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The document is a repair manual for TS Series Tractors by New Holland, detailing general instructions, engine specifications, and various overhaul procedures. It includes sections on engine, cooling, lubrication, fuel systems, air cleaners, electric lift pumps, and injectors, with specific chapters dedicated to fault finding and special tools. Each section provides tightening torques, specifications, and operational descriptions necessary for maintenance and repair.

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0% found this document useful (0 votes)

42 views1,875 pages

NH 13

Uploaded by

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NEW

HOLLAND
Repair Manual -- TS Series Tractors

CONTENTS

GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1

ENGINE SECTION 10
Engine Overhaul Chapter 1
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cooling Chapter 2
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubrication Chapter 3
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

604.55.041.01 - 10-- 1998

Contents Continued:

Fuel General Chapter 4

Air Cleaners Chapter 5

Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electric Lift Pump Chapter 6
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injectors Chapter 7
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injection Pump Chapter 8
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump Removal, Timing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger Chapter 9
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

604.55.041.01 - 10-- 1998

Contents Continued:

Manifold Chapter 10
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CLUTCHES SECTION 18
Clutches Chapter 1
Page
Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Overhaul -- Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clutch Pilot Bearing and PTO Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Overhaul -- Hydraulic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TRANSMISSION SYSTEM SECTION 21

×16) Transmission
Electroshift (16× Chapter 1
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Finding, Calibrations, Pressure Testing and Limp Home . . . . . . . . . . . . . . . . . . . . . . 33
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
×12) Transmission
Synchro Command (12× Chapter 2
Page
Specifications and Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction to Overhauling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Installed -- Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission Removed -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transmission Components Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
×2) Transmission
Econoshift (8× Chapter 3
Page
Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear Shift Levers and Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Front End -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission -- Complete Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

604.55.041.01 - 10-- 1998

Battery Chapter 7
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Common Causes of Battery Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wiring Diagrams Chapter 8
Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump
Circuit 2 Transmission and EDC Processor (C128 Black Connector) -- Part 1
Circuit 3 Transmission and EDC Processor (C128 Black Connector) -- Part 2
Circuit 4 Transmission and EDC Processor (C127 Red Connector) -- Part 1
Circuit 5 Transmission and EDC Processor (C127 Red Connector) -- Part 2
Circuit 6 Instrument Clusters and associated sensors (C079)
Circuit 7 Instrument Clusters and associated sensors (C080)
Circuit 8 Electronic Instrument Cluster (C081)
Circuit 9 Four Wheel Drive and Differential Lock
Circuit 10 Power Take Off
Circuit 11 Transmission Circuits
Circuit 12 Electronic Draft Control
Circuit 13 Electronic Draft Control
Circuit 14 Indicator & Hazards
Circuit 15 Main Lights
Circuit 16 Work Lamps
Circuit 17 Wipers & Washers
Circuit 18 Air--Conditioning & Cab Heating
Circuit 19--21 Cab Accessories
Electroshift (16x16) System Diagram
Dual Command (24x24) System Diagram
Connectors and Harnesses Chapter 9
Page
Harnesses -- general layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Harness to harness connector location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Earth location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lighting harness (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine harness (emmissionized engines, all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission (Chassis) harness -- All 16x16 Electroshift models . . . . . . . . . . . . . . . . . . . 12
Transmission (Chassis) harness -- All 24x24 Dual Command models . . . . . . . . . . . . . . . 16
Cab (main rear) harness -- 16x16 Electroshift and 24x24 Dual Command . . . . . . . . . . . . 20

604.55.041.01 - 10-- 1998

Contents Continued:

Electrical Component Testing Chapter 10

Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. Thermostart Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. Handbrake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11. Low Transmission Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12. Oil Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13. 40"" C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
14. Low Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
15. Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
16. Load Sensing Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
17. Lift Lever Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
18. Lift Arm Cross Shaft Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
19. Electronic Draft Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
20. Electronic Draft Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Panel Connector Resistance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
21. PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
22. Transmission Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
23. Brake Pedal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
24. Forward/Reverse Dump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
25. 16x16 Transmission Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
26. Clutch Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
27. Clutch Pedal Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
28. PWM Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
29. Upshift/Downshift Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
30. Differential Lock Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
31. Differential Lock, PTO, Creep, 4WD & Dump Solenoids . . . . . . . . . . . . . . . . . . . . . . 42
32. Transmission Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
33. Transmission Status Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34. Multifunction Switch Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
35. Multifunction Switch Wiper/Wash Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Diagnostic ’H’ Routines Chapter 11
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16x16 Transmission ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12x12 Dual Command Transmission ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electronic Draft Control ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

604.55.041.01 - 10-- 1998

SECTION 00 -- GENERAL -- CHAPTER 1 1

GENERAL INSTRUCTIONS

IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by New Holland
authorised workshops. All instructions should be carefully observed and special equipment where indicated
should be used.
Anyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible for any damage caused.

NOTES FOR EQUIPMENT

Equipment which NEW HOLLAND proposes and shows in this manual is:
-- studied and designed expressly for use on NEW HOLLAND tractors;
-- necessary to make a reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working life.

NOTICES
The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat
oriented to the normal direction of movement of the tractor.

SAFETY RULES

PAY ATTENTION TO THIS SYMBOL

This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety
In this manual you will find this symbol together with the following key--words:
WARNING -- it gives warning about improper repair operations and potential
consequences affecting the service technician’s personal safety.
DANGER -- it gives specific warning about potential dangers for personal safety of the
operator or other persons directly or indirectly involved in the operation.

TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in A wise and careful service technician is the best
workshops are due from non--observance of some precautions against accidents.
essential rules and safety precautions.
Careful observance of this only basic precaution
The possibility that an accident might occur with any would be enough to avoid many severe accidents.
type of machines should not be disregarded, no DANGER: Never carry out any cleaning, lubrication
matter how well the machine in question was or maintenance operations when the engine is
designed and built. running.
604.55.041.00 -- 01 -- 1998
2 SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY RULES
Generalities ! Disconnect the batteries and label all controls to
warn that the tractor is being serviced. Block the
! Carefully follow specified repair and machine and all equipment which should be
maintenance procedures. raised.

! Never check or fill fuel tanks or batteries, nor use

starting liquid if you are smoking or near open
! Do not wear rings, wristwatches, jewels, flames as such fluids are flammable.
unbuttoned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open ! The fuel filling gun should always remain in
zips which could get caught on moving parts. Use contact with the filler neck. Maintain this contact
approved safety clothing such as anti--slipping until the fuel stops flowing into the tank to avoid
footwear, gloves, safety goggles, helmets, etc. possible sparks due to static electricity build--up.

! Wear safety glasses with side guards when

cleaning parts using compressed air.
! To transfer a failed tractor, use a trailer or a low
loading platform trolley if available.
! Damaged or frayed wires and chains are
unreliable. Do not use them for lifting or towing.

! To load and unload the machine from the

! Wear suitable protection such as approved eye
transportation means, select a flat area providing
protection, helmets, special clothing, gloves and
a firm support to the trailer or truck wheels. Firmly
footwear whenever welding. All persons
tie the machine to the truck or trailer platform and
standing in the vacinity of the welding process
block wheels as required by the transporter.
should wear approved eye protection. NEVER
LOOK AT THE WELDING ARC IF YOUR EYES
ARE NOT SUITABLY PROTECTED.

! Always use lifting equipment of appropriate

capacity to lift or move heavy components.
! Never carry out any repair on the machine if
someone is sitting on the operator’s seat, except
if they are qualified operators assisting in the
operation to be carried out.
! Chains should always be safely fastened.
Ensure that fastening device is strong enough to
hold the load foreseen. No persons should stand
near the fastening point.
! Never operate the machine or use attachments
from a place other than sitting at the operator’s
seat or at the side of the machine when operating
the fender switches. ! The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of
water or oil.
! Never carry out any operation on the machine
when the engine is running, except when
specifically indicated. Stop the engine and ! Never use gasoline, diesel oil or other flammable
ensure that all pressure is relieved from hydraulic liquids as cleaning agents. Use non--flammable
circuits before removing caps, covers, valves, non--toxic proprietary solvents.
etc.

! Do not pile up grease or oil soaked rags, as they

! All repair and maintenance operations should be constitute a great fire hazard. Always place them
carried out with the greatest care and attention. into a metal container.
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 3

START UP HYDRAULIC SYSTEMS

! Never run the engine in confined spaces which ! Some fluid coming out from a very small port can
are not equipped with adequate ventilation for be almost invisible and be strong enough to
exhaust gas extraction. penetrate the skin. For this reason, NEVER USE
YOUR HANDS TO CHECK FOR LEAKS, but use
a piece of cardboard or a piece of wood for this
purpose. If any fluid is injected into the skin, seek
! Never bring your head, body, arms, legs, feet,
medical aid immediately. Lack of immediate
hands, fingers near fans or rotating belts.
medical attention may result in serious infections
or dermatitis.

! Always take system pressure readings using the

appropriate gauges.

ENGINE
! Always loosen the radiator cap very slowly before
removing it to allow pressure in the system to WHEELS AND TYRES
dissipate. Coolant should be topped up only when ! Check that the tyres are correctly inflated at the
the engine is stopped. pressure specified by the manufacturer.
Periodically check for possible damage to the
rims and tyres.
! Do not fill up fuel tank when the engine is running.
! Stay at the tyre side when inflating.
! Never adjust the fuel injection pump when the
tractor is moving. ! Check the pressure only when the tractor is
unloaded and tyres are cold to avoid wrong
readings due to over--pressure.
! Never lubricate the tractor when the engine is
running. ! Never cut, nor weld a rim with the inflated tyre
assembled.

! To remove the wheels, block both front and rear

tractor wheels. Raise the tractor and install safe
and stable supports under the tractor in
accordance with regulations in force.
ELECTRICAL SYSTEMS
! Deflate the tyre before removing any object
! If it is necessary to use auxiliary batteries, cables caught into the tyre tread.
must be connected at both sides as follows: (+) to
(+) and (--) to (--). Avoid short--circuiting the
terminals. GAS RELEASED FROM BATTERIES ! Never inflate tyres using flammable gases as they
IS HIGHLY FLAMMABLE. During charging, may originate explosions and cause injuries to
leave the battery compartment uncovered to bystanders.
improve ventilation. Avoid sparks or flames near
the battery area. Do no smoke.

! Do not charge batteries in confined spaces.

REMOVAL AND INSTALLATION
! Lift and handle all heavy components using lifting
! Always disconnect the batteries before equipment of adequate capacity. Ensure that
performing any type of service on the electrical parts are supported by appropriate slings and
system. hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
604.55.041.00 -- 01 -- 1998
4 SECTION 00 -- GENERAL -- CHAPTER 1

HEALTH AND SAFETY

Contents Page
HEALTH AND SAFETY PRECAUTIONS 4
ACIDS AND ALKALIS 5
ADHESIVES AND SEALERS -- see Fire 5
ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. 5
ARC WELDING -- see Welding. 6
BATTERY ACIDS -- see Acids and Alkalis. 6
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. 6
BRAZING -- see Welding. 6
CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. 6
DO’S 6
DO NOTS 7
CORROSION PROTECTION MATERIALS -- see Solvents, Fire. 7
DUSTS 7
ELECTRIC SHOCK 7
EXHAUST FUMES 8
FIBRE INSULATION -- see Dusts. 8
FIRE -- see Welding, Foams, Legal Aspects. 8
FIRST AID 8
FOAMS -- Polyurethane -- see Fire. 8
FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. 9
GAS CYLINDERS -- see Fire. 9
GENERAL WORKSHOP TOOLS AND EQUIPMENT 10
LEGAL ASPECTS 10
LUBRICANTS AND GREASES 10
PAINTS -- see Solvents and Chemical Materials -- General. 11
SOLDER -- see Welding. 11
SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. 12
SUSPENDED LOADS 12
WELDING -- see Fire, Electric Shock, Gas Cylinders. 12

HEALTH AND SAFETY PRECAUTIONS associated with them. The precautions

necessary to avoid these hazards are identified.
Many of the procedures associated with vehicle
maintenance and repair involve physical The list is not exhaustive and all operations and
hazards or other risks to health. This section procedures and the handling of materials,
lists, alphabetically, some of these hazardous should be carried out with health and safety in
operations and the materials and equipment mind.
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 5

ACIDS AND ALKALIS -- see Battery acids, e.g. of toxic or harmful chemicals through the skin.
caustic soda, sulphuric acid. Splashes can damage the eyes.

Used in batteries and cleaning materials. Provide adequate ventilation and avoid skin and
eye contact. Follow manufacturers instructions.
Irritant and corrosive to the skin, eyes, nose and
throat. Causes burns. Anaerobic, Cyanoacrylate and other Acrylic
Adhesives
Avoid splashes to the skin, eyes and clothing.
Wear suitable protective gloves and goggles. Many are irritant, sensitizing or harmful to the
Can destroy oridnary protective clothing. Do not skin. Some are eye irritants.
breathe mists.
Skin and eye contact should be avoided and the
Ensure access to water and soap is readily manufacturers instructions followed.
available for splashing accidents.
Cyanoacrylate adhesives (super--glues) must
not contact the skin or eyes. If skin or eye tissue
ADHESIVES AND SEALERS -- see Fire is bonded cover with a clean moist pad and get
medical attention. do not attempt to pull tissue
apart. Use in well ventilated areas as vapours
Highly Flammable, Flammable, combustible.
can cause irritation of the nose and eyes.

Generally should be stored in “No Smoking” For two--pack systems see Resin based
areas; cleanliness and tidiness in use should be adhesives/sealers.
observed, e.g. disposable paper covering
benches; should be dispensed from applicators
where possible; containers, including Isocyanate (Polyurethane) Adhesives/
secondary containers, should be labelled. Sealers -- see Resin based Adhesives.

Solvent based Adhesives/Sealers -- See Individuals suffering from asthma or respiratory

Solvents. allergies should not work with or near these
materials as sensitivity reactions can occur.
Follow manufacturers instructions.
Any spraying should preferably be carried out in
exhaust ventilated booths removing vapours
Water based Adhesives/Sealers and spray droplets from the breathing zone.
Individuals working with spray applications
Those based on polymer emulsions and rubber should wear supplied air respirators.
lattices may contain small amounts of volatile
toxic and harmful chemicals. Skin and eye ANTIFREEZE -- see Fire, Solvents e.g.
contact should be avoided and adequate Isopropanol, Ethylene Glycol, Methanol.
ventilation provided during use.
Highly Flammable, Flammable, Combustible.
Follow manufacturers instructions.
Used in vehicle coolant systems, brake air
Resin based Adhesives/Sealers -- e.g. pressure systems, screenwash solutions.
epoxide and formaldehyde resin based.
Vapours given off from coolant antifreeze
Mixing should only be carried out in well (glycol) arise only when heated.
ventilated areas as harmful or toxic volatile
chemicals may be released.
Antifreeze may be absorbed through the skin in
toxic or harmful quantities. Antifreeze if
Skin contact with uncured resins and hardeners swallowed is fatal and medical attention must be
can result in irritation; dermatitis and absorption found immediately.
604.55.041.00 -- 01 -- 1998
6 SECTION 00 -- GENERAL -- CHAPTER 1

ARC WELDING -- see Welding. superficial; life threatening; or may reduce

life--expectancy.

BATTERY ACIDS -- see Acids and Alkalis.

DO’S

Gases released during charging are explosive.

Never use naked flames or allow sparks near
charging or recently charged batteries. Do remove chemical materials from the skin
and clothing as soon as practicable after soiling.
Change heavily soiled clothing and have it
cleaned.
BRAKE AND CLUTCH FLUIDS
(Polyalkylene Glycols) -- see Fire.

Do carefully read and observe hazard and

precaution warnings given on material
Combustible. containers (labels) and in any accompanying
leaflets, poster or other instructions. Material
health and safety data sheets can be obtained
from Manufacturers.
Splashes to the skin and eyes are slightly
irritating. Avoid skin and eye contact as far as
possible. Inhalation of vapour hazards do not
arise at ambient temperatures because of the
Do organise work practices and protective
very low vapour pressure.
clothing to avoid soiling of the skin and eyes;
breathing vapours/aerosols/dusts/fumes;
inadequate container labelling; fire and
explosion hazards.
BRAZING -- see Welding.

Do wash before job breaks; before eating,

smoking, drinking or using toilet facilities when
CHEMICAL MATERIALS -- GENERAL -- see handling chemical materials.
Legal Aspects.

Do keep work areas clean, uncluttered and free

Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids, of spills.
antifreeze, brake fluids, oils and grease should
always be used with caution and stored and
handled with care. They may be toxic, harmful,
corrosive, irritant or highly inflammable and give Do store according to national and local
rise to hazardous fumes and dusts. regulations.

The effects of excessive exposure to chemicals

may be immediate or delayed; briefly Do keep chemical materials out of reach of
experienced or permanent; cumulative; children.
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 7

DO NOTS conditions of adequate ventilation and not in

confined spaces.
Do Not mix chemical materials except under the
manufacturers instructions; some chemicals Cutting -- see Welding.
can form other toxic or harmful chemicals; give
off toxic or harmful fumes; be explosive when De--Waxing -- see Solvents and Fuels
mixed together. (Kerosene).

Do Not spray chemical materials, particularly DUSTS

those based on solvents, in confined spaces
e.g. when people are inside a vehicle. Powder, dusts or clouds may be irritant, harmful
or toxic. Avoid breathing dusts from powdery
Do Not apply heat or flame to chemical chemical materials or those arising from dry
materials except under the manufacturers’ abrasion operations. Wear respiratory
instructions. Some are highly inflammable and protection if ventilation is inadequate.
some may release toxic or harmful fumes.
ELECTRIC SHOCK
Do Not leave containers open. Fumes given off
can build up to toxic, harmful or explosive Electric shocks can result from the use of faulty
concentrations. Some fumes are heavier than electrical equipment or from the misuse of
air and will accumulate in confined areas, pits equipment even in good condition.
etc.
Ensure that electrical equipment is maintained
Do Not transfer chemical materials to in good condition and frequently tested.
unlabelled containers.
Ensure that flexes, cables, plugs and sockets
are not frayed, kinked, cut, cracked or otherwise
Do Not clean hands or clothing with chemical
damaged.
materials. Chemicals, particularly solvents and
fuels will dry the skin and may cause irritation
with dermatitis. Some can be absorbed through Ensure that electric equipment is protected by
the skin in toxic or harmful quantities. the correct rated fuse.

Never misuse electrical equipment and never

Do Not use emptied containers for other use equipment which is in any way faulty. The
materials, except when they have been cleaned results could be fatal.
under supervised conditions.
Use reduced voltage equipment (110 volt) for
Do Not sniff or smell chemical materials. Brief inspection and working lights where possible.
exposure to high concentrations of fumes can
be toxic or harmful. Ensure that the cables of mobile electrical
equipment cannot get trapped and damaged,
Clutch Fluids -- see Brake and Clutch Fluids. such as in a vehicle hoist.

Clutch Linings and Pads -- see Brake and Use air operated mobile equipment where
Clutch Linings and Pads. possible in preference to electrical equipment.

In cases of electrocution:--
CORROSION PROTECTION MATERIALS --
see Solvents, Fire.
-- switch off electricity before approaching victim

Highly flammable, flammable. -- if this is not possible, push or drag victim from
source of electricity using dry non--conductive
These materials are varied and the material
manufacturers instructions should be followed.
They may contain solvents, resins, petroleum -- commence resuscitation if trained to do so
products etc. Skin and eye contact should be
avoided. They should only be sprayed in -- SUMMON MEDICAL ASSISTANCE
604.55.041.00 -- 01 -- 1998
8 SECTION 00 -- GENERAL -- CHAPTER 1

EXHAUST FUMES Splashes in the eye should be flushed with clean

water for at least ten minutes.
These contain asphyxiating, harmful and toxic
chemicals and particles such as carbon oxides, Soiled skin should be washed with soap and
nitrogen oxides, aldehydes, lead and aromatic water.
hydrocarbons. Engines should only be run
under conditions of adequate extraction or
general ventilation and not in confined spaces. Inhalation affected individuals should be
removed to fresh air immediately.
Gasolene (Petrol) Engine
If swallowed or if effects persist consult a doctor
There may not be adequate warning properties with information (label) on material used.
of odour or irritation before immediate and
delayed toxic or harmful effects arise.
Do not induce vomiting (unless indicated by
manufacturer).
Diesel Engine

Soot, discomfort and irritation usually give FOAMS -- Polyurethane -- see Fire.
adquate warning of hazardous fume
concentrations.
Used in sound and noise insulation. Cured
foams used in seat and trim cushioning.
FIBRE INSULATION -- see Dusts.

Used in noise and sound insulation. Follow manufacturers instructions.

The fibrous nature of surfaces and cut edges Unreacted components are irritating and may
can cause skin irritation. This is usually a be harmful to the skin and eyes. Wear gloves
physical and not a chemical effect. and goggles.

Precautions should be taken to avoid excessive

Individuals with chronic respiratory diseases,
skin contact through careful organisation of
asthma, bronchial medical problems or histories
work practices and the use of gloves.
of allergic diseases should not work with or near
uncured materials.
FIRE -- see Welding, Foams, Legal Aspects.
The components, vapours, spray mists can
Many of the materials found on or associated cause direct irritation, sensitivity reactions and
with the repair of vehicles are highly flammable. may be toxic or harmful.
Some give off toxic or harmful fumes if burnt.

Observe strict fire safety when storing and Vapours and spray mists must not be breathed.
handling flammable materials or solvents, These materials must be applied with adequate
particularly near electrical equipment or welding ventilation and respiratory protection. Do not
processes. remove respirator immediately after spraying,
wait until vapour/ mists have cleared.
Ensure before using electrical or welding
equipment but that there is no fire hazard Burning of the uncured components and the
present. cured foams can generate toxic and harmful
fumes.
Have a suitable fire extinguisher available when
using welding or heating equipment.
Smoking, open flames or the use of electrical
equipment during foaming operations and until
FIRST AID vapours/mists have cleared should not be
allowed. Any heat cutting of cured foams or
Apart form meeting any legal requirements it is partially cured foams should be conducted with
desirable for someone in the workshop to be extraction ventilation (see Body Section 44
trained in first aid procedures. Legal and Safety Aspects).
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 9

FUELS -- see Fire, Legal Aspects, Chemicals Irritation of the mouth and throat may result from
-- General, Solvents. swallowing. The main hazard from swallowing
arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause
Used as fuels and cleaning agents. irritation or dermatitis. Splashes in the eye may
be slightly irritating.
Gasolene (Petrol).
In normal circumstances the low volatility does
not give rise to harmful vapours. Exposure to
Highly flammable. mists and vapours from kerosene at elevated
temperatures should be avoided (mists may
Swallowing can result in mouth and throat arise in de--waxing). Avoid skin and eye contact
irritation and absorption from the stomach can and ensure there is adequate ventilation.
result in drowsiness and unconsciousness.
Small amounts can be fatal to children. Gas--Oil (Diesel Fuel) -- see Fuels (Kerosene).
Aspiration of liquid into the lungs, e.g. through
vomiting, is a very serious hazard.
Combustible.

Gasolene dries the skin and can cause irritation

and dermatitis on prolonged or repeated Gross or prolonged skin contact with high
contact. Liquid in the eye causes severe boiling gas oils may also cause serious skin
smarting. disorders including skin cancer.

Motor gasolene may contain appreciable GAS CYLINDERS -- see Fire.

quantities of benzene, which is toxic upon
inhalation and the concentrations of gasolene
vapours must be kept very low. High Gases such as oxygen, acetylene, carbon
concentrations will cause eye, nose and throat dioxide, argon and propane are normally stored
irritation, nausea, headache, depression and in cylinders at pressures of up to 2000 lb/sq. in.
symptoms of drunkeness. Very high (13,790 kn/m2) and great care should be taken
concentrations will result in rapid loss of in handling these cylinders to avoid mechanical
consciousness. damage to them or to the valve gear attached.
The contents of each cylinder should be clearly
identified by appropriate markings.
Ensure there is adequate ventilation when
handling and using gasolene. Great care must
be taken to avoid the serious consequences of Cylinders should be stored in well ventilated
inhalation in the event of vapour build up arising enclosures, and protected from ice and snow, or
from spillages in confined spaces. direct sunlight. Fuel gases (e.g. acetylene and
propane) should not be stored in close proximity
to oxygen cylinders.
Special precautions apply to cleaning and
maintenance operations on gasolene storage
Care should be exercised to prevent leaks from
tanks.
gas cylinders and lines, and to avoid sources of
ignition.
Gasolene should not be used as a cleaning
agent. It must not be siphoned by mouth. Only trained personnel should undertake work
involving gas cylinders.
Kerosene (Paraffin)
Gases -- see Gas Cylinders.
Used also as heating fuel, solvent and cleaning
agent. Gas Sheilded Welding -- see Welding.

Flammable. Gas Welding -- see Welding.

604.55.041.00 -- 01 -- 1998
10 SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL WORKSHOP TOOLS AND " The Factories Act (1961).

EQUIPMENT
" The Asbestos Regulations (1969).
It is essential that all tools and equipment are
maintained in good condition and the correct
" Highly Flammable Liquids and Liquified
safety equipment used where required.
Petroleum Gases Regulations (1972).

Never use tools or equipment for any purpose

other than that for which they were designed. " Deposit of Poisonous Waste Act (1972).

Never overload equipment such as hoists, " Control of Pollution Act (1974).
jacks, axle and chassis stands or lifting slings.
Damage caused by overloading is not always
" Health and Safety at Work Act (1974).
immediately apparent and may result in a fatal
failure the next time that the equipment is used.
" The Packaging and Labelling of Dangerous
Do not use damaged or defective tools or Substances Regulations (1978).
equipment, particularly high speed equipment
such as grinding wheels. A damaged grinding " Control of Lead Regulations (1981).
wheel can disintegrate without warning and
cause serious injury.
Workshops should be familiar, in detail, with
these and associated laws and regulations.
Wear suitable eye protection when using Consult local factory inspectorate if in any
grinding, chiselling or sand blasting equipment. doubt.

Wear a suitable breathing mask when using

sand blasting equipment, working with asbestos LUBRICANTS AND GREASES
based materials or using spraying equipment.
Avoid all prolonged and repeated contact with
Glues -- see Adhesives and Sealers. mineral oils, especially used oils. Used oils
contaminated during service (e.g. routine
service change sump oils) are more irritating
High Pressure Air, Lubrication and Oil Test and more likely to cause serious effects
Equipment -- see Lubricants and Greases. including skin cancer in the event of gross and
prolonged skin contact.
Always keep high pressure equipment in good
condition and regularly maintained, particularly Wash skin thoroughly after work involving oil.
at joints and unions. Proprietary hand cleaners may be of value
provided they can be removed from the skin with
water. Do not use petrol, paraffin or other
Never direct a high pressure nozzle at the skin solvents to remove oil from the skin.
as the fluid may penetrate to the underlying
tissue etc. and cause serious injury.
Lubricants and greases may be slightly irritating
to the eyes.
LEGAL ASPECTS
Repeated or prolonged skin contact should be
avoided by wearing protective clothing if
Many laws and regulations make requirements necessary. Particular care should be taken with
relating to health and safety in the use of used oils and greases containing lead. Do not
materials and equipment in workshops. Some allow work clothing to be contaminated with oil.
of these laws which apply in the U.K. are listed. Dry clean or launder such clothing at regular
Similar laws exist for other territories:-- intervals. Discard oil soaked shoes.
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 11

Do not employ used engine oils as lubricants or respiratory protection. Those doing small scale
for any application where appreciable skin repair work in the open shop should wear
contact is likely to occur. Used oils may only be supplied air respirators.
disposed of in accordance with local
regulations, e.g. in the U.K., the Control of
Pollution Act. Paint Thinners -- see Solvents.

There are publications describing the problems Petrol -- see Fuels (Gasolene).
and advising on precautionary measures. For
the U.K. these include:
Pressurised Equipment -- see High Pressure
Air, Lubrication and Oil Test Equipment.

SHW 295: Effects of mineral oil on the

skin Resistance Welding -- see Welding.
SHW 295A: Cancer of the skin caused by
oil
SHW 397: Cautionary notice: Effects of Sealers -- see Adhesives and Sealers.
mineral oil on the skin

SOLDER -- see Welding.

Noise Insulation Materials -- see Foams, Fibre
Insulation.
Solders are mixtures of metals such that the
melting point of the mixture is below that of the
constituent metals (normally lead and tin).
PAINTS -- see Solvents and Chemical Solder application does not normally give rise to
Materials -- General. toxic lead fumes, provided a gas/air flame is
used. Oxy--acetylene flames should not be
used, as they are much hotter and will cause
lead fumes to be evolved.
Highly Flammable, Flammable.
Some fumes may be produced by the
application of any flame to surfaces coated with
One Pack. Can contain harmful or toxic grease etc. and inhalation of these should be
pigments, driers and other components as well avoided.
as solvents. Spraying should only be carried out
with adequate ventilation.
Removal of excess solder should be
undertaken with care, to ensure that fine lead
dust is not produced, which can give toxic
Two Pack. Can also contain harmful and toxic effects if inhaled. Respiratory protection may be
unreacted resins and resin hardening agents. necessary.
The manufacturers instructions should be
followed and the section of page 05--2 on resin
based adhesives, isocyanate containing
Adhesives and Foams should be consulted. Solder spillage and filing should be collected
and removed promptly to prevent general air
contamination by lead.

Spraying should preferably be carried out in

exhausted ventilated booths removing vapour High standards of personal hygiene are
and spray mists from the breathing zone. necessary in order to avoid indigestion of lead or
Individuals working in booths should wear inhalation of solder dust from clothing.
604.55.041.00 -- 01 -- 1998
12 SECTION 00 -- GENERAL -- CHAPTER 1

SOLVENTS -- see Chemical Materials -- keep containers tightly sealed. Do not use in
General Fuels (Kerosene), Fire. confined spaces.

When the spraying material contains solvents,

e.g. Acetone, white spirit, toluene, xylene, e.g. paints, adhesives, coatings, use extraction
trichlorethane. ventilation or personal respiratory protection in
the absence of adequate general ventilation.

