1 0 ---------:300R1 .0
15A
,------+----------------- 303T75
OPERATOR ,--------------- 910Y 75
SEAT ,------------- 917LB1 .0
S~TCH
(CLOSED ,----------- 580Y 75
W/OPER
r -1~~~n~~~~~~~===========j
IN SEAT) 918LB 75 (#917LB ·7_5:..
)
500BR 1.0 ------------------- 500BR 1 .0~
'--- - - 500BR 1.0 500BR1 .0
921 LB.75 -----------I-:------
----O-R-, .-O----
SP2
~"a:., ~ 11 i
o
o HIGH/LOW ;:: ~.
..: RANGE g
~ SWITCH It) ~
10Rl 0 - - -",-.--+--580Rl .0 ___________________..J_
f 3_~6~M
RESlSTOR
u~
/ '-+-_ _ _ 921 R.75 - - - - - , A
SP5 0 580V 75
,--------- - - 921 LB.75
1.2KOHMS 1.2KOHMS
FLYWHEEL o
SPEED
"
--~l----~»~»"»"»"""'------------------------------~-----CHASSISGROUND --------~----~~~----------------G~1~~
SENSOR
--t!~--------------------------------------~-----CLEANGROUND -------~--------------------------~---
continued ... .
SM 8-12101 Issued 09-2004
56 SECTION 10006
- Fuse Blown
NOTE: If the fuse blows when the declutch switch is depressed check wire 928 Yellow between the
declutch switch and the controller connector pin 5 for shorting to ground.
NOTE: If the fuse blows when the operator sits on the seat check wire 303 Tan between the operator
presence switch and the controller connector pin 4 for shorting to ground.
NOTE: If the fuse blows when the high range is selected check wire 580 Yellow between the highllow
range switch and the controller connector pin 3 for shorting to ground.
STEP 4
Disconnect connectors 28 (instrument panel harness to right hand console harness), 40 (right hand console
harness to transmission harness) and 48 (transmission controller) and check for continuity between the right
hand console harness side of connector 28 pin 2 and chassis ground.
- If continuity is detected , the circuit has shorted to ground check the following .
Wire 500 Red between connector 28 and splice SP1.
Wire 500 Red between splice SP1 and connector 48 pins 28 and 42.
Wire 500 Red between splice SP1 and connector 40 .
Wire 500 Red between splice SP1 and the declutch switch.
Wire 300 Red between splice SP1 and the operator presence switch.
Wire 279 Red between splice SP1 and the audible alarm.
Wire 279 Yellow between the audible alarm and the controller connector.
- If continuity is not detected go to Step 5.
STEPS
Check for continuity between the instrument panel harness side of connector 28 pin 2 and chassis ground .
- If continuity is detected check wire 500 Red between connector 28 and fuse 28.
- If continuity is not detected go to Step 6.
STEP 6
Disconnect the flywheel sensor, high/low range switch and clutch speed sensors A and B. Check for continuity
between connector 40 pin 13 and chassis ground.
- If continuity is detected, the circuit has shorted to ground check the following .
Wire 500 Red between connector 40 and splice SP5 .
Wire 500 Red between splice SP5 and connector 48 pin 13.
Wire 500 Red between splice SP2 and the flywheel speed sensor connector.
Wire 500 Red between splice SP2 and the clutch speed sensor 1 connector.
Wire 500 Red between splice SP2 and the clutch speed sensor B connector.
Wire 500 Red between splice SP2 and the high/low range switch connector.
8M 8-12101 Issued 09-2004
SECTION 10006 57
--------------------------------------------- BATTERYPOWER(B~ --------------------------------------------___
------~C?~------------------------------------S~TCHEDPOWER - -- ------------------------------------ ---------
.------&OOR10~~Rl0------, ~--SC)()IR1 .0--C> TO DECLUTCH SWITCH
.--1If<::---------~279Rl 0 -----1[::> TO AUDIBLE ALARM
FUSE SPl
300Rl0 48 TRANSMISSION CONTROLLER
23
15A 500Rl0 CN-2B 12V S~TCHED POWER
500Rl .0 CN-42 12V SWITCHED POWER
303T 75 CN-4 SEAT SWITCH
OPERATOR 9l0Y 75 CN-16 FLYWHEEL SPEED SENSOR SIGNAL
SEAT 917LB1 .0 CLUTCH SPEED SENSOR B SIGNAL
S~TCH
(CLOSED 5BOY 75 HIGHILOW RANGE SWITCH
WIOPER 918LB 75 (#917LB.75) CN-18 CLUTCH SPEED SENSOR A SIGNAL
IN SEAT) CN-15 CHASSIS GROUND
CN-29 CHASSIS GROUND
500BR 1.0 -------------------
L----500BR10 _____________________
r-=~Rl0
<> HIGH/LOW
..: RANGE
15 SWITCH
co WITH
3.9 OHM
10Rl0 ----~-~~WIRl0----------~- T
. / "--t--- -- 921 R 75
RESSlOR
SP5
r-------- 921LB_75
1.2KOHMS , 2KOHMS
Ir
<Xl
<>
;;; FLYWHEEL
SPEED
SENSOR
--+---:rmrmm----------------t--- CHASSIS GROUND ----~~-"""'l"'"'~w,---------4G.l-~
---4~--------------------------------------~------CLEANGROUND--------~--------------------------~~-
SM 8-12101 Issued 09-2004
58 SECTION 10006
No Error Code
No Forward Drive
Fault Description.
No forward signal voltage from the forward/neutral/reverse switch.
System Response.
- Tractor will not drive when forward is selected - tractor drives in reverse.
Possible Cause.
1. Bad circuit between the F/N/R switch and the forward and reverse resistor pack .
2. Bad F/N/R switch .
Circuit Checks.
IMPORTANT: Before carrying out the fol/owing tests, refer to Circuit Testing "Circuit Testing General
Information " on page 21.
STEP 1
Turn the key OFF and disconnect the forward and reverse resistor pack. Turn the key to the ON position and
put the F/N/R lever in forward. Check for approximately 4.5 volts at terminal 5 (wire 503 Tan) of the resistor pack.
- If voltage is not detected check wire 503 Tan between the F/N/R switch connector and the resistor pack
connector for damage. also check the F/N/R switch .
- If voltage is detected replace the resistor pack.
No Error Code
No Reverse Drive
Fault Description.
No reverse signal voltage from the forward/neutral/reverse switch .
System Response.
- Tractor will not drive when reverse is selected - tractor drives in forward .
Possible Cause.
1. Bad circuit between the F/N/R switch and the forward and reverse resistor pack.
2. Bad F/N/R switch.
Circuit Checks.
IMPORTANT: Before carrying out the fol/owing tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
STEP 1
Turn the key OFF and disconnect the forward and reverse resistor pack. Turn the key to the ON position and
put the FIN/R lever in reverse . Check for approximately 4 .5 volts at terminal 2 (wire 507 Tan) of the resistor pack.
- If voltage is not detected check wire 507 Tan between the F/N/R switch connector and the resistor pack
connector for damage, also check the F/N/R switch.
- If voltage is detected replace the resistor pack.
8M 8-12101 Issued 09-2004
SECTION 10006 59
BATTERY POWER (B+)
SVv1TCHED POWER
TRANSMISSION CONTROLLER
-
48 POWERSHIFT
RESISTOR
POVv1ERSHIFT SELECTOR SIGNAL CN·32 927Y 75 927'(.75 PACK
SENSOR RETURN (.) CN·1 923BR.75
I~
R1 = 33 KOHMS
SENSOR 5 VOLT SUPPLY (+) CN·14 921Rl 0 R2 = 5.6 K OHMS
INCHING PEDAL POSITION SIGNAL CN·31 924Y75 R3 = 33.0 K OHMS
R4 = 3.3 K OHMS
FORWARD/NEUTRAUREVERSE SELECTOR SIGNAL CN·34
~"~
I.... '"'" ..,'"
on
";
III
..... 0'1
TO PTO NEUTRAL
START SWITCH FORWARD/NEUTRAL!
'"
>
REVERSE RESISTOR II'>
":
;'!;
Q
PACK ~
R1 = 1.5 K OHMS N
FROM KEY
R2 = 2.2 K OHMS
R3 = 2 7 K OHMS
'"
SWITCH R4 = 1,0 K OHMS ....
I/')
TERMINAL 2 ...
>
N
'"
s: ....
Ii
;,- FORWARD/NEUTRAL N
N
!1l ~ !'l /REVERSE ... ...r-:....:...
Ll)
,.:
Ll) Ll)
~ ....
'"
ei
28
SHUTILE ei
<") ..... on III 922Y 75
SVv1TCH 0 00 N ~
Ll) on on 0'>
924Y75
'"
r - - - - --9921 Rl .. o---- - - - '
~ l ~'"''
": POVv1ERSHIFT
--- I
I+J
0:: 3 POSITION
---- 2
on
....
ei
~ 3
SWTCH
505T75
N
0'>
on
SP3
f-G:..EA::....R-+~S'v'In
:..;..:;~TC=H_..:L..:OG=IC:.... ~
L21R. 75-S- - -- - - - - - - - - 921R 75 S1 52 ~ It)
~ G.~" J1
1 ....0::on
*
2 21 R.7 2
3 924Y.75 - - -- - -----1r---+-' 3 <II
M
N
1 923BR. 76 --------+----e 0>
INCHING PEDAL
POTENTIOMETER
SP4
SP7
l
923BR.75 - - - - -+--41'--- 923BR .76 - - - - - -- - -- - 92JBR 75
r - -- '921R 75 921R.7
- - CHASSIS GROUND --:jr7i1",iI"I.'l':/)r7i1""---------------------------:;,,,tJ"/~'l':Z""/)r7I1"'f-- CHASSIS GROUND - - - - - -
- - - CLEAN GROUND CLEAN GROUND - - - - - - -
SM 8-12101 Issued 09-2004
60 SECTION 10006
No Error Code
No Forward or Reverse Drive
Fault Description.