Used in cleaning materials, de--waxing, paints, Do not apply heat or flame except under specific
plastics, resins, thinners etc. and detailed manufacturers instructions.

Highly Inflammable, Flammable. Sound Insulation -- see Fibre Insulation,

Foams.

Skin contact will degrease the skin and may Spot Welding -- see Welding.
result in irritation and dematitis following
repeated or prolonged contact. Some can be
absorbed through the skin in toxic or harmful
quantities. SUSPENDED LOADS.

There is always a danger when loads are lifted

Splashes in the eye may cause severe irritation or suspended. Never work under an
and could lead to loss of vision. unsupported suspended or raised load, e.g.
jacked up vehicle, suspended engine, etc.

Brief exposure to high concentrations of

vapours or mists will cause eye and throat Always ensure that lifting equipment such as
irritation, drowziness, dizziness, headaches jacks, hoists, axle stands, slings, etc. are
and in the worst circumstances, adequate and suitable for the job, in good
unconsciousness. condition and regularly maintained.

Never improvise lifting tackle.

Repeated or prolonged exposures to excessive
but lower concentrations of vapours or mists, for
which there might not be adequate warning Underseal -- see Corrosion Protection.
indications, can cause more serious toxic or
harmful effects.
WELDING -- see Fire, Electric Shock, Gas
Cylinders.
Aspiration into the lungs (e.g. through vomiting)
is the most serious consequence of swallowing.
Welding processes include Resistance Welding
(Spot Welding), Arc Welding and Gas Welding.
Avoid splashes to the skin, eyes and clothing.
Wear protective gloves, goggles and clothing if
necessary. Resistance Welding

This process may cause particles of molten

Ensure good ventilation when in use, avoid metal to be emitted at high velocity and the eyes
breathing fumes, vapours and spray mists and and skin must be protected.
604.55.041.00 -- 01 -- 1998
SECTION 00 -- GENERAL -- CHAPTER 1 13

Arc Welding prevent leakage of these gases, with

consequent risk of fire and explosion.
This process emits a high level of ultraviolet
radiation which may cause eye and skin burns to The process will produce metal spatter and eye
the welder and to other persons nearby. and skin protection is necessary.
Gas--shielded welding processes are
particularly hazardous in this respect. Personal The flame is bright and eye protection should be
protection must be worn, and screens used to used, but the ultra--violet emission is much less
shield other people. than that from arc welding, and lighter filters may
be used.
Metal spatter will also occur and appropriate
The process itself produces few toxic fumes, but
eye and skin protection is necessary.
such fumes and gases may be produced from
coatings on the work, particularly during cutting
The heat of the welding arc will produce fumes
away of damaged body parts and inhalation of
and gases from the metals being welded and
the fumes should be avoided.
from any applied coatings or contamination on
the surfaces being worked on. These gases and In brazing, toxic fumes may be evolved from the
fumes may be toxic and inhalation should metals in the brazing rod, and a severe hazard
always be avoided. The use of extraction may arise if brazing rods containing cadmium
ventilation to remove the fumes from the are used. In this event particular care must be
working area may be necessary, particularly in taken to avoid inhalation of fumes and expert
cases where the general ventilation is poor, or advice may be required.
where considerable welding work is anticipated.
In extreme cases where adequate ventilation SPECIAL PRECAUTIONS MUST BE TAKEN
cannot be provided, supplied air respirators BEFORE ANY WELDING OR CUTTING
may be necessary. TAKES PLACE ON VESSELS WHICH HAVE
CONTAINED COMBUSTIBLE MATERIALS,
Gas Welding E.G. BOILING OR STEAMING OUT OF FUEL
TANKS.
Oxy--acetylene torches may be used for welding
and cutting and special care must be taken to White Spirit -- see Solvents.

604.55.041.00 -- 01 -- 1998
14 SECTION 00 -- GENERAL -- CHAPTER 1

604.55.041.00 -- 01 -- 1998
SECTION 10 - ENGINE - CHAPTER 1 1

SECTION 10 - ENGINE
Chapter 1 - Engine Overhaul
CONTENTS
Section Description Page

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SPECIFICATIONS
TS80 TS90 TS90 TS100 TSS110
Model PS N/A N/A N/A TURBO TURBO
( T=Turbocharged )
Emissionised NO NO YES YES YES
No of Cylinders 4 4 4 4 4
(450 NF) (450 NA) (450 NE) (450 T/PF) (450 T/PD)
Bore mm 111.8 111.8 111.8 111.8 111.8
ins 4.4 4.4 4.4 4.4 4.4
Stroke mm 127.0 127.0 127.0 127.0 127.0
ins 5.0 5.0 5.0 5.0 5.0
Displacement cu cm 4987 4987 4987 4987 4987
cu in 304 304 304 304 304
Compression Ratio 17:5-1 17:5-1 17:5-1 17:5-1 17:5-1
Cylinder Bore Compres- bar 25.5 25.5 25.5 25.5 25.5
sion at cranking speed of
200 R.P.M lbs in2 375 375 375 375 375
Firing Order 1342 1342 1342 1342 1342
Idle Speed Revs/min ± 50 750 750 750 750 750
Maximum no Load Speed 2320 2320 2320 2320 2320
Revs/min
Rated Engine Speed 2170 2170 2170 2170 2070

604.55.041.00 01 -1998
2 SECTION 10 - ENGINE - CHAPTER 1

CYLINDER BLOCK
Taper of Cylinder Bore 0.025mm (0.001 in) Repair Limit
0.127mm (0.005 in) Wear Limit

Cylinder Bore out of Round 0.03mm (0.0015 in) Repair Limit

0.127mm (0.005 in) Wear Limit

Cylinder Bore Diameters 111.778-1 11.841mm (4.4007-4.4032 in)

Rear Oil Seal Bore Diameter 140.77-140.87mm (5.542-5.546 in)

Block to Head Surface Flatness 0.08mm (0.003 in) in any 152mm (6 in)
0.03mm (0.001 in) in any 25.40mm (1 in)
CYLINDER HEAD
Valve Guide Bore Diameter 9.469-9.495mm (0.3728-0.3738 in)

Head to Block Surface Flatness 0.03mm (0.001 in) in any 25.4mm (1 in),
or 0.127mm (0.005in) overall limit
EXHAUST VALVES
Face Angle 44°15’-44 °30’ Relative to the Head of Valve

Stem Diameter Std :9.401-9.421mm (0.3701-0.3709 in)

0.076mm (0.003 in)
Oversize :9.477-9.497mm (0.3731-0.3739 in)
0.38mm (0.015 in)
Oversize :9.781-9.802mm (0.3851-0.3859 in)
0.030 in (0.76mm)
Oversize :10.163-10.183mm (0.4001-0.4009 in)

Head Diameter 42.88-43.13mm (1.688-1.698 in)

Stem to Guide Clearance 0.048-0.094mm (0.0019-0.0037 in)

Lash Clearance (Cold) 0.43-0.53mm (0.017-0.021 in)

INTAKE VALVES
Face Angle 29°15’-29 °30’ Relative to Head of Valve

Stem Diameter Std :9.426-9.446mm (0.3711-0.3719 in)

0.076mm (0.003 in)
Oversize :9.502-9.522mm (0.3741-0.3749 in)
0.381mm (0.015 in)
Oversize :9.807-9.827mm (0.3861-0.3869 in)
0.762mm (0.030 in)
Oversize :10.188-10.208mm (0.4011-0.4019 in)

Head Diameter 47.37-47.63mm (1.865-1.875 in)

Stem to Guide Clearance 0.023-0.069mm (0.0009-0.0027 in)

Lash Clearance (Cold) 0.36-0.46mm (0.014-0.018 in)

VALVE SPRINGS
Number per Valve 1

Free Length 60.7mm (2.39 in)

Length, loaded at 27.7-31.3kg (61.69 lb) 48.26mm (1.900 in)
Length, loaded at 61-69kg (135-153 lb) 35.69mm (1.405 in)

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 3

VALVE TIMING
Intake Opening 12° Before Top Dead Centre

Intake Closing 38° After Bottom Dead Centre

Exhaust Opening 48° Before Bottom Dead Centre

Exhaust Closing 12° After Top Dead Centre

VALVE INSERTS

Exhaust Valve Insert Intake Valve Seat Insert

Insert Oversize Counter bore Diameter Counter bore Diameter
in Cylinder Head in Cylinder Head

0.254mm (0.010 in) 44.17-44.20mm (1.739-1.740 in) 50.01-50.04mm (1.969-1.970 in)

0.508mm (0.020 in) 44.42-44.45mm (1.749-1.750 in) 50.27-50.29mm (1.979-1.980 in)

0.762mm (0.030 in) 44.68-44.70mm (1.759-1.760 in) 50.52-50.55mm (1.989-1.990 in)

VALVE SEATS
Exhaust Valve Seat Angle 45°00’ - 45°30’

Intake Valve Seat Angle 30°00’ - 30°30’

Interference Valve Face Angle

to Valve Seat Angle 0°30’ - 1°15’

Concentricity With Guide

Diameter 0.051mm (0.002 in) Total Indicator Reading Max

Seat Width Exhaust Valve 1.8-2.3mm (0.072-0.092 in)

Intake Valve 1.9-2.5mm (0.078-0.098 in)
CAMSHAFT IDLER GEAR
Number of teeth 47

End Play 0.076-0.35mm (0.003-0.014 in)

Bushing Inside Diameter 50.813-50.838mm (2.005-2.0015 in)

Adaptor Outside Diameter 50.762-50.775mm (1.9985-1.9990 in)

Backlash with Crankshaft Gear 0.15-0.46mm (0.006-0.018 in)

Backlash with Camshaft Gear 0.025-0.381mm (0.001-0. 015 in)

Backlash with Fuel Injection Pump 0.10-0.15mm (0.004-0.006 in)

CAMSHAFT GEAR
Number of Teeth 52

Timing Gear Backlash 0.025-0.38mm (0.001-0.015 in)

604.55.041.00 01 -1998
4 SECTION 10 - ENGINE - CHAPTER 1

ROCKER ARM SHAFT

Shaft Diameter 25.40-25.43mm (1.000-1.001 in)

Shaft Support Internal Diameter 25.45-25.20mm (1.002-1.004 in)

ROCKER ARM
Inside Diameter 25.48-25.50mm (1.003-1.004 in)
TAPPETS
Clearance to Bore 0.015-0.053mm (0.0006-0.0021 in)

Tappet Diameter 25.118-25.130mm (0.9889-0.9894 in)

Tappet Bore Diameter 25.15-25.17mm (0.9900-0.9910 in)

CAMSHAFT
Bearing Journal Diameter 60.693-60.719mm (2.3895-2.3905 in)

Bearing Clearance 0.025-0.076mm (0.0010-0.0030 in)

End Play 0.051-0.18mm (0.0020-0.0070 in)

CONNECTING RODS
Small End Bushing (Internal Diameter)
Normally Aspirated 38.113-38.120mm (1.5005-1.5008 in)
Turbocharged 41.288-41.259mm (1.6255-1.6258 in)

Clearance Bushing to Piston Pin 0.013-0.025mm (0.0005-0.0010 in)

Side Float 0.13-0.33mm (0.0050-0.0130 in)

Maximum Twist 0.30mm (0.0120 in)

Maximum Bend 0.10mm (0.0040 in)

PISTON PIN
Outside Diameter
Normally Aspirated Engine 38.095-38.100mm (1.4998-1.5000 in)
Turbocharged Engine 41.270-41.275mm (1.6248-1.6250 in)
PISTONS
Skirt to Cylinder Clearance
Naturally Aspirated 0.140-0.171mm (0.0055-0.0067 in) - New, unrun engines
0.140-0.28mm (0.0055-0.011 in) - Run engines

Skirt to Cylinder Clearance

Turbocharged 0.162-0.188mm (0.0064-0.0074 in) - New, unrun engines
0.162-0.28mm (0.0064-0.011 in) - Run engines

Taper (Out of Round) 0.063-0.127mm (0.0025-0.0050 in)

Grading Diameter (at Right Angles to 111.64-1 11.74mm (4.3951-4.3991 in)

Piston Pin) 0.0127mm (in increments of 0.0005 in)

Piston Pin Clearance 0.0030-0.0140mm (0.00012-0.00055 in)

at 21°C (70°F)

Piston Crown to Block Face,

Naturally Aspirated 0.28-0.58mm (0.011-0.023 in)
Turbocharged 0.0-0.3mm (0.0-0.012 in)

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 5

PISTON RINGS
Compression rings,
Number and Location 2 off -1st and 2nd from the top of the piston
Naturally Aspirated,
Top Compression Ring Parallel Sides-Inner Chamfer or no Chamfer
2nd Compression Ring Straight Face-Inner Step
Turbocharged,
Top Compression Ring Keystone Tapered With Internal Chamfer to Top
2nd Compression Ring Straight Face-Inner Step

Oil Control,
Number and Location 1 off,-Directly above the Piston Pin,
Type Slotted With Expander

Side Face Clearance To Ring Groove,

Top Compression Ring 0.112-0.155mm (0.0044-0.0061 in)
2nd Compression Ring 0.099-0.142mm (0.0039-0.0056 in)
Oil Control Ring 0.061-0.104mm (0.0024-0.0041 in)

Gap Width,
Top Compression Ring 0.38-0.84mm (0.015-0.033 in)
2nd Compression Ring 0.66-1.12mm (0.026-0.044 in)
Oil Control Ring 0.38-0.84mm (0.015-0.033 in)
CRANKSHAFT
Main Journal Diameter- 85.631mm (3.3713 in) 85.656mm (3.3723 in)

Main Journal Length

(except thrust, rear, or intermediate) 36.96-37.21mm (1.455-1.465 in)

Main Journal Wear Limits 0.127mm (0.005 in) Maximum

Main and Crankpin Fillet Radius 3.048-3.556mm (0.12-0.14 in)

Thrust Bearing Journal Length 37.06-37.1 1mm (1.459-1.461 in)

Intermediate Bearing Journal Length 36.96-37.21mm (1.455-1.465 in)

Rear Bearing Journal Length 37.97-38.48mm (1.495-1.515 in)

Crankpin Journal Length 42.62-42.72mm (1.678-1.682 in)

Crankpin Diameter 69.840-69.850mm (2.749-2.7500 in)

End Play 0.10-0.20mm (0.004-0.008 in)

Crankpin Out of Round 0.005mm (0.0002 in) Total Indicator Reading

Taper Surface Parallel to Centre Line

of Main Journal 0.005mm (0.0002 in)

Crankshaft Rear Oil Seal Journal Diameter 122.12-122.28mm (4.808-4.814 in)

Crankshaft Pulley Journal Diameter 44.45-44.48mm (1.750-1.751 in)

Crankshaft Timing Gear Journal Diameter 46.23-46.25mm (1.820-1.821 in)

Crankshaft Flange Runout 0.038mm (0.0015 in) Maximum

604.55.041.00 01 -1998
6 SECTION 10 - ENGINE - CHAPTER 1

CRANKSHAFT DRIVE GEAR

Number of teeth 26
MAIN BEARING
Liner length (except thrust liner) 27.94-28.19mm (1.10-1.1 1 in)
Liner Length (Thrust Liner) 39.91-39.96mm (1.453-1.455 in)
Vertical Assembled Bearing Clearance 0.055-0.1 17mm (0.0021-0.0046 in)
CRANKPIN BEARINGS
Liner Length 35.56-35.81mm (1.40-1.41 in)
Vertical Assembled Bearing Clearance 0.035-0.094mm (0.0014-0.0037 in)
CRANKSHAFT RE-GRINDING
When re-grinding a crankshaft the main and crankpin journal diameters should be reduced the same amount as
the undersize bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60° Chamfer of the pilot bearing bore.

UNDERSIZE BEARING AVAILABLE MAIN JOURNAL DIAMETERS

0.051mm (0.002 in) 85.580-85.593mm (3.3693-3.3698 in)

0.254mm (0.010 in) 85.390-85.402mm (3.3618-3.3623 in)

0.508mm (0.020 in) 85.136-85.148mm (3.3518-3.3523 in)

0.762mm (0.030 in) 84.882-84.894mm (3.3418-3.3423 in)

1.016mm (0.040 in) 84.628-84.640mm (3.3318-3.3323 in)

UNDERSIZE BEARING AVAILABLE CRANKPIN JOURNAL DIAMETERS

0.051mm (0.002 in) 69.789-69.799mm (2.7476-2.7480 in)

0.254mm (0.010 in) 69.956-69.606mm (2.7400-2.7404 in)

0.508mm (0.020 in) 69.342-69.352mm (2.7300-2.7304 in)

0.762mm (0.030 in) 69.088-69.098mm (2.7200-2.7204 in)

1.016mm (0.040 in) 68.834-68.844mm (2.7100-2.7104 in)

BALANCER
Gear Backlash 0.05-0.25mm (0.002-0.010 in)

Shaft to bushing clearance 0.0127.0-0.038mm (0.0005-0.0015in)

Shaft Diameter 25.133-25.40mm (0.9895-1.000 in)

Backlash between balancer / crankshaft gear 0.05-0.20mm (0.002-0.008 in)

End float balancer gear to support 0.20-0.51mm (0.008-0.020 in)

FLYWHEEL
Ring Gear Runout 0.63mm (0.025 in)

Flywheel Runout 0.27mm (0.005 in)

Maximum depth to be skimmed from face 3 mm (0.118 in)

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 7

OIL PUMP
Rotor Clearance 0.025-0.15mm (0.001-0.006 in)

Rotor to Pump Housing Clearance 0.15-0.28mm (0.006-0.01 1 in)

Rotor End Play 0.025-0.089mm (0.001-0.0035 in)

Oil Pressure 1.24 bar (18 lbs in2) minimum at idle speed,
2.76 bar (40 lbs in2) minimum at rated speed

Pump Gear to Camshaft Gear Backlash 0.40-0.56mm (0.016-0.022 in)

OIL FILTER SUPPORT
Relief Valve, Operating Pressure 4.0 bar (59 lb in2)

Flow Rate 68 litres/min (15 imp gals/min) 18-20 US gals/min

Relief Valve, Spring Free Length 52.8mm (2.08 in)

API Engine Oil & Filter

Temperature Oil Viscosity and Type Classification Change Period (hours)
Low Ash , SAE 5W 150
-12 °C or Low Ash SAE 5W/20 SF/CD / CF-4 150
(Below 10°F) or SAE 10W-30 150
-12 °C to 4°C Low Ash , SAE 10W Series 3 SF/CD / CF-4 150
(10°F to 40°F ) or SAE 10W-30 300
0°C to 32°C Low Ash , SAE 30W Series 3 SF/CD / CF-4 300
(32°F to 90°F) or SAE 10W-40 300
Above 24°C Low Ash , SAE 30W Series 3 SF/CD / CF-4 300
( 75°F ) or SAE 15W-40

NOTE: When using diesel fuel with a sulphur content below 1.0%, Series 3 diesel engine oil with an A.P.I.
classification of CD may be used instead of CF-4 oil , but the oil and filter interval must be reduced to 150 hours .

When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the oil
and filter change period to every 50 hours .

ENGINE OIL CAPACITIES (With Oil Filter)

Model Litres Imp Gals U.S. Gals

4 CYL 11.4 2.5 3.0

THERMOSTAT
Opening Temperature 79-83 °C (174-181°F)
Fully Open 93-96 °C (199-205°F)
RADIATOR CAP
Opening Pressure 0.9 bar (13 lbs in2)
WATER PUMP
Type Centrifugal
Drive Multi V Belt

604.55.041.00 01 -1998
8 SECTION 10 - ENGINE - CHAPTER 1

COOLING SYSTEM CAPACITIES

Model Litres Imp gals U.S. gals
4 CYL (with cab) 16 3.5 4.2
4 CYL (less cab) 14.5 3.2 3.8

COOLING FLUID
Content Mixture - Use Anti-freeze (50%) plus clean, soft water (50%)
Type Ambra Agriflu (NH 900 A)

MINIMUM HARDWARE TIGHTENING TORQUES

IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS

NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD

1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61* (6.9) 86* (9.8) 1/4
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37) 125* (14) 176* (20) 5/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35) 3/8
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42 (57) 7/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64 (88) 1/2
9/16 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65 (88) 92 (125) 9/16
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90 (122) 127 (172) 5/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160 (217) 226 (306) 3/4
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258 (350) 364 (494) 7/8
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739) 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8

REGULAR NUTS SAE GRADE 5 SAE GRADE 8

HEX NUTS HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION GRADE IDENTIFICATION GRADE IDENTIFICATION

GRADE A NO MARKS GRADE A NO MARKS
GRADE A NO NOTCHES
GRADE B LETTER B GRADE B THREE MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE C LETTER C GRADE C SIX MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES MARKS NEED NOT BE LOCATED
AT CORNERS

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 9

TORQUE VALUES - VARIOUS Nm lbf ft Kgf m

Main Bearing Bolts 197 145 20.0

Connecting Rod Bolts 149 110 15.2
Cylinder Head Bolts (with Engine Cold) 217 160 22.0
Intake Manifold-to-Cylinder Head 35 26 3.5
Exhaust Manifold-to-Cylinder Head 38 28 3.9
Exhaust Pipe-to-Flange 31 23 3.2
Flywheel-to-Crankshaft 197 145 20.0
Oil Pan Drain Plug 41 30 4.2
Valve Rocker Cover Bolts 24 18 2.4
Crankshaft Pulley-to-Crankshaft 224 210 23.0
Self-Locking Screw - Valve Rocker Arm 24 18 2.4
Injector Attachment Bolts 23 17 2.3
Cover Bolts 31 23 3.1
Oil Pump to Block 23 17 2.3
Water Pump-to-Cylinder Block 48 35 3.6
Water Pump Cover-to-Pump 27 20 2.8
Oil Pan-to-Cylinder Block (Cast) 38 28 3.9
Injector Line Nuts 24 18 2.4
Leak-of f Tube Banjo Fitting Bolts 11 8 1.1
Injection Pump-to-Front Cover 24 18 2.4
Camshaft Idler Drive Gear-to-Block 237 175 24.0
Front Cover-to-Cylinder Block 24 18 2.4
Thermostat Housing Bolts 24 18 2.4
Camshaft Gear Bolt 69 51 7.0
Camshaft Rear Gear Plate Bolts 47 35 4.8
Oil Filter Adaptor Bolts 42 31 4.2
Oil Filter Mounting Bolt Insert 34 25 3.5
Starting Motor-to-Rear Adaptor Plate 31 23 3.2
Injection Pump-to-Gear Nut 79 58 8.0
Oil Pressure Switch Assembly 31 23 3.2
Turbocharger-to-Exhaust Manifold Nut 44 33 4.5
Fan Blade to Support Body 27 21 2.8
Crankshaft Rear Oil Seal Retainer -
Initial Tightening 12 9 1.2
Final Tightening 23 17 2.3
Belt Tensioner Pulley Bolt 54 40 5.5
Temperature Senders 20 15 2.0
Tensioner to Water Pump Bolt 54 40 5.5
Idler Pulley Bolt 54 40 5.5
Pump Connector to Block 24 18 2.4

604.55.041.00 01 -1998
10 SECTION 10 - ENGINE - CHAPTER 1

CYLINDER BLOCK PLUG TORQUES Nm lbf ft Kgf m

1/4 in-27 NPT 11 8 1.1

1/4 in-18 NPT 29.8 22 3.0
3/4 in-18 NPT 38 28 3.8
3/4 in-14 NPT 27 20 2.7

SPECIAL TOOLS

DESCRIPTION V.L. CHURCHILL NUDAY NH

TOOL No. TOOL No. TOOL No.
Adjustable Bridge Puller 518 9539 09539

Shaft Protectors 625-A 9212 09212

Step Plate Adaptors 630-S 9210 09210

Bushing Kit 818 9514 09514

Valve Guide Reamer Kit FT.6202 (SW.502) 2136 (SW.502) 02136

Camshaft Bearings -
Remover/Installer FT.6203 1255 (SW.506) 01225
Handle N6261-A 1442 01442

Water Pump Seal Replacer FT.6209 4672 T87T-6312-A

Connecting Rod Bush -

Removal NH 00035
Installation OTC 134-00002

Crankshaft Seal Replacer

Front Seal NH10-103
Rear Seal FT 6212 NH 01301

GREASE and SEALANTS

PART NUMBER TYPE NAME

Ambra GR9 NH 1 710 A Grease -General Purpose

Ambra GR75MD NH 1 720 A Grease-Molybdenum Disulphide
82995768 ESE-M4G194-B Sealer-Anaerobic Low strength
82995776 ESE-M4G195-A Sealer-Silicone
82995774 SP-M4G91 12-A Sealer-Polyester Urethane
82995773 SP-M4G91 12-C Sealer-Polyester Urethane
82995772 ESE-M4G217-A Sealer-Anaerobic
82995771 SP-M2G9121-B Sealer-R TV Silicone rubber
82995782 Gasket Removal - Spray

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 11

FAULT FINDING

IMPORTANT: When effecting a repair the cause of

the problem must be investigated and corrected to
avoid repeat failures.

PROBLEM POSSIBLE CAUSES REMEDY

Engine does not 1. Clogged air cleaner 1. Clean or renew element

develop full power
2. Fuel line obstructed 2. Clean

3. Faulty injectors 3. Clean and reset

4. Incorrect valve lash 4. Check and reset

adjustment

5. Burnt, worn or sticking valves 5. Replace valves with new or

oversize, and/or machine the
valve guide bores

6. Blown head gasket 6. Check head flatness and fit

new gasket

7. Incorrect fuel delivery 7. Check injectors and pump

8. Low cylinder compression 8. Renew piston rings or

re-bore/re-sleeve as
necessary
Oil pressure warning 1. Bulb burnt out 1. Renew bulb
light fails to operate
2. Warning Light pressure 2. Renew pressure switch
switch faulty

3. Warning light circuit faulty 3. Check and renew wiring

Excessive exhaust 1. Oil leak on compressor or 1. Overhaul turbocharger

smoke turbine side of turbocharger,
where fitted

2. Exhaust leak on exhaust 2. Fit new gasket

manifold side of turbocharger,
where fitted

3. Air cleaner dirty or restricted 3. clean

4. Excessive fuel delivery 4. Overhaul injection pump and

injectors

Water temperature 1. Faulty temperature sender 1. Renew sender switch

gauge fails to reach
normal operating 2. Incorrect or faulty thermostat 2. Renew thermostat
temperature
3. Faulty water temperature 3. Renew temperature gauge
gauge

604.55.041.00 01 -1998
12 SECTION 10 - ENGINE - CHAPTER 1

PROBLEM POSSIBLE CAUSES REMEDY

Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for

damage, change as required.
Drain and refill with specified
oil and renew filter. Ascertain
cause of dilution

2. Insufficient oil supply 2. Check oil level and top up as

necessary. Overhaul or renew
pump as necessary. Check oil
filter is not clogged

3. Low oil pressure 3. Overhaul pump or relief valve

as necessary

4. Excessive crankshaft end 4. Install new thrust bearing liner

play

5. Flywheel or ring gear run-out 5. Skim flywheel or fit new ring

excessive gear

6. Excessive connecting rod or 6. Install new bearing inserts

main bearing clearance and/or re-grind crankshaft

7. Bent or twisted connecting 7. Renew connecting rods

rods

8. Crankshaft journals out- 8. Re-grind crankshaft and fit

of-round undersize bearing inserts

9. Excessive piston-to- 9. Re-bore/re-sleeve block and

cylinder bore clearance fit new pistons

10. Excessive piston ring 10. Fit new pistons and rings
clearance

11. Broken rings 11. Fit new rings, check bore and
pistons for damage

12. Excessive piston pin 12. Fit new piston or pin

clearance

13. Piston pin retainer loose or 13. Install new retainer, and check
missing bore/pistons for damage

14. Excessive camshaft play 14. Install new thrust plate

15. Imperfections on timing gear 15. Renew timing gear

teeth

16. Excessive timing gear 16. Renew timing gear

backlash

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 13

PROBLEM POSSIBLE CAUSES REMEDY

Engine overheats
1. Hose connection leaking or 1. Tighten hose connection,
collapsed renew hose if damaged

2. Radiator cap defective or not 2. Renew radiator cap

sealing

3. Radiator leakage 3. Repair/renew radiator

4. Improper fan belt adjustment 4. Re-adjust fan belt

5. Radiator fins restricted 5. Clean with compressed air

6. Faulty thermostat 6. Renew thermostat

7. Internal engine leakage 7. Check for source of leakage,

renew gasket or defective
parts

8. Water pump faulty 8. Overhaul water pump

9. Exhaust gas leakage into 9. Renew cylinder head gasket,

cooling system check head for damage or
distortion

10. Coolant aeration 10. Tighten all connections and

check coolant level is correct.
Ensure cylinder head gasket
has not blown

11. Cylinder head gasket 11. Renew cylinder head gasket

improperly installed

12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system

13. Obstruction to radiator air 13. Remove the obstruction

flow

14. Extended engine idling 14. Do not allow engine to idle for
long periods

15. Oil cooler tube blocked 15.Clean

16. Radiator core tubes blocked 16. Check free flow

604.55.041.00 01 -1998
14 SECTION 10 - ENGINE - CHAPTER 1

PROBLEM POSSIBLE CAUSES REMEDY

Low oil pressure 1. Engine oil level low 1. Top up, as necessary
2. Wrong grade of oil 2. Drain and refill with correct
grade of oil

3. Blocked oil pump sump 3. Clean pump screen

screen

4. Oil pressure relief valve faulty 4. Fit new relief valve

5. Oil pump worn 5. Renew Oil Pump

6. Excessive oil pump rotor and 6. Overhaul pump

shaft assembly clearance

7. Excessive main or 7. Install new bearings inserts

connecting rod bearing and / or re-grind crankshaft
clearance

Excessive oil 1. Engine oil level too high 1. Reduce oil level
consumption
2. External oil leaks 2. Renew gaskets and seals,
where necessary. Check
mating surfaces for damage
or distortion

3. Worn valves, valve guides or 3. Renew

bores

4. Cylinder head gasket leaking 4. Renew gasket. Check head

for damage or distortion

5. Oil loss past the pistons and 5. Renew rings and/or rebore/
rings re-sleeve block as necessary

6. Oil cooler leak 6. Repair/renew oil cooler

assembly

7. Rocker cover oil filter blocked 7. Change filter

Engine tends to 1. Air cleaner dirty or 1. Clean or renew element

keep firing after fuel restricted
is shut off
2. Oil leak on compressor side of 2. Overhaul turbocharger
turbocharger where fitted

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 15

DESCRIPTION AND OPERATION incorporated in the centre main bearing of the

crankshaft.
All TS range tractor engines are 4 cylinder and
available in naturally aspirated and turbocharged Front and rear crankshaft oil sealing is effected by
forms. one piece seals that are designed for long and
durable service life.
All engines feature cross flow cylinder heads, with CONNECTING RODS (OP NO 10 105)
the inlet and exhaust manifolds on opposite sides of
the cylinder head. The fuel and air combustion Connecting rods (wedge) shaped at the small end
process, takes place in the specially designed bowl have been designed to reduce the reciprocating
in the crown of the pistons. weight at the piston end. The connecting rods are of a
heavy beam construction and are assembled as a
matched set to each engine, attached to the
CYLINDER HEAD ASSEMBLY (OP NO 10 101) crankshaft, by means of insert-type bearings.
The cylinder head incorporates valves and springs,
with the valve rocker arm shaft assembly bolted to They are retained in position by the connecting rod
the cylinder block through the cylinder head. Cylinder big end cap and secured by two bolts per rod. The
head retaining bolts are evenly spaced with a six small end of the connecting rod is fitted with a
point pattern around each cylinder, this ensures an replaceable bronze bushing, through which the free
even clamping load across the cylinder head area. floating piston pin is fitted. The steel pin being held in
place within the piston by two snap rings.
The intake and exhaust manifolds are bolted to the PISTONS (OP NO 10 105)
head, the intake manifold is mounted on the right
hand side of the engine, with the diesel injectors Pistons are constructed of an aluminium silicon alloy
mounted outside the rocker cover. The exhaust with an iron insert for the top ring. The combustion
manifold is mounted on the left hand side of the chamber being recessed into the piston crowns.
engine. Water outlet connections and thermostat Each piston has two compression rings and one oil
being attached to the front of the cylinder block control ring, to reduce friction and increase positive
directly behind the radiator. sealing. All rings are located above the piston pin.