No signal voltage from the forward/neutral/reverse switch.
System Response.
- Tractor will not drive when forward or reverse is selected
Possible Cause.
1. Bad circuit between the transmission controller and the F/N/R switch.
2. Bad F/N/R switch.
Circuit Checks.
IMPORTANT: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General
Information" on page 21.
STEP 1
Turn the key OFF and disconnect the F/N/R switch. Turn the key to the ON position and check for approximately
5 volts at terminal 2 (wire 921 Red) of the F/N/R switch connector.
- If voltage is not detected check wire 921 Red between the F/N/R switch connector and splice 3.
- If voltage is detected check the F/N/R switch.
SM 8-12101 Issued 09-2004
SECTION 10006 61
BATTERY POWER (B+)
SV'I1TCHED POWER
r-
TRANSMISSION CONTROLLER 48 POWERSHIFT
RESISTOR
POWERSHIFT SELECTOR SIGNAL CN-32 927Y 75 927Y75 PACK
SENSOR RETURN (-) CN-' 923BR.75
R1 = 33 KOHMS
SENSOR 5 VOLT SUPPLY (+) CN-14 21R1 .0 R2=56KOHMS
INCHING PEDAL POSITION SIGNAL CN-31 R3 = 33.0 K OHMS
.l!
924Y 75
R4 = 33 KOHMS
FORWARDINEUTRAUREVERSE SELECTOR SIGNAL CN·34
"w"~
TO PTO NEUTRAL
I - ..,'"
":
cr
N
N
'"
START SWITCH FORWARD/NEUTRAL/
REVERSE RESISTOR
PACK
'"....>-
.
"-
~
N
0>
R1=15KOHMS
R2=22KOHMS iil
FROM KEY R3=2.7KOHMS II>
SWITCH R4 = 1 0 KOHMS .....
TERMINAL 2 ~
al
t-
o:
N 10 :" FORWARD/NEUTRAL N
m !" !" IREVERSE II>
I'-; ........ I'-'"
"'''' ~
SHUTTLE
SlMTCH
t-
'"
0
~~ ci
.... 0'" N
0
,.,'"ci 922Y75
'" '" '"
II> N
0> 924Y.75
921R1 .
I
:!!
i 923BR75
ci
N
'""- ...--... , POWERSHIFT
G~2
ci 3POSITIOl'l
I~
..,III "'--"' 2
SlMTCH
~ .~ 6 s: 3
cr '83' 3 50ST 75
N
'" ---------+~1
SP3
GEAR SV\oITCH LOGIC '">'
"-
<D
('oj
L 2 1 R 75-5--------- - - ------------ 921R . 75 S1 52 m on
OJ.
t-
II)
1 1 ":
.
*
2 21R.7 2
:~
1 0::
III
3 924Y75 ----------------4-------~ 3 0
, 923BR.75 ------- - - -- - - -__1-----.... S1 '"
N
O>
t-
ci
('oj
INCHING PEDAL '"
POTENTIOMETER
21 R.75-------------..J SP4
SP7
923BR 75 --------I--4¥-- 9236R .7S - - - - -- - - -- - 923BR 75
1 - - --921R.7 921R.7
- CHASSIS GROUND m»JJIIII mmm;; CHASSIS GROUND - - - - - -
- - - CLEAN GROUND - ------------------------------------------------- - - -------------- -- -- CLEAN GROUND - - - - - - - - - - --
SM 8-12101 Issued 09-2004
62 SECTION 10006
No Error Code
Return to Neutral Light on when Forward or Reverse Selected
Fault Description.
Transmission controller has not detected a signal from the operator presence switch or detected a change of
state of the switch (ON to OFF).
System Response.
- Tractor will not drive when forward or reverse is selected - Return to neutral light illuminates when forward or
reverse is selected.
Possible Cause.
1. Bad circuit between the transmission controller and the operator presence switch.
2. Bad operator presence switch .
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information"
on page 21.
STEP 1
Turn the key OFF and disconnect the operator presence switch. Turn the key to the ON position and check for
approximately 12 volts at terminal B (wire 300 Red) of the operator presence switch connector.
- If voltage is not detected check wire 300 Red between splice 1 and the operator presence switch.
IMPORTANT: For the following test DO NOT sit or put weight on the seat.
STEP 2
Turn the key OFF and check for continuity between terminals A and B of the operator presence switch
connector.
- If continuity is detected replace the operator presence switch.
STEP 3
Sit on the seat and check for continuity between terminals A and B of the operator presence switch connector.
- If continuity is not detected replace the operator presence switch.
STEP 4
Disconnect the transmission controller and check for continuity between terminal A of the operator presence
switch connector and pin 4 (wire 303 Tan) of connector 48.
- If continuity is not detected check wire 303 Tan between the operator presence switch connector 48 for
damage.
STEP 5
Connect the transmission controller and the key ON, check for voltage at terminal operator presence switch
connector terminal A.
- If a voltage is detected check wire 303 Tan between the operator presence switch connector and connector
48 for damage (shorting to another circuit).
8M 8-12101 Issued 09-2004
SECTION 10006 63
- - - - - - - - - - - - - - - - - - - - - BATTERY POWER (B+) - - - - - - - - - - - - - - - - - - - - - _
------<?----- - - - - -- -- -- - - - - -- - - -- - - -- -- - - - - SWTCHEDPOWER - - - -- -- - - - - - - - - -- - - - - -- -- - - -- - - - - - - - - - - -- -- -_
...-----~DOIR1. 0 ~500R1 0- - ---, ,,----5(lOIR1 0 -----C> TO DECLUTCH SWITCH
r-_j~---------:279R1 0 -------1[:> TO AUDIBLE ALARM
FUSE SP1
28
-----300R1 0
1M
500R10
...-----1------------- 303T 75
OPERATOR ...---- - - - - - - 910Y 75
SEAT
...---- -- -- -- 917LB1 0
SWTCH
(CLOSED , - -- -- 580Y 75
W/OPER. 918LB 75 (#917LB 75)
r---a~~~=====~
IN SEAT)
500BR 1.0 - - - - - - - - - - - - - - - - - - 500BR , . 0 ; ; r
L -_ _ _ 500BR1.0 500BR1.0
I ""'"
SP2
~'~:"~ 11
"'"
q
~R' .O
>
o
0;
r-
o HIGHILOW
.; RANGE ~ ~
ct: SWITCH
~
U1
WITH
I 3.9 OHM
,OR1 0 - --,,--.--+--slIORl 0-------------------' RESSTOR
/ '-+---- 921 R 75
SP5
.------ -- -- -- 921lB,75
q
ct:
'"
o
o
an
1.2KOHMS 1.2KOHMS
FLYWHEEL
SPEED
SENSOR
--+-~~~~---------------+_--- CHASSISGRO U ND ---~~-~~~~-------~G~
' ~~
--~----------------------------------_j._-----CLEANGRO UN D --------e_------------------------~~-
# Early Production Tractors Only
STEP 6
Connect the transmission controller and the key ON, check for voltage at terminal operator presence switch
connector and pin 4 (wire 303 Tan) of connector 48 .
- If continuity is not detected check wire 303 Tan between the operator presence switch connector 48 for
damage.
SM 8-12101 Issued 09-2004
64 SECTION 10006
No Error Code
No Drive in 1st Speed Powershift
Fault Description.
The 1st speed powershift solenoid circuit failed.
System Response.
- Tractor will not drive when 1st speed powershift is selected - tractor dives in 2nd and 3rd speed powershift.
Possible Cause.
1. Bad 1st speed powershift solenoid.
2. Bad circuit between the transmission controller and the 1st speed powershift solenoid.
3. Circuit between the transmission controller and the 1st speed powershift solenoid shorted to ground.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information"
on page 21.
STEP 1
Turn the key OFF and disconnect the 1st speed powershift solenoid, check the resistance between terminals 1
and 2 of the 1st speed powershift solenoid .
- The resistance reading should be approximately 8.5 ohms at 20° C (68° F) replace the 1st speed powershift
solenoid coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity between
connector 40 pin 24 and terminal 2 of the 1st speed powershift solenoid connector.
- If continuity is not detected check wire 918 Light Blue between the 1st speed powershift solenoid and splice
SP8 for damage.
STEP 3
Check for continuity between terminal 1 of the 1st speed powershift solenoid connector and connector 40 pin
20.
- If continuity is not detected check wire 911 Yellow between the 1st speed powershift solenoid connector
and connector 40 for damage.
STEP 4
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48, pin CN-22 and terminal 1 of the 1st speed powershift
solenoid connector.
- If continuity is not detected check wire 911 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
STEP 5
Check for continuity between connector 48, pin CN-22 and ground.
- If continuity is detected check wire 911 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
SM 8-12101 Issued 09-2004
SECTION 10006 65
______________________________________________________________________________ BATTERY POW£R (B+) __________________
------------------------------------------- -- -- -_______________________________ S~TC HEDPOW£R ----------------___
911Y1 .0 ------------- -------------------- 911Y1 .0
912Yl .0 912Y1 0 ~
913Y10 l I
1
q q q
~ ~
a; en
E
0)
POW£RSHIFT POW£RSHIFT POWERSHIFT
SOLENOID 1 SOLENOID 2 SOlENOIDS
2 2
----+-=
q q q
;:: ;:: ;::
L--- 918LB1 .0 ---.J '"c;N
c;
!- 920LB1 0
914LB' ,O 914LB10
0;
Sl'S
TRANSMISSION CONTROLLER 48
r jP~OIWiEIRiSiHil~FTSO!lL~E~NiO~IDIiR~ET~U~R~N~~~~~~~llCiN~-213ti!l~~~9~14~L~B~1~O~~;;
POWERSHIFT SOLENOID 3 CN-26 913Y1 .0
POW£RSHIFT SOLENOID 2 CN-24 912Yl0
POW£RSHIFT SOLENOID 1 CN-22 911Y1 .0
- CHASSIS GROUND -..,;I7lIJ'l':II'l':f~"»""-------------------------------------------------..,.>.I7lJ).I7lJ}'l':)j'l':IJ",,_- CHASSIS GROUND - - - - - - - - - - -
------ CLEAN GROU ND CLEAN GROUND ------- ------
SM 8-12101 Issued 09-2004
66 SECTION 10006
No Error Code
No Drive in 2nd Speed Powershift
Fault Description.
The 2nd speed powershift solenoid circuit failed .
System Response.
- Tractor will not drive when 2nd speed powershift is selected - tractor dives in 1st and 3rd speed powershift .
Possible Cause.
1. Bad 2nd speed powershift solenoid .
2. Bad circuit between the transmission controller and the 2nd speed powershift solenoid.
3. Circuit between the transmission controller and the 2nd speed powershift solenoid shorted to ground.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information "
on page 21.
STEP 1
Turn the key OFF and disconnect the 2nd speed powershift solenoid , check the resistance between terminals
1 and 2 of the 2nd speed powershift solenoid.
- The resistance reading should be approximately 8.5 ohms at 20° C (68 ° F) replace the 2nd speed
powershift solenoid coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity between
connector 40 pin 24 and terminal 2 of the 2nd speed powershift solenoid connector.
- If continuity is not detected check wire 919 Light Blue between the 2nd speed powershift solenoid and splice
SP8 for damage .
STEP 3
Check for continuity between terminal 1 of the 2nd speed powershift solenoid connector and connector 40 pin
21.
- If continuity is not detected check wire 912 Yellow between the 2nd speed powershift solenoid connector
and connector 40 for damage.
STEP 4
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48, pin CN-24 and terminal 1 of the 2nd speed powershift
solenoid connector.
- If continuity is not detected check wire 912 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48 .
STEP 5
Check for continuity between connector 48 , pin CN-24 and ground .
- If continuity is detected check wire 912 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
8M 8-12101 Issued 09-2004
SECTION 10006 67
__________________________________________________________________________ BA~YPOWER(B+) -------------- __
_______________________________________________________________________________ S~TCHEDPOWER ------------_______
911Yl 0
912Yl0 ---------- 912Yl 0
913Yl0
911Yl.0
:=--l
l I
1
POWERSHIFT POWERSHIFT POWERSHIFT
SOLENOID 1 SOLENOID 2 SOLENOID 3
q q q
L- 918LB10 ~ ;:: ;::
N
C;; 0; 0;
F ' _O_----.J
, : ' :-B- __ 914LBl 0
SP8
TRANSMISSION CONTROLLER 48
t~PiOIWiIERiSiHil~FTiSOiL~EINiOiIDIiR~ET~U~R~N~~~~~~~~CiN~-213~!I~~~9~14~L~B~1-~O~~;;
POWERSHIFT SOLENOID 3 CN-26 91 3Yl0
POWERSHIFT SOLENOID 2 CN-24 912Yl 0
POWERSHIFT SOLENOID 1 CN-22 g11Yl .0
- CHASSIS GROUND -""l;~))"II"f).,,))":;/.,.----------------------------------....,;~II"j}.,,».,,;;,,»_- CHASSIS GROUND - - - - - -
- - CLEAN GROUND CLEAN GROUND -------------
SM 8-12101 Issued 09-2004
68 SECTION 10006
No Error Code
No Drive in 3rd Speed Powershift
Fault Description.
The 3rd speed powershift solenoid circuit failed.
System Response.
- Tractor will not drive when 3rd speed powershift is selected - tractor dives in 1st ans 2nd speed powershift.
Possible Cause.
1. Bad 3rd speed powershift solenoid .
2. Bad circuit between the transmission controller and the 3rd speed powershift solenoid.
3. Circuit between the transmission controller and the 3rd speed powershift solenoid shorted to ground.
4. Bad circuit between the transmission controller and the powershift resistor.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information"
on page 21.
STEP 1
Turn the key OFF and disconnect the 3rd speed powershift solenoid, check the resistance between terminals
1 and 2 of the 3rd speed powershift solenoid.
- The resistance reading should be approximately 8.5 ohms at 20 0 C (68 0 F) replace the 3rd speed powershift
solenoid coil as necessary.
STEP 2
Disconnect connector 40 (transmission harness to right hand console harness) and check for continuity between
connector 40 pin 23 and terminal 2 of the 3rd speed powershift solenoid connector.
- If continuity is not detected check wire 920 Light Blue between the 3rd speed powershift solenoid and splice
SP8 for damage.
STEP 3
Check for continuity between terminal 1 of the 3rd speed powershift solenoid connector and connector 40 pin 23.
- If continuity is not detected check wire 913 Yellow between the 3rd speed powershift solenoid connector
and connector 40 for damage.
STEP 4
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48, pin CN-26 and terminal 1 ofthe 3rd speed powershift
solenoid connector.
- If continuity is not detected check wire 913 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
STEP 5
Check for continuity between connector 48, pin CN -26 and ground.
- If continuity is detected check wire 913 Yellow between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
STEP 6
Disconnect the powershift resistor pack and check for continuity between connector 48, pin CN-1 and terminal
3 of the powershift resistor pack connector.
- If continuity is not detected check wire 923 Brown between splice 7 and the powershift resistor pack
connector damage.
- If continuity is detected replace the powershift resistor pack.
8M 8-12101 Issued 09-2004
SECTION 10006 69
__________________________________________________________________________ BATTERYpoWER(B+) ____------______
_______________________________________________________________________________ ------------_______
S
~
T
C
H
E
D
P
O
W
E
R
911Yl 0
912Yl0 912Yl0
"""II l
913Yl .0
q q q
;:: ;::N E
'"a; a; a;
POWERSHIFT POWERSHIFT POWERSHIFT
SOLENOID 1 SOLENOID 2 SOLENOID 3
q q C>
;:: ;:: E
t - 918LB1 .0
F~-:_B_'.-O--1--
M N
a; a; C;;
914L81 0
SP8
TRANSMISSION CONTROLLER 48
~ ~PiOiWEi RiSiHiI~SiOIL~Ei
FT NIOiIDIiR~ET~U~R~N~~~~~~~ilCiN~.2i3~!I~~~9~14~L~B~1.~O~-~:-;-~--~
POWERSHIFT SOLENOID 3 CN·26 913Yl 0
POWERSHIFT SOLENOID 2 CN·24 912Yl .0
POWERSHIFT SOLENOID 1 CN·22 911Yl a
- CHASSIS GROUND --..,h~I~/;~II."II."I;-------------------------.,})."/~.").,,»..,,»,,,,-- CHASSIS GROUND - - - - - - - - - -
- - CLEAN GROUND CLEAN GROUND -------------
8M 8-12101 Issued 09-2004
70 SECTION 10006
No Error Code
No Drive in 1st, 2nd or 3rd Speed Powershift
Fault Description.
The powershift solenoid return circuit failed.
System Response.
- Tractor will not drive when 1st, 2nd or 3rd speed powershift is selected.
Possible Cause.
1. Bad powershift solenoid return circuit.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information"
on page 21 .
STEP 1
Turn the key OFF and disconnect connector 40 (transmission harness to right hand console harness) and the
1st speed powershift solenoid . Check for continuity between connector 40 pin 24 and terminal 2 of the 1st speed
powershift solenoid connector.
- If continuity is not detected check wire 914 Light Blue between the connector 40 and splice SP8 for damage.
STEP 2
Connect connector 40 (transmission harness to right hand console harness) and disconnect the transmission
controller. Check for continuity between connector 48, pin CN-23 and terminal 2 of the 1st speed powershift
solenoid connector.
- If continuity is not detected check wire 914 Light Blue between connector 48 and connector 40 for damage.
- Also check connectors 40 and 48.
8M 8-12101 Issued 09-2004
SECTION 10006 71
-------------------------------------------------------------------------- BATTERYpoW£R(B~ --------_________
------------------------------------------------------------------------------- S~TCHEDPOW£R -------------------
911Yl 0
912Yl0 912Yl0
913Yl0
' II' ' l
C! C! C!
..,;:: ;:: ;::
N
mmm
POWERSHIFT POWERSHIFT POWERSHIFT
SOLENOID 1 SOLENOID 2 SOLENOID 3
C! C! C!
.,Ui-' §
p _."
CD
...J
0; '"
m
c
'"'" C! C! C!
..,;:: ;:: ;::
L- 918LB1 .0 -.--J mmm
N
914LB1 a 914lBl a
SP8
TRANSMISSION CONTROLLER 48
~~P~OIW£!lRIS~H~,~FT~SOi L;ilOi,D!iR~ETU~R~N~~~~~~~IlCiN
EN ~.i23~!I~~~9~14~L~B~1~O~~~
POWERSHIFT SOLENOID 3 CN-26 913Yl0 ____ ...J
POWERSHIFT SOLENOID 2 CN-24 912Yl .0
POW£RSHIFT SOLENOID 1 CN-22 911Yl .0
- CHASSIS GROUND --.,»"IJ")'l'l}Z'l':)J.'l':IJ,...--------------------------------------.,»"II"'""'/i.'l'lj""71""- CHASSIS GROUND - - - - - - - - - - -
- - CLEAN GROUND CLEAN GROUND -------------
SM 8-12101 Issued 09-2004
72 SECTION 10006
No Error Code
Defaults to 1st Speed Powershift 1 when 2nd Speed Powershift Selected
Fault Description.
The transmission controller receiving an incorrect signal from the powershift selector switch.
System Response.
- Tractor defaults to 1st speed powershift when 2nd speed powershift is selected - tractor dives in 1st and 3rd
speed powershift .
Possible Cause.
1. Bad circuit between the powershift resistor pack and the powershift selector switch.
2. Bad powershift selector switch.
3. Bad powershift resistor pack.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information"
on page 21.
STEP 1
Turn the key OFF and disconnect the powershift selector switch and powershift resistor pack. Check for
continuity between terminal C of the powershift switch connector and terminal 2 of the powershift resistor pack
connector (wire 926 Yellow).