MANIFOLDS (OP NO 10 254)

Valve guides are integral in the cylinder head, and
valves with oversize stems are available in service. The cross flow design aluminium intake, and cast
Special replaceable cast alloy valve seats are iron exhaust manifolds, are on opposite sides of the
pressed into each valve port during manufacture, cylinder head. This is designed to maintain balanced
with oversize valve seats also available in service. heat distribution within the cylinder head. The
configuration of the manifolds also ensures minimum
heat transfer to the intake manifold.
The exhaust valves are fitted with positive valve
rotators with all valves using umbrella type oil seals. The intake manifold is connected through tubing to
Valve lash is maintained by adjustment of the self the air cleaner and in the rear end of the manifold a
locking adjusting screw, mounted in each of the tapped hole is provided for installation of a
rocker arms. thermostart or an ether cold starting aid (North
America Only).
CAMSHAFT ASSEMBLY (OP NO 10 106)
NOTE: On tractors where cold start equipment is not
The camshaft runs in 3 replaceable bearings. The installed ensure the plug in the intake manifold is kept
camshaft drive gear is in mesh with and driven by the tight at all times. Considerable damage to the
camshaft idler gear and crankshaft timing gear. cylinder bores, may be incurred by entry of dust or
other foreign material if the plug is left loose or
Camshaft end thrust is controlled by a thrust plate missing. Also dirt and grit may be drawn through the
bolted to the block, and located between the air cleaner connections if they are not properly
secured.
camshaft gear and the front camshaft journal.
CYLINDER BLOCK ASSEMBLY (OP NO 10 001)
A helical gear is mounted on the rear of the camshaft, The cylinder block is an alloy cast iron with deep
and drives the engine oil lubrication pump mounted cylinder skirts, and water jackets for cooling the
forward of the flywheel. cylinders. The cylinder bores are machined integral
with the cylinder block, during the manufacturing
CRANKSHAFT ASSEMBLY (OP NO 10 103) process.

The crankshaft is supported in the cylinder block by 5 Cylinders are in line and vertical and numbered from
main bearings. The crankshaft is manufactured from 1 to 4 from the front to the rear of the engine. They
nodular cast iron with machined finished crank webs. can be bored oversize for the fitment of sleeves,
End thrust is controlled by a thrust bearing which are available in service.

604.55.041.00 01 -1998
16 SECTION 10 - ENGINE - CHAPTER 1

The oil pan which is attached to the bottom of the An integral radiator/engine oil cooler is fitted. Oil
cylinder block, is the reservoir for the engine oil flows from the filter to main oil gallery, which runs the
lubrication system. An aluminium engine front cover length of the block and intersects the camshaft
and front plate is attached to the front of the engine follower chamber.
and covers all of the timing gear assembly.
The main gallery also supplies oil to the crankshaft
TIMING GEARS (OP NO 10 106) main bearings, connecting rods, big ends, small
ends. The underside of the pistons and pins, are
The crankshaft timing gear is heated and press fitted lubricated by oil pressure jets mounted adjacent to
on to the front of the crankshaft, to a high degree of each main journal housing.
accuracy during manufacturing. This enables
precise timing being maintained during the life of the
engine. The crankshaft gear drives the camshaft The camshaft drive gear bushing is pressure
idler gear which is attached to the front of the cylinder lubricated through a drilled passage from the front
block. The idler gear then drives the camshaft and main bearing. The gear has small oil passages
the injection pump via meshing helical gears. The machined on both sides allowing excess oil to
camshaft gear is bolted to the front of the camshaft, escape.
and is keyed to maintain position of the gear on the
camshaft. Timing gears are lubricated by splashed oil from the
cam follower chamber, and the pressure lubricated
camshaft drive gear bushing.
LUBRICATION SYSTEM (OP NO 10 304)
Lubrication of the engine, figure 1, is maintained by a An intermittent flow of oil is directed to the valve
rotor type oil pump mounted in the rear of the engine rocker arm shaft assembly via a drilled passage in
block, behind the flywheel. The oil pump is driven the cylinder block. This is located vertically above
from the rear of the camshaft and draws oil from the above No 1 camshaft bearing, and aligns to a hole in
engine oil pan through a tube and screen assembly. the cylinder head. The rotation of the camshaft
allows a controlled intermediate flow of lubrication.
A spring loaded relief valve is integral with the oil filter
body mounted on the left hand side of the engine The turbocharger where fitted, is supplied with oil
block, and prevents over pressurisation of the from the oil filter support housing, mounted on the left
system. hand side of the engine.

Engine Oil Flow 1

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 17

COOLING SYSTEM (OP NO 10 400)

NOTE: Do not operate an engine without a
thermostat. It is recommended that a solution of a
50% clean water, and 50% recommended
antifreeze, see specifications, is used. When the
recommended Antifreeze is not used, a 5%
solution of the recommended inhibitor must be
added to the cooling system.

The function of the water pump mounted at the

front of the engine, is to maintain a continuous flow
of water around the cooling system. This is
essential to ensure correct engine temperature,
and performance, during vehicle operation.

The pump is driven by a ‘Multi V’ Belt from the

crankshaft pulley, when the engine is running.
The cooling system for the new generation
engines, is of the recirculating by-pass type with
full length water jackets for each cylinder. The
coolant is drawn from the bottom tank of the
radiator by the water pump, which passes the
coolant to the cylinder block. This coolant then
cools the cylinder walls.
Passages in the cylinder head gasket allow coolant
to flow from the cylinder block, into the cylinder
head. Cored passages also conduct the coolant to
the fuel injector nozzle locations, before AP10100
re-entering the water pump below the thermostat. 2 2
The thermostat is located in the top of the water
pump body, and controls the flow of the water as
required by temperature changes.

NOTE: A faulty thermostat may cause the engine

to operate at too hot, or cold, an operating
temperature. If not replaced this could result in a
damaged engine, or impaired engine performance.

When the thermostat is closed Figure 2, a

recirculating by-pass is provided to allow the
coolant to recirculate from the head to the block to
effect a faster warm-up.
AP101003
3
Once the engine has reached its normal operating
temperature, the thermostat will open Figure 3 and
allow water to be drawn through the radiator by the
pump action. Cooled water then returns to the
engine system.

Cooling occurs as the coolant passes down

through the radiator cores, which are exposed to
the air as it is drawn through the radiator by the fan.

The cooling system incorporates a drain plug on

the right hand side of the cylinder block (1),
Figure 4.

604.55.041.00 01 -1998
18 SECTION 10 - ENGINE - CHAPTER 1

DIESEL ENGINE DISASSEMBLY

WARNING: Allow the engine to cool to S Oil pump relief valve.

ambient temperature before cleaning.
Cleaning a hot engine in cool water could result in
damage to the Fuel Pump and other components.
S Oil pan and gasket.

In the following procedures and illustrations the

S Turbocharger.
engine in the main is shown removed from the
tractor.

S Front timing cover/timing gear removal.

The engine overhaul procedure initially describes the

assembly process for rebuilding an engine using all
new components. Following this section are defined S Oil pan removal for access to crankshaft,
headings which describe detailed repair bearing shells, piston removal, and oil pump
specifications and procedures, where components suction tubing.
are suitable for re-use. Refer to the specifications
section to ensure components are serviceable.

S Front pulley and damper assembly.

Where overhaul of components is required without

engine being removed from the tractor refer to the
following headings, and the relevant paragraphs, in
the main overhaul procedure.
Operations or repairs that can be performed with
the engine removed from the vehicle and
separated from the transmission housing, with
oil pan removed.

Operations or repairs that can be performed with

the engine still in the tractor.
S Crankshaft rear oil seal and carrier removal,
(with oil pan removed).

S Cylinder head and associated components.

S Oil pump and drive gear removal.

S Fuel injection pump and related parts.

NOTE: All gaskets, seals, and ‘O’ rings must be

replaced with new upon re-assembly. Where new
S Water pump, thermostat, and associated sealant is to be applied refer to ‘‘Engine
components. Specifications”.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 19

Right Hand View of Engine - Emisionised Engine 5

1. Air Filter 6. Alternator 10. Fuel Filter
2. Coolant Recovery Tank 7. Water Pump 11. Engine Oil Dipstick
3. Air Conditioning Condenser 8. Fuel Sedimentor Separator 12. Starter Motor
(where fitted) 9. Fuel Injection Pump - 13. Electric Fuel Pump
4. Coolant Radiator Emisionised 14. Cold Start
5. Hydraulic Oil Cooler

Left Hand View of Engine (Turbo) 6

1. Air Conditioning Compressor 3. Engine Block Coolant Drain Plug
2. Turbo - where fitted 4. Oil Filter Head Incorporating Relief Valve

604.55.041.00 01 -1998
20 SECTION 10 - ENGINE - CHAPTER 1

Separating Front Axle from Engine (with

reference to Figures

1. Disconnect battery, earth lead first.

2. Disconnect power steering hoses from

cylinder. Figure 7.

3. Remove front wheel drive propshaft guard

and propshaft, if fitted.

7
4. Disconnect the front differential lock
hydraulic tube on FWD models. Figure 8.

5. If air conditioning is fitted, withdraw the

condenser from the radiator and remove the
receiver dryer. Carefully move both items
away from the front of the tractor and secure to
the side of the engine ensuring that they are
not allowed to hang on their tubes.

6. Slide out the oil cooler from the radiator and

tie up out of the way, again ensuring that the
cooler is not allowed to hang on its hoses.

8
7. Drain the cooling system fluid into a clean
container and disconnect the radiator hoses.
Disconnection of the radiator lower hose
provides a suitable drain point.

8. Disconnect air cleaner inlet tube.

9
9. Position splitting Tool, MS2700.C with engine
supports, MS2700-C-8 in position. If splitting
tool is not available use an overhead crane with
suitable straps. Strap at the front and rear of
the front support to maintain balance.

NOTE: It will be necessary to remove the

engine hood.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 21

10. Support the engine at the front of the

transmission and position wedges between
axle and support to prevent articulation.
Remove hardware securing the engine to the
front support and wheel the front axle and
support away from the engine.

11
Separating Engine From Transmission (with
reference to Figures 10and 6)

1. Remove the exhaust muffler.

2. Disconnect hood harness connector, and

remove the engine hood assembly, Figure 10.

3. Disconnect the fuel filter (2), starter motor

wiring and retaining bolts (1) and remove
starter motor, Figure 12.

4. Disconnect the fuel lines to the fuel sedimenter

and the overflow return to tank.
12
5. Disconnect fuel pump control cable, Figure 13.

6. Disconnect steering and lubrication pipes,

near bellhousing.

7. Disconnect the heater hoses near bellhousing.

8. Disconnect air conditioning at quick release

connectors.

13
9. Support the engine using a suitable hoist, tool
No.290740 with brackets 50075 and 50076.
Remove the buckle up bolts between the
engine and transmission, ensuring that all
wires and tubes are disconnected. Disconnect
cab main cable to engine connector Figure 14.

10. Place the engine onto a suitable stand for

repair.

604.55.041.00 01 -1998
22 SECTION 10 - ENGINE - CHAPTER 1

Engine installation

Installation of the engine is the reversal of the

removal procedure, noting the following points.

S Ensure all attaching hardware is tightened to

the correct torque value as detailed in the
specifications.

S After connection of the battery it will be

necessary to reset the radio/clock.
15

S Depending upon operations undertaken it may

be necessary to bleed air from the fuel injection
system. See Section 10, chapter 8.

S Ensure after installation that all fluid levels are

correct prior to start up. Start and run the
engine until correct operating temperature is
achieved to purge air from cooling system.
Stop engine, check for leaks, rectify as
required and recheck fluid levels.

ENGINE DISASSEMBLY

Cylinder Head, Valves, And Related Parts

(Op. 10 101)

Cylinder head removal

NOTE: The cylinder head can be removed with the

engine installed in the tractor.

Remove or disconnect the following components

to allow removal of the cylinder head:-

S Remove the engine hood, side brackets and

gas struts, fold back hood against cab front.

S Drain the engine coolant into a clean

receptacle.

S Disconnect/remove the air cleaner, air cleaner

tubes and muffler assembly.
16

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 23

S Disconnect low pressure fuel lines to the filters,

injector leak off tube, thermostart feed tube, ilft
pump and filter(1) and (4), injector to injection
pump high pressure tubes, (cap all exposed
openings), and sedimentation/water separator
(2).

S Disconnect and remove the rocker cover

ventilation tube.

NOTE: Removal of the radiator will greatly assist 17

water pump removal.

S Remove the engine fan belt guards, the fan

belt, alternator and water pump.

Clean around the injectors and remove the

injector/washer assembly

NOTE: Ensure injectors and washers have been

removed prior to placing the cylinder head on to a
bench as they protrude below the head face.

S Remove the turbocharger oil pipes where

fitted.

18
S Remove the rocker cover and gasket.

S Remove the cylinder head bolts (1) which pass

through the rocker shaft supports and remove 1
the rocker shaft assembly as an assembly.
Remove the push rods (2), check for
concentricity and place in a numbered rack for
re-assembly .

S Remove remaining cylinder head bolts working

2
inwards from the end of the cylinder head,
alternately to the centre of the cylinder head.
AP101018
19
S Using a crane carefully lift the cylinder head
assembly with inlet and exhaust manifold away
from the engine block.

604.55.041.00 01 -1998
24 SECTION 10 - ENGINE - CHAPTER 1

CYLINDER HEAD DISASSEMBLY (10 101)

1 2 3
Rocker Shaft Disassembly

NOTE: Leave bolts (1), Figure 19 in the rocker

shaft supports during removal as they retain the
support on the shaft (5).

1. Remove the cylinder head bolts (3) and

withdraw the supports (2), springs (1), rockers 6 5 4
(4) and spacers (6). TA6010010
20

Valve and Spring Assembly Removal

2. Using a valve spring compressor (1) remove

the retainer locks (2), springs (3), seals,
rotators and place in a numbered rack.

2
3

TA6010011
21

NOTE: The exhaust valves are fitted with inner (1)

and outer (2) rotators

Inspection and Repair, Cylinder Head

IMPORTANT: Before cleaning the cylinder head

inspect for signs of discolouration, leaking or
cracks, once cleaned concerns may not be
apparent.
22

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 25

1. Clean the cylinder head, and remove carbon

deposits from around the valve heads.

2. Cylinder head core plugs if discoloured (rusty),

or leaking will require changing. Before fitting
new plugs remove all old sealer from the
cylinder head. Apply sealant (82995772), refer
to ‘Specifications’, to the new plug mating
faces, and drive the new plugs into location, .

23
Core plugs required in the Cylinder Head:-

4 off, In the top of the cylinder head

1 off, in the rear of the cylinder head.
3 off, are mounted in the intake face.

3. Scrape all gasket surfaces clean and wash

cylinder head in a suitable solvent, also
cleaning valve guide bores.

4. Inspect cylinder head for nicks and burrs on

mating face, Remove using a suitable abrasive
and ensure faces are clean after repair.

5. Using a straight edge, and feeler gauge, check

flatness of cylinder head in all directions does
not exceed,
0.03mm (0.001 in) in any 25.4mm (1 in), or
0.127mm (0.005 in), overall limit.

6. If the cylinder head has been resurfaced, 2 3 4 5 6 6 7 8

determine all head bolt faces will seat. By

placing the cylinder head less gasket, on the
cylinder block and installing bolts hand tight.

TA6010012
24
7. Ensure rocker shaft supports are fitted with
long bolts (1). Using a feeler gauge (2), check
clearance between underside of bolt heads
and cylinder head or rocker shaft support.

8. If a 0.25mm (0.010 in) feeler gauge can be

inserted under the bolt head the bolt has
bottomed. Therefore the cylinder block thread
must be increased using a 9/16-13 UNC-2A
Thread tap. Identify the bolt heads and ensure
they are reinstalled in the bolt holes they were
checked in.

604.55.041.00 01 -1998
26 SECTION 10 - ENGINE - CHAPTER 1

Valve Inserts

Counter Bore in Cylinder Head

Insert Oversize Exhaust valve insert Intake valve insert

0.25mm (0.010 in) 44.17-44.20mm (1.739-1.740 in) 50.01-50.04mm (1.969-1.970 in)

0.58mm (0.020 in) 44.42-44.45mm (1.749-1.750 in) 50.27-50.29mm (1.979-1.980 in)
0.76mm (0.030 in) 44.68-44.70mm (1.759-1.760 in) 50.52-50.55mm (1.989-1.990 in)

NOTE: Refacing the valve seat should always be

co-ordinated with refacing of the valve to ensure a
compression tight fit.

1. Examine the valve seat inserts and reface if

pitted, renew if loose or damaged.

2.. To install a new valve insert, the cylinder head

must be counter bored, as described in the
above chart. The new insert must be chilled in
dry ice prior to installation.

Valve Seat Specifications.

Valve seat angle (1),
Intake =30.0°-30.30 ° 3
Exhaust =45.0°-45.30 ° 1

Valve seat width (2),

Intake =1.9-2.4mm (0.078-0.098 in)
Exhaust =1.8-2.3mm (0.072-0.092 in)

Valve Head Face to Cylinder Head Face Depth (3),

Intake =0.86-1.32mm (0.034-0.052 in)

Exhaust =1.2-1.6mm (0.047-0.065 in) 2
TA6010013
26
NOTE: Valve inserts of 0.25mm (0.010 in) and
0.5mm (0.020 in) oversize on diameter are
sometimes installed during manufacture. Cylinder
Heads with oversize inserts are stamped
SO15OS, SO20OS, on the exhaust manifold side
in line with the valve seat concerned.

3. Check the width of the valve seat inserts, and

as required reface by grinding.

4.. Measure the concentricity of valve seats, using

a dial indicator and measure concentricity of
seat to the valve guide bore.
Total Indicator Reading should not exceed
0.051mm (0.002 in). 27

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 27

5. Use a seat cutter to correct any seat

eccentricity, or clean up of pits and grooves.
Ensure after any rework that seat width is
within specified limits.
6. Rotate a new or refaced valve in the seat
using engineering blue, ensure all the blue is
transferred to the valve head protrusion, If any
blue remains below or around the seat raise or
lower the seat accordingly, in the following
manner.
Lower, the valve seats, by removing material from
the top of seat (1) by using:-
30° grinding wheel for, Exhaust valves and a 15° TA6010016
grinding wheel for, Intake valves. 28
Raise, the valve seats, by removing material from
the bottom of seat (2) by using:-
60° grinding wheel for, Exhaust valves and a 45°
grinding wheel for, Intake valves.

Valve Guides

1. Using a telescopic gauge (1), and micrometer

(2), measure the valve guide bore clearance,
and ensure it does not exceed,
0.023-0.069mm (0.0009-0.0027 in),
on the intake valve stem,
0.048-0.094mm (0.0019-0.0037 in),
on the exhaust valve stem. TA6010018
29

NOTE: Production cylinder heads may have one

or more machined, oversize valve guide bores, or
valves installed, 0.38mm (0.015 in). Such cylinder
heads have 15 or VO15OS stamped on the
cylinder head exhaust manifold side adjacent to the
valve concerned.

2. Using a suitable reamer, ream out the valve

stem guide, with three reamer and pilot
combinations as follows:-

3. When going from a standard valve stem to an

oversize, always use reamers in sequence.

0.076mm (0.003 in) oversize reamer, and

standard diameter pilot.

0.38mm (0.015 in) oversize reamer, and

0.076mm (0.003 in) oversize pilot.

0.76mm (0.030 in) oversize reamer, and

0.38mm (0.015 in) oversize pilot.

604.55.041.00 01 -1998
28 SECTION 10 - ENGINE - CHAPTER 1

Valve Springs

1. Checked on a flat surface squareness, should

not exceed 1.52mm (0.060 in), between the
square, and spring at the top edge.

Length of valve springs should be checked on both

free length, and loaded length.

Free length = 60.7mm (2.39 in)

Installed length = 47.2-49.6mm (1.86-1.95 in)

30
Loaded length = 48.26mm (1.9 in) using a weight
of 28-31 kg (61-69 lb)

Loaded length = 35.69mm (1.4 in) using a weight

of 61-69 kg (135-153 lb)

Ensure the valve spring retainer locks are in good

condition, and replace if worn or damaged.

Rocker Shaft Inspection and Re-assembly

1. Inspect rocker arm adjusting screws, and push

rod ends of the rocker arm, including the ball
end of the screws for nicks, damage, or excess
wear.
2. Also inspect the inside diameter of the rocker
arm for damage or wear. If any of these
characteristics are not to specification replace
with new parts.

3. Check the ends of the push rods for damage or

wear. If not to specification or push rods were
found not to be straight during dismantling
install new rods.

NOTE: Do not attempt to straighten bent push

rods, replace with new.
TA6010023
31
4. Check the rocker shaft for signs of wear or
damage, on internal and external diameters
respectively. If not to specification replace with
new. If re-used, before re-assembly clean
thoroughly in solvent making sure all oil
passages are clear.
5. Position the shaft identification groove,
Figure 33, forwards and upwards. This
ensures oil grooves and holes face
downwards.
6. Assemble rocker shaft support with long head
bolts, ensuring springs and spacers are
re-assembled and torque to 217 Nm (160 lbf TA6010024
ft). 32

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 29

CYLINDER HEAD RE-ASSEMBLY

2 1
1. Insert the valves into the guide bores from
which they were removed and lap with a
suitable paste, ensure all traces of paste are
removed after lapping.

2. Lubricate all components with clean engine oil

on re-assembly. Use a spring compressor to
reassemble the valves, valve springs, rotators,
and collets, with new umbrella seals.

NOTE: Exhaust valves are fitted with inner (1) and

outer (2) rotators, Figure 32 TA6010014
33
3. Coat all components with clean engine oil prior
to assembly, and insert each push rod into its
original position, ensuring each ball end is
seated in its cam follower.

CYLINDER HEAD INSTALLATION

Installation of the cylinder head assembly and

components is the reverse of the removal
procedure, observing the following,

1. Install new cylinder head, intake and exhaust

manifold gaskets.

NOTE: Ensure exhaust manifold gasket is fitted

correctly to suit profile of exhaust ports.

2. Tighten the cylinder head bolts in sequence

from the centre of the head, progressively in
three stages.

Stage 1, 156 Nm (115 lbf ft) 15.6 kgf m

Stage 2, 190 Nm (140 lbf ft) 19.3 kgf m

Stage 3, 217 Nm (160 lbf ft) 22.0 kgf m

34
NOTE: Bolts to be lubricated prior to assembly,
and should be tightened to torque specification,
with the engine cold.

3. Adjust valve lash setting with each piston in

turn at Top Dead Centre, and rockers free to
move, by adjusting the rocker bolt.

Intake Valve Lash,

0.36-0.46mm (0.014-0.018 in).
Exhaust Valve Lash,
0.43-0.53mm (0.017-0.021 in).
NOTE: Valve lash is to be set, only when the
engine is cold. 35

604.55.041.00 01 -1998
30 SECTION 10 - ENGINE - CHAPTER 1

4. Install the injectors with new seat washers,

cork seals, and torque to 23Nm (17 lbf ft).

5. Install the injector lines, and leak off pipes with

new washers, and torque the leak off banjo
bolts to, 10Nm (8 lbf ft).

NOTE: Hold the leak off plastic tubing when

tightening to prevent the pipes pivoting, during
torque up.

36
6. Exhaust manifold bolts are to be refitted and
tightened to a torque of, 38Nm (28 lbf ft).

7. Refit intake manifold bolts and tightened to a

torque of, 38Nm (28 lbf ft).

ENGINE FRONT COVER AND TIMING GEAR

REMOVAL (Op. 10 102 & 10 106)

NOTE: Timing cover and gears can only be

serviced after removing the radiator.

1. Remove the fan belt and withdraw the bolt and

washer, from the crankshaft pulley.

2. Using puller, No.518 or FT.9539, and shaft

protector No 625-A or 9212, remove pulley,
spacer and O-ring from the shaft.

TA6010027
37
3. Withdraw the bolts retaining the front cover
plate, and remove the front plate.

IMPORTANT: The crankshaft timing gear must not

be removed. The gear is heat shrunk on to the
crankshaft and aligned to the crankshaft No1 pin,
to within 0.10mm (0.004 in). If the gear is damaged
a new crankshaft is required.

4. Before removing the timing gears, use a dial

indicator or feeler gauge, to measure the
backlash between each set of gears.

TA6010029
38

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 31

5. Rotate the gears and check the backlash,

using a feeler gauge, or dial indicator at four
equal points on the gears. Renew if the
backlash exceeds the following.

Backlash to camshaft gear (1),

0.15-0.46mm (0.006-0.018 in)

Backlash to crankshaft gear (2),

0.15-0.46mm (0.006-0.018 in)

Backlash to fuel injection pump gear(3),

0.10-0.15mm (0.004-0.006 in)

39
CAMSHAFT DRIVE GEAR

1. Pry the camshaft gear using a lever (1), away

from thrust plate. Using a dial indicator or feeler
gauge (2), check the clearance, if outside of
0.076-0.35mm (0.002-0.007 in) limit, fit a
new camshaft thrust plate.

2. Remove the camshaft idler gear retaining bolt,

gear, and adaptor from the block, then remove
the camshaft gear bolt and disassemble.

40
3. Remove retaining nut, and washer from the
fuel pump and remove the gear from the shaft
using a puller.

4. If required the timing gear rear cover may now

be removed. Remove the six retaining bolts
and carefully pry the cover from the engine
block.

Inspection and repair of gears

5. Wash the gears using a suitable solvent, and

examine gear teeth for wear, burrs, or
scratches. Minor marks can be removed using
a fine abrasive, thoroughly clean before
re-assembly .

6. Ensure the camshaft idler gear adaptor is free

from obstruction and bushing is not damaged.
Camshaft key and key-way should be
checked for damage and repaired as required.

604.55.041.00 01 -1998
32 SECTION 10 - ENGINE - CHAPTER 1

Installation

1. Position piston no.1 at Top Dead Centre, set

using flywheel timing marks, install the
camshaft gear, and tighten bolt to 69 Nm
(51 lbf ft) 7.0 kgf m.

2. Install the camshaft idler gear to the block,

aligning the timing marks to the crankshaft and
camshaft gears and torque to 250 Nm (184lbf
ft).

41
DPS - Non Emissionised Engine
3. With piston No1 at Top Dead Centre, assemble
the fuel injection pump with a new ‘O’ ring,
aligning the mark on pump flange to the timing
mark on the front cover to 0°. Torque pump
retaining bolts to 22 Nm (18 lbf ft ) 2.2 kgf m.
Install the pump gear over the pump shaft.
Align timing marks to the idler gear and torque
to pump shaft 79 Nm (58 lbf ft). Holding the
idler gear, check the backlash between the
pump and idler gear with a feeler gauge or dial
indicator.

42
DP200 - Emissionised Engine

NOTE: Emissionised Engine and fuel pump,

correct timing procedure must be followed.

With engine at 28 BTDC compression stroke, set

using flywheel timing marks, assemble the
’LOCKED’ (2) Figure 44 pre-timed fuel enjection
pump with a new ’O’ ring,, to the front cover. Torque
pump retaining bolts to 24 Nm (18 lbf ft). Install the
pump gear over the pump shaft. Asemble the 1
washer and nut to the shaft, leaving loose at this
stage to allow the gear to rotate freely on the pump
shaft. APB10008
43
NOTE: DO NOT TIGHTEN THE INJECTION
PUMP SHAFT NUT AT THIS STAGE. PROCEED
TO REASSEMBLE THE FRONT COVER.

4. Initially tighten the injection pump gear nut to a

torque of 9Nm, (6.7 lbf.ft.) while holding the
gear in a counter clockwise position to remove
backlash from gears. ’UNLOCK’ the pump by
releasing the locking bolt and installing the
spacer between the pump body and bolt head
(1), Figure 44 . The pump gear retaining nut
can now be fully tightened to a torque value of
81 Nm, (60 lbf.ft.)
44

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 33

5. The front oil seal should be replaced, every

time the front plate is removed. Drive out the
old seal using a punch, taking care not to
damage the front plate. Assemble the front too
Engine as described below and then install the
seal

6. Ensure the front cover mating face and

cylinder block face are thoroughly clean before
re-assembly . Apply a 2mm (0.078in) wide
bead of sealer 82995774 along the centre of
each mating face. Position a new gasket on the
front cover.

7. Install the front cover ensuring alignment with

dowel pins and tighten the bolts in order of
sequence, Figure 45.

5/16 in-18 UNC bolts tighten to 18-24 Nm

(13-18 lbf ft).

3/8 in-16 UNC bolts tighten to 34-41 Nm

(25-30 lbf ft).

45
Seal Installation

8. Clean all parts and install new ’O’ ring, Figure

46.

9. Lubricate seal (1) and push onto the seal

installer, (3). Special tool NH. 10-103

10. Press seal into front cover using tool

NH10-103. Install the seal sleeve into the
seal.

46
11. Install the Access cover for the injection pump
gear nut. Clean surfaces and apply a 3mm
bead of flexible gasket sealant. tighten the
retaining bolts to 37 Nm (28 lfbf.ft.)

604.55.041.00 01 -1998
34 SECTION 10 - ENGINE - CHAPTER 1

OIL PAN REMOVAL (Op. 10 102)

1. Drain engine oil through oil pan plug (1) and

into a suitable clean receptacle and remove oil
level indicator.

NOTE: To facilitate the oil pan (2) removal it may

be necessary to first remove the propshaft.

2. Remove oil pan bolts and lower to ground.

48
Inspection and repair
1. Clean gasket material from sump face, clean
sump in a suitable solvent, inspect sump for
cracks damaged threads or damaged sump
face.
Installation
1. Installation is the reverse of removal but with
the following requirements.
2. Ensure block face is clean and free of gasket
material. Install a new gasket to the front cover,
and oil pan. Ensure sealer 82995774 is applied
to the front plate, and rear oil seal return joints. 49
3. Position the oil pan and install a bolt at each
corner finger tight to hold in position, install
remaining bolts, and torque from the centre of
the pan to the end to 38 Nm (28 lbf ft) 3.9
kgf m.

CONNECTING RODS, BEARINGS, PISTONS,

AND RINGS, REMOVAL. (Op. 10 105)

NOTE: The connecting rods and pistons can be

removed with the engine installed after removal of
the cylinder head and oil pan sump .
50
1. With cylinder head removed clean off any ridge
from the top of the cylinder bores, with a ridge
remover to enable removal of the pistons, this
is essential if old pistons are to be re-used as
failure to do so could result in ring land
damage.
2. With the piston at the bottom of the stroke
remove the end cap bolts, cap, and liner. Using
the handle end of a hammer push the piston
assembly out through the top of the block, and
remove the bearing liner from the connecting
rod.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 35

NOTE: Bearing caps and liners must be kept with

their respective connecting rods.

3. Turn the crankshaft again and repeat the

process for the remaining pistons.

4. Remove piston pin snap rings from each side

of piston and remove pin. Using an expander,
remove the piston rings.

5. Ensure each piston and rod assembly, remains

matched together for re-assembly into the
same location within the cylinder block.

52
Inspection and Repair

1. Clean the piston, and connecting rod

assembly, in a suitable solvent and inspect for
damage to ring lands, skirts, or pin bosses.

2. Check connecting rod components for

damage, and place in an alignment fixture to
check for distortion, and ensure that any
distortion, is within specification as follows.

Maximum Twist ‘A’ 0.30mm (0.012 in).

Maximum Bend ‘B’ 0.10mm (0.004 in).

53
3. Check piston pin bushing for damage or wear
in the following manner.

Measure the outside diameter of the piston pin, and

inside diameter of the connecting rod bushing, to
the following,

Piston Pin Outside Diameter

Naturally Aspirated,
38.095-38.100mm (1.4998-1.500 in).
Turbocharged,
41.270-41.275mm (1.6248-1.625 in).

Connecting Rod Bush internal Diameter

Naturally Aspirated,
38.113-38.120mm (1.5005-1.5008 in).
Turbocharged,
41.288-41.295mm (1.6255-1.6258 in)

604.55.041.00 01 -1998
36 SECTION 10 - ENGINE - CHAPTER 1
CONNECTING ROD BUSH

T1B10029

Connecting Rod Bush Installation 55

Removal Installation
1. Washer 6. Pins 11. Remover Insert 3
2. Collar 7. Fixture 12. Connecting Rod Location
3. Installation Insert 1 8. Connecting Rod Facing up 13. Washer
4. Bush 9. Remover Insert 1 14. Location Plate
5. Installation Insert 2 10. Remover Insert 2

4. If not to specification use tool No FNH 00053,

and press out the old bush using the removal
fixture as shown. Press fit a new bush through
the fixture using the installation detail, and into
the connecting rod. After fitting a new bush
ensure all sharp edges and burrs are removed.

IMPORTANT: Ensure the split in the small end

bush is at right angles to centre line of connecting
rod.

Connecting rods should only be changed as

matched sets.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 37

5. Where special tooling is not available for the

removal or fitment of the connecting rod bush,
a standard bush can be fitted in the following
manner.

6. Place the connecting rod securely in a bench

press. Manufacture from suitable bar stock, a
press tool with the end face ground at an angle,
to suit the connecting rod bush side face.
Position the tool on the bush, and gently drive
the bush from its position. It is recommended a
guide is manufactured to assist alignment of
the bar stock during this operation.

7. A new bush can then be fitted in a similar

manner, by using a suitable piece of bar stock,
with an end face machined flat to suit the
standard parallel bush. Use a guide as
described, and gently drive in the new bush
into the connecting rod.

NOTE: The seam of the new bush must be placed

at 90° to the centre line of the connecting rod.

8. After installation, grind the side faces of the

new bush to match the side faces of the
connecting rod. Ensure all sharp edges are
removed, and loose chippings are cleaned 6010035
from the connecting rod before re-assembly 56
into the engine.

9. With a new bush fitted drill a hole through the

top of the connecting rod using a
4.6mm (0.187 in) bit. Drill through the existing
oil hole.

10. Use an expanding reamer to obtain correct

bushing to piston pin clearance referring to
specification section. Remove burrs, and
chippings, before refitting.
TA6010036
57
CYLINDER BLOCK OVERHAUL. (Op. 10 105)

1. Cylinder block plugs, and senders, require

changing if leaking or rusty, and must be
replaced. Clean the old sealant off the block,
and fit new plugs with sealer, figure 46 refers to
the front and left hand side of the cylinder
block.

NOTE: New part mating faces, and threads,

should be coated in sealant, refer to
‘‘Specifications”. Assemble in the following
manner.

604.55.041.00 01 -1998
38 SECTION 10 - ENGINE - CHAPTER 1

Front and left hand side of the engine block.

1
Plug (1) Apply sealant 82995772 and drive in to
block.

Plug (2) Apply sealant 82995768 and torque to

8-14 Nm (6-10 lbf ft).

Fitting (3) Apply sealant 82995768 and torque to

24-34 Nm (18-25 lbf ft).

Plug (4) Apply sealant 82995768 and torque to

68-95 Nm (50-70 lbf ft). 5 6
2

Fitting (5) Apply sealant 82995768 and torque to

24-34 Nm (18-25 lbf ft).

Plug (6) Apply sealant 82995768 and torque to

27-47 Nm (20-35 lbf ft). 4 3

APB10052
58
Rear and right hand side of the engine block.

Plug (1) Apply sealant 82995772 and drive in to 1 1

block.

Oil Jets (2) replace with new if damaged, apply

engine oil only on re-assembly ‘‘Do not use
sealant”.

Fitting (3) Apply sealant 82995768 and torque to 2

8-14 Nm (6-10 lbf ft).

Plug (4) Apply sealant 82995768 and torque to

54-81 Nm (40-60 lbf ft) 1 3

APB10053
59

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 39

CYLINDER BORE
1. Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can
be felt by running a finger over the surface. To
check ovality, wear, or taper, use a telescopic
gauge.
Measure lengthwise,
A, to B, and C, to D, and compare dimensions.
Variances between the readings will indicate
‘‘taper”.
Measure crosswise,
C, to D, and compare dimensions lengthwise. A, to
TA6010040
B. Variances will indicate ovality.
60
NOTE: ‘Repair Limit’ refers to the tolerance
allowed after a repair has been performed. The C
‘Wear Limit’ is the tolerance prior to repair.
A
Taper of cylinder bore,
repair limit-0.025mm (0.001 in)
wear limit -0.127mm (0.005 in)
Cylinder bore out of round,
repair limit-0.03mm (0.0015 in)
wear limit-0.127mm (0.005 in) B
Cylinder bore diameter,
111.778-1 11.841mm (4.4007-4.4032 in). TA6010041
D
61
2. Where only minor imperfections exist and
bores are to specification, hone the bores prior
to installing new piston rings, provided piston
to bore clearance, is less than 0.250mm
(0.011 in)

3. Sleeving of the cylinder bores becomes

expedient when.

- Cylinder bore is beyond specification limits.

- Replacing sleeves already installed in
service.

SLEEVING - BORING AND HONING

1. Measure the outside diameter of the sleeve in
several places, and average the dimension.
Counter bore the cylinder block (see step 2)
using the average dimension to obtain a press
fit, between bore and sleeve. Interference of
sleeve to the cylinder bore is to be:
0.025-0.076mm (0.001-0.003 in).
2. Counter bore (1), Figure 57, to a depth of
204.7mm (8.06 in), from the block face,
surface finish of the bore is not to exceed (80
microns). Leave a step at the bottom of the
bore a minimum of 9.60-10.16mm
(0.38-0.400 in), allowing for run out of
chamfers. 62

604.55.041.00 01 -1998
40 SECTION 10 - ENGINE - CHAPTER 1

3. Bore through diameter, to the diameter of,

113.13-1 13.18mm (4.454-4.456in). 0.127
45°
1.0

ÉÉ ÉÉ
4. Clean the cylinder bores and thoroughly dry.

5. Grease the sleeve with Ambra GR75MD

ÉÉ 1.5
ÉÉ
NH720A or similar, and press the sleeve home
ÉÉ ÉÉ
ÉÉ ÉÉ
to the lip in the bore. The top of the sleeve
should protrude through the top of the block, 210.8
0.127-1.0mm (0.005-0.040in).
ÉÉ ÉÉ
ÉÉ ÉÉ
1
215 204.7

ÉÉ ÉÉ
6. Bore the sleeve to,
111.7-1 11.76mm (4.3985-4.400in).

7. Skim the block face, and top of sleeves, to

achieve the specified flatness of,
ÉÉ
ÉÉ ÉÉ
ÉÉ
9.6
10.16

0.08mm (0.003 in) in any 6 in (152mm)

0.001 in (0.03mm) in any 1 in (25.4mm).
A chamfer in the internal diameter at the top of
ÉÉ 113.13-1 13.18
ÉÉ
the sleeve to 45°x0.020 in (0.5mm) should be
maintained, to prevent piston damage on
re-assembly .
APB10057
63
8. Break the sharp edge at the bottom of the
sleeve prior to honing.

9. Hone the cylinder bore to give the correct

cylinder to bore clearance as described on
page 41.

NOTE: Surface finish to be an average of 20 to 30

Microns, cross hatched at 35°-55 °.

Maximum Taper,
0.025mm (0.001in) through to bottom of the bore.

Maximum Ovality,
0.038mm (0.0015in) through to bottom of the bore.

Re-Assembly

NOTE: Pistons that are replaced must be of the

same type that were removed and have the same
identification letters and numbers, as embossed on
the underside of the old piston.

1. Upon re-assembly with the piston at Top Dead

Centre, ensure the piston to block height is
correct using a dial indicator.

Naturally Aspirated,
0.28-0.58mm (0.011-0.023 in)
TA6010043
Turbocharged, 64
0-0.3mm (00.00-0.012 in)

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 41

2. Check the piston to bore clearance in the

following manner:-

Measure the cylinder bore diameter from the top of

the block to point
‘‘A’’, 82.6mm (3.25 in.) A

Measure the diameter of the piston at point:-

‘‘B’’, 97.28mm (3.83 in) for 5.0 in Naturally
Aspirated engine
‘‘B’’, 97.28mm (3.83 in) for 5.0 in Turbocharged B
engine
TA6010044
65

Subtract piston diameter from the bore diameter

and the resultant figure for a new, unrun engine
should be:-
0.140-0.171 mm (0.0055-0.0067 in )
Naturally Aspirated
0.166-0.188 mm (0.0064-0.0074 in)
Turbocharged engines.

After an engine has run and settled down the

maximum bore to piston clearance allowed is
0.250mm (0.011in)

NOTE: Pistons are only available as standard.

New pistons should always be fitted if the
clearance exceeds specification.
If clearance is ‘‘greater” try a similar new piston, if
limit is still exceeded it will be necessary to rebore
and resleeve.
If the clearance is ‘‘less” hone bore to obtain
desired clearance.
IMPORTANT: Prior to re-assembly ensure the
letter or grade mark on the piston is aligned to the
pip on the connecting rod and installed facing to the
front of the engine.
66
3. Lubricate all of the components with engine oil
and assemble the connecting rod/piston.

4. Check the piston ring gap width, using a feeler

gauge, in a vertical position at the top, middle,
and bottom of the bore to:-

Top compression ring.

0.38-0.84mm (0.015-0.033 in),
2nd compression ring.
0.66-1.12mm (0.026-0.044 in),
Oil control ring.
0.38-0.84mm (0.015-0.033 in),
TA6010046
67

604.55.041.00 01 -1998
42 SECTION 10 - ENGINE - CHAPTER 1

5. Using a new piston ring, check with a feeler

gauge, the gap between the ring and groove.

Top compression ring

.0.0044-0.0061 in (0.112-0.155mm)

2nd compression ring

0.0039-0.0056 in (0.099-0.142mm)

Oil control ring.

0.0024-0.0041 in (0.061-0.104mm)

6010048
68

6. Ensure the correct expander is used to remove

or install rings.

7. Install new piston rings but note the following,

6010047
69
8. Install the top and second compression rings
with the word top towards the top of the piston. A
A = Naturally Aspirated

B = Turbocharged

NOTE: Before installing new pistons and rings into

a used cylinder bore , remove the high polish from
the cylinder walls by honing as previously
described.
TA6010049A
70
Ensure the ring gaps are staggered equally around
the piston circumference. B

TA6010049B
71

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 43

Piston Assembly Installation, Into Block

1. Select the correct bearing liners as in the

following crankshaft section, and install in the
rod and cap, ensure the liner tang locates in the
slots of the rod and cap.

2. Turn the crankshaft to position No 1 crankpin at

the bottom of the stroke, and lubricate all parts
with new engine oil. Using a ring compressor,
and a soft drive, slide pistons into bores,
ensuring grade letter on pistons, is towards the
front of the engine.
6010050
72
NOTE: Replaceable bearing liners are installed in
production, to ensure correct crankshaft journal to
bearing clearance is maintained in service. The
main bearings can be overhauled with the engine in
the tractor. The crankshaft can only be serviced
after removal from the tractor.

73
3. Ensure the connecting rod bearing liner, seats
on the crankpin with the bearing cap fitted, to
the connecting rod as a matched assembly. It
is recommended that new bolts are fitted and
lubricated with oil and tightened to a torque
value of 149Nm (110 lbf ft).

4. Using feeler gauges, check the side clearance

of each connecting rod to crankshaft and
continue for remaining assemblies.
0.13-0.33mm (0.005-0.013 in)

74
BALANCER / VIBRATION DAMPER
(OP NO 10 110)

Removal

1. Remove the oil pan to expose the balancer,

and using a dial indicator gauge, check
backlash between crankshaft gear, and
balancer drive gear. Position the dial plunger to
the face of one of the drive gear teeth, then
rock the gear to measure backlash. Readings
should be taken at 90° intervals around the
drive gear, to 0.05-0.30mm (0.002-0.012 in).
If the specification is exceeded, install
new balancer gears. 75

604.55.041.00 01 -1998
44 SECTION 10 - ENGINE - CHAPTER 1

Balancer Assembly 76
1. Roll Pins 4. Balancer Gears
2. Balancer Housing 5. Washers
3. Washers 6. Balancer Gear Shafts

Disassembly

1. Extract the roll pins (1), securing the shafts to

the housing and disassemble the balancer.

Inspection and repair

1. Measure the outside diameter of shafts (6) and

the inside diameter of the gear bushings (4),
and establish if clearance is to specification
0.012-0.038mm (0.0005-0.0015 in). If
exceeded replace shaft and or gear
assembly.

Re-Assembly

1. Position balancer gears and thrust washers in

the housing, with timing marks aligned, and
facing the roll pin side of the balancer. Install
shafts from the opposite side and secure with
roll pins.
2. Using a feeler gauge measure end float, of
assembled gears is to the specification of,
0.20-0.51mm (0.008-0.020 in).
3. Position a dial indicator gauge to the tooth of
one gear, and hold the other firmly. Rocking the
free gear measure backlash at 90° intervals, 77
around the gears to, 0.05-0.25mm
(0.002-0.010 in).
4. Examine shafts and balancer gear teeth for
wear and damage, and replace as necessary.
Ensure lubrication holes in the shafts are free
from obstruction upon reassembly.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 45

Installation
1

1. Clean all the mating surfaces, and install a new

seal around the lubrication passage.

2. Rotate crankshaft until timing mark on

crankshaft gear aligns with timing mark on
balancer drive gear, position balancer on
dowels install the bolts and torque to 108-120
Nm (80-90 lbf ft) 11-12.4 kgf m. APB10072
78

3. Recheck the gear backlash between

crankshaft and balancer gear, as previously
described and replace the oil pan.

MAIN BEARING REMOVAL

1. Remove oil pan, and balancer, to gain access

to the crankshaft. Remove the main bearing
caps, and install one set at a time.

Inspection and Repair

1. Thoroughly clean bearing liners, journals,

TA6010033
caps, and inspect for wear, scores, or damage
79
replace as required.

Installation

2. Coat all parts in new engine oil prior to

assembly. Position bearing cap with locking
tang, towards camshaft side of engine and fit
the bolts, 190-203Nm (140-150 lbf ft)
19.3-20.1 kgm

3. If fitting a new thrust bearing liner it must be

aligned as in the following crankshaft chapter.

604.55.041.00 01 -1998
46 SECTION 10 - ENGINE - CHAPTER 1

FLYWHEEL REMOVAL

NOTE: To remove the flywheel, the engine

requires to be split from the transmission housing
refer to ”Separating the Unit’’.

1. To gain access to the flywheel separate the

engine to transmission.

NOTE: Prior to removal and using a dial indicator,

rotate the flywheel and measure to specification
0.127mm (0.005 in) Total Indicator Reading. If not
to specification check crankshaft to flywheel TA6010053
seating. 80
Inspection and Repair
Ring Gear
1. Inspect the flywheel ring gear, and if damaged
renew in the following manner,

Cut old ring gear free from the flywheel.

Clean the mating surfaces of the new ring gear, and

flywheel.

2. Use temperature indicating crayons to mark

the side face of the ring gear in six equal
places, mark with a 204°C (400°F) crayon at a
point 13mm (0.5 in) below the root of the teeth,
and mark with a 212°C ( 450°) crayon at a
point just below root of the teeth.
3. Use an oxy-acetylene torch with a tip size of
No 2 maximum, and direct the flame against
the internal face of the gear.

4. Stop applying heat when the 204°C (400°F)

crayon mark melts but before the 212°C
(450°F) crayon mark melts.
81

5. Quickly place the hot gear on the flywheel, with

flat face against the shoulder on the flywheel.
The gear to flywheel runout should be checked
using a dial indicator and should not exceed a
Total Indicator Reading of 0.63mm (0.025 in).

Flywheel Surface
1. In the event of flywheel surface damage due to
excessive clutch wear the surface may be
skimmed. A maximum of 3 mm (0.118 in) is to
be removed from the face of the flywheel.

Installation APB10076
1. Clean the crankshaft rear flange and mating 82
surface of the flywheel, install the flywheel, and
torque the bolts to,197N m (145 lbf ft) 20 kgf
m.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 47

REAR COVER PLATE REMOVAL (Op. 10 102)

To gain access to the engine oil pump, camshaft

gear, or end of crankshaft remove the oil pan as 1
previously described along with the rear cover, in
the following manner.

1. With rear of engine exposed loosen and

remove the 12 attaching bolts, and gently pry
off cover plate.

2. Clean off all sealer, remove crankshaft oil seal,

and check for damage or distortion around the
sealing faces. P396-E-54
83
Installation

1. Ensure rear of block face is clean and free of

old sealer, install a new gasket and apply
sealer to faces (1). With the plate in the recess
install and leave the bolts loose. 1

2. Apply a liberal coating of new engine oil on a

new oil seal and position the rear seal over the
end of the crankshaft. Locate tool, No FNH
01301, on the end of the crankshaft using the
three attaching bolts. Tighten evenly, and
squarely, until the seal is fully seated.
TA6010054
84
As an alternative the rear crankshaft oil seal can be
installed using the following installation tool.

3. Apply a liberal coating of clean engine oil to the

rear seal retainer, seal, and journal. A new
seal should be mounted on the crankshaft,
then bolt tool FT 6212 to crankshaft end and
install the new seal squarely.

4. Secure centre stock of tool to crankshaft flange

with two screws. Assemble cylinder end plate
to centre stock and secure with nut and
1
washer. Tighten the nut until outer diameter of
tool abuts retainer. Tool must not be over
tightened as stress and distortion could be
imposed on the retainer.

5. Remove the tool after assembly and check the

crankshaft seal run out as shown in Figure 87.

NOTE: The first seal replacement should be

pushed into retainer with plain end of tool and
subsequent seals with stepped end of tool which TA6010055
will reposition seal 1.52mm (0.060 in) further in. 85

604.55.041.00 01 -1998
48 SECTION 10 - ENGINE - CHAPTER 1

6. Tighten the twelve bolts, in sequence (1) to,

16-23N m (12-17 lbf ft) 1.6-2.3 kgf m.

11 9
2 7
5
4 3
6
8 1
10 12

TA6010128
86
7. With new crankshaft seal installed, place a dial
indicator, on the end of the crankshaft and
ensure seal runout is within 0.51mm (0.020 in)
Total Indicator Reading.

TA6010056
87
OIL PUMP REMOVAL (10 304)

NOTE: The oil pump can only be removed with the

1
engine split from the transmission, and the
flywheel, back plate, engine oil pan, and oil pump
tube removed. 1

1. Prior to pump removal check pump gear to

camshaft gear backlash, does not 1
exceed, 0.40-0.56mm (0.016-0.022 in).

TA6010057
88
2. Loosen and remove the camshaft gear, to
expose the oil pump, detach the 3 pump
mounting bolts, and withdraw the pump from
the block.

TA6010058
89

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 49

Installation

1. Clean and coat parts in new engine oil.

2. Fit a new O-Ring to the pump output tube and

into suction port. lubricate and insert the pump
into the block tightening the bolts, to,
23.0-28.4N m (17-21lbf ft) 2.3-2.9kgfm

TA6010059
90
3. Insert tube/screen assembly into pump
through bottom of engine. Fitting a new gasket,
and torque the attaching bolts to,
27-34N m (20-25 lbf ft) 2.7-3.4 kgf m,

Oil Filter Support Assembly

Removal TA6010062
91
1. Unscrew and discard the old filter (1). Loosen
the attaching bolts and oil connections and
remove the filter support assembly from the
block. Discarding the O-Rings.

2. Clean assembly in a suitable solvent and

ensure all ports are free of dirt.

Installation

1. Lubricate the pressure relief valve and spring

and insert into housing, ensuring free 1
movement.
Fit a new ‘O’-Ring to the plug and torque to, TA6010063
55N m (42 lbf ft ). 92

NOTE: On some models including the

turbocharged version the pressure relief valve ‘‘end
plug’’ is replaced by an oil return tube from the
engine block. Where this pipe is fitted a plug is used
to blank the oil return port to the engine block.

2. Fit tube to the connector and torque to 27Nm 2 1

(20 lbf ft).

3. Refit the oil filter head to the engine block with

new O-rings and plug where required as
above and torque the bolts to, 34-47 Nm
(26-35 lbf ft) APB10087
93

604.55.041.00 01 -1998
50 SECTION 10 - ENGINE - CHAPTER 1

CRANKSHAFT REMOVAL (Op. 10 103)

1. Remove the engine from the tractor and place

on an engine stand.
2. Remove the flywheel, rear cover plate,
crankshaft pulley and engine front cover.

NOTE: If crankshaft is removed with cylinder head

in position ensure all timing marks are realigned
prior to re-assembly. This action will prevent
possible interference between valves and pistons
during reassembly.
3. Remove the oil pan and oil pump. TI
APB10088
94
4. Remove the connecting rod caps, main
bearing caps and liners, and identify to
facilitate re-assembly.

5. Carefully remove crankshaft from cylinder

block.

Inspection and repair

NOTE: Current production engines may have a

crankshaft with main or crankpin journals ground
0.010 in (0.25mm) undersize. These are identified
with the letters 010 MUS and or 010 PUS
respectively, letters being stamped on one of the
crankshaft counter balance weights.

1. If crankshaft timing gear teeth are worn or

damaged replace as necessary as described.

2. Wash the crankshaft and drilled passages in a

suitable solvent. Dress minor imperfections
using an oil stone but for severely marked
journals, machine to the next size to suit B
available service bearings. A D
C

3. Measure diameter of each journal in four

places to determine out-of-round, taper, or
wear.
TA6010067
Measuring, A, compared with B, indicates 95
vertical taper.
Measuring, C, compared with D, indicates
horizontal taper.
Measuring, A and B, compared with C and D,
indicates journal out-of-round.

4. If the journal exceeds specified limits refer to

‘‘specifications” and refinish journal to the next
service bearing available.

5. Examine the rear oil seal journal for score

marks, remove minor imperfections with fine
emery cloth, and if severely damaged renew
the crankshaft.

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 51

With the crankshaft removed check the oil

lubrication jets situated in the block journals are
clear and free of contaminates.

If replacing the oil jets gently tap out the old ones
and replace with new.

396-E-26 TI
96
CRANKSHAFT RE-ASSEMBLY

NOTE: Normally main bearing journals wear

evenly and will not be out-of-round, but if a liner
which is to specification is fitted to an out-of round
journal, ensure liner suits maximum diameter of
journal.

1. If these combinations of liners do not produce

specified clearance refinish crankshaft and fit
suitable service bearings.
396-E-9 TI
97
IMPORTANT: Engines may be assembled with
liners of different material, but liners of the same
material must be used on the same journal.

2. Position the bearing liners and caps in the

block and coat with oil. If the crankshaft has
been refinished, fit the correct service bearing
liners.

3. Ensure the bearing surfaces are clean and

bearing liner tangs, align with slots in the block
and cap.

4. Align the timing mark on the crankshaft gear,

with that of the camshaft idler gear and install
the crankshaft. Install a thrust bearing cap with
flange type bearing liner first, installing
remaining bearing caps to their original
location.

5. Tighten all bearing caps (except thrust bearing

cap, leave finger tight) to a torque of 197 Nm
(145 lbf ft) 19.5 kgf m.

6010069
98

604.55.041.00 01 -1998
52 SECTION 10 - ENGINE - CHAPTER 1

6. Pry the crankshaft forward against thrust

surface of bearing, hold crankshaft forward
and pry bearing cap rearwards taking care not
to pry against flange of bearing liner. This will
align thrust surfaces of both halves of bearing,
hold forward pressure on crankshaft and
tighten bearing cap bolts to a torque of 197N m
(145 lbf ft) 19.5 kgf m.

NOTE: Do not pre-install seal into retainer. To

ensure seal concentricity, it must be assembled
with rear plate and installation tool when fitted to
crankshaft.

7. Check crankshaft end play with a dial indicator

gauge, pry crankshaft towards front of engine
and set dial indicator to zero. Pry crankshaft
towards rear of engine and note reading on dial
if end play exceeds 0.10-0.20mm
(0.004-0.008 in) fit a new thrust bearing liner.

8. If the end play is less than specification check

thrust bearing for burrs, scratches, or dirt, and
re-align thrust bearing as in operation12.

TA6010070
99
9. Install rear crankshaft oil seal as previously
described in back plate removal.

CAMSHAFT REMOVAL (Op. 10 106)

NOTE: The camshaft bearings and tappets can

only be serviced with engine removed from the
tractor.

1. Remove the engine front cover, and cylinder

head.

2. Check the camshaft end play, see timing gears

section, and remove gear, or remove the thrust 1
plate bolts for removal of gear and camshaft as
an assembly.

3. After removal of the flywheel, and rear cover,

remove the camshaft oil pump drive gear.

4. Invert the engine on the stand, if camshaft

bearings are to be replaced, and remove the oil
pan.

5. Carefully withdraw the camshaft from the rear

of engine. APB10094
100

604.55.041.00 01 -1998
SECTION 10 - ENGINE - CHAPTER 1 53

6. Lift out the tappets and place in a numbered

rack for reassembly.

396-E-23 TI

101
Inspection and repair

1. Inspect the camshaft journals, lobes, for

damage, pitting, or heat discolouration. If any
of these conditions exist install a new
camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage is apparent fit
new gears.
3. Check each tappet for wear or damage and
check diameters, if not to specification renew,
25.15-25.17mm (0.9900-0.9910 in).
4. Measure the diameter and out-of-round
condition of bearing journals, if exceeded fit a
new camshaft,
60.693-60.719mm (2.389-2.390 in).