- If continuity is not detected check wire 926 Yellow between powershift resistor pack connector and the
powershift switch connector for damage.
- If continuity is detected go to Step 2.
STEP 2
Check the resistance readings between the following powershift speed selector switch connector terminals. If
any of the readings are incorrect replace the speed selector switch.
1ST SPEED 2ND SPEED 3RD SPEED
TERMINALS
SELECTED SELECTED SELECTED
A and B Approximately Approximately No Continuity
3.9 ohms 3.9 ohms
A and C No Continuity Approximately Approximately
3.9 ohms 3.9 ohms
- If the readings are correct replace the powershift resistor pack.
8M 8-12101 Issued 09-2004
SECTION 10006 73
- -- - - - - - - - - - - - - - - - - -- - - -- - - - - -- - - - - - - - - - - -___ BATTERYpOWER~+) ----------------------------------____________
------------------------------------------------ S~TCH EDPOWER - -- ------------------------ ---------_____________
TRANSMISSION CONTROLLER
-48 POWERSHIFT
~ iPOi~i!~RS!H~I;FT~SE:~LE~CT~0~R~SiliG;N;AiL;:::::~~~~l!C~N~.3~2;1;1~~~927Y75
RESISTOR
- -- - - - - - 927Y 75 PACK
SENSOR RETURN (.J
SENSOR 5 VOLT SUPPLY (+)
CN·1
CN·14
923BR 75 - - - - - - - - - - - - - -- -- -----_,
21R1 0>----------------------,
I
I R1 = 3 3 K OHMS
R2 = 5 6 K OHMS
1~ i
INCHING PEDAL POSITION SIGNAL CN·31 924Y 75 --- -- ----------------. R3 = 33.0 K OHMS
C_r_~._34 ~
R4=33KOHMS
FORWARDINEUTRALlREVERSE SELECTOR 5 IG,..N_A_L_____ _______ _, 922Y 75
TO PTO NEUTRAL ';: v,
START SWITCH FORWARD/NEUTRAL! >'
REVERSE RESISTOR ~ ~
PACK ~
R1=15KOHMS ::l
R2 = 22 K OHMS r:;,
FROM KEY R3 = 2 7 K OHMS
SWITCH R4 = 1.0 K OHMS
TERMINAL 2
FORWARD/NEUTRAL
/REVERSE ~ 28
SHUTILE ci
ro 922y71'> --- --#71
S~TCH
""en
N
924Y75 --I~
1I
921 Rl .
923BR75
....
<Ii
N
"'.... PO~SHrFT
6~2
ci "'-""1
OJ ,..-..., 2 3 POSITION
'+J
~TCH
~ '86' 6 '"en
N
3
~ 'S3' ~ 5OST,75
II>
SP3 .....
GEAR ~TCH LOGIC ~
L 2 1 R 75-5--- - - -- - - -- -- - - - - - - - - 921R 75 51 52 l\j In
1 1
*, 2
3
1
21R7
924Y75 --------------~~-----r~
923BR.75 --------------+------e
2
3
1
0
S1
....
ci
N
INCHING PEDAL '"
POTENTIOMETER
21R.75-------------' SP4
23BR ,75 5P7
C
' - - --
28
1 -
--IIH! 5
- - - 923BR 71'> ---------+---. - 923BR.76
21 R 75-- -- -.....~-9
923BR 75
921R7
- CHASSIS GROUND --"'l~'l':;;" J ---------------------------------------------------
rJ"J/."h"z". __ ""..,...- CHASSIS GROUND
WI;/JIII
- - - CLEAN GROUND --------------------------------------------------------------------- - - CLEAN GROUND
SM 8-12101 Issued 09-2004
74 SECTION 10006
No Error Code
Defaults to 3rd Speed Powershift 3 when 1st and 2nd Speed
Powershift Selected
Fault Description.
The transmission controller receiving an incorrect signal from the powershift selector switch .
System Response.
- Tractor defaults to 3rd speed powershift when 1st and 2nd speed powershift selected - tractor dives in 3rd
speed powershift only.
Possible Cause.
1. Bad circllit between the powershift resistor pack and the powershift selector switch .
2. Bad powershift selector switch.
3. Bad powershift resistor pack.
Circuit Checks.
NOTE: Before carrying out the following tests, refer to Circuit Testing "Circuit Testing General Information "
on page 21 .
STEP 1
Turn the key OFF and disconnect the powershift selector switch and powershift resistor pack. Check for
continuity between terminal B of the powershift switch connector and terminal 1 of the powershift resistor pack
connector (wire 925 Yellow).
- If continuity is not detected check wire 925 Yellow between powershift resistor pack connector and the
powershift switch connector for damage.
- If continuity is detected go to Step 2.
STEP 2
Check for continuity between terminal A of the powershift switch connector and terminal 3 of the powershift resistor
pack connector (wire 923 Brown).
- If continuity is not detected check wire 923 Brown between the powershift switch connector and splice 7 for
damage.
- If continuity is detected go to Step 3.
STEP 3
Check the resistance readings between the following powershift speed selector switch connector terminals. If
any of the readings are incorrect replace the speed selector switch .
1ST SPEED 2ND SPEED 3RD SPEED
TERMINALS
SELECTED SELECTED SELECTED
A and B Approximately Approximately No Continuity
3.9 ohms 3.9 ohms
A and C No Continuity Approximately Approximately
3.9 ohms 3.9 ohms
- If the readings are correct replace the powershift resistor pack.
SM 8-1 2101 Issued 09-2004
SECTION 10006 75
BATTERY POWER (B+)
SWITCHED POWER
TRANSMISSION CONTROLLER
--
48 POWERSHIFT
RESISTOR
POWER SHIFT SELECTOR S1GNAL CN·32 927Y 75 927Y 75 PACK
SENSOR RETURN (.J CN·1 923BR 75
d
R1 = 3.3 K OHMS
SENSOR 5 VOLT SUPPLY (+) CN·14 21R1 0 R2=56KOHMS
INCHING PEDAL POSITION SIGNAL CN-31 924Y 75 R3 = 33.0 K OHMS
R4 = 33 K OHMS
FORWARD/NEUTRAUREVERSE SELECTOR SIGNAL CN·34
"~'"~
TO PTO NEUTRAL
I - ...'"
~
Ii
N
N
START SWITCH '"
~
FORWARD/NEUTRALI ~
REVERSE RESISTOR
PACK
'".... N
0>
R1 = 15K OHMS ~
FROM KEY
R2 = 2 2 K OHMS
R3 = 2 7 K OHMS
".
U'>
SWITCH R4 = 10K OHMS "-
TERMINAL 2 >'
"-
N
'"
N ~
'"
N
!O
it>
!O
..
!O
FORWARD/NEUTRAL
/REVERSE II>
"-
II> II>
~ '"....ci 28
Ii
N
SHUTTLE t;; ~~ Ii
N tD 922Y 75
SWITCH ~ ~~
'" "'
N
m 924Y 75
921Rl
'" t-
.... \I')
I
on
"-
Ii
i 923BR75
ci
tD ~
N
M
N Sl ~ POWERSHIFT
m
Ii "'--"'1
tD ,..--.., 2 3 POSITION
M SWITCH
~ N 3
Ii '"
Si
GEAR SWITCH LOGIC
....,.:
It)
ID
L
fE::
21R.75-5- - - - - - - --
~21R. 7
--
, 51
1
52
a
N
'" '"
2 1 1
~ ~ :;;:~5--------+----+--' 3 a
51
1
52
"-
;'i
N
0>
INCHING PEDAL
POTENTIOMETER
21R75-
· ----------~ SP4
":
SP7
'"
N
923BR .75
21R ,7 , R 75 921R.7
SP6
- CHASSIS GROUND -""I;'l'»"'rI"'f~"'Z""j}""J--------------------------""I'l'''''''-"..- lIII/II,m CHASSIS GROUND
- - - - - CLEAN GROUND - - - -- - -- - - - -- - - - - - - - -- - -- - - - - -- - - - - - - - CLEAN GROUND
SM 8-12101 Issued 09-2004
76 SECTION 10006
This Page Has Been Left Blank
SM 8-12101 Issued 09-2004
SECTION 10006 77
HARNESS LAYOUT AND CHASSIS GROUND LOCATION
,,
I I
,,
I
. I
... : : --:;:}
, , ~ . ..:-- .:-!
I I I
I'
I'
I
I
I -,- - - ....
,I I
I
.•. I
I
I
I
.
I •
,
I
I ,
I
"-1 1 J
\
- _--
.... ... ' '\
• I
,.. -- ...
\
l..J \ : )
---- --- ... _--- _____ I
- - - - - - ...... _,,11
- ... _-- - -- ...... - ," ,,
, I .. ~~: -: __ : : : : ::.._~ .. "
, I
- - ... -- - - - - - - -- - ... ~
.,
I I I
~ .. ------.1..--- . . / I , MI03F061
1. CONNECTOR 1 - TO CAB HARNESS 17. UPPER/LOWER HEADLIGHT SWITCH (0)
2. POWERSHIFT CLUTCH PEDAL POSITION 18. KEY SWITCH
POTENTIOMETER 19 . RS232 CONNECTOR
3. ROTARY LIGHT SWITCH 20. FORWARD/NEUTRAL/REVERSE RESISTOR PACK
4. FUSE BLOCK 21 . CAB POWER RELAY
5. COLD START SWITCH 22 . HEADLIGHT DIPPER RELAY
6. INSTRUMENT CLUSTER CONNECTOR C2 23 . FLASHER RELAY
7. SWITCHED POWER STUD 24 . BLOWER MOTOR CIRCUIT BREAKER
8. REAR WORK LIGHT RELAY 25. LEFT HAND BRAKE PEDAL SWITCH
9. FRONT WORK LIGHT RELAY 26 . RIGHT HAND BRAKE PEDAL SWITCH
10. ACCESSORY POWER RELAY 27 . 3 PIN ACCESSORY POWER CONNECTOR
11. BRAKE POWER RELAY 28. UNSWITCHED POWER STUD - BATTERY POWER
12. BRAKE EITHER RELAY 29. CONNECTOR 71 - SELF CANCELLING TURN SIGNAL
13. BRAKE BOTH RELAY 30. CONNECTOR 32 - STALK SWITCH
14 . INSTRUMENT CLUSTER CONNECTOR C1
15. HAZARD WARNING SWITCH (*) G1 . CHASSIS GROUND CONNECTION G1
16. WORK LIGHT SWITCH
(0) European Specification Tractors Only
SM 8-12101 Issued 09-2004
78 SECTION 10006
I I
I I
I I I'"
I I
I
\ I
\
I
, I
, \
I
I
I
I
r---
I I
I I
I
....... - .. - - - .... - _.. _" .... ----_
- ... _-- ---- ____ ;,' II
,
, ----- ... - ... - _- "
"
... - - - ... I
I
- - - --
,. - - - - - - - - .... --"
\ '.
\
I
------------------~,
,
I __ ----.1.. ... - .. ... _.... I
, I
MI03C034
1. CONNECTOR 1 -TO CAB HARNESS 16. RS232 CONNECTOR
2. POWERSHIFT CLUTCH PEDAL POSITION 17. FORWARD/NEUTRAL/REVERSE RESISTOR PACK
POTENTIOMETER 18. CAB POWER RELAY
3. ROTARY LIGHT SWITCH 19. HEADLIGHT DIPPER RELAY
4. FUSE BLOCK 20 . FLASHER RELAY
5. COLD START SWITCH 21 . BLOWER MOTOR CIRCUIT BREAKER
6. INSTRUMENT CLUSTER CONNECTOR C2 22 . LEFT HAND BRAKE PEDAL SWITCH
7. SWITCHED POWER STUD 23 . RIGHT HAND BRAKE PEDAL SWITCH
8. REAR WORK LIGHT RELAY 24 . 3 PIN ACCESSORY POWER CONNECTOR
9. FRONT WORK LIGHT RELAY 25 . UNSWITCHED POWER STUD - BATTERY POWER
10. ACCESSORY POWER RELAY 26. CONNECTOR 71 - SELF CANCELLING TURN SIGNAL
10. INSTRUMENT CLUSTER CONNECTOR C1 27. CONNECTOR 32 - STALK SWITCH
12. HAZARD WARNING SWITCH (.)
13. WORK LIGHT SWITCH G1 . CHASSIS GROUND CONNECTION G1
14. UPPER/LOWER HEADLIGHT SWITCH (.)
15. KEY SWITCH (.) European Specification Tractors Only
SM 8-12101 Issued 09-2004
SECTION 10006 79
Right Hand Console Harness Components
- Tractors Without Ride Control
1. CONNECTOR #26 - 15. POWERSHIFT RESISTOR
TO INSTRUMENT PANEL HARNESS 16. CONNECTOR #40 - TO TRANSMISSION HARNESS
2. CONNECTOR #27 - 17 . CONNECTOR #52 - TO REAR FENDER HARNESS
TO INSTRUMENT PANEL HARNESS) 18 . HITCH CONTROL MODULE
3. CONNECTOR #28 - 19 . AUDIBLE ALARM
TO INSTRUMENT PANEL HARNESS 20 . SEAT SWITCH CONNECTOR
4. CONNECTOR #29 - 21 . OPERATOR PRESENT SWITCH CONNECTOR
TO INSTRUMENT PANEL HARNESS 22 . SHIFTABLE PTO SWITCH - IF EQUIPPED
5. FRONT PTO RELAY - IF EQUIPPED 23. AUXILIARY POWER CONNECTOR
6. MFD RELAY 24 . CIGAR LIGHTER
7. DIFFERENTIAL LOCK RELAY 25. HITCH CONTROLS - REFER TO SECTION 10002
8. HITCH ENABLE RELAY 26 . TRANSMISSION CONTROLLER
9. POWERSHIFT SPEED SELECTOR SWITCH 27. LOAD CONTROL POTENTIOMETER
10. DECLUTCH SWITCH 28. POSITION CONTROL POTENTIOMETER
11 . REAR FOG LIGHT SWITCH - IF EQUIPPED (0) 29 . MFD SWITCH - IF EQUIPPED
12. ROTARY BEACON LIGHT SWITCH - IF EQUIPPED 30. DIFF LOCK SWITCH
13. FRONT PTO SWITCH - IF EQUIPPED 31. HITCH ENABLE SWITCH
G2 . CHASSIS GROUND CONNECTOR
(0) European Specification Tractors Only
SM 8-12101 Issued 09-2004
80 SECTION 10006
Right Hand Console Harness Components
- Tractors With Ride Control
1. CONNECTOR#26- 16. CONNECTOR #40 - TO TRANSMISSION HARNESS
TO INSTRUMENT PANEL HARNESS 17. CONNECTOR #52 - TO REAR FENDER HARNESS
2. CONNECTOR #27 - 18. HITCH CONTROL MODULE
TO INSTRUMENT PANEL HARNESS) 19. AUDIBLE ALARM
3. CONNECTOR #28- 20. SEAT SWITCH CONNECTOR
TO INSTRUMENT PANEL HARNESS 21 . OPERATOR PRESENT SWITCH CONNECTOR (ee)
4. CONNECTOR #29 - 22 . SHIFTABLE PTO SWITCH - IF EQUIPPED
TO INSTRUMENT PANEL HARNESS 23. AUXILIARY POWER CONNECTOR
5. FRONT PTO RELAY - IF EQUIPPED 24. CIGAR LIGHTER
6. LEFT BRAKE RELAY 25 . HITCH CONTROLS - REFER TO SECTION 10002
7. RIGHT BRAKE RELAY 26. TRANSMISSION CONTROLLER
8. MFD RELAY 27. LOAD CONTROL POTENTIOMETER
9. POWERSHIFT SPEED SELECTOR SWITCH 28 . POSITION CONTROL POTENTIOMETER
10. DECLUTCH SWITCH 29 . SLIP CONTROL SWITCH (IF EQUIPPED
11 . RIDE CONTROL SWITCH 30 . MFD SWITCH - IF EQUIPPED
12. REAR FOG LIGHT SWITCH - IF EQUIPPED (*) 31 . DIFF LOCK SWITCH
13. ROTARY BEACON LIGHT SWITCH - IF EQUIPPED 32 . HITCH ENABLE SWITCH
14. FRONT PTO SWITCH - IF EQUIPPED
15. POWERSHIFT RESISTOR G2. CHASSIS GROUND CONNECTOR
(*) European Specification Tractors Only
SM 8-12101 Issued 09-2004
SECTION 10006 81
Transmission Harness Components
- -.:. -..II-.
, t, 1 ,', ....
J..... :.. ~J..
"1
~ ---------
- ..:::--j
1. CONNECTOR 40 - TO RIGHT HAND CONSOLE HARNESS
2. HITCH LOAD PIN CONNECTOR
~' 3. HITCH LOWER SOLENOID
, 4. HITCH RAISE SOLENOID
./ , . ~
5. PARK BRAKE SWITCH CONNECTOR
, ,r,
I 6. DIFFERENTIAL LOCK SOLENOID
, I <,I 7. HIGH/LOW RANGE SWITCH
,, ...:::
,, I B. PTO NEUTRAL START SWITCH
I
I
I
I
,"
I
I
\
.' 9.
10 .
DIFFERENTIAL LOCK WARNING LIGHT SWITCH
3RD/4TH SHIFT RAIL NEUTRAL START SWITCH
'""- ;
I,~
/".
,-.- V
. /." I
11 . 1ST/2ND SHIFT RAIL NEUTRAL START SWITCH
, " 1'1
I 1,' 12 . FUEL LEVEL SENDER
~,
- r' (1/
~. " 13. CONNECTOR 11 - TO ENGINE HARNESS
. ~ rt ( "
.... , . •. _ 1 ,
.... 'J ..J,
I r-'
,I
I '
I
"I .
( ' ,(,1
, I ':'"
/~
:1
"
I :~
".. _
.
.:-' , V,
,
,
,,
r-
'-./
, 14.
15.
16.
FLYWHEEL SENSOR CONNECTOR
CLEAN GROUND - BATTERY NEGATIVE TERMINAL
FORWARD SOLENOID
II
1,..-
"
",
: I" I,
~
.....' "
', , ' 17 . REVERSE SOLENOID
, _~. I J 'I
1\
'\
'<~
... , ~. I)," ! .. ",,'
I (,1'
I I 18 . POWERSHIFT SOLENOID 2
,'" I , I '.
~: ,,' ,
t
I
,t
, 't .......- __ ..",.,- ....