CAMSHAFT BEARINGS

1. Inspect the camshaft bearings for wear or

damage. Measure the clearance between the
internal diameter of bearing and outside
diameter of respective journal,
0.025-0.076mm (0.001-0.003 in).
2. If specification is exceeded install new
bearings using, Remover/Replacer Tool No
FT 6203, or 1255 and handle, Tool No N
6261-A or 1442.
3. To remove, Position tool against bearing to be
TA6010071
removed and attach handle, driving bearing
from bore. 102

4. To install, Align oil holes of new bearing with

holes in block, and drive bearing into bore
using tools as described.
NOTE: A positive alignment check can only be
made with crankshaft removed when an 4.6mm
(0.018 in) rod can be passed down the oil passage
from the crankshaft main bearing. Liner is correctly
positioned when end of rod passes through oil hole
in the liner.

604.55.041.00 01 -1998
54 SECTION 10 - ENGINE - CHAPTER 1
Installation 5. Install a proprietary engine compression test
gauge into the injector bore, using a new seat
washer and the injector mounting bolts.
1. Apply petroleum jelly to each tappet foot, and
coat tappet body with oil. Install tappets in bores
from which they were removed. 6. Connect the gauge and hose to the adapter.

2. Oil camshaft journals and apply petroleum jelly 7. Crank the engine at 200 rev/min with the engine
to the cam lobes, and install camshaft into stop cable pulled out where fitted, or the electric
engine. fuel shut off wire disconnected to prevent
engine start up.

3. Install new spacer and keyway on end of

camshaft. 8. Observe the gauge reading, and repeat the
compression test, steps 5-7 for each cylinder.

4. Install a new thrust plate prior and torque

41-54 Nm (30-40 lbf ft). 9. All cylinder compressions should be uniformly
within 1.7 bar (25 lbf in2) of each other.

5. Install camshaft gear, and align the camshaft

gear timing mark and torque bolt to 55-77 Nm 10. A reading of more than the 1.7 bar (25 lbf in2)
(43-58 lbf ft), and recheck end play. below the other cylinders indicates leakage at
the cylinder head gasket, piston rings or valves.

6. Apply sealant 82995782 to the sealing flange of

11. A reading of more than 1.7 bar (25 lbf in2)
the front cover plate on re-assembly.
above the other cylinders indicates excessive
carbon deposits on the piston and cylinder
head.

12. A low even compression in two adjacent

cylinders indicates a cylinder head gasket leak.
Check this item before condemning the rings or
valves.

TEST CONCLUSION

To determine whether the rings or the valves are at

ENGINE COMPRESSION TEST ( Op. 10 001) fault, squirt the equivalent of a tablespoon of heavy
oil into the combustion chamber. Crank the engine
TEST PROCEDURE to distribute the oil and repeat the compression test.

The oil will temporarily seal any leakage past the

1. Be sure battery performance meets
rings. If approximately the same reading is
specifications.
obtained, the rings are satisfactory, but the valves
are leaking.
2. Warm up the engine by operating for a minimum
of half an hour at 1200 rev / min If compression has increased over the original
reading, there is leakage past the rings.
3. Stop the engine and remove the injector and
seat washer from no1 cylinder. During a compression test, if the pressure fails to
climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
4. Clean the injector bore and crank the engine to succeeding strokes, or fails to climb during the
blow out any loose carbon particles. entire test, suspect a sticking valve.

604.55.041.00 01 -1998
SECTION 10 -- ENGINE -- CHAPTER 2 1

SECTION 10 -- ENGINE

Chapter 2 -- Cooling

CONTENTS
Section Description Page

10 200 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS

THERMOSTAT
Opening Temperature 79--83!C (174--181!F)
Fully Open 93--96!C (199--205!F)

RADIATOR CAP
Opening Pressure 0.9 bar (13 lbs in2)

WATER PUMP
Type Centrifugal
Drive Multi ‘V’

COOLING SYSTEM CAPACITIES

Model Litres Imp Gals U.S. Gals

4 CYL with cab 16 3.5 4.2

4 CYL less cab 14.5 3.2 3.8

COOLING FLUID
Content Mixture -- Water 50%, Antifreeze 50% . If the recommended antifreeze is not used, a heavy duty
antifreeze must be used with a 5% solution of Inhibitor. This inhibitor must be added to the cooling system and is
available from Dealers Part No FW 15.

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 2

TORQUES

TORQUE VALUES -- VARIOUS Nm lbf ft Kgf m

Water Pump--to--Cylinder Block 48 35 3.6

Water Pump Cover--to--Pump 27 20 2.8
Thermostat Housing Bolts 24 18 2.4
Fan Blade to Support Body 27 21 2.8
Temperature Senders 20 15 2.0

SPECIAL TOOLS

(Prior Tool Numbers, where applicable, shown in brackets)

DESCRIPTION V.L. CHURCHILL NUDAY FNH

TOOL No. TOOL No. TOOL No.
Water Pump Seal Replacer FT.6209 4672 T87T--6312--A

SEALANTS

Part Number Name

82995768 Sealer--Anaerobic Low strength

82995776 Sealer--Silicone

82995774 Sealer--Polyester Urethane

82995773 Sealer--Anaerobic

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 3

FAULT FINDING

IMPORTANT: When effecting a repair the cause of The following table lists problems and their possible
the problem must be investigated and corrected to causes with recommended remedial action.
avoid repeat failures.

PROBLEM POSSIBLE CAUSES REMEDY

Engine overheats 1. Hose connection leaking or 1. Tighten hose connection,

collapsed renew hose if damaged

2. Radiator core tubes blocked 2. Check free flow

3. Radiator cap defective or not 3. Renew radiator cap

sealing

4. Radiator leakage 4. Repair/renew radiator

5. Radiator fins restricted 5. Clean with compressed air

6. Faulty thermostat 6. Renew thermostat

7. Internal engine leakage 7. Check for source of leakage,

renew gasket or defective parts

8. Water pump faulty 8. Overhaul water pump

9. Exhaust gas leakage into 9. Renew cylinder head gasket,

cooling system check head for damage or
distortion

10. Coolant aeration 10. Tighten all connections and

check coolant level is correct.
Ensure cylinder head gasket
has not blown

11. Cylinder head gasket 11. Renew cylinder head gasket

improperly installed

12. Hot spot due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system

13. Obstruction to radiator air flow 13. Remove the obstruction

14. Extended engine idling 14. Do not allow engine to idle for
long periods

15. Oil cooler tube blocked 15. Clean

Water temperature gauge fails to 1. Faulty temperature sender 1. Renew sender switch
reach normal operating tem-
perature 2. Incorrect or faulty thermostat 2. Renew thermostat

3. Faulty water temperature 3. Renew temperature gauge

gauge

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 2

COOLING SYSTEM DESCRIPTION AND

OPERATION (OP NO 10 400)

NOTE: Do not operate an engine without a thermo-

stat. It is recommended that a solution of a 50%
clean water, and 50% recommended antifreeze,
see specifications, is used. When the recom-
mended Antifreeze is not used, a 5% solution of
the recommended inhibitor must be added to the
cooling system.

The cooling system for the new generation of en-

gines, is of the recirculating by--pass type with full
length water jackets for each cylinder. The coolant
is drawn from the bottom tank of the radiator by the
water pump, which passes the coolant to the cylin-
der block. This coolant then flows through cored
passages to cool the cylinder walls.

The thermostat is located in the top of the water

pump body, and controls the flow of the water as re-
quired by temperature changes.

NOTE: A faulty thermostat may cause the engine

to operate at too hot, or cold, an operating tempera-
ture. If not replaced this could result in a damaged
engine, or impaired engine performance.

When the thermostat is closed, Figure 1, a recir-

culating by--pass is provided to allow the coolant to
recirculate from the head to the block to effect a
faster warm--up.

1
Once the engine has reached its normal operating
temperature, the thermostat will open, Figure 2 and
allow water to be drawn through the radiator by the
pump action. Cooled water then returns to the en-
gine system.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 5

OVERHAUL

Radiator Removal

1. Raise hood, disconnect battery

2. Remove the engine coolant drain plug (1)

situated behind the oil filter body on the left
hand side of the engine and drain the coolant
into a suitable clean container.

Remove:

3. Air conditioning (3) and oil cooler (4) radiators if

fitted from front of radiator.

4. Side guards from radiator shell (5)

5. Remove the expansion radiator cap (1) or

radiator cap (2) to speed up the draining, using
caution if the system is hot.

4
6. Lower radiator hose -- Drain into suitable
container

7. Engine oil cooler connection

8. Heater hose connection

RIGHT HAND SIDE

9. Top hose

10. Engine oil cooler connection

11. Ensure all pipes are disconnected, looms are

unclipped, and away from the radiator
assembly.

12. Remove the attaching bolts and lift the radiator

(6) up and clear of the vehicle.

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 2

Inspection and Repair

1. Inspect the fins for damage and repair as

required, ensuring they are free from any
obstruction.

2. Check the radiator for leaks, and repair as

required. The radiator is fitted with an engine oil
heat exchanger in the lower tank which should
be checked for leaks.

Installation

Installation of the radiator follows the removal pro-

cedure in reverse, but upon installation observe the
following requirements.

1. Refill the system through the coolant recovery

radiator pressure cap (1) until completely full.
Re--install the 0.9bar (13 lbf in2) radiator cap
(2) and continue filling through the expansion
tank until full. Refit expansion cap.

2. If engine oil cooler tubes have been disturbed

check the engine oil level.
5
3. Run the engine for several minutes checking
for leaks, topping up any fluid levels that may
have settled during testing.

THERMOSTAT REMOVAL

1. Drain the coolant system below that of the level

of the thermostat housing.

2. Remove the thermostat housing retaining bolts

(1), and move the housing with tube attached
to one side.

3. Withdraw the thermostat (2) from the housing,

along with the gasket.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 7

Inspection and Repair

1. Place the thermostat in a container of water,

and raise the temperature to 100!C (212!F). If
the thermostat fails to open when hot, or close
properly when cooled, it must be replaced.

7
Installation

Installation of the thermostat is the reverse of the

removal procedure but observing the following:

1. Prior to re--assembly ensure the thermostat

housing faces are clean and free of old sealer
or gasket material. Clean the faces with a small
stone or fine grit paper.

2. Coat a new gasket with sealer 82995774 and

position in the recess on the thermostat
housing, prior to installing the thermostat.

3. Coat the edge of the thermostat with grease

and install, with the heat element located in the
cylinder head.

4. Refit the thermostat housing and torque the

two bolts to 20--28Nm (15--21 lbs ft).

5. Ensure the correct grade, and quantity of

antifreeze, is added to the coolant.
Recommended content mixture is Water 50%,
with 50% Ambra Agriflu specification.

TEMPERATURE WARNING SENDER

1. The engine temperature warning (1), is located

on the thermostat housing.
Installation

1. If a fault occurs fit a new sender and apply

sealant to the threaded portion of the sender
body and torque to, 16--24Nm (12--18 lbf ft).

604.55.041.00 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 2

Fan Belt Tensioner 8

A. Fan Belt with Air Conditioning B. Fan Belt less Air Conditioning

1. Air conditioning Compressor (optional) 6. Water Pump Pulley

2. Idler Pulley (with Air Conditioning only) 7. Alternator
3. Crankshaft Pulley 8. Torque Wrench
4. Tensioner Assembly 9. Tensioner Attaching Bolt
5. Idler Pulley

FAN BELT TENSIONER REMOVAL Raise the lever up through an arc of 20!
maximum. If the torque bar does not ”break”
1. The fan belt should be removed in the following within the range a new tensioner assembly is
manner. Place a lever with socket attachment required.
onto the tensioner retaining bolt and gently
lever the tensioner up, Figure 7. Remove the 2. Ensure the tensioner pulley rotates freely by
fan belt from the pulley and allow the tensioner hand. If not replace with new parts.
to return to its untensioned position once the
belt has been removed. Re--Assembly
2. Remove the tensioner from the pump by
loosening and removing the centre attaching 1. Fit a new pulley to the assembly if required, and
bolt. torque the attaching bolt to 34.5--44 lbf ft
(46.5--60 Nm) 4.7--6.1 kgfm.
Inspection and Repair 2. To re--assemble the arm assembly, position the
tensioner on to the water pump, fit the mounting
1. Checking of the tensioner assembly operation bolt through the assembly, and torque the bolt
should be carried out with the tensioner to 34.5--44 lbf ft (46.5--60 Nm) 4.7--6.1 kgfm.
assembly still attached to the water pump. To
check the spring load, place a ”break back” 3. Refitment of the fan belt is the reverse of the
torque bar pre--set to 52--63 lbf ft (70--85 Nm) removal procedure, but ensure the ”Poly V” belt
7.1--8.7 kgfm, on to the pulley attaching bolt. is positioned correctly onto all of the pulleys.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 9

IDLER PULLEY

1. One or two idler pulleys are fitted to the vehicle,

dependent on the model. One is fitted to the
right hand side of the engine front cover, in
front of the oil filler cap. The other, where air
conditioning is fitted, is situated to the left hand
side of the front cover close to the crankshaft,
Figure 7.

2. Check that the idler pulley rotate freely, if tight

or worn, replace with new. Removal and
replacement is by the attaching bolts through
the centre of the bodies. Torque the bolts to
34.5--44 lbf ft (46.5--60Nm) 4.7--6.1 kgfm.

WATER PUMP REMOVAL

1. Drain the cooling system.

2. Remove the radiator.

3. Loosen or lever the fan belt tensioner to ease

the tension and remove the fan belt from the
vehicle.

4. Withdraw the four bolts which pass through the

water pump (4) and into the block and slide the
pump forward and away from its rear
connector (1), removing the two sealing ’O’
rings (2), Figure 9. 9

5. Alternatively withdraw six bolts, four in the

water pump and two in the pump to block
connector and remove from the engine as a
complete unit, discarding the gaskets (3),
Figure 9.

Disassembly

1. To remove the fan and clutch assembly hold

the pump pulley in a fixed position, and placing
an open ended spanner on the nut to the rear of
the clutch assembly spacer, loosen the nut in a
clockwise direction.

2. Using a puller Tool (1) No. 1002 or 9198 and a

sleeve (2) slightly smaller than the pulley shaft,
ease the pulley from its shaft, Figure 10.

Water Pump Pulley Removal 10

1. Tool No FT 1002
2. Sleeve
3. Pump Body
4. Support

604.55.041.00 01 - 1998
10 SECTION 10 -- ENGINE -- CHAPTER 2

3. Using a pair of heavy snap ring pliers, remove

the snap ring (1) from the rear of the pump
body. Carefully ease out the backplate (2).
Remove and discard the ’O’ ring (3), Figure 11.

11
4. To remove the impeller/shaft assembly, place
the pump body (3) impeller side down. Support
the pump in a manner to allow the impeller
diameter to drop clear of the pump as it is
pressed out (1) from the pump body using the
correct tool (2), Figure 12.

NOTE: Apply pressure to the outer bearing race

and shaft simultaneously to remove, using the
correct tool. Do not press the centre shaft only as
the shaft may move, leaving the outer bearing case
in the pump body.

5. With the impeller/shaft assembly (3) removed 12

from the pump, place the impeller (2) on
supports (4) and press out the shaft (3)
assembly from the impeller, Figure 13.

6. The seal assembly (5) attached to the bearing

shaft (3) is not removable or serviceable.
During the manufacturing process the seal is
pressed onto the shaft and is destroyed on
removal, this is to meet pre load conditions and
maintain an effective water seal.

Inspection and Repair

1. Check the bearing shaft and seal assembly for

signs of wear or leaks and if evident, the
assembly must be replaced with new parts.

13
2. The impeller should be checked for worn or
damaged vanes and must be replaced if not to
an acceptable standard.

3. Clean and check the pump body for signs of

cracks, erosion or leaks. If any of these faults
are in evidence and likely to cause pump failure
at a later date, the pump body must be repaired
or replaced with a new one.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 11

Re--Assembly

1. To install the bearing (2) into the pump body

(3), place the body rear face down onto a flat
surface. Install the bearing with the longer
stepped end of the shaft (1) in the body and
using a sleeve (4) that contacts the bearing
outer race only, press (5) the bearing into the
body. Once installed in the body the bearing
case end face must be flush with the pump
front face to within 0.000--0.006 in 0.00--0.076
mm). Reference ”6”, Figure 14.

14
2. With the water pump (5) placed front face down
and the shaft (1) supported, place the seal
assembly (4) on the end of the shaft, with its
smallest diameter uppermost. To insert the
seal assembly place Tool No. FT6209 or 4672
(3) over the seal and press (2), until the lip on
the seal body seats on the pump body,
Figure 15.

15
3. With the seal installed correctly the seal
working height should be maintained at
0.470--0.490 in (11.9--12.4 mm), Reference
”A”, Figure 16.

16
4. With the water pump rear face up (2) and the
shaft (4) supported, place the impeller (3) over
the shaft and press (1) the impeller into the
water pump body. Installed correctly the face
of the impeller fins to the operating face of the
water pump should be 0.010--0.035 in
(0.25--0.88 mm), Reference ”A” Figure 17.

5. Check the dimension from the rear face of the

impeller to the rear face of the pump. The
dimension should be maintained at 0.46--0.485
in (11.6--12.2 mm), Reference ”B”, Figure 17.

604.55.041.00 01 - 1998
12 SECTION 10 -- ENGINE -- CHAPTER 2

6. With the pump rear face down and the shaft

supported, press the pulley onto the shaft
ensuring that the pulley front face to the ear
face of the pump dimension is, 5.091--5.101 in
(127--129 mm), Reference ”A” Figure 18

7. Ensure a new ’O’ ring is fitted and place the

water pump backplate in position, refitting the
snap ring into its groove, Figure 10. Make sure
the water pump pulley/impeller assembly
rotates freely by hand prior to re--assembly. If
not disassemble and recheck the relevant
dimensions.
18

Installation

1. Installation of the water pump to the engine is

the reverse of disassembly, but observing the
following requirements.

Clean the block face and fit a new gasket (3)

between the connector and block face, Figure 9,
then torque the two bolts to 15--21 lbs ft (20--28
Nm) 2.0--2.9 kgfm.

Fit two new ’O’ rings (2) over the connector outlet
port (1) as required, Figure 19. 19

Place the water pump (4) over the connector and

install and torque the four pump bolts to 45--50 lbs
ft (61--68 Nm) 6.2--6.9 kgf m.

Ensure the fan belt tensioner pulley rotates freely

and the swinging arm of the tensioner returns to
rest freely. Gently lever the arm up to enable the
fan belt to be seated in the grooves on the pulleys.
Refit the fan blade assembly.

After installation of the radiator, refill the cooling

system as previously described and run the engine
checking for leaks.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 2 13

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 3 1

SECTION 10 -- ENGINE
Chapter 3 -- Lubrication
CONTENTS

Section Description Page

10 304 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS

Oil Pump

Rotor Clearance 0.025--0.15mm (0.001--0.006 in)

Rotor to Pump Housing Clearance 0.15--0.28mm (0.006--0.011 in)

Rotor End Play 0.025--0.089mm (0.001--0.0035 in)

Oil Pressure 1.24 bar (18 lb/in2) minimum at idle speed,

2.76 bar (40 lb/in2) minimum at rated speed

Pump Gear to Camshaft Gear Backlash 0.40--0.56mm (0.016--0.022 in)

Oil Filter Support

Relief Valve, Operating Pressure 4.0 bar (59 lbs in2)

Flow Rate 68 litres/min (15 imp gals/min) 18 US gals/min

Oil Type

API Engine Oil & Filter

Temperature Oil Viscosity and Type Classification Change Period (hours)

Low Ash , SAE 5W 150

--12!C or Low Ash SAE 5W/20 CF--4/SG 150
(Below 10!F) or SAE 10W--30 150
--12!C to 4!C Low Ash , SAE 10W Series 3 150
or SAE 10W--30 CF--4/SG 300
(10!F to 40!F )

0!C to 32!C Low Ash , SAE 30W Series 3 300

(32!F to 90!F) CF--4/SG 300
or SAE 10W--40
Above 24!C Low Ash , SAE 30W Series 3 300
( 75!F ) CF--4/SG
or SAE 15W--40

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 3

When using diesel fuel with a sulphur content between 1% and 1.3% use only oils listed above but reduce the oil
and filter change period to every 50 hours .

ENGINE OIL CAPACITIES (With Oil Filter)

Model Litres Imp Gals U.S Gals

4 CYL 11.4 2.5 4.8

TORQUE VALUES

TORQUE VALUES -- VARIOUS Nm lbf ft Kgf m

Oil Pan Drain Plug 41 30 4.2

Oil Pump to Block 23 17 2.3
Oil Filter Adaptor Bolts 42 31 4.2
Oil Filter Mounting Bolt Insert 34 25 3.5
Oil Pressure Switch Assembly 31 23 3.2
Idler Pulley Bolt 54 40 5.5
Pump Connector to Block 24 18 2.4

SPECIAL TOOLS

DESCRIPTION V.L. CHURCHILL NUDAY FNH

TOOL No. TOOL No. TOOL No.
Adjustable Bridge Puller 518 9539 09539

Shaft Protectors 625--A 9212 09212

Step Plate Adaptors 630--S 9210 09210

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 3 3

DESCRIPTION AND OPERATION lubricated by oil pressure jets mounted adjacent to

each main journal housing.
LUBRICATION SYSTEM (OP NO 10 304)
The camshaft drive gear bushing is pressure
Lubrication of the engine, figure 1, is maintained by a lubricated through a drilled passage from the front
rotor type oil pump mounted in the rear of the engine main bearing. The gear has small oil passages
block, behind the flywheel. The oil pump is driven machined on both sides allowing excess oil to
from the rear of the camshaft and draws oil from the escape.
engine oil pan through a tube and screen assembly.

Timing gears are lubricated by splashed oil from the

A spring loaded relief valve is integral with the oil filter cam follower chamber, and the pressure lubricated
body mounted on the left hand side of the engine camshaft drive gear bushing.
block, and prevents over pressurisation of the
system.
An intermittent flow of oil is directed to the valve
A spin on type oil filter is mounted externally to its rocker arm shaft assembly via a drilled passage in
support housing, on the left hand side of the engine. the cylinder block. This is located vertically above
Oil flows from the filter to the main oil gallery, which above No 1 camshaft bearing, and aligns to a hole in
runs the length of the cylinder block, which also the cylinder head. The rotation of the camshaft
intersects the camshaft follower chamber. allows a controlled intermediate flow of lubrication.

The main gallery also supplies oil to the crankshaft The turbocharger where fitted, is supplied with oil
main bearings, connecting rods, big ends, small from the oil filter support housing, mounted on the left
ends. The underside of the pistons and pins, are hand side of the engine.

Engine Lubrication System With Turbocharger Fitted 1

Engine Oil Flow

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 3

FAULT FINDING

PROBLEM POSSIBLE CAUSES REMEDY

Oil pressure warning 1. Bulb burnt out 1. Renew bulb

light fails to operate
2. Warning Light pressure 2. Renew pressure switch
switch faulty

3. Warning light circuit faulty 3. Check and renew wiring

Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for

damage, change as required.
Drain and refill with specified
oil and renew filter. Ascertain
cause of dilution

2. Insufficient oil supply 2. Check oil level and top up as

necessary. Overhaul or renew
pump as necessary. Check oil
filter is not clogged

3. Low oil pressure 3. Overhaul pump or relief valve

as necessary

4. Excessive timing gear 4. Install new thrust bearing liner

backlash

Engine overheats 1. Oil cooler tube blocked 1. Check free flow

Excessive oil con- 1. Engine oil level too high 1. Reduce oil level
sumption
2. External oil leaks 2. Renew gaskets and seals,
where necessary. Check
mating surfaces for damage
or distortion

3. Worn valves, valve guides or 3. Renew

bores

4. Cylinder head gasket leaking 4. Renew gasket. Check head

for damage or distortion

5. Oil loss past the pistons and 5. Renew rings and/or rebore/
rings re--sleeve block as necessary

6. Oil cooler leak 6. Repair/renew oil cooler

assembly

7. Blocked rocker cover filter 7. Replace filter

8. Damaged rocker cover or 8. Repair damage

breather pipe

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 3 5

PROBLEM POSSIBLE CAUSES REMEDY

Low oil pressure 1. Engine oil level low 1. Top up, as necessary
2. Wrong grade of oil 2. Drain and refill with correct
grade of oil

3. Blocked oil filter 3. Replace filter

4. Oil pump drawing air 4. Repair leak
5. Blocked oil pump sump 5. Clean pump screen
screen

6. Oil pressure relief valve faulty 6. Fit new relief valve

7. Oil pump worn 7. Renew Oil Pump
8. Excessive oil pump rotor and 8. Overhaul pump
shaft assembly clearance

9. Excessive main or 9. Install new bearings inserts

connecting rod bearing and / or re--grind crankshaft
clearance

OIL PUMP OVERHAUL

NOTE: The oil pump can only be removed with the

engine split from the transmission, and the
flywheel, back plate, engine oil pan, and oil pump
tube removed.

1. Prior to pump removal check pump gear to

camshaft gear backlash, does not
exceed, 0.40--0.56mm (0.016--0.022 in).

2. Loosen and remove the camshaft gear, to

expose the oil pump, detach the 3 pump
mounting bolts, and withdraw the pump from
the block.

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 3

Disassembly

1. Loosen and remove the pump face plate to

body bolts (1). Disassemble the pump and
discard the O--rings (2).

3.
Inspection and Repair

1. Wash all parts in a suitable solvent and inspect

inside of pump plate, and body, for excessive
wear or damage. If visually okay check in the
following manner.

2. Invert pump plate/rotor assembly, and place

outer rotor over inner rotor. Placing a ruler (1)
across top of both, slide a feeler gauge (2),
between ruler and inner rotor, to
0.025--0.089mm (0.001--0.0035 in).

4.
NOTE: If not to specification replace the oil pump,
as reduced pump pressure through wear could
result in reduced engine life.

3. Place outer rotor in pump body and check

clearance, by inserting a feeler gauge (1)
between the rotor and body. Check to a max of
0.55mm (0.022 in). If exceeded a new pump is
required.

5.
Installation

1. Clean and coat parts in new engine oil. Place

outer rotor in pump body, and ensure free
rotation. Insert inner rotor, and pump plate
assembly, into the body and ensure that shaft
is fully seated into bushing.

2. Assemble the front plate to the body

bolts,and torque to,
23.0--28.4Nm (17--21 lbf ft) 2.3--2.9kgf m.

IMPORTANT: After tightening ensure the drive

gear rotates freely by hand, at least 5 revolutions, if
not ‘‘disassemble” and repeat the exercise.
6.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 3 7

3. Fit a new O--Ring to the output tube, lubricate

and insert the pump into the block tightening to,
23.0--28.4Nm (17--21lbf ft).

4. Fit a new O--Ring into suction port. Lubricate

and insert tube/screen assembly (1) into pump
through bottom of engine. Fitting a new gasket
(2), torque the attaching bolts (3) to,
27--34Nm (20--25 lbf ft).

5. Refit gears and check backlash as previously

described, refer to chapter 1.

7.
6. Ensure the engine backplate is fitted correctly
and the bolts are torqued up in sequence.
Refer to chapter 1.

8.
Oil Filter Support Assembly

Removal

1. Unscrew and discard the old filter. Loosen the

4 attaching bolts and oil connections and
remove the filter support assembly from the
block. Discarding the O--Rings.

2. Clean the filter support in a suitable solvent.

3. Remove pressure relief valve plug (3),

removing valve (1) and spring (2). To ensure
correct operation of the pressure relief valve,
check spring length,
Free length = 52.8mm (2.08 in).
Compressed length = 37.0mm (1.46 in) using
a weight of 15.6 kgs (34.3 lbs).

4. Check the parts for damage, wear, and replace

as necessary. Failure to do so could result in
premature wear to the engine, due to oil
bypassing the filter and returning back to the
system.

604.55.041.00 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 3

Installation

1. Lubricate the pressure relief valve and spring

and insert into housing, ensuring free
movement.
Fit a new ‘O’--Ring to the plug and torque to,
55N m (42 lbf ft).

NOTE: On some models including the

2
1

APB10011
10.
2. Fit tube (1) to the connector and torque to
27Nm (20 lbf ft).

3. Refit the oil filter head to the engine block with

new O--rings (2) and plug where required as
above and torque the bolts to,
34--47Nm (26--35 lbf ft)

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 4 1

SECTION 10 -- ENGINE

Chapter 4 -- Fuel General

CONTENTS

Section Description Page

10 200 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Injection Pump Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hand and Foot Cable Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Tank and Fuel Filter Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIFICATIONS

Turbocharger type: Garrett T250

LUCAS C.A.V. pump

Type DPS or DPS 200 Series, integral speed governor

and advance device

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2 SECTION 10 -- ENGINE -- CHAPTER 4

Fuel System - General MODEL

8¢2 16¢4 12¢12 24¢24 16¢16

Fuel Tank Capacity . . . . . . . . . . . . 130 litres 160 litres

28 imp. galls 35 imp. galls
34 U.S. galls 42 U.S. galls

Fuel Filter Type . . . . . . . . . . . . . . . . Single Disposable Element and Separator

Fuel Filter Change Interval . . . . . . 600 hours 600 hours 600 hours 600 hours 600 hours

Injector Nozzle Opening DPS = 240--250 bar DP200 = 290 -- 300 bar
Pressure . . . . . . . . . . . . . . . . (3480--3590 lbs in2) (4230--4350 lbs in2)
Reset at . . . . . . . . . . . . . . . . . 225 bar --275 bar
(3260 lbs in2) (--3990 lbs in2)

Injection Pump Type . . . . . . . . . . . DPS DPS DP203 DP203 DP203

Distributor Distributor Distributor Distributor Distributor

Pump Rotation Firing Order . . . . . Clockwise Clockwise Clockwise Clockwise Clockwise

1342 1342 1342 1342 1342

Injector Change Interval . . . . . . . . 1200 hours 1200 hours 1200 hours 1200 hours 1200 hours

Maximum No-Load Speed . . . . . . 2320 (except TS110 Turbo = 2220)

Idle Speed  50 . . . . . . . . . . . . . . 750 750 750 750 750

Rated Speed . . . . . . . . . . . . . . . . . . 2170 (except TS110 Turbo = 2070)

TORQUE VALUES

DESCRIPTION N∙m ft. lbs. kgf/m

Throttle Cable Locknuts 50 37 5.1
Throttle Lever Stop Bolt Locknut 10 7 1.0
Fuel Tank Strap Retaining Nut 2.5 1.8 0.25
Fuel Tank Strap Locknut 25 18 2.5
Fuel Tank Shutoff Valve 14 10 1.4
Fuel Tank Leak-Off Elbow 14 10 1.4
Leak-Off Pipe to Elbow 24 18 2.4
Thermostart Plug 37 27 3.8
Thermostart Pipe Union 10 7 1.0
Leak-Off Pipe to Injector Line 24 18 2.4
Fuel Tank Sender Retaining Screws 2.5 1.8 0.25
Fuel Filter Element Retaining Bolt 10 7 1.0
Fuel Filter Retaining Bolts 30 22 3.1
Exhaust Muffler Retaining Clamp 35 26 3.6
Air Cleaner Retaining Bolts 55 40 5.6
Air Cleaner Hose Clamps 2.5 1.8 0.25
Air Cleaner Restriction Indicator Switch 12 9 1.2

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SECTION 10 -- ENGINE -- CHAPTER 4 3

DESCRIPTION AND OPERATION

Right Hand View of Engine -- Emisionised Engine 1

1. Air Filter 6. Alternator 10. Fuel Filter
2. Coolant Recovery Tank 7. Water Pump 11. Engine Oil Dipstick
3. Air Conditioning Condenser 8. Fuel Sedimentor Separator 12. Starter Motor
(where fitted) 9. Fuel Injection Pump -- 13. Electric Fuel Pump
4. Coolant Radiator Emisionised 14. Cold Start
5. Hydraulic Oil Cooler

FUEL SYSTEM (OP NO 10 200) DP203

The fuel is drawn from the fuel tank, through the

The diesel fuel system consists of a fuel tank, sediment separator and fuel filter by the electric lift
mechanical or electric lift pump, fuel filter/sediment pump, and then fed into the injector pump.
separator, D.P.S or D.P.S. 200 series fuel injection
pump, fuel injectors and inter-connecting fuel lines.
A dry type air cleaner removes dirt and contaminants
The transfer pump delivers fuel to the injection pump
from the air intake.
to supply fuel at high pressure to each injector and
also provides extra fuel which lubricates and cools
DPS the injection pump. This extra fuel is recirculated via
a fitting on the fuel injection pump governor control
housing to the fuel tank by means of the injector
The fuel is drawn from the fuel tank by a mechanical leak-off line.
lift pump which pumps fuel into the sediment
separator. The fuel is then drawn from the sediment
separator to the fuel injection pump inlet via the fuel On all models the excess fuel that leaks past the
filter by means of the vacuum created by the transfer needle valve of the injectors is directed back into the
pump which forms an integral part of the fuel injection fuel tank at the filler neck by means of the injection
pump. leak-off line.

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4 SECTION 10 -- ENGINE -- CHAPTER 4

FUEL TANK (OP NO 10 216)

All models have a ”Plastic” fuel tank located on the

left of the vehicle below the driver platform. The
tank is vented through the breather and has a
lockable filler cap (1).

2
LIFT PUMP ELECTRIC EMISSIONISED
ENGINE ONLY (OP NO 10 210)

Mounted on the right hand side of the engine above

the fuel filter is an electrical lift pump (1). The pump
draws fuel through the sediment separator (2) and
the fuel filter (4). The fuel is then pressurised and
fed into the fuel injection pump.

3
SEDIMENT SEPARATOR (OP NO 10 206)

Positioned on the right hand side of the engine is

the fuel sediment separator. The assembly
consists of a cast head which is bolted to the
engine, and a glass sediment separator.

The fuel is fed into the sediment separator side of

the head to be directed down and around the edges
of the separator cone, the larger particles of dirt
and water (which are heavier than fuel oil) are
separated out and sink to the collecting bowl. The
cleaned fuel is then fed into the fuel filter.
4

FUEL FILTER (OP NO 10 206)

The filter (3) positioned on the right hand side of the

engine behind the fuel pump directs the fuel
through the filter head (2) to be directed down
through the filter paper (3) into the base chamber.
The filtered fuel then flows up the center tube of the
element to the filter head outlet and flows onto the
injection pump.

The drain plug (4) permits contaminated fuel to be

drained from the filter. 5

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SECTION 10 -- ENGINE -- CHAPTER 4 5

THERMOSTART (OP NO 10 210)

To aid engine starting in cold weather conditions, a

thermostart system incorporating an integral
reservoir system is available on all models.

The thermostart system is made up of a plug

assembly screwed into the intake manifold, a fuel
line connected to the injector leak-off tube and an
electrical circuit, connected to the ignition switch.

The plug assembly consists of a check valve and

electrically heated element.
6
Fuel is gravity fed to the plug assembly and, when
operating the key start/stop switch and the
thermostart switch, the heater and “igniter” coils 1
are both energized. The “heater” coil opens a
check valve which allows diesel fuel to flow through
the thermostart. The fuel is ignited by the “igniter”
coil in the manifold, heating the intake manifold air
prior to it entering the combustion chamber.

When the thermostart switch is released to the off

position, the electrical current is disconnected from
the thermostart and the check valve closes.

7
FUEL PUMP (OP NO 10 210)

The fuel injection pump fitted to these vehicles is

either the Lucas/CAV DPS (non emissionised),
Figure 7, or DP203 (emissionised), Figure 8, type.
The fuel pump which is fed by either an electric lift
pump or draws fuel into itself via the transfer pump,
supplies fuel at high pressure to the fuel injectors.

8
INJECTORS

The fuel injectors mounted in the cylinder head

supply fuel in the form of a spray pattern into the
cylinder bores. The controlled amounts of fuel
ensure optimum engine performance throughout
the operating range.

Emissionised and non emissionised injectors have

different characteristics and are not
interchangeable.

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6 SECTION 10 -- ENGINE -- CHAPTER 4

FAULT FINDING

DIESEL ENGINES

IMPORTANT: Whenever making a repair, the reason for the cause of the problem must be investigated and cor-
rected to avoid repeat failures.

The following tables list problems and their possible causes with recommended corrective action.

GENERAL

PROBLEM POSSIBLE CAUSES CORRECTION

Fuel not reaching injection pump 1. Restricted fuel filters 1. Check and flush the fuel
filters clean.
2. Air in system 2. Bleed the fuel filters.
3. Fuel leakage 3. Check the fuel lines and
connectors for damage.

Fuel reaching nozzles but engine 1. Low cranking speed 1. Check the cranking speed
will not start
2. Incorrect throttle 2. Check the throttle control
adjustment rod travel
3. Incorrect pump timing 3. Check the pump timing
4. Fuel leakage 4. Check the fuel lines and
connectors for leakage
5. Faulty injectors 5. See injector
troubleshooting
6. Low compression 6. Check the engine
compression

Engine hard to start 1. Low cranking speed 1. Check the cranking speed
2. Incorrect pump timing 2. Check the pump timing
3. Restricted fuel filters 3. Replace filters
4. Contaminated fuel 4. Check for water in the fuel
5. Low compression 5. Check the engine
compression
6. Air in system 6. Check for air leaks on the
suction side of the system

Engine starts and stops 1. Fuel starvation 1. Check and flush clean
restricted fuel lines or fuel
filters
2. Contaminated fuel 2. Check for water in the fuel
3. Restricted air intake 3. Check for restrictions in the
air intake
4. Engine overheating 4. Check cooling system
5. Air in system 5. Check for air leaks on the
suction side of the system

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SECTION 10 -- ENGINE -- CHAPTER 4 7

PROBLEM POSSIBLE CAUSES CORRECTION

Erratic engine operation (surge, 1. Fuel leakage 1. Check the injector lines and
misfiring, poor governor connectors for leakage
regulation)
2. Fuel starvation 2. Check and flush clean
restricted fuel lines or
filters
3. Incorrect pump timing 3. Check the pump timing
4. Contaminated fuel 4. Check for water in the fuel
5. Air in system 5. Bleed the fuel system
6. Faulty or sticking injector 6. See injector
nozzles troubleshooting
7. Incorrect engine timing 7. Check for faulty engine
valves

Engine emits black smoke 1. Restricted air intake 1. Check for restricted air
intake
2. Engine overheating 2. Check cooling system
3. Incorrect timing 3. Check the pump timing
4. Faulty injectors 4. See injector
troubleshooting
5. Low compression 5. Check the engine
compression
6. Incorrect engine timing 6. Check the engine valves

Engine does not develop full 1. Incorrect throttle 1. Check for insufficient
power or speed adjustment throttle control movement
2. Incorrect maximum no-load 2. Check maximum no-load
speed speed adjustment
3. Fuel starvation 3. Check and flush clean
restricted fuel lines and
filters
4. Air in system 4. Check for air leaks on the
suction side of the system
5. Incorrect timing 5. Check pump timing
6. Low compression 6. Check engine compression
7. Incorrect engine timing 7. Check for improper valve
adjustment or faulty valves

604.55.041.01 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 4

ADJUSTMENTS FUEL INJECTION PUMP

(OP NO 210)

PRIMING THE FUEL SYSTEM

NOTE: The fuel system should be primed

whenever fuel system components are removed or
disconnected in order to expel any air in the
system.

1. Make sure there is sufficient fuel in the tank

and all connections are tight.

2. Operate key start switch to activate the electric

fuel pump. An audibel difference is dectectable
when the system is primed, this may take up to
5 minutes.

NOTE: The bleed screw in the filter head is on the

intake side and must be kept closed during priming.

10
3. Operate the hand primer on the filter head, to
pump fuel into the filter assembly. Continue to
pump the hand primer until resistance is felt,
indicating that the system is pressurised
(primed).

NOTE: Attempt to start the engine. If it does not

start, continue through Step 5.

11
4. With the throttle in the maximum no-load
speed position, operate the starting motor to
crank the engine. The fuel injection pump is
self-venting and does not require bleeding.

IMPORTANT: Do not crank the starting motor con-

tinuously for more than 60 seconds as doing so
may cause starting motor failure.

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SECTION 10 -- ENGINE -- CHAPTER 4 9

5. If the engine fails to start after 60 seconds,

repeat the priming procedure outlined above.

6. Run the engine and check for leaks.

NOTE: Turbocharged engines only - The high

operating speed of the turbocharger makes it
essential that adequate lubrication is assured
when the engine is started. Therefore, idle the
engine at 1000 RPM for one minute before driving
the tractor.

IDLE SPEED ADJUSTMENT (ALL ENGINES)

1. With the engine running and at normal

temperature, disconnect the throttle cable at
the injection pump.
2. Loosen the locknut and adjust the idle speed
stop screw (1) until the specified idle speed of
700--800 RPM is obtained. Tighten the locknut
and reconnect the throttle cable. 1
3. Operate the throttle lever several times and
check that the idle speed is correct. If
excessive free play is felt in either the foot or
hand throttle after adjustment, proceed to 12
“Throttle Linkage Adjustments” in this section.

MAXIMUM NO-LOAD SPEED ADJUSTMENT

(ENGINES WITH DPS NON EMISSIONISED
ONLY)

IMPORTANT: The maximum no-load speed screw

is adjusted and sealed at the factory for correct fuel
delivery and maximum no-load speed. If the maxi-
mum no-load speed is above or below the specifi-
cation , adjustment may be made as follows:
1. With the engine running and at normal
operating temperature, disconnect the throttle
cable at the injection pump.
2. Cut and remove the maximum no-load speed
stop screw sealing wire and remove the
locking sleeve.
3. Set the throttle lever at the injection pump in
the maximum no-load speed position, then
loosen the locknut and adjust the screw (1)
until the specified maximum no-load speed is
obtained. Tighten the locknut, and secure the
adjustment with a new sealing wire and locking 1
sleeve.
4. Be sure the throttle cable can be reconnected
to the injection pump and adjust the cable
length if necessary, see “Throttle Linkage 13
Adjustments” later in this section.

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10 SECTION 10 -- ENGINE -- CHAPTER 4

5. Reconnect the throttle cable and recheck the

maximum no-load and idle speeds using the
hand and foot throttles. If the maximum
no-load or idle speeds cannot be obtained,
proceed to “Throttle Linkage Adjustments.”

Foot Throttle Cable Replacement and

Adjustment (Op No. 10 220)

A single cable directly from the foot pedal operates

the fuel pedal lever.

1. Raise the engine hood

2. Remove the cable retaining clip and pull the

rubber adjusting nut from its support.

3. Remove the right hand instrument console

lower panel and remove the clip retaining the
cable to the foot throttle linkage (1), Figure 15
14
4. Remove the cable from the engine side.

5. Installation is the reverse of removal.

Adjustment

6. Adjust the cable at the injection pump.

Figure15, to remove all slack at the idle
position. Depress the pedal fully and ensure
that full throttle is achieved. If not achieved
adjust the stop bolt, (2) Figure 15, on the pedal
to allow further movement. If full throttle is
achieved too early in the pedal movement
again adjust the pedal stop to coincide with 6010085
injection pump full throttle. 15
Hand Throttle Cable Replacement and
Adjustment

A single cable from the hand lever attaches to a

pivot plate at the foot pedal assembly. This
actuates the injection pump, via the foot throttle
cable.

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SECTION 10 -- ENGINE -- CHAPTER 4 11

1. Remove the transmission lever console lower

panel. Remove the clip retaining the cable to 1
the lever, (1) Figure 16, and slacken the outer
cable adjusting nuts (2) and (3) Figure 16, and
slide the cable from the bracket. 2

6010086
16
2. Remove the right hand instrument console
lower panel and remove the clip retaining the
cable to the pivot plate (1) Figure 17.

3. Remove the cable from the tractor.

4. Installation is the reverse of removal.

6010085
17
Adjustment

1. Ensure that the foot throttle cable is correctly

adjusted as described above. Adjust the hand
throttle cable, using the two outer cable nuts, to
remove all slack from the cable when in the idle
position. Ensure that there is a slight clearance
between the hand throttle pivot plate and the
foot throttle assembly.

FUEL TANKS, FILTERS AND FUEL LINES

OVERHAUL (OP NO 10 216)

FUEL TANK Removal

NOTE: Prior to removing the fuel tank from the

tractor, first determine the quantity of fuel left in the
tank. It will be necessary to drain the tank of fuel.

1. Disconnect the battery, earth lead first.

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12 SECTION 10 -- ENGINE -- CHAPTER 4

Fuel Tank Removal

1. Remove left hand cab step. Lower rung.

2. Disconnect sender wiring from rear of tank.

3. Disconnect the two quick release fuel lines at

the engine to transmission buckle up point.

4. Loosen the front and rear tank retaining strap

nuts and unclip straps.

5. Remove the two tank support brackets.

(Remove ’R’ clips and withdraw clevis pins)
19
6. Lower tank to ground and withdraw from
vehicle.

7. Plug the exposed pipes to prevent

contamination.

20
Installation

Reinstall the fuel tank to the tractor and secure.

Connect the fuel line.

Fill the tank with approximately 22.7 Litres (5

gallons) 6 US gallons of diesel fuel and check for
leaks. If leakage occurs determine cause and
correct.

21
FUEL FILTER/SEDIMENT SEPARATOR
(OP NO 10 206)
Removal
1. Drain the filter and sediment separator of fuel,
by removing the bowl retaining nut (3).
2. Disconnect and remove the fuel lines from the
head of the filter/sediment separator assembly
and plug the exposed openings to prevent
contamination.
3. Remove the retaining bolts, then remove the
assembly from the tractor.
22

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 4 13

Disassembly
1. Remove the center retaining bolts and
separate the filter components.

2. Using clean fuel, wash out the filter bowl and

the glass bowl on the sediment separator.

Reassembly
Reassembly of the fuel filter/sediment separator
follows the disassembly procedure in reverse. On
reassembly, observe the following requirements:

1. Install a new filter element and sealing rings, be

sure the sealing rings are correctly positioned.

2. Tighten the center retaining bolts.

Installation
Installation of the fuel filter/sediment separator
assembly follows the removal procedure in
reverse. On installation, observe the following
requirements:
1. Tighten the retaining bolts.
2. Assemble the fuel pipes to the connectors in
the head and tighten the nuts until the stop is
reached (metal to metal contact).
3. Bleed the fuel system as previously described.

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14 SECTION 10 -- ENGINE -- CHAPTER 4

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 5 1

SECTION 10 -- FUEL
Chapter 5 -- Air Cleaners
CONTENTS

Section Description Page

10 202 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIFICATIONS

AIR CLEANER
Type . . . . . . . . . . . . . . . . . . . . . . Dry, Dual Element
Change Interval . . . . . . . . . . . . 600 hours (or more frequently when operating in adverse conditions)
Type . . . . . . . . . . . . . . . . . . . . . . Oil Bath
Service Interval . . . . . . . . . . . . 10 and 50 hours
Oil Type . . . . . . . . . . . . . . . . . . . Ambra Super Gold API CF--4 15G

TORQUE VALUES

DESCRIPTION ft. lbs. N∙m kgf/m

Air Cleaner Retaining Bolts 40 55 5.6

Air Cleaner Hose Clamps 1.8 2.5 0.25
Air Cleaner Restriction Indicator Switch 9 12 1.2

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 5

DESCRIPTION AND OPERATION

DRY AIR CLEANER

The tractors feature a dry element type air cleaner

located beneath the engine top hood panel.

Air enters the cleaner in a circular direction and

centrifugal force results in heavier particles being
thrown to the outside of the container and collecting
in the bottom of the cleaner. The lighter particles
are collected on the (outer) primary element.

The inner (secondary) element is located within the

outer element. The element protects the engine
from the finer dust particles that may have passed
through the outer element.

A vacuum indicator switch is mounted in the air

cleaner outlet tube and illuminates a warning light
on the instrument console when the air cleaner
requires servicing.

1
If the air cleaner restriction warning light illuminates
when the engine is running, stop the engine and
service the air cleaner.

2
IMPORTANT: The safety element must be re-
placed if damaged or clogged with dust, or if, after
cleaning or installing a new outer element, the
warning light remains on when the engine is run-
ning.

If the warning light remains on after installation of

both inner and outer elements, check the switch for
faulty operation by replacing with a switch known
to function correctly.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 5 3

WET AIR CLEANER

The pre cleaner removes large particles of debris.

The pre cleaned air is then drawn into the air

cleaner downwards to the surface of the oil bath
sump, where particles of dust pass and are
retained in the oil.

Air is then drawn through the oil soaked gauze filter,

where the fine particles of dirt in the air cling to the
oil in the gauze. Finally a dual paper element
removes any remaining particles. This ensures
that only clean air is drawn into the inlet manifold of
3
the engine.

IMPORTANT: The air cleaner will only fulfill this

function if it is correctly and regularly maintained.
A poorly maintained air cleaner will mean loss of
power, excessive fuel consumption and a
reduction in engine life.

FAULT FINDING

PROBLEM POSSIBLE CAUSES REMEDY

Air Cleaner Warning Light 1. Clogged Air Cleaner 1. Clean or renew outer element
illuminates
2. Clogged wet oil air cleaner 2. Clean gauze
gauze

Air Cleaner Warning Light 1. Vacuum Switch Faulty 1. Replace switch with a new one
illuminates, after filter service

OVERHAUL

REMOVAL (AIR FILTER ELEMENT)

1. Raise the engine hood.

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4 SECTION 10 -- ENGINE -- CHAPTER 5

DISASSEMBLY

2. Remove the wing nut and extract the outer

element.

3. With the outer element removed extract the

inner element.

5
INSPECTION AND REPAIR

1. Clean and examine the outer canister. Repair

any damaged seams.

2. Check the condition and fit of the rubber dust

collector.

3. If dust is present inside the outer element, it

must be replaced. If satisfactory, clean the
element.

4. Wearing safety goggles and using

compressed air not exceeding 2 bar (29 lbf/in2)
clean the element. Insert the air line nozzle
inside the element and blow the dust from the
inside to the outside. Blow loose particles from
the outside of the element by holding the
nozzle at least 150 mm (5.9in) from the
element.

5. If undamaged, wash the element every 300

hours or after five dry cleanings, whichever
occurs first, using the following procedure:

6
IMPORTANT: Never use fuel oil, solvent, or water
hotter than the hand can stand, otherwise the ele-
ment may be damaged.

A. Seal the small hole at the closed end of the

filter with a strip of adhesive tape and place
the filter, open end up, in a deep
flat-bottomed container or tub. Add a small
amount of non-sudsing washing powder
(automatic washing machine type) to the
inside of the filter element. Add warm
water35! C (100! F) to the inside of the
element until the level in the container is
just below the open end of the element. 7
Allow the element to soak for at least 15
minutes (but never more than 24 hours) in
the cleaning solution.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 5 5

B. After soaking, gently agitate the element,

being careful not to allow dirty cleaning
solution from the container to splash into
the inside of the element.

C. Rinse the element in clean cold water,

allowing water to flow from the inside
through the element until the water comes
through clear. If using a hose do not use a
pressured flow, a slow trickle is sufficient.
Make sure water is allowed to flow through
the entire element.

8
D. Remove the adhesive tape and shake
excess water from the filter element and
allow to dry naturally. The element will
need 24-48 hours to dry thoroughly. Install
a new element at this stage, retaining the
washed element for the next service.

IMPORTANT: Do not attempt to dry the element

with compressed air or install before thoroughly dry
as it may rupture. It is recommended that a new
element is installed at this service and the washed
element allowed to dry and retained for installation
at the next service.

6. When dry, check the element for damage by

inserting a lamp into the middle of the element
and observing the element surface. An even,
fine pattern of light indicates the element is
clean, undamaged and suitable for further
service.

7. Every 600 hours the element must be

replaced.

INSTALLATION

Installation of the dry type air cleaner is the removal

procedure in reverse, on installation observe the
following requirements:

8. Tighten the retaining bolts.

9. Tighten the outlet hose clamp.

REASSEMBLY

Reassembly of the dry type air cleaner is the

disassembly procedure in reverse.

On reassembly, make sure the outer element

sealing ring is secure.

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 5

OVERHAUL

Removal

NOTE: The sump of the wet air cleaner can be

serviced, without the need of being removed from
the vehicle.

1. To remove the oil bath from the vehicle,

slacken the clamp (4) between the pre--cleaner
and the oil bath (3), Figure 1 and remove the
mounting bolts.

NOTE: Do not tilt the bowl during removal as oil in

the bowl may be spilt.
1
2. With the assembly removed from the vehicle,
lift the lid off the bowl. Lift out the gauze filter
(1) and drain the old oil away.

3. The pre--cleaner can be removed for cleaning

or replacement. This is done by removing the
wing nut and unscrewing the mounting clip.

Re--Assembly

1. Mount the oil bath without the filter or lid

installed onto the manifold tube. Slide the oil
bath cleaner clamp into position and torque to
”Specification”.

2. Refill the oil bath with new engine oil to the

correct level as shown in the sight glass.
Replace the pre--cleaner into the bowl, refit the
lid and hand tighten the wing nut.
NOTE: The oil bath air cleaner should be checked
daily or more often when operating in dusty
conditions. In extreme conditions, it may be
necessary to service the air cleaner two or three
times a day.

Visually check the condition and level of oil in the

bowl. I there is more than 0.5 in. (12 mm) of
sediment present, clean the bowl and refill with
fresh engine oil.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 5 7

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 6 1

SECTION 10 -- FUEL

Chapter 6 -- Electric Lift Pump

CONTENTS
Section Description Page

10 210 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter head mounted 12 volt supply Electric Lift Pump

Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanically Actuated
Output Pressure at 2000 revs/min . . . . . . . . . . . . . . . . 0.27--0.47 bar (3--6 lbs in2)

DESCRIPTION AND OPERATION

(OP NO 10 210)

The electric lift pump is installed on all models fitted

with the DP203 fuel injection pump engines.

The pump (1) is mounted into the head of the fuel

filter and is activated via the key--start switch.

The fuel is drawn up from the tank through he

separator and filter assemblies and then out to the
FIP inlet.

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 6

1. If there is no/little delivery, and voltage and fuel

are present at the pump, the pump should be
replaced.

2. With the key start on is there 12V between the

terminals of the pump (1)? If 12V is not present
check fuses, relay and wiring.

Removal of Electric Pump

1. Disconnect battery

2. Remove the two wires from the pump.

3. Unscrew the filter head/pump assembly

connection and lift away from filter assembly.

Installation is reverse procedure, ensure ’O’ rings

(1) are serviceable

Pump Testing
Fuel pump may be checked on the vehicle.

Ensure initially that the filter is serviceable and

there are no other restrictions between the fuel
tank and filters (2).

Disconnect the filter outlet to pump tube and

reconnect to the filter, allowing the outlet to be
positioned into a suitable measuring jar.

Turn the key start to the first position for a

measured amount of time and record the fuel
delivered (1). 4

Compare against specification

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 6 3

FAULT FINDING

PROBLEM POSSIBLE CAUSES CORRECTION

Low pressure at pump outlet 1. Low or no fuel in tank 1. Refill tank

2. Blocked filter in lift pump 2. Clean filter
3. Actuating Shaft Worn 3. Replace Shaft
4. Pump Worn 4. Replace Pump

Air in the fuel from pump outlet 1. Blocked fuel tank breather 1. Clear blockage
2. Loose fuel connections 2. Check and tighten
3. Fuel Pump Diaphragm 3. Replace Pump
Perforated
4. Fuel pump body seam 4. Replace Pump
Leaking
5. Pump Worn 5. Replace Pump

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 6

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 7 1

SECTION 10 -- FUEL
Chapter 7 -- Injectors
CONTENTS

Section Description Page

10 218 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIFICATIONS

INJECTORS LUCAS C.A.V.

Adjustment Variable
Quantity, nozzle holes 5 Hole
Pressure Setting 240--247 bar (3480--3580 lbs in2) (non emissionized).
290 bar (4205 lbs in2) (emissionized)
Injector change interval 1200 hours

TORQUE VALUES
Application Nm ft. lbs. kgf/m
Injector Nozzle Retaining Nut 48 35 4.9
Injector Retaining Bolts 22 17 2.2
Injector Leak-Off Line Banjo Bolts 12 10 1.2
High Pressure Gland Nuts at Injector 32 23 3.3
High Pressure Gland Nuts at Fuel Pump 33 23 3.3

TOOLS

Application VL CHURCHILL TOOLS NUDAY TOOLS

Injector Nozzle Nut Socket CT9009 8126

Nozzle Reverse Flush Adaptor CT9024 8124
Injector Cleaning Kit* DX730 1720

Tallow Obtain Locally Obtain Locally

Polishing Sticks Obtain Locally Obtain Locally

Timing Gauge MS64-B

Timing Gauge PD67-2
Timing Fixture PD67-3
*Kit consists of:

Nozzle Cleaning Wires -- Pressure Chamber Drills -- Pressure Chamber Scraper -- Valve Seat
Scraper -- Brass Wire Brush -- Pin Vise.

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 7

Description and Operation The fuel, pressurized by the injection pump, lifts the
needle valve off the seat against the action of a
The engine injector function is to inject fuel into a spring. The fuel is then forced, in an atomized state,
pressurized cylinder in a fully atomized condition so through the five holes in the nozzle tip. When the
as to burn efficiently with a minimum of smoke. pressure from the injection pump drops, the needle
valve snaps back onto the seat under pressure from
the spring.
Each injector consists of a nozzle assembly,
containing a needle valve, and an injector body
assembly housing the injector needle valve
regulating spring. To provide lubrication of the injector, a small amount
of fuel is permitted to leak up between the needle
Fuel from the fuel injection pump enters the injector valve and the nozzle body. The excess fuel rises to
fuel inlet and passes down through a drilling in the the top of the injector and returns to the fuel tank via
injector body to the needle valve seat. an injector leak-off line.

FAULT FINDING

PROBLEM POSSIBLE CAUSES CORRECTION

Engine emits black smoke 1. Faulty injectors 1. Overhaul or replace
injectors
Nozzle does not “buzz” while 1. Dirty or sticking needle 1. Clean or replace needle
injecting valve valve and nozzle holder
2. Valve seat leakage 2. Clean or replace valve and
nozzle assembly
3. Damaged nozzle retaining 3. Replace retaining nut
nut
Nozzle leak back 1. Worn needle valve 1. Replace needle valve and
nozzle holder
2. Dirty nozzle and/or holder 2. Clean or replace nozzle
and holder
3. Loose nozzle retaining nut 3. Tighten nut
Nozzle opening pressure 1. Adjusting nut loose 1. Tighten nut
incorrect 2. Damaged nozzle or seized 2. Replace needle valve and
needle valve nozzle holder
3. Blocked nozzle holes 3. Clean nozzle
4. Incorrect shims fitted 4. Adjust shim pack
Nozzle seat leakage 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle
holder and nozzle holder
2. Sticking needle valve 2. Clean or replace needle
valve and nozzle holder
Incorrect spray pattern 1. Dirty nozzle and/or nozzle 1. Clean or replace nozzle
holder and nozzle holder
2. Restricted nozzle holes 2. Clean or replace nozzle
and nozzle holder
3. Damaged needle valve or 3. Replace needle valve and
nozzle nozzle holder

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 7 3

OVERHAUL
1. Loosen the high pressure fuel pipe gland nuts
at the injection pump.
2. Clean the area around the injectors.
3. Remove the banjo bolts (1) and discard the two
copper washers from each bolt. Remove the
leak-off pipe (3).
4. Unscrew the gland nuts and disconnect the
high pressure pipes (2) from the injectors.
5. Remove the two retaining bolts from each
injector and withdraw from cylinder head. 1

6. If a replacement set of injectors is not

immediately available, cover the ends of the
pipes and the cylinder head openings to
prevent the entry of dirt and foreign material.

7. Discard the cork dust washer (1) and the

copper sealing washer(2).

NOTE: The copper sealing washer may have to be

extracted from the bore in the cylinder head.