. .- II'"": i 19 . POWERSHIFT SOLENOID 1
..... I ( '\ .. =-;. . 20 . POWERSHIFT SOLENOID 3
21 . CLUTCH SENSOR (B)
( - -
- - - ..~I,.' ~ ;
22 . CLUTCH SENSOR (A)
23 . LOADER CONTROL CONNECTOR
24 . AIR TRAILER BRAKE PRESSURE SWITCH CONNECTOR
25. WHEEL SPEED SENSOR
26. MFD SOLENOID
27. HITCH POSITION POTENTIOMETER CONNECTOR
G3 . CHASSIS GROUND CONNECTION G3
MI03B072
SM B-12101 Issued 09-2004
82 SECTION 10006
SCHEMATIC CIRCUIT
------------------- BATTERYPOW£R (B+) - - - - - - - - - - - - - - - - - - - - - - - -____________________________________________________________________________________- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BATTERYPOW£R (B+) ___________________
____________________ S~TC HEDPOWER C?r------------------~C?r------------------------------------------------------------------------------------------------------------------------------- S~TCHEDPOWER - - - - - - - - - -- -- - - -- ---
f',~r l,J
TO INSTRUM ENT CLUSTER "l "! ~
} N ~ r---------5500R10 ~500Rl .0--------, - - - - -- - - -- - - - - - - -- - - -- - - - - -'500R 1 0 - - - - - - - - - - - - - - -- -- - - - - - - - - -- -- 500R1 0----
r------U-P-~-\;-co{~> ,i~ii;~"'~Jio"~:" ',~~' ":-:w-~-;-l-:-R---i-.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ! 5 0 0 R 1 .0 500Rl 0 ____
z - - - - - - - - - - - - - - - - - - - : 2 7 9 R l . 0 -- ----,
:;:
oo --300R1 0
Ii;
«
LI.
l>
SWTCH 0 (CLOSED AUDIBLE
DECLUTCH
~ WIOPER. S'MTCH
ALARM
-------"""~
IN SEAT)
'-------- - -- - - - - - - -- - - - - -:279Yl 0 (#269Yl 0) - - - -
928Yl .0 - - -- -- - - - -_ __ ____ _________________ 928Yl 0 - -
----~---------------------- 303T75 - - -- -- - - - -- - -- - - - - -- - - - -- - - -- -- - - - - - - -- - -- -- -- - 303T75 - -
TO PTO NEUTRAL START SWITCH 922Y1 .0 - - - - - - - - - -- - - - - - -- - 922Y1 0 922Y10----
FROM KEY SWITCH TERMINAL 2 924Y1 0 924Y1 0 924Y1 .0----
28
=fiI= ~
FORWARD/NEUTRAU INSTRU MENT CLUSTER 269Y 75 269Y 75 - -
REVERSE RESISTOR
TO HITCH CONTROLER
PACK PARK BRAKE LAMP 269Y 75 - - - -- - -- - - - - - - - - - - - - 269Y 75 ~------- 269Y 7 5 - -
REFER TO SECTION 10002 R1=15KOHMS POWERSHIFT 1 930T.75 930T 75 930T 75 930TJ5 - -
R2 = 2.2 K OHMS
FORWARD/NEUTRAL R3 = 2.7 K OHMS o POWERSHIFT 2 931T.75 931T 75 8 931T 75 931T 75 - -
IREVERSE
SHUTTLE
R4= 1 0 KOHMS cr 27
SWTCH 8 NEUTRAL INDICATOR LIGHT son 75 - - - - - - - - - - - - - - -- -- - - - - - - -- - - -- - - - - - - - -- 50n 75 - -
~R~E~VE~R~S~E~I~N~D~IC~A~T~O~R~L~IG~H~T=====l~~l*--.:~~~--------;::;::;;:::;:;----------------------575R.75 (#500R 75)
TO SLIP CONTROL SWITCH SEE NOTE 1
REFER TO SECTION 10002 --
WHEEL SPEED SENSOR SIGNAL C2·A·5 215Y 75 - - . - 215Y 75 ~
277 r-- 215Y 75 - - - - - - - - - - - - - - 2l5Y 75 - -
TO IMPLEMENT INTERFACE CONNECTOR <J-- 215Y75 ~ ~ ~ ~ r - = 910y.75 9l0Y75--
~
TO HITCH REMOTE SWITCHES
TO HITCH CONTROLLER REFER TO SECTION 10002 ~"'N-
>=
~.
N
.-~.
>-
, -917Y 75
I
'"
9l7LB10-
918LB 75 (#9l7LB 75) ---
REFER TO SECTION 10002 L-- - -- - - - --5CIO:R l .0 - - - , 0 t--.
21SR.75 - - - - - - - 215R.75 215Y.75 215Y 75 _ _ _,,-..J a; ~ 580Y75 - -
r - - -- - 9l0Y 75 - - - - - - - - - - - - - - - 910Y. 75 - - - . . . .
I ;;;I
9l7Y 75 _ _ _ _ _-..J.
922Y.75
Rl.0
. 3 E 5 8 0 R l .0 - - -- - I - - - - - - - - - --saORl 0
r-------------~--__S10R1 0 _ SP5
~ :i"' 17R1.0 921R75
$ ~
If) ~ ~ U")
t'-- ~
~ ~ ' - - - - - - - 910Y.75
'">-
f
HI GH/LOW t'--
INCHING PEDAL SP3\ J~ RANGE
S~TCH
o
'"'"
POTENTIOMETER L - g21R 755 -- - - - - - - - - - - - - - - - - 921R 7 ~ ~ NC
..~ q
\b- ~~:~:
~
~:---------------------- :~;~;:--_+----+_
;23BR 75 923BR 75
92.4Y.75
SP4
7 WHEEL
SPEED
SEN-SOR
CLUTCH
~TH
3.9 OHM
RESISTOR
SEE NOTE 1
(LOW RANGE'
SPEED
SHO~)
SENSOR B
L 1 SR.75 - - -- - - - - -- - - - - -- - - -- - - - - - - - - -- - - - - - - - - - -215R 75 - + ------i-- - ---'215R.75 (BOTTOM)
'------ 92.3BRTh -------~--------_+-----------_r- - - -- - - - - - - - - -- - - - - - - - - - - -- - - -- - - - + - - - -- - - -- -- 923BR75-
921R . 7&------------------------I----------------~--------------------~~21 R 7~----------------------------------~------------_921 R 7 ~
____________________ CHASSISGROUND --""~~----------------------------------~~~~------------------------------------------~------~""""~----+------------------------+------------------------7."-""""----------------~--- CHASSIS GROUND - - - - - - - -
- - -- - - - - - - - - - - - - CLEAN GROUND CLEAN GROUND - - - - - - - -
MI03B016
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur.
(#) Early Production Tractors Only.
SM8-12101 Issued 09-2004
SECTION 10006 83
SCHEMATIC CIRCUIT
l
___________________ BATTERY POWER(B+) -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------BATTERY POWER(B+) --------------------
- - -- - - - - - - SW1TCHED POWER SW1TCHED POWERR----- - - - - - -
CAN CONNECTOR 3 PIN 911Yl0 ~916R1.0 - - - - - - - - - - 9 1 6 R 1 0
I1=
OOOY75 9l1Yl .0
- - SOOR1.0 - - - - - - - - - - - - - - - - - , 1 =CAN HIGH
2=CAN LOW 2 OOOLG. 75 --~ 912Yl 0 - -- - - 912Yl 0 ~
I i915Rl0
- - SOOR1 .0 - - - - - -- - - - - - - - - ,
3 = CAN GROUND 3 900BR 75 --~ 913Yl0 l I
28
~ q o 0 q ~
RS232 0:
>= >= >= r;; r;;
COMUNICATION '"g ~ ~ ~ '"0; '"0;<D
0; 0; 0; '"
CONNECTOR - 500Rl0
'"
9 PIN : !7 500Rl 0 POWERSHIFT
SOLENOID 1 II POWERSHIFT
SOLENOID 2 II POW1ERSHIFT
SOLENOID 3 II FORWARD
SOLENOID
REVERSE
SOLENOID
iJ=
929Y 7 5 9 929Y 75
3
5
929DG 75
929BR. 75
101-- - -- --
11
9200.75
929BR. 75
~2 ~2 ~2
--279Yl 0 (#269Yl 0) 279Yl 0 (#269Yl .0) q q q 2
- - 928Y 75 928Y 75 iii
...I
§ en
- - 303T 75 3031 75 CD
;;; '"
0;
...I
~ q q q i q r-- 915Yl 0
- - 922Yl .0 922Yl .0
~ >= >= ~ a
F
I (0 r-- 916Yl 0 - - - - - - - - 916Y1
- - 924Yl 0 924Yl .0 L - 918LB1 .0 920LBI 0 -----.J en ~ m ..- . --
CN-39
I
914LB10 - - - 914LBI 0 J J 1'" J '"I '"I POWERSHIFT r--;===::._
r -- - -- - - - ,
- - 269Y 75 - - - - - - - -- -- - - - - - - 269YJ5 RESISTOR
- - 269Y 75 - - - - - - , spa 1~~ I~I~~IA::I; :t:RI PACK
CN·38
124123121 120 128 125 126 129 1401 Rl = 3.3 K OHMS
- - 930T.75 ------1---- - - - - - - - - 930T 75 I R2 = 5.6 K OHMS
- - 931T 75 931T 75 I r - - - 914LBI a _ _____ 914LBI 0 _ _ _ --'J I I I I R3 = 33.0 K OHMS
~ ~ q q R4 = 3.3 K OHMS
'2s CN·37 r--- 913Yl 0 - - - - - - -- 913Yl0 _ _ _...J ~ ~ ~ ~
- - 507T 75 I\:';; 1'j11f-------- 575R.75 I ; - - 912Yl a 912Y1.0 - 0; 0; 0; 0;
- - 575R.75 (#500R.75) ~~ 507T.75 I . . - 911Yl a - - - -- -- - -- 91'IY1 0 I
_ _ 215Y 75 '-'- L:.::J
- - 910Y 75 - - - - - 11 - - - - - - - - - - - - 910Y 75
215Y 75
I
I
r - - 9l6R1 0 - - - - - - - - - - - - - - - "
. - - - 915R10 --------------~
II
--917LB10
- - 918LB 75 (#917lB 75)
917LB10
918lB 75 (#917lB 75)
I
I
r - 915Y1 a
r - 916Yl a ______________---J I
- - 580Y 75 S80Y 75 927Y 75 ~
L- 269Y 75 W 269YJ 5
CN·23
CN·26
I-- 914LBI 0
I-- 913Yl 0
. . - 927Y75 - - -- - - - - -- -- - -- - - -
""-- 1
""-- 2
CN·24 I-- 912Yl 0 ...... 1'"- 3
CN·22 7- I-- 911Yl 0
CN·7 7- I-- 9l6Rl a
CN·S ~ I-- 915Rl 0 POWERSHIFT GEAR SV'IITCH LOGIC
~
269Y75 3 POSITION
CN-8 ~ I-- 915Yl .0 SW1TCH SI 52
""
"'
r- 2 '- 1 1
CN·9 ~ I-- 9l6Yl a SEE NOTE 1 0
d~'
2 1 1
CN·32 ~ - 927Y75 3 0 1
CN·l ~- 923BR.75 SI 52
CN·14 - - 921R75
[ BRAKE
I~ S~6CH
MI02Kl02
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test
lamp or damage to the switches may occur.
(#) Early Production Tractors Only.
8M 8-12101 Issued 09-2004
84 SECTION 10006
This Page Has Been Left Blank
SM 8-12101 Issued 09-2004
SECTION 10006 85
MAIN CONNECTORS
Connector 26 Connector 27
Location: Right Hand Console Location: Right Hand Console
I-- f-- f-- I-- 480196
F= F= INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
478196
Cavity Wire Circuit
No
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
1 240 Y AIR TRAILER BRAKE PRESSURE
Cavity Wire Circuit SWITCH
No 2 515 R LOADER CONTROLS B+
A 542 LB MFD INDICATOR LIGHT 3 . - - -- OPEN
B 707 P LH TAIUPOSITION LIGHT 4 563 LB IMPLEMENT SWITCH
C 708 P RH TAIUPOSITION LIGHT 5 930 T POWERSHIFT SPEED INDICATOR
D 500 R HITCH B+ 6 233 Y FUEL LEVEL SENDER
E 622W PTO NEUTRAL START 7 215 Y WHEEL SPEED SENSOR
F 735 LB DIFF LOCK INDICATOR LIGHT 8 931 T POWERSHIFT SPEED INDICATOR
G 784 P REAR FENDER WORK LIGHTS 9 929 Y RS232 TX
H 810 R SEAT 8+ 10 929 DG RS232 RX
J 5301 MFD AND DIFF LOCK B+ 11 929 BR RS232 GROUND
540 R 12 ----- OPEN
K 134 R AUXILIARY POWER CONNECTOR
SWITCHED B+
L 757 PI RH TURN SIGNAL
756 P
M 756 PI LH TURN SIGNAL
757 P
N 282Y RADAR PRESENT
P 133 R AUXILIARY POWER
FENDER HARNESS
CONNECTOR H OR
7 PIN CONNECTOR (**)
R 135 R RH CONSOLE AUXILIARY POWER
UNSWITCHED B+
S 817 R CIGAR LIGHTER
T 269Y PARK BRAKE WARNING LIGHT
U 702 R BRAKE LIGHTS (*)
V 281 Y RADAR SIGNAL
W 785 R REAR FOG LIGHTS H
X 622W PTO NEUTRAL START
Y 296 Y 1000 RPM PTO SWITCH
Z 509 LB HITCH DOWN SWITCH
(*) European Specification Tractors Only.
(**) American Specification Tractors Only.
(***) Tractors With Ride Control Only.
SM 8-12101 Issued 09-2004
86 SECTION 10006
Connector 28 Connector 29
Location: Right Hand Console Location: Right Hand Console
W
IL
qu 00
00
00
o
482196
480196
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire Circuit
Cavity Wire Circuit No
No A 8350 FRONT WINDSCREEN WASHER
1 923 BR SENSOR (-) B 8450 REAR WINDSHIELD WASHER
2 500R TRANSMISSION CONTROLLER B+ C 550 R FRONT PTO B+
3 500 BR TRANSMISSION CONTROLLER D 551 LB FRONT PTO CLUTCH
GROUND
E -- - .. ~ OPEN
4 922 Y FNRSENSOR
F 531 LB RIGHT HAND BRAKE RELAY (***)
5 921 R SENSOR (+)
G 776 P ROTARY BEACON LIGHT
6 900Y CAN HIGH - NOT USED
H 775 R ROTARY BEACON LIGHT B+
7 900 DG CAN LOW - NOT USED
8 900 BR CAN GROUND - NOT USED
9 924 Y INCHING PEDAL SWITCH
10 507 T REVERSE INDICATOR LIGHT
11 575 R NEUTRAL INDICATOR LIGHT
12 536 LB LEFT HAND BRAKE RELAY (***)
(***) Tractors With Ride Control Only
SM 8-12101 Issued 09-2004
SECTION 10006 87
Connector 30 Connector 31
Location: Instrument Cluster Location: Instrument Cluster
iI!!I!!i
DO DO
DO 00
DO DO
DO 00
DO 00
DO DO
DO 00
DO 00
DO 00
DO 00
DO 00
DO 00
IIiiiiI1
483196 483196
INSTRUMENT CLUSTER CONNECTOR C1 INSTRUMENT CLUSTER CONNECTOR C2
Cavity Wire Circuit Cavity Wire Circuit
No No
A1 770P 2ND TRAILER TURN SIGNAL A1 ............... OPEN
A2 200 R SWITCHED POWER B+ A2 280 BR GROUND SPEED RADAR GROUND
A3 280 R GROUND SPEED RADAR B+ OUT A3 507 T SHIFT TO NEUTRAL LAMP
A4 ...... - ... - OPEN A4 216 Y ALTERNATOR'W'TERM!NAL,
ENGINE RPM
A5 769 P 1ST TRAILER TURN SIGNAL
A5 215 Y WHEEL SPEED SIGNAL
A6 735 LB DIFF LOCK WARNING LIGHT
A6 266 Y AIR FILTER RESTRICTION
720 BR
TURN SIGNAL GROUND
(-) A7 121 Y ALTERNATOR D+ TERMINAL,
A7 WARNING LIGHT AND EXCITE
750 BR
TURN SIGNAL GROUND A8 200 BRI CLEAN GROUND
H
W
A8 -... - - - OPEN
A9 723 P HIGH BEAM WARNING LIGHT
A9 202 R UNSWITCHED B+ - CLOCK
A10 281 Y GROUND SPEED RADAR SIGNAL
768
TURN SIGNAL LIGHTS A11 255 Y ENGINE OIL PRESSURE
PH
A10 A12 ............... OPEN
755 P RIGHT HAND TURN SIGNAL
B1 726P BACK LIGHTING - ANALOGUE
H WARNING LIGHT
B2 282 Y GROUND SPEED RADAR PRESENT
A11 542 LB MFD
B3 563 LB TRAILED IMPLEMENT SWITCH
A12 - .. - - - OPEN
B4 509 LB HITCH IMPLEMENT SWITCH
B1 240 Y AIR TRAILER BRAKE PRESSURE
B5 ...... ......... OPEN
B2 ............... OPEN
B6 ............ . . OPEN
B3 201 R ACCESSORY POWER B+
B7 . ...... . . OPEN
B4 235 Y ENGINE COOLANT TEMPERATURE
B8 575 R REVERSE INDICATOR LAMP
B5 269 Y PARK BRAKE WARNING LIGHT
B9 930T POWERSHIFT SPEED INDICATOR
B6 - ...... -- OPEN
B10 931 T POWERSHIFT SPEED INDICATOR
B7 784 V LOWER WORK LIGHT WARNING
B11 ..... ... .... OPEN
B8 231Y COOLANT LEVEL
B12 - ... ...... . . OPEN
B9 267Y HYDRAULIC FILTER RESTRICTION
B10 276 Y 1000 PTO WARNING LIGHT
B11 233 Y FUEL LEVEL
706 P
POSITION LIGHT
(*)
B12
754 P LEFT HAND TURN SIGNAL
H WARNING LIGHT
(*) European Specification Tractors.
(**) American Specification Tractors.
SM8-12101 Issued 09-2004 I
j
88 SECTION 10006
Connector 40
Location: Cab Floor (Right Hand Console)
Ulil9A036
RIGHT HAND CONSOLE TO TRANSMISSION HARNESS
Cavity Wire Circuit Cavity Wire Circuit
No No
1 543 LB MFD SOLENOID B+ 24 914 LB POWERSHIFT SOLENOID RETURN
2 233 Y FUEL LEVEL SENDER 25 915 R FORWARD SOLENOID
3 507 R +8 V POSITION POTENTIOMETER 26 915 Y FORWARD SOLENOID RETURN
4 507 LB POSITION SIGNAL 27 530 T NOT USED
5 507 BR POSITION POTENTIOMETER LOW 28 916 R REVERSE SOLENOID
6 481 Y NOT USED 29 916 Y REVERSE SOLENOID RETURN
7 500 CLEAN GROUND HITCH 30 917 LB CLUTCH SPEED SENSOR B
BR/W CONTROLLER
31 240 Y AIR TRAILER BRAKE PRESSURE
8 269 Y PARK BRAKE WARNING LIGHT
32 921 LB CLUTCH SPEED SENSOR A
9 532 LB DIFF LOCK SOLENOID B+
33 .. - .... - OPEN
10 511 R HITCH SOLENOID B+ ,
34 622W PTO NEUTRAL START
DIFF LOCK LIGHT B+
35 624 W PTO NEUTRAL START
11 513 LB HITCH RAISE SOLENOID RETURN
36 - - ....... OPEN
12 514 R HITCH PIN +8 VOLTS
37 ...... .. .. OPEN
13 500 R SPEED SENSOR B+
38 735 LB DIFF LOCK LIGHT
14 514 BR HITCH PIN LOW
39 516 T LOADER SOLENOID IN
15 514 LB HITCH PIN SIGNAL
40 515 T LOADER SOLENOID OUT
16 580 Y HIGH/LOW RANGE SWITCH
41 .......... OPEN
17 512 LB HITCH LOWER SOLENOID
RETURN 42 T LOADER SOLENOID
18 215 Y WHEEL SPEED SIGNAL 43 215 R WHEEL SPEED SENSOR B+
44 .. ...... .. OPEN
19 910 LB FLYWHEEL SPEED SIGNAL
20 911 Y POWERSHIFT SOLENOID S1 45 - ..... - .. OPEN
21 912 Y POWERSHIFT SOLENOID S2 46 .......... - OPEN
22 .. - ...... OPEN 47 ......... - OPEN
23 913 Y POWERSHIFT SOLENOID S3 48 ........... OPEN
SM 8-12101 Issued 09-2004
SECTION 10006 89
Connector 48
Location: Right Hand Console I
I I
>
>
(
(
RIGHT HAND CONSOLE HARNESS TO TRANSMISSION CONTROLLER
Cavity Wire Circuit Cavity Wire Circuit
No No
1 923 BR SENSOR RETURN (-) 22 911 Y POWERSHIFT SOLENOID S1
2 ..... - - .. OPEN 23 914 LB POWERSHIFT SOLENOID RETURN
3 580 Y HIGH/LOW RANGE SWITCH 24 912Y POWERSHIFT SOLENOID S2
4 303 Y OPERATOR PRESENCE SEAT 25 -- ... -- OPEN
SWITCH
26 913 Y POWERSHIFT SOLENOID S3
5 928 Y DECLUTCH SWITCH .............