8. To establish if overhaul or replacement is

necessary, test the injectors according to the
following procedure. Before testing, install a
protective cap to the inlet union and clean the
outside of the injectors with a soft wire brush
and a carbon solvent.

TESTING
WARNING: The spray from a fuel injector
tester can pierce human skin with fatal re-
sults. When an injector is spraying, the nozzle
holder should be turned away from the operator
and any other persons.

During the Nozzle Opening Pressure and Spray

Pattern Tests, collect the spray in a container
partly filled with rags to absorb the spray.

When conducting the Nozzle Seat Leakage Test,

release the injector tester pump pressure before TA6010115
touching the nozzle tip with a sheet of blotting 3
paper.

WARNING: The spray is flammable make

sure no open flames are in the area of the
tester and do not generate excessive vapor.

1. Fill the injector tester with a calibrating type

fuel oil and leave the filler cap loose to prevent
a vacuum forming during testing.

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 7

2. Prime the tester until oil is emitted from the

tester line, then connect the injector.

3. Make sure the knob on the right-hand side of

the tester is screwed in to prevent the gauge
being over-pressurized if the injector nozzle is
blocked.

4. Pump the tester and check the nozzle is free to

open. Open the pressure gauge valve and
begin injector testing. If the nozzle is blocked or
the needle jammed, disassemble the injector.

5. Nozzle Opening Pressure Setting - Slowly

pump the injector tester and observe the
pressure at which the needle valve lifts and fuel
is injected from the nozzle tip. By rotating
clockwise or anti clockwise the adjuster
located in the top of the injector, the pressure
setting can be varied. The opening pressure
required 240 bar (non--emissionized), 290 bar
(emissionized).

6. Spray Pattern - Pump the tester rapidly (80 to

90 strokes per/min.) and observe the spray
pattern from the holes. An atomized spray free APB10004
from distortion and irregular streaks of fuel 4
should be observed. The tester is not regarded
as providing a suitable test for atomization
under working conditions, but gives an
indication of the working of the nozzle.

7. Nozzle Seat Leakage - Wipe the nozzle tip dry

and apply a pressure to 230 bar (3335 lbf/in2),
i.e., 10 bar (145 lbf/in2) below the opening
pressure. The nozzle tip and bottom face must
remain essentially dry and there must be no
tendency for blobs of fuel to collect or drip. A
slight dampness can be ignored. If there is any
leakage from the nozzle seat, the nozzle
assembly must be scrapped.

8. Nozzle Back Leakage - Apply a pressure of

230 bar (3335 lbf/in2) 10 bar (145 lbf/in2) below
the opening pressure, then release the handle
and the time/pressure drop should be between 5
148-99 bar) within 45 to 6 seconds, if below 6
seconds, the nozzle assembly must be
scrapped. If above 45 seconds, check for
carbon on the valve and/or blocked back leak
drillings.

NOTE: If the injectors meet the tests carried out

then refit the injectors to the engine.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 7 5

DISASSEMBLY

1. Place the injector in a holding fixture with the

nozzle uppermost. Do not clamp the injector
body in a vise. Use socket, tool #CT9009 or
8126, to loosen the nozzle retaining nut.

2. Remove the nozzle retaining nut, complete

with the nozzle body, needle valve and the
dowelled adaptor plate.

6
3. Remove the injector body from the holding
fixture, invert and carefully remove the spring
seat, spring and adjustment shims. To avoid
damage, place all dismantled components in
suitable baths of clean fuel oil.

NOTE: To prevent corrosion of injector

components after cleaning, rinse in clean fuel oil
and place in a suitable bath of clean fuel oil.

7
INSPECTION AND REPAIR

1. Clean the injector body by soaking in a carbon

solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and
pressure face, making sure the holes in the
injector nozzle are thoroughly clean with no
signs of corrosion or pitting.

2. Clean the spring and spring seat using a brass

wire brush and check for scoring, pitting or
corrosion.

8
3. Clean the dowelled adaptor plate using a brass
wire brush. Inspect the plate for loose or bent
dowels, a damaged pressure face or
corrosion.
4. Clean the needle valve and body by soaking in
a carbon solvent and brushing with a brass
wire brush. Using the tools included in the
Injector Nozzle Cleaning Kit, Tool #DX730,
clean the nozzle as follows:
NOTE: If the needle valve is in any way damaged
or blued, it must be discarded and a new matched
needle valve and nozzle body assembly obtained.
It is not possible to grind or lap the three special 9
angles on the valve point.

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 7

A. Clean the spray holes with a nozzle clean-

ing wire held in a pin vise so that it pro-
trudes for only 1.5 mm (0.06 in.), thereby
giving maximum resistance to bending. In-
sert the wire into each hole, pushing and
rotating gently until each hole is cleared.

10
B. Clean the needle valve seat using the
valve seat scraper by rotating and pushing
the tool onto the valve seating.

C. Clean the fuel port using the fuel port

scraper. Insert the scraper into the port,
press hard against the side of the cavity
and rotate to clear all carbon deposits from
this area.

11
5. Use a Reverse Flush Nozzle Adaptor, Tool
#CT9024, on the injector tester and reverse
flush the nozzle to remove the carbon
loosened during cleaning, Step 4.

6. After flushing the nozzle, polish the valve seat

by placing a very small amount of tallow on the
end of a polishing stick and rotate in the nozzle.

12
7. Clean the top of the needle valve using a
needle valve scraper.

8. Clean the nozzle retaining nut using a brass

wire brush and check to see that the threads
are not damaged and are free from carbon
deposits.

APB10013

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 7 7

RE--ASSEMBLY

1. Make sure all parts are absolutely clean and

undamaged prior to re--assembly. Rinse all
parts in clean fuel oil and assemble the
components while still wet.
2. Place the spring and spring seat into the
injector body bore. Place the injector body into
the holding fixture.
3. Assemble the needle valve into the nozzle
body and then position the dowelled adaptor
plate onto the nozzle body. Insert this
assembly into the nozzle retaining nut.
14
4. Carefully assemble the dowelled adaptor plate
and the nozzle retaining nut assembly onto the
injector body, tighten the retaining nut to 48 Nm
(35 ft. lbs) torque.

To set the nozzle opening pressure, connect the

injector to the test rig as described in ‘‘Testing’’ and
alter the adjusting nut until the specified opening
pressure is achieved.

15
INSTALLATION

1. Remove any blanking plugs from cylinder head

openings and pipe ends.

2. Insert the new/replacement injector in the

cylinder head, having used a new cork dust
washer and a new copper sealing washer.

3. Secure each injector with the two retaining

bolts and tighten to 22 Nm (17 ft. lbs).

4. Reconnect the leak-off pipe using new

washers either side of the banjo fittings and
tighten banjo bolts to the 12 Nm (10 ft. lbs).

5. Reconnect high pressure fuel pipes to injectors

and tighten gland nuts to 32 Nm (23 ft. lbs).

6. Tighten high pressure fuel pipe gland nuts at

the injection pump to 32 Nm (23 ft. lbs).

7. Bleed the fuel system as detailed previously.

8. If the injectors are to be stored before

installation, clean in calibrating oil. Storage for
longer than 6 months may result in the
necessity of disassembling and cleaning the
injectors before installation.

604.55.041.00 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 7

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 8 1

SECTION 10 -- FUEL

Chapter 8 -- Injection Pump

CONTENTS

Section Description Page

10 248 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump Removal, Timing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONS
LUCAS C.A.V. pump

Type DPS/DP203 Series Distributor type, integral speed governor and

advance device
Pump rotation Clockwise
Firing order 1342

Model TS80 TS90 TS90 TS100 TS110

Pump Type DPS DPS DP203 DP203 DP203
Engine Timing BTDC Engine -- -- 28! 28! 28!
Position
Pump Timing, Locking Bolt Position -- -- 29! 29! 29!
Overcheck
Pump Scribe Mark to Engine Plate 0! 0! -- -- --
Timing Mark
Pump Internal Timing 262 263 -- -- --

TORQUE VALUES

DESCRIPTION Nm lbf.ft
Fuel Inlet Connection 59 43
Delivery Valve Holders 41 30
Fuel Injection Pump to Front Plate -- DPS 40 29
-- DP203 20--24 15--18
Front Plate Bolts Cover Bolts 22 16
Pump Locking Bolt DP203 13 10
Drive Gear 75--81 55--60

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 8

FUEL INJECTION PUMP -- SPECIAL TOOLS

DESCRIPTION
General LESLIE HARTRIDGE TOOL No

Pump Mounting Plate 7244 -- 200

Cam Advance Screw Socket 7244 -- 125B
Transfer Pump Rotor Box Spanner 7044 -- 889
Timing Adaptor Assembly 7144 -- 262
Flange Making Tool 7244 -- 27
Insert for Flange Making Tool 7244 -- 30
Static Timing Gauge 7244 -- 449
Relief Valve 7144 -- 155
Stirrup Pipe 7144 -- 262A
Blank Off Bolt 7144 -- 558
Plunger Timing Tool 7244 -- 448
Transfer Pressure Adjuster 7244 -- 410A
Adaptor Hydraulic Head for
Transfer Pressure Gauge 7244 -- 382
Advance Measuring Gauge 7244 -- 447
Pressure End Plug Test Plug 7244 -- 435
Punch and Adaptor Drive Shaft Seal 7244 -- 445
Dial 23764
Dial Indicator Holder ST 183
Dial Indicator Holder Adaptor 89559

Protection Caps

Head Locating Fitting 7044 -- 897

Latch Valve Body Seals 7144 -- 18
Latch Valve Restrictor Plug Seal 7144 -- 124
Latch Valve Sleeve Nut Seal 7144 -- 458C
Throttle Shaft Seals 7144 -- 458C
Fuel Shut Off Seals 7144 -- 458C
Auto Advance Cap and Plug Seals 7044 -- 898

Fuel Injection Pump Drive Gear Puller

1. Bolt 5/16 -- UNF x 2 in (51mm), With integral washer (3 Bolts required)
2. Bolt 3/4 x 16 -- UNC x 2 in (51mm)
3. Holes 0.375 in (9.5mm) dia on 2.2 in (56.87mm) dia equally spaced material of
0.394 in (10mm) Plate HRLC P&O Steel.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 8 3

DESCRIPTION (OP NO 10 210)

DPS (NON--EMISSIONISED) AND DP203

The TS range of tractors may be installed with

either the DPS, Figure 1 or DP203 Figure 2 fuel
injection pump. The DPS pump is installed onto
non--emissionised engines, and the DP203 is fitted
to emissionised engines.

The pump is flange mounted at the front right hand

side of the engine and gear driven from the
crankshaft via an idler gear. 1

During operation all moving parts are lubricated by

fuel oil under pressure preventing dust, water and
other foreign matter from entering.

The DP203 fuel pumps are basically sealed items

with only minimal parts being supplied in service.
Components that are replaceable during normal
service are the Fuel Shut off Solenoid (1).

If the fuel injection pump is suspected of being

faulty the pump assembly should be taken to a
specialist Lucas/CAV agent for repair. Without
specialist equipment these pumps cannot be
correctly set up. Unauthorised repair will also
invalidate warranty and may cause the vehicle to
break local emission regulations.

DPS NON EMISIONISED AND

DP203 EMISIONISED

SOLENOID SHUTOFF VALVE

An electrically operated fuel shutoff valve is fitted

into the top of the fuel pump. The unit consists of
a solenoid, which controls a spring loaded piston
and is located between the transfer pump outlet
and the metering valve.

When the valve is energized on starting the

solenoid lifts the piston against spring pressure and 3
allows fuel at transfer pressure to pass to the
metering valve.

When the solenoid is de-energized, by cutting the

electrical supply, the return spring pushes the
piston back against its seat and prevents the rotor
from filling thereby stopping the engine.

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 8

PUMP REMOVAL

NOTE: Dismantling, assembly, testing and

adjustment of the pump must be carried out by an
authorized CAV Dealer.

1. Clean all dirt from the injection pump and the

surrounding parts.
2. Disconnect and remove all fuel lines from the
injection pump and cap all openings to prevent
entry of dirt.

3. Disconnect the throttle cable, fuel shutoff

solenoid wire and wax motor wire, where fitted.
4. Remove the pulley guard.
5. Remove the fan drive belt.
6. Remove the idler pulley

7. Remove the rocker cover breather tube.

8. Remove the engine timing cover from the
engine front cover.

DP203 ONLY

9. If the pump is to be reinstalled without being

serviced, rotate the engine to approximately
40! BTDC compression stroke, loosen the
pump timing gear bolt. DO NOT REMOVE
GEAR. Rotate the engine in the direction of
rotation to 28! BTDC compression and lock the
pump locking tag using the bolt, to 13 Nm.
Locking tab location 1 is unlocked, 2 is locked.

10. Remove the pump timing gear bolt DPS pump.

11. Fabricate a puller (see tools) and Install the
puller to the drive gear using three bolts and 4
remove the gear.

12. Remove the pump retaining bolts, then remove

the pump from the engine front cover plate.
Cap all openings to prevent entry of dirt.

1
INJECTION PUMP TIMING

IMPORTANT: The distributor type pump to engine

timing cannot be checked by alignment only, of the
scribed line on the pump flange with the zero
degree mark on the rear of the engine front plate.

The timing can only be established by internal

timing of the pump after removal from the tractor. 5

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 8 5

If the pump is not to be internally timed, then prior

to removal note the setting of the pump relative to
the zero degree mark on the rear of the engine front
plate. Mark the plate with a center punch to align
with the pump flange scribed line.

This mark may be used as a reference point to

which the original, re-conditioned or new pump
should be set on installation.

D.P.S. AND DP203 FUEL INJECTION PUMP

MS.67--B
TIMING TOOLS
Timing gauge, splined shaft and slotted
IMPORTANT: Whenever a replacement fuel arm
injection pump is being installed or poor engine
performance is evident, the use of the following
timing tool is recommended.

V.L. Churchill Ltd tools are available and

recommended, to check the fuel injection pump PD.67--2
timing of all Lucas CAV D.P.S. type fuel injection
pumps. These tools are used for: Timing gauge, adaptor for D.P.S. fuel
injection pump
1. Engine front plate timing marks in relation to
flywheel timing marks.

2. Fuel injection pump internal timing.

PD.67--3
D.P.S. Fuel injection pump timing mark,
checking fixture

MODEL PUMP TIMING INTERNAL PUMP TIMING STATIC

TS 80 DPS 262! 10_

TS 90 DPS 263! 10_

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 8

CHECKING ENGINE TIMING MARKS

(DPS ONLY)

The engine should be rotated to approximately 30d

Before Top Dead Centre with No.1 cylinder on the
compression stroke, check this at the flywheel (1).

The fuel injection pump must then be removed

from the engine. 1

APB10008
8

With the fuel pump removed, position the tapered

splined adaptor (PD 67--2) into the fuel pump timing
gear, inplace of the fuel injection pump.

Set the timing gauge arm on tool (MS 67--B) to the

‘specified’ internal pump timing degrees marking
indicated in the table, i.e TS 80 = 262! then position
the timing tool into the splined Adaptor (PD 67--2),
locating the slotted arm against the timing cover.
Rotate the engine slowly until the static engine
timing mark on the flywheel is aligned on the
compression stroke No. 1. i.e 10! .
The timing gauge arm slot indicates the correct
timing position for alignment (of the fuel injection
pump timing mark) when the pump is reassembled.
Highlight this point on the engine front plate.
10

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 8 7

DPS FUEL INJECTION PUMP INTERNAL

TIMING --TOOL NO MS 76--B

The injector tester is connected to the specified

pump high pressure outlet, number 1 injector.

Attach the checking fixture (PD 67--3) to the pump

shaft and engage the timing gauge (MS 67--B) on
to the checking fixture with the slotted arm over the
pump flange.

Set the timing gauge arm to the ‘specified’ degree

marking.

Turn the gauge counter-clockwise so that the ‘V’

notch in the gauge arm is aligned with the end of the
flange slotted hole (1).

Using a suitable injector tester, raise the fuel

pressure to 55 bar (798 lbf/in2) and slowly turn the
gauge clockwise until the pump locks. When the
pump shaft ’locks’, pressurised fuel from the outlet
has entered the rotor drillings and forced the
plungers and rollers in contact with the cam ring.
This is the point of commencement of injection.

The gauge arm slot should align with the flange

timing mark, if the existing mark is correct.
Re--mark the pump flange if incorrect.

604.55.041.00 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 8

DP203 FUEL INJECTION PUMP TIMING 3. Install the pump drive gear, aligning the gear with
the woodruff key on the pump drive shaft. Also
ensure that the drive gear timing mark aligns with
If the DP203 pump has been removed from the the gear timing mark.
tractor ’UNLOCKED’ or the pump timing needs
verifying the following procedure should be followed,
with the pump removed from the tractor, Figure 14.
4. Install the lock washer and retaining nut to the
pump drive shaft and tighten.
D Obtain a suitable woodruff key and install tool
No. PD67--3 to the pump, Figure 15.
Tighten the Gear Nut.

D Set tool No. MS67--B to 29! and lock at this point.

Gear Retaining Nut: 75--81 Nm (55--60 lbf.ft)
Install the tool onto the pump over tool PD67--3
and rotate until the slotted arm aligns with the
scribed mark on the pump, Figure 16.
DPS and DP203 Pumps
D Lock the pump at the point and remove the
timing tools.
5. Position a new inspection cover gasket and
install the inspection cover to the engine front
D Rotate the engine to the correct position, 28! cover. Tighten the retaining bolts.
BTDC, Figure 17, and install the pump on the
engine, with a new ’O’ ring installed onto the front
of the pump. 20--24 Nm (15--18 lbf.ft)
6. Connect the fuel lines to the injection pump and
tighten.
D Initially tighten the pump gear retaining nut to 20
Nm (15 lbf.ft) and ’unlock the pump.

7. Reconnect the throttle and fuel shutoff controls

D Fully tighten the nut to 75--81 Nm (55--60 lbf.ft) to the injection pump.

8. Turn on the key start and prime the system using

the electric lift pump or hand primer. Start the
INSTALLATION tractor and adjust the engine idle and maximum
no-load speeds, see “Adjustments for the DPS
Distributor Type Fuel Injection Pump” earlier in
DPS Pump
this section.

1. Install a new pump to front engine plate O-ring on

the pump mounting flange.

2. Install the three injection pump to engine front

plate mounting bolts. INJECTION PUMP STORAGE

If the pump has not been internally timed, align If, after overhaul, an injection pump is being stored,
the scribed line on the pump flange with the cen- the body should be filled with calibrating oil and all the
ter punch reference mark previously made on connections sealed with dust plugs and caps.
the rear of the engine front plate.

Tighten the mounting bolts. If the pump is stored for a period of six months or
more, the unit should be re-tested according to the
Pump Mounting Bolts: 40 Nm (29 lbf.ft) Test Plan before use in service.

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 8 9

APB10008
17

604.55.041.00 01 - 1998
10 SECTION 10 -- ENGINE -- CHAPTER 8

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 9 1

SECTION 10 -- FUEL
Chapter 9 -- Turbocharger
CONTENTS
Section Description Page

10 250 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SPECIFICATIONS

TURBOCHARGER
Compressor Shaft Axial End Play 0.025 mm - 0.10 mm (0.001in - 0.004in)
Bearing Radial Clearance 0.4 mm - 0.5 mm (0.016in - 0.021in)

TORQUE VALUES

GENERAL TORQUES Nm lbf ft kgf m

Turbine Housing Bolts 20--25 15--18 2.0--2.5

Turbocharger to Manifold 41--47 30--35 4.1--4.7

Oil Feed Tube to Turbocharger 30--40 22--30 3.0--4.0

(Banjo Bolt)

Oil Feed Tube to Filter Head 18--20 13--15 1.8--2.0

Connector

Connector to Filter Head 54--81 40--60 5.4--8.1

Oil Return Tube bolts from 20--25 15--18 2.0--2.5

Turbocharger

Oil Return Tube to Block 60--70 45--50 6.0--7.0

Connector

Oil Return Connector to Block 27 20 2.7

Inlet Hose Clamps 1.7--2.3 (15--20 lbs in)

TOOLS

SEALER

Type Sealer Anaerobic Low Strength Part No 82995768

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 9

DESCRIPTION AND OPERATION

The turbocharger consists of gas turbine and air

compressor wheels mounted on opposite ends of
a common shaft. The wheels are enclosed by a
housing, and the shaft by a center housing.

The exhaust turbine is a centripetal (from outside

to center), radial inflow designed mechanism
consisting of a cast turbine wheel, wheel shroud,
and a specially designed housing that encloses the
wheel and directs the flow of gas through the
turbine.
The intake compressor is a centrifugal, radial
outflow mechanism consisting of a cast
compressor wheel, a backplate assembly, and a
specially designed housing that encloses the
wheel and directs the flow of air through the
compressor.
The center housing supports the compressor and
turbine wheel shaft in a pair of identical bearings
which contain oil holes for directing oil to the
bearing bores and shaft journals. Passages drilled
in the center housing provide for directing oil,
supplied by the engine, from the inlet port to oil
grooves machined in the bearing bores, which
align with holes in the bearings.

Piston rings are installed at each end of the shaft

between the bearing and the adjacent turbine or
compressor wheel to prevent lubricating oil from
entering the turbine and the compressor area. A

The turbocharger is mounted on the engine

exhaust manifold.

During operation of a turbocharged engine,

exhaust gas from the engine exhaust manifold B
flows into the turbine (B). The exhaust gas
pressure and the heat energy extracted from the
gas cause the turbine wheel to rotate which, in turn, APB10501
causes the compressor wheel to rotate. 1
The cooled and expanded exhaust gas leaving the
turbine wheel is directed by the turbine housing to
the engine exhaust system, which expels it to the
atmosphere.

Rotation of the compressor wheel causes ambient

air (A) from the engine air cleaner to be drawn into
the compressor housing, where it is compressed
and delivered to the engine intake manifold.

A B

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SECTION 10 -- ENGINE -- CHAPTER 9 3

The increased volume and density of the air cool down and present any possible distortion of
delivered to the engine cylinders permit a components, idle the engine at 1000 RPM for
corresponding increase in the volume of fuel that can approximately one minute before stopping the
be introduced into the cylinders while maintaining the engine.
air/fuel ratio required for proper combustion. Since
engine power output is a function of the volume of
fuel burned, the increase in the volume of fuel
introduced as a result of turbocharger operation
results in an increase in engine power output. IMPORTANT: To ensure adequate lubrication of the
turbocharger, allow the engine to idle at 1000 RPM
for approximately one minute after starting the
To allow the turbocharger and exhaust manifold to engine.

TURBOCHARGER FAULT FINDING

It is important when troubleshooting a suspected Furthermore, failure to take appropriate steps to

turbocharger malfunction to keep in mind that a ensure correct installation, such as repairing or
turbocharger cannot compensate for incorrect replacing defective clamps or ducting, could cause
engine operating procedures; deficiencies of the the replacement unit to fail in a similar manner.
engine air intake, fuel, or exhaust systems; or for
damaged engine components such as valves,
pistons, rings, liners, etc. Replacing a good
turbocharger with another will not correct engine The following chart contains information pertaining to
deficiencies. probable failure modes of turbocharged engines,
possible causes for such failures, and the
maintenance action required to remedy each
possible cause. It is not represented that this
Consequently, systematic troubleshooting of a
information is all-inclusive. On the contrary, this
suspected turbocharger failure is essential for two
information should be considered primarily as
very important reasons. First, it must be determined
representative of the methods or techniques that
what, if anything, is wrong with the turbocharger so
should be employed in troubleshooting a
that it can be repaired. Second, it must be
turbocharged engine malfunction.
determined what action will prevent a recurrence of
the failure.

In general, those troubleshooting procedures that

In many cases, the evidence required to determine can be performed with the least effort and in the least
the cause of a malfunction is destroyed in the amount of time should be performed first. No
process of removing the turbocharger from the removal or disassembly procedures should be
engine. For example, if a turbocharger failed as the performed until all visual inspections and sensory
result of a faulty installation (such as loose duct tests (sight and feel) that can be accomplished with
connections that permitted ingestion of dirt by the the turbocharger installed have been performed. The
compressor), this fact would not be evident once the possible causes and procedure are generally
turbocharger was removed from the engine. arranged in the order of ease of accomplishment.

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 9

FAULT FINDING

PROBLEMS POSSIBLE CAUSES

1. Engine lacks power or emits black Dirty air cleaner
smoke Loose compressor-to-intake manifold connections
Leak at engine intake at turbocharger mounting flange
Turbo rotating assembly binding
Air cleaner to turbocharger duct restricted
Compressor to intake manifold duct restricted
Engine exhaust system restricted
Engine malfunction (rings, pistons, valves and associated
parts).
2. Engine exhaust emits blue smoke Dirty air cleaner
Loose compressor-to-intake manifold connections
Leak at engine intake manifold
Plugged engine oil filter
Restricted duct between air cleaner and turbocharger
compressor
Seal leak at compressor end of turbocharger
Engine malfunction (rings, pistons, valves
3. Excessive engine oil consumption Wrong type or viscosity of engine lubricating oil
Seal leaks at compressor end of turbocharger (indicated by
oil in housing or on wheel)
Oil in engine exhaust manifold (caused by malfunction of
rings, pistons, valves and associated parts).
4. Noisy turbocharger Dirty air cleaner
Foreign material or object in compressor-to-intake manifold
duct
Foreign object in engine exhaust system
Carbon buildup in turbine housing
Turbocharger rotating assembly binding or dragging
5. Turbocharger rotating assembly Damaged compressor wheel
binding or dragging
Damaged turbine wheel
Compressor or turbine wheel rubbing on housing due to
worn bearings, shaft journals or bearing bores
Excessive dirt buildup in compressor (housing or wheel)
Excessive carbon buildup behind turbine wheel (overhaul
turbine)
Slugged or coked center housing (check engine lube
system, overhaul turbocharger)

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SECTION 10 -- ENGINE -- CHAPTER 9 5

PROBLEM POSSIBLE CAUSES

6. Seal leaks at compressor end of Dirty air cleaner
turbocharger Restricted duct between air cleaner and turbocharger
Loose compressor-to-intake manifold dust connections
Leaks at engine intake manifold
Restricted turbocharger oil drain line
Plugged engine crankcase breather
Worn or damaged compressor wheel (worn bearings, bores
or journals)
Excessive piston blowby or high internal crankcase
pressure

7. Seal leaks at turbine end of Excessive pre-oiling

turbocharger Plugged engine crankcase breather
Restricted turbocharger oil drain line
Sludged or coked center housing
Worn turbocharger bearings, bearing bores, or shaft
journals.
8. Worn turbocharger bearings, bores Inadequate pre-oiling following turbocharger installation or
or journals engine lube servicing
Contaminated or improper grade of engine oil used in
engine
Insufficient oil supplied to turbocharger due to “oil lag”
Restricted turbocharger oil feed line
Plugged engine oil filter
Abrasive wear due to flaking of “coked” particles from
center housing interior surface
Insufficient lube oil supplied to turbocharger due to engine
oil pump malfunction

604.55.041.00 01 - 1998
6 SECTION 10 -- ENGINE -- CHAPTER 9

NOTES: cleaner, a restriction in the air cleaner- to-com-

pressor duct, or a heavy buildup of dirt in the
compressor housing or on the compressor
wheel.
A. Refer to Engine portion of Service Manual for
servicing procedures.

B. With engine stopped, check duct clamping de- I. Internal inspection of the center housing can be
vices for tightness. accomplished by removing the oil drain line and
looking through the oil drain opening. When a
sludged or coked condition exists, a heavy
sludge buildup will be seen on the shaft between
WARNING: Always start the engine from the bearing journals and in the center housing
the tractor seat. never start the engine from from the oil drain opening back of the turbine
the ground. end.

C. With engine running at idle speed, lightly spray

duct connections with starting fluid. Leaks at
connections will be indicated by an increase in J. Thorough cleaning of the air induction system is
engine speed due to the starting fluid being essential following compressor wheel damage
drawn into the compressor and pumped into the due to foreign object impact. In many cases,
engine combustion chambers. metal pieces from the wheel become imbedded
in the air cleaner element. If the element is not
changed in such cases, these metal pieces can
be drawn into the replacement turbocharger and
D. With engine running at idle speed, check duct cause it to fail in the same manner as the original
connections for leaks by applying lightweight oil unit.
or soap suds to areas of possible leakage and
looking for bubbles. Exhaust gas leakage be-
tween the cylinder head, exhaust manifold and
the turbocharger inlet will also create a noise
level change. K. With the air inlet and exhaust gas ducting re-
moved from the turbocharger, examine both the
compressor and turbine wheels for blade dam-
E. With engine running at idle speed, check for un- age. Examine the outer blade tip edges for evi-
usual noise and vibration. If either condition is dence of rubbing on adjacent housing surfaces.
noted, shut down the engine immediately to pro-
tect the turbocharger and engine from further
damage. With the engine stopped, check the tur-
bocharger shaft steel assembly for damage as
outlined in Note I, below. NOTE: A light is required for examining the turbine
wheel blade tips, which are positioned inside the
turbine housing. The surfaces requiring inspection
can be viewed from the outlet end of the turbine
F. With engine running, a change in the noise level housing.
to a higher pitch can indicate air leakage be-
tween the air cleaner and the engine, or a gas
leak between the engine block and the turbo-
charger inlet.
Rotate the rotating assembly by hand and feel for
smooth turning, dragging or binding. Push the
rotating assembly sideways while rotating to feel for
G. Exhaust gas leakage may be indicated by heat
wheel rub. If there is any indication of rubbing,
discoloration in the area of the leak.
perform the bearing clearance inspection
procedures outlined in this manual under Preventive
Maintenance. If the rotating assembly rotates freely
H. With the engine running, noise level cycling from and there is not evidence of binding or rubbing, it can
one level to another can indicate a plugged air be assumed that the turbocharger is serviceable.

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SECTION 10 -- ENGINE -- CHAPTER 9 7

OVERHAUL -- REMOVAL

1. Remove the exhaust stack tube and fully raise

the hood.