27 OPEN
6 915 R FORWARD SOLENOID
28 500 R SWITCHED POWER B+
7 916 R REVERSE SOLENOID
29 500 BR CHASSIS GROUND
8 915 Y FORWARD SOLENOID RETURN
30 .. - . . . . - OPEN
9 916 Y REVERSE SOLENOID RETURN
31 924 Y INCHING PEDAL POSITION
10 ....... - .. OPEN SIGNAL
11 - - - ... . . OPEN 32 927 Y POWERSHIFT SELECTOR SIGNAL
12 269Y PARK BRAKE SWITCH 33 575 R RETURN TO NEUTRAL LIGHT
13 929 BR RS232 GROUND 34 922Y F/N/R SELECTOR SIGNAL
14 921 R SENSOR 5 VOLT SUPPLY (+) 35 930 T POWERSHIFT INDICATOR LIGHT
15 500 BR CHASSIS GROUND 36 931 T POWERSHIFT INDICATOR LIGHT
16 910Y FLYWHEEL SENSOR SIGNAL 37 900Y CAN HIGH
17 917 LB CLUTCH SPEED SENSOR B 38 900 DG CAN LOW
SIGNAL
39 900 BR CAN GROUND
18 918 LB CLUTCH SPEED SENSOR A
40 279 Y AUDIBLE ALARM
(# 917 SIGNAL
(#269 Y)
LB)
41 507 T REVERSE INDICATOR LIGHT
19 215 Y WHEEL SPEED SIGNAL
42 500 R SWITCHED POWER B+
20 929Y RS232 TX
21 929 DG RS232 RX
(#) Early Tractors Only.
SM 8-12101 Issued 09-2004
Section
10010
PROGRAMMING HITCH/MFD/DIFFERENTIAL LOCK
CONTROLLER
CX Series Tractors
(Equipped With Ride Control)
~ © 2001 McCormick Tractors International Limited .
McCORMICK SM 8-10570 March 2001
2 SECTION 10010
TABLE OF CONTENTS
SPECIAL TOOLS ..... ............................. ........ ................ .......... .. .............. ................... ........................... ....... ............ 3
GENERAL INFORMATION .................................... ....... ........ .. ....... .... .... ... ................ ........... ................. ... ...... ...... ... . 4
CONTROLLER PROGRAMMING ............... ........................... ........ ... ...... ................. ......... ... ............... ... .............. ... . 5
8M 8-10570 Issued 03-2001
SECTION 10010 3
SPECIAL TOOLS
DOOOA113
DOWNLOAD TOOL
MC2563
8M 8-10570 Issued 03-2001
4 SECTION 10010
GENERAL INFORMATION
The PTO and Hitch Systems may require the controller to be reprogrammed with the correct software, also if a new
controller (supplied without software) is to be installed it to will have to be programmed with the correct software.
After programming the new software into the Hitch Controller, the Hitch System must be calibrated (refer to Section
10002).
The Hitch Controller can be programmed or reprogrammed using the a Desktop/Laptop computer and the
download tool MC2563.
IMPORTANT: Before reprogramming the controller MAKE SURE all error codes have been erased, refer to Section
10002 (Hitch Controller).
~.t Download Tool · MX Ma •• urn ---- - . - I!lIi! £j
fie loci ~ew t~r)$ ~i1dow l:ielp
-'I '-1 T~ I ~
SET UP CON TflOLlER FOR DOWNLOADING
CootrclJol S~on --=-- ---~--,.-----:-.,..-",-=---::---
. .
PT O Con ti'ol Un i t
DOWNLOAD STATUS
COMPUTER SCREEN MAIN DIALOGUE WINDOW
SM 8-10570 Issued 03-2001
SECT/ON 10010 5
CONTROLLER PROGRAMMING
STEP 1 STEP 4
Park the tractor on hard level ground, apply the
.... - .- .
parking brake, turn the key to the OFF position and .: ;:: ~ •• " Ie
put blocks in front and behind the rear wheels. ~ ::.. -.. . ~ ,r
r::
. I'
STEP 2
~"J
Remove the lower right hand console side cover.
STEP 3
DDOOK013
Connect download tool (A) MC2563 to the serial port
to your desktop/laptop computer.
STEP 5
Turn the desktop/laptop computer ON .
STEP 6
DPOOHOT3 If using a desktop/laptop computer not previously
used for controller programming , install the
programming CD ROM into the CD drive to
automatically install the software onto the computer
and the main dialogue box, as shown on Page 4, will
appear, go to STEP 8.
STEP 7
Download
DDOOK0 12
Remove the plug from the controller programming
connector (1) , connect the download tool (A) If using the desktop/laptop computer previously used
MC2563 (Europe) to the hitch controller for controller programming select the icon shown and
programming connector (1) . the main dialogue window as shown on Page 4 will
appear, go to STEP 8.
SM 8-1 0570 Issued 03-2001
6 SECTION 10010
STEP 8 STEP 10
- Conlrolor SeIri'ction--====:':""-=-=======::...J
, ,
Download Tool •
PIO Cont~o l Un it
The following Information was received for the
Hitch Control Unit
The manufacturing feu identifier is ECU_ 485er~Pr
The hardware identifier is ECU 485
The boot code version is 0.0.0.9
The application code software id is _......
The appfication code versi~5.2. 0.0
Highlight Hitch Control Unit as shown. L:=
: : :=
r.:::1 ~' Q~::::::::~~:JJ
STEP 9 To view the software currently installed in the
Download Tool 13 controller select ' VIEW CONTROLLER
INFORMATION'. The dialogue box shown wi"
i Please turn the vehICle's key 8wkh OFF and then back ON. appear. After checking the installed software click OK
on the dialogue box.
When tI~fi~compIeted. c~ck on ,tie tJK bullon.
Click on \he CANCEL button to abort. STEP 11
CHDOSE PROGRAM FILE NAME 6£i
PLEASE NOTE THAT IT WILL TAKE ABOUT 5 SECONDS
FOllD\I/ING CLICKING THE OK BUTTON BEFORE THE
CAPTURE INDIC6.TOR WILL APPEAR NEXT TO THE !:l3087S3'\2. Io~"
SELECTED CmJTROLLER N.6.ME IN THE CONTROLLER ~ 335393a1.he><
SELECTION LIST . /' ~ 33725ll1>.1.hel<
~
mJ Cancelj
• Controller Selection
~
FleJl.Ome: 1- I Qpen
FiIe$ ollYpe: IProgram Files (" he~) iJ C~
To download the software to the controller select
'BROWSE '. The dialogue 'CHOOSE PROGRAM
FILE NAME' box shown wi" appear. Highlight the
correct software to be downloaded.
Select 'SET UP CONTROLLER FOR
PROGRAMMING' to establish a communication link
between the computer and controller, dialogue box
(A) will appear. Follow the instructions and turn the
key to the ON position. Click OK on dialogue box (A)
and the arrow up/down symbol (B) will then appear
as shown on the controller selection window.
SM 8·10570 Issued 03·2001
SECT/ON 10010 7
( STEP 12 STEP 13
OOWNLOIID FILE IN FORMII liON
The selected download file contan, the f~ inlormalio"
,.» .
Omrmlo"tI tunl
'"""onlho_WihIl!>..-_....
1Xl ....... (8_~od ••• ~tllo";"!I"'IIIC....
CkI<,., 'OK' 1o wli-.....
D~Fk ~A"d
SoItw6!loV6IUon. 5.:W,O Cl<k"''t_I.~''Ibo ..og'''Cllthe''''''''OI«.
tQ.:I. Cc>1J.... download file roo MX8IlC/90CllOOC s.,ie. hodo"
and MX100111 01120113511501170 .or....act.. s ' !rnrll c-I
I 1"'110 " "'''' 101 D<IlOI3J/l UJ ....... hactOls with dell...
lith with ride conlrol feature, With the correct programme file highlighted in STEP
11, click 'PROGRAM DOWNLOAD' and the dialogue
box shown will appear. Click OK on the dialogue box.
STEP 14
Du",nlnm1 fuo1 EI
...€J P.AOliRAl<l>lING COMPlETED SUCCESSFULLY I
ThoVO\1l.,.fft .Itkh .......~I\.. beonN«."IU)I _ _.'ItO ..A.!Ie<tH<ero"'"'.
~ ,'"'
"./
lor?f When the software downloading is complete the
dialogue box shown will appear, click 'OK' on the
dialogue box. Turn the key to the OFF position and
To view the file information for the selected disconnect MC 2551 or MC 2563 from the hitch
programme, click 'Open' in the dialogue box shown in controller programming connector. Shut down the
STEP 11 and the dialogue box shown above will computer.
appear with the file information. Check the
programme file information and click 'OK' on the STEP 15
dialogue box.
Calibrate the Hitch System, refer to Section 10002,
NOTE: If the selected programme file information is and check the operation of the hitch. Check the hitch
correct for the controller, go to STEP 13. for Error Codes and correct as necessary.
NOTE: If the information is not correct, repeat STEP
11 and STEP 12. STEP 16
Install the lower right hand console side cover.
8M 8-10570 Issued 03-2001
, )
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