2. Loosen the exhaust muffler to turbo clamp (1),

remove the muffler bracket bolt and lift muffler
away.

3. Disconnect the air cleaner to turbocharger

tube (3) and the turbocharger to intake
manifold tube (2) by loosening the tube hose
clamps.
3
4. Disconnect the oil supply and return tubes from
the turbocharger ( 4). Cap the ends of the tubes
and the oil ports of the turbocharger to prevent
future bearing failures due to entry of foreign
material.
4
5. Remove the turbocharger (5) and gasket from
the exhaust manifold. Cover the opening in the
exhaust manifold to prevent the entry of dirt
which could cause damage to the turbine
wheel blades after installation and start-up.
3

4
NOTE: Before removing and cleaning the charger
look for signs of oil or gas leakage or wear to the
wheel that may not be evident after cleaning.

DISASSEMBLY

1. Clean the exterior of the turbocharger using a

non-caustic cleaning solvent to remove
outside dirt before disassembly.

2. Mark the compressor housing, turbine housing

and center housing with a punch or scribe (1) to
ensure proper reassembly.

NOTE: Exercise care when removing the

compressor housing to avoid damaging the
compressor wheel blades. Tap the turbine housing
with a soft faced hammer if force is needed for
removal.
5

604.55.041.00 01 - 1998
8 SECTION 10 -- ENGINE -- CHAPTER 9

3. Remove compressor housing ‘C’ clip from

centre housing intake side (1).

NOTE: Exercise care when removing the

compressor housing to avoid damaging the
compressor wheel blades. Tap the turbine housing
with a soft faced hammer if force is needed to
remove

6
4. Loosen and remove bolts from the turbine
housing exhaust side, and lockplates

CLEANING

Before cleaning inspect all parts for burning,

rubbing, or impact damage that may not be evident
after cleaning. Clean all parts in a non caustic
solution, using a soft bristle brush, a plastic blade
scraper, and dry compressed air to remove
residue.

7
DO NOT-- use abrasive cleaning methods which
might damage or destroy machined surfaces.
DO NOT-- immerse CHRA in solvent.
DO NOT-- blow under compressor wheel with
compressed air.
DO NOT-- permit wheel/shaft assembly to spin
when blowing off solvent and residue.

INSPECTION

1. Inspect the compressor housing assembly for

the following defects,
Wheel rub damage in the contour area that cannot
be polished out with 80 grit silicon carbide abrasive
cloth.

Worn, broken, or corroded snap ring grooves

Nicks, dents, or distortion that could prevent proper

sealing between the compressor housing and the
CHRA. (centre housing and rotating assembly)

NOTE: Replace the compressor housing if any of

the above defects are found.

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SECTION 10 -- ENGINE -- CHAPTER 9 9

2. Inspect the turbine housing assembly for the

following defects,

Wheel rub damage in the contour area that cannot

be polished out with 60 grit silicon carbide abrasive
cloth.

Worn, broken, or corroded snap ring grooves (snap

ring turbine housing models).

Nicks, dents, or warpage that could prevent proper

sealing between the turbine housing and the
CHRA.

NOTE: If there is any compressor or turbine wheel

blade damage, the CHRA must be replaced.
Operating a turbocharger with damaged blades will
result in further damage to component parts or the
engine.
Blades cannot be straightened in service.

CENTRE HOUSING and ROTATING ASSEMBLY

(CHRA)

IMPORTANT: The CHRA as an assembly, has

been balanced at the factory, under precision
conditions. As such it must not be disassembled in
any way. If disassembled the balance will be
destroyed, and a new CHRA must be fitted.

CENTRE SHAFT RADIAL CHECK

Check the journal bearing radial clearance,

whenever there is reason to suspect that the
bearings are worn enough to allow either the
compressor wheel, or the turbine wheel, to rub on
its housing. This may be heard as a high pitched
whine.

1. With the turbocharger removed attach an

indicator with a dog leg probe to the centre
housing. The indicator plunger should extend
through the oil outlet port, and contact the shaft
of the turbine wheel assembly. 8
2. Manually apply equal and simultaneous
pressure, to the compressor and turbine
wheels to move the shaft as far as it will go
away from the dial indicator probe.

604.55.041.00 01 - 1998
10 SECTION 10 -- ENGINE -- CHAPTER 9

3. Set the dial indicator to zero.

4. Manually apply equal and simultaneous

pressure to the wheels to move the shaft as far
as it will go toward the plunger. Make a note of
the shaft movement shown on the indicator
dial.

NOTE: To make sure the reading indicated is the

maximum possible, roll the wheels slightly in both
directions while applying pressure.

5. Manually apply equal, and simultaneous

pressure to the compressor, and turbine
wheels, to move the shaft away from the
plunger again. Note that the indicator pointer
returns exactly to zero.

6. Repeat the steps 2 to 5 several times, to

ensure that maximum radial clearance is
indicated by maximum shaft movement, has
been measured

7. If the maximum clearance is less than

0.056mm (0.0022 in), or greater than
0.127mm (0.0050 in), replace the CHRA.

Trouble shoot the engine to find the cause of the

bearing failure, and correct the problem before
resuming operations.

AXLE CLEARANCE CHECK

Check the thrust bearing axial clearance as

follows,

1. Place a dial indicator with the probe on the

compressor end of the turbocharger shaft
assembly.

2. Manually move the compressor/turbine wheel

assembly, as far as it will go away from the
plunger.
3. Set the dial indicator at zero
4. Manually move the compressor/turbine wheel
assembly as far as it will go toward the dial
indicator plunger. Make a note of the shaft
movement shown on the indicator dial.
5. Manually move the compressor/turbine wheel
assembly as far as it will go away from the
plunger. Note that the indicator plunger returns
to zero. 9

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SECTION 10 -- ENGINE -- CHAPTER 9 11

6. Repeat steps 2 to 5, several times to make

sure that the maximum axial clearance, as
indicated by maximum shaft movement, has
been measured.

7. If the maximum clearance is less than

0.0254mm (0.0010 in), or greater than
0.084mm (0.0039 in), replace the CHRA

RE--ASSEMBLY

1. It is recommended replacing the following with

factory authorized parts only, at each overhaul
or whenever parts are removed.

Snap ring, compressor housing retainer

O--Ring seal, compressor housing

Retainer Plates, turbine housing

Bolts, turbine housing retainers

2. Parts that require changing if faulty or

damaged,
CHRA, turbine assembly
Compressor Housing
Turbine Housing
3. Inspect all mating surfaces and snap ring
groove, to insure that they are free of burrs,
foreign matter and corrosion deposits.

4. Transfer scribe marks from old snap rings to

new, and coat with a light coating of new engine
oil.

5. Install oiled snap ring on compressor end of

CHRA , with beveled face toward the turbine
end.
6. Install an ‘O’ ring on the centre housing
compressor end flange and place compressor
housing assembly in position. Be careful not to
damage the compressor wheel blades.
7. Carefully rotate the compressor housing onto
the CHRA to line up scribed marks.
8. Install the oiled snap ring, lug first, into the
compressor housing groove. Be sure that the
beveled side faces the turbine end and the
scribe marks are aligned. 10

604.55.041.00 01 - 1998
12 SECTION 10 -- ENGINE -- CHAPTER 9

9. Tap the inner circumference or lug ends of the

ring with an appropriately sized drift to ensure
proper seating.

NOTE: When installing a new CHRA or turbine

housing, transfer scribed alignment marks from the
old, to the new parts.

10. Position the turbine housing discharge side

down, on a flat, level surface. Place the CHRA
turbine wheel end into the housing, use care to
avoid damaging the wheel blades. Check
visually for proper alignment.
11
11. Carefully rotate the CHRA in the turbine
housing to line up the scribed marks. Recheck
for proper alignment and position the locking
plates.

12. Coat the bolts (1) in a suitable anti seize

compound, and tighten to
20--25Nm (15--18 lbf ft).

12
Installation

1. Prior to installation fill the turbocharger centre

housing with new clean oil, and rotate the main
shaft to lubricate the bearings.

2. Installation of the turbocharger follows the

removal procedure in reverse. Install a new
manifold gasket, and tighten manifold bolts to,
41--47Nm (30--35 lbf ft).

13
3. Replace the washers and re--connect the oil
Feed tube banjo bolt and torque to 22--30 lbf ft
(30--40Nm).

4. The oil feed tube connector, to oil filter head

assembly if disturbed should be refitted. Apply
sealer to connector ‘‘See Specifications and
torque to, 54--81Nm (40--60 lbf ft).

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SECTION 10 -- ENGINE -- CHAPTER 9 13

5. Apply sealer ‘‘See Specifications”, assemble

the oil feed tube to the oil filter head connector
and tighten, 18--20Nm (13--15 lbf ft)

6. Place a suitable receptacle below the oil outlet

port and, WITH THE ELECTRICAL
SOLENOID WIRE DISCONNECTED AT THE
FUEL INJECTION PUMP, crank the engine
until oil flows from the outlet port.

7. Reconnect the oil outlet tube using a new

gasket and tighten the retaining bolts at the
turbocharger to 20--25Nm (15--18 lbf ft).

8. Tighten the oil return tube to cylinder block

connector,to 54--81Nm (45--50 lbf ft).

9. If disturbed the oil return tube to block

connector should have sealer applied ‘‘See
Specifications” and torqued to
27Nm (20 lbf ft).

10. Re--connect the air inlet, and outlet tubes, with

the hose clamps, torque to
1.7--2.3Nm (15--20 lbs in).

11. Reconnect the fuel injection pump solenoid

wire.

12. Check the engine oil level and add oil if

required. Idle the engine and check all tubes
and gaskets for leaks.

13. Run the engine at rated speed and listen for

sounds of metallic contact from the
turbocharger. If any noise is apparent, stop the
engine immediately and correct the cause.

NOTE: After the unit has obtained operating

temperatures, the rotating assembly should coast
freely to a stop after the engine is stopped. If the
rotating assembly jerks to a sudden stop, the cause
should be corrected immediately.

604.55.041.00 01 - 1998
14 SECTION 10 -- ENGINE -- CHAPTER 9

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 10 1

SECTION 10 -- FUEL

Chapter 10 -- Manifolds

CONTENTS

Section Description Page

10 254 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SPECIFICATIONS

Inlet Manifold Aluminium -- with Plenum Chamber

Exhaust Manifold Cast Iron

TORQUE VALUES

TORQUE VALUES -- VARIOUS Nm lbf ft Kgf m

Intake Manifold--to--Cylinder Head 35 26 3.5

Exhaust Manifold--to--Cylinder Head 38 28 3.9
Exhaust Pipe--to--Flange 31 23 3.2

604.55.041.00 01 - 1998
2 SECTION 10 -- ENGINE -- CHAPTER 10

DESCRIPTION AND OPERATION tight at all times. Considerable damage to the

cylinder bores, may be incurred by entry of grit or
other foreign material if the plug is left loose or
MANIFOLDS (OP NO 10 254) missing. Also dirt and grit may be drawn through the
air cleaner connections if they are not properly
secured.
The cross flow design aluminium intake, and cast
iron exhaust manifolds, are on opposite sides of the
cylinder head. This is designed to maintain balanced
heat distribution within the cylinder head. The
The inlet manifold attached to the right hand side of
configuration of the manifolds also ensures minimum
the engine block is a one piece cast aluminium
heat transfer to the intake manifold.
plenum chamber that directs the air from the air
cleaner and into the cylinder head.
The intake manifold is connected through tubing to
the air cleaner and in the rear end of the manifold a
tapped hole is provided for installation of a
thermostart or an ether cold starting aid. The exhaust manifold attached to the right hand side
of the engine block is a one piece cast iron unit that
NOTE: On tractors where cold start equipment is not channels the spent exhaust fumes into the muffler by
installed ensure the plug in the intake manifold is kept way of tubing and clamps.

FAULT FINDING

PROBLEM POSSIBLE CAUSES REMEDY

Engine power poor or 1. Intake manifold leaking at joint 1. Fit new gasket or fit new
runs roughly face or cracked manifold

Excessive exhaust 2. Exhaust leak on exhaust 2. Fit new gasket

smoke manifold side of turbocharger,
where fitted

604.55.041.00 01 - 1998
SECTION 10 -- ENGINE -- CHAPTER 10 3

OVERHAUL

IMPORTANT: Whenever it is necessary to remove

the intake or exhaust manifolds from the engine
new sealing gaskets must be fitted upon
re--assembly.

INSPECTION

1. Clean the intake manifold in a solvent that is

suitable for aluminium and check for cracks or
damage repair where practical. Small
imperfections on the joint face can be dressed
with a stone, but where they exceed a stone
repair the manifold must be changed.

NOTE: Intake manifold bolts have ‘O’ ring seals

fitted.

1
2. Clean the exhaust manifold in a suitable
solvent removing the carbon deposits with a
wire brush. check for cracks or damage to the
joint face that could create an air leakage.
Small imperfections can be dressed with a
stone, but where they exceed a stone repair
the manifold must be changed.

2
INSTALLATION

1. Prior to refitting the manifolds clean the

cylinder head faces with light grit paper to
remove any trace of old gaskets that may have
remained on the head face during
disassembly.

2. Place the bolts through the manifold to be fitted

and through a new gasket, attach the manifold
and gasket onto the cylinder head and torque
the bolts on the:
Intake manifold to 35Nm (26 lbf ft)
Exhaust manifold bolts to 38Nm (28 lbf ft) 3

604.55.041.00 01 - 1998
4 SECTION 10 -- ENGINE -- CHAPTER 10

NOTES PAGE

604.55.041.00 01 - 1998
SECTION 10 – ENGINE – CHAPTER 11 1

SECTION 10 – ENGINE SYSTEM

Chapter 11 – TS115 With Emissionised Engine

CONTENT

Section Description Page

Specifications 1
Special Tools 1
10 000 Description and Operation 2
10 246 Pump Removal, Timing and Installation 3

SPECIFICATIONS
Pump Type DP203
Manufacturer Lucas CAV
Pump rotation Clockwise
Firing Order 153624
Engine Timing 29° BTDC
Pump Timing Locking Bolt Position Overcheck 40°

TORQUE VALUES
Fuel Injection Pump to Front Plate 20–24 Nm 15–18lbf.ft
Pump Locking Bolts 13Nm 10lbf.ft
Drive Gear 75–81Nm 55–60lbf.ft

SPECIAL TOOLS
Timing Gauge, splined shaft and slotted arm 297119 Prior number MS67–B
Fuel Injection pump Timing mark Checking Fixture 297513 Prior Number PD.67–3

Fuel Injection Pump Drive Gear Puller

1. Bolt 5/16 – UNF x 2 in (51mm), With integral washer (3 Bolts required)
2. Bolt 3/4 x 16 – UNC x 2 in (51mm)
3. Holes 0.375 in (9.5mm) dia on 2.2 in (56.87mm) dia equally spaced material of
0.394 in (10mm) Plate HRLC P&O Steel.

604.55.041.03 – 07 – 2001
2 SECTION 10 – ENGINE – CHAPTER 11

DESCRIPTION AND OPERATION

1
The TS115 6 cylinder tractor manufactured with cause the vehicle to break local emissions
emissionised engine are installed with the DP 203 regulations.
rotary injection pump (4). Fuel supply to the injection pump is through an
The pump is of the same family as fitted to the 4 electrical lift pump (1) mounted above the fuel filter
cylinder TS90, TS100 and TS110 emissionised which draws fuel through the sediment separator (3)
engines and are basically sealed items with only and the fuel filter. The fuel is then pressurised and fed
minimal parts being supplied in service. The only into the injection pump.
component replaceable during normal service is the The DP 203 injection pump is fitted with a thermal
fuel shut of solenoid (2). wax motor (5). The wax motor is a thermal operated
If the fuel injection pump is suspected of being faulty device which responds to engine coolant
the pump assembly should be taken to a specialist temperature and automatically adjusts the pump
Lucas/CAV agent for repair. Without specialist timing after the engine has been started from a cold
equipment these pumps cannot be correctly set up. condition.
Unauthorised repair will invalidate warranty and may

604.55.041.03 – 07 – 2001
SECTION 10 – ENGINE – CHAPTER 11 3

When the engine coolant temperature reaches

normal operating temperature the temperature
sensor (1) on the top of the water pump closes and
energises a heating element within the wax motor.
The element heats the wax in the motor which
causes the motor mechanism to advance the pump
engine timing. The pump timing is now regulated in
accordance with operating temperature as well as
speed for improved emissions.

2
PUMP REMOVAL
(Op. 10 246)
1. Clean all dirt from the injection pump and
surrounding parts.
2. Disconnect and remove all fuel lines from the
injection pump and cap all openings to prevent
entry of dirt.
3. Disconnect the throttle cable, fuel shutoff
solenoid wire and wax motor wire.

3
4. Remove pulley guard.
5. Remove fan drive belt.
6. Remove idler pulley.
7. Remove rocker cover breather tube.
8. Remove timing cover from engine front cover.
9. Rotate the engine to approximately 40° BTDC on
compression stroke

4
10. Loosen pump timing gear bolt (1). Do Not
Remove Gear.

604.55.041.03 – 07 – 2001
4 SECTION 10 – ENGINE – CHAPTER 11

11. Rotate engine in the direction of rotation to 29°

BTDC on compression stroke and lock the pump
by putting the locking tab in position (2), Figure 6.
Torque bolt to 13Nm.

6
12. Fabricate a puller (see tools). Remove timing
gear bolt (1). Attach the puller to the timing gear
using three bolts and remove the gear (3).
13. Remove the three pump retaining bolts (2),
Figure 5 and withdraw the pump from the engine.
14. Cap all openings to prevent entry of dirt.

7
FUEL INJECTION PIMP TIMING
If the DP203 pump has been removed from the
tractor ’UNLOCKED’ or the pump timing needs
verifying the following procedure should be followed. 297513
Timing tools 297513 and 297119 are necessary to
time the fuel injection pump.

297119

8
1. Obtain a suitable woodruff key (1) and locate
adaptor gear (2) tool 297513 (prior tool number
PD67–3) onto the shaft on the end of the pump.

604.55.041.03 – 07 – 2001
SECTION 10 – ENGINE – CHAPTER 11 5

2. Set timing gauge tool 297119 to 40° and lock in

position.

10
3. Locate timing gauge tool (1) onto end of pump.

11
4. Rotate tool until the slotted arm (1) aligns with the
scribed mark on the pump.

12
5. Move the pump locking tag into position 1 and
tighten the bolt to ‘lock’ the pump in the timed
position.
6. Remove the timing tools when the pump has
been ‘locked,.

604.55.041.03 – 07 – 2001
6 SECTION 10 – ENGINE – CHAPTER 11

7. Rotate the engine to 29° BTDC on compression

stroke.

14
8. Fit a new ‘O’ ring onto the front of the pump and
install pump onto the engine. Tighten the three
retaining bolts (2) to 20–24Nm (15–18lbf.ft).
9. Initially tighten the pump gear retaining nut (1) to
20Nm (15lbf.ft)

15
10. ‘Unlock’ the pump by moving the locking tab to
position (2).
11. Fully tighten the pump gear retaining nut to
75–81Nm (55–60lbf.ft).

16
12. Using a new gasket install the timing cover.
13. Connect the fuel lines to the injection pump and
tighten.
14. Reconnect the throttle cable, fuel shutoff
solenoid wire and wax motor wire.

604.55.041.03 – 07 – 2001
SECTION 18 -- CLUTCHES -- CHAPTER 1 1

SECTION 18 -- CLUTCHES

Chapter 1 -- CLUTCHES
Section Page
18 000 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
18 110 Clutch Overhaul -- Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clutch Pilot Bearing and PTO Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 104 Clutch Overhaul -- Hydraulic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

18 000 SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS

Components

Disc Assembly 13in (330 mm) Single Disc Dry Plate

Type
Material Organic Non Asbestos
Pressure Plate Assembly Belleville (diaphragm) Spring
Type (Self Adjusting -- No Maintenance)
Release Bearing Mechanically Operated with 8x2 (16x4) Transmissions
Type Hydraulically Operated with 12x12 Transmission
Clutch Pedal Free Play
Adjustment -- (Mechanically 1.1 -- 1.6 in (28 -- 41 mm)
Operated Clutch Only)
Transmission Input Shaft Ambra lithium and molybdenum disulphide grease GR75MD
Lubricant
Hydraulic Clutch oil Ambra brake LHM (NH 160 A)
Master Cylinder 0.6 mm (0.024 in) Minimum
Push Rod to Plunger Clearance

TIGHTENING TORQUES

Components lbf.ft Nm

Clutch Cover to Flywheel Bolts 26 35

Clutch Pedal Operating Rod Turnbuckle 25 34
Locknut
P.T.O. Drive Plate Bolts 95 129
Cross shaft Release Bearing fork 35 47
Retaining Bolt
Hydraulic Slave Cylinder Retaining Bolts 18 25
Master Cylinder Retaining Bolts 17 23
Hydraulic Tube Connections 16 22

604.55.041.00 - 01 - 1998
2 SECTION 18 -- CLUTCHES -- CHAPTER 1

SPECIAL TOOLS

Description V.L. Churchill Ltd Nuday

Tools Tools

Clutch Friction Disc Locator FT.7102 (SW.14) 1262 (SW.509)

Bushing Kit 818 9514 (818)

Puller 1002 9198 (1002)

Puller Attachment 951 9190 (951)

Puller 943 9507 (943)

Slide Hammer 943S 9567 (943S)

Step Plate Adaptor 630--12 --

FAULT FINDING

PROBLEM POSSIBLE CAUSES REMEDY

No drive when gear selected 1. Rear axle or transmission 1. Engage differential lock. If
and clutch pedal released faulty tractor drives, fault indicated
from output of differential unit.
If still no drive, possible
transmission or rear axle fault.
Note: If FWD fitted, engage
FWD, if tractor drives,
transmission O.K.

2. Clutch incorrectly adjusted 1. Adjust clutch

(mechanical)

3. Clutch bearing not releasing 1. a). Inspect linkage

(mechanical)
b). Pedal not releasing fully on
hydraulic system, keeping
bearing engaged.
c). Fault in master or slave
cylinders.

4. Friction disc completely worn 1. Replace friction disc

5. Pressure plate faulty 1. Repair or replace pressure

plate

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 3

PROBLEM POSSIBLE CAUSES REMEDY

Engine speed increases without 1. Clutch friction disc slipping 1. Check clutch adjustment
a corresponding rise in road
speed, clutch pedal released. 2. Worn friction disc

3. Pressure plate faulty

4. a). Release bearing of

hydraulic clutch not fully
releasing, check that pedal to
master cylinder rod has some
free play
b). Master or slave cylinder
faulty

Difficulty engaging gears 1. Clutch Dragging (not fully 1. Check clutch adjustment
disengaging)

2. Worn friction disc

3. Faulty pressure plate

4. On hydraulic systems:
a). Air in system, bleed
system
b). Faulty seals in either
master or slave cylinder

Impossible to engage gears, 1. Clutch not disengaging 1. Check clutch adjustment

engine stalls when tractor
halted, clutch pedal depressed 2. Linkage disconnected / faulty
(mechanical)

3. No / low oil (hydraulic system)

4. Faulty seals in master or

slave cylinder (hydraulic)

5. Clutch disc seized onto

flywheel, pressure plate or
input shaft splines

6. Pressure plate faulty, repair or

replace as necessary

Noise from transmission bell 1. Release bearing worn 1. Replace release bearing
housing noise changes when
housing,
pedal is depressed and released 2. Clutch pilot bearing worn 2. Replace pilot bearing

Clutch fails to engage smoothly 1. Defective clutch friction disc 1. Replace friction disc

2. Defective pressure plate 2. Replace pressure plate

3. Worn clutch pilot bearing 3. Replace pilot bearing

4. Defective flywheel 4. Inspect flywheel as detailed in

the Engine Section

604.55.041.00 - 01 - 1998
4 SECTION 18 -- CLUTCHES -- CHAPTER 1

DESCRIPTION AND OPERATION

The TS range of tractors utilises two methods of In the clutch ‘engaged’ position the spring loaded
clutch operation. pressure plate forces the clutch disc into contact
The clutch system of the 12x12 transmission is a with the engine flywheel.
hydraulically operated single plate clutch with a 13
in. (330 mm) non asbestos dry friction disc, The frictional contact between the clutch disc
designed for high durability and low effort material and the surfaces of the flywheel and
operation. The clutch is conventionally located at pressure plate enables drive from the flywheel to
the front of the transmission, connecting the engine be transmitted via the clutch disc to the input shaft
to the transmission input shaft. The hydraulic of the transmission.
actuation is provided with a simple master/slave
cylinder arrangement. This provides self A clutch operating pedal is either connected
adjustment of the clutch system to maintain mechanically, by a rod and lever, or hydraulically to
optimum clutch performance. The pressure plate is a release bearing. The release bearing contacts
a diaphragm spring type also self adjusting and the operating fingers of the pressure plate.
requiring no maintenance.
The clutch system of the 8x2 non synchromesh Depression of the clutch pedal causes the release
transmission is a mechanically operated system bearing to move forward and depress the pressure
with a single non asbestos dry friction disc clutch plate diaphragm, thus drawing the pressure plate
plate of 13 in. (330 mm) diameter. The pressure away from the clutch disc and releasing the disc
plate is of the same diaphragm spring type used in from contact with the flywheel. The frictional drive
the 12x12 transmission. from the engine to the transmission is thereby
The 16x16 transmission does not use a disconnected.
conventional clutch arrangement. Engine power is
transmitted to the transmission via a damper When the clutch pedal is released a spring returns
assembly attached to the engine flywheel. The the pedal to its free position and the release
function and operation of the clutch pedal is bearing is drawn away from the release levers of
described in detail in the 16 ¢ 16 Section. the pressure plate assembly.
Operation
The main springs of the pressure plate assembly
The principle of clutch operation is the same then re--assert pressure on the pressure plate
whether the clutch is Hydraulically or mechanically moving it towards the friction disc and into contact
operated. with the flywheel, re--establishing the drive
between engine and gearbox.

CLUTCH ADJUSTMENT

The only clutch adjustment required is to check

and, if necessary, adjust the clutch pedal free
travel. This is the amount of pedal movement from
the fully released position to the point where
resistance is first encountered. This adjustment is
only required on the mechanically operated clutch
system.
ADJUSTMENT PROCEDURE:
With reference to Figure 1.
The clutch free travel should be
28 -- 41 mm (1.1 -- 1.6 in.) at the clutch pedal.
If adjustment is required, loosen the locknut, (1)
remove the split pin (4) and clevis pin (3). Turn the
clevis (3) to lengthen or shorten the operating rod, 1
as required. Secure the clevis pin (3) with a new
split pin (4) and tighten the locknut (1).

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 5

18 110 CLUTCH OVERHAUL -- MECHANICAL OPERATION

REMOVAL
1. Separate the tractor between the engine and
transmission, refer to section 90,
‘SEPARATING THE TRACTOR’.
2. Remove the bolts securing the clutch pressure
plate and cover assembly to the flywheel and
remove the pressure plate assembly together
with the clutch disc.
NOTE: The bolts must be slackened evenly and
diagonally across the clutch to prevent distortion of
the cover assembly.

3. Remove the clutch release fork retaining bolt,

(3) Figure 3, and withdraw the clutch release
shaft (4) from the casing. Remove the clutch
release fork (2) from the transmission. Slide
the clutch release bearing (1) and hub from the
clutch release hub support.

4. To remove the clutch pedal (2), carefully lever

off the pedal return spring (1), remove the
clutch pedal shaft retaining snap ring, withdraw
the shaft (6) and pull the pedal (2) from the
tractor.

604.55.041.00 - 01 - 1998
6 SECTION 18 -- CLUTCHES -- CHAPTER 1

INSPECTION AND REPAIR

Friction Disc

1. Inspect the clutch disc to ensure the linings are

not loose, cracked, worn or contaminated with
oil. Check the rivets are secure. If signs of
overheating due to clutch slippage or
excessive wear are evident, the disc must be
discarded and a new one installed.

IMPORTANT: Investigate the source of any oil or

grease on the facings and rectify before installing
a new disc.

Pressure Plate

2. Examine the pressure plate assembly, ensure

the diaphragm fingers are all at the same
height, there is no discolouration due to
excessive heat and that the assembly
operates smoothly. Check the face of the
pressure plate for cracks, scoring or distortion.
Discard the pressure plate if any faults are
found.

NOTE: The diaphragm type clutch has no

serviceable components. A new assembly will be
required if any faults are found during inspection.

Release Bearing

3. Examine the release bearing assembly,

ensure the bearing hub moves freely over the
transmission hub carrier. Ensure the bearing
rotates smoothly and the face of the bearing is
not damaged or worn. Examine the clutch
release fork, ensure the fork is not cracked or
bent, i.e, the fork ends align and that the ends
are not worn. Discard and replace any worn or
damaged parts.
Use puller attachment, Tool No. 951 (3), puller
Tool No. 1002 (1) and a suitable step plate (4)
to separate the release bearing from the hub
(2) if necessary to renew either component, 5
Figure 5.

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 7

Clutch Pedal

4. Inspect the clutch pedal ensuring there are no

cracks in the pedal assembly and there is no
excessive free play between the bushes and
pedal shaft when installed in the pedal. Discard
and replace any worn or damaged parts.

Clutch Release Cross Shaft

5. Inspect the clutch release cross shaft and

transmission housing bushes. The shaft
should rotate smoothly in the bushes without
any free play between the bushes and shaft. If
the bushes are worn or damaged remove and
replace using bushing kit, Tool No. 818.

INSTALLATION

IMPORTANT: When installing a new pressure

plate assembly, the pressure plate friction face
must be wiped clean with white spirit to remove the
protective coating.

1. Lightly lubricate the hub splines of the

transmission input shaft with a suitable
non--fibrous lithium base grease.

2. Position the clutch disc on the flywheel with the

marked face and damper springs towards the
flywheel, use locator, Tool No. SW 14, to
centralise the disc.

3. Locate the pressure plate assembly onto the

flywheel and tighten the retaining bolts to a
torque of 35 Nm (26 lbf.ft).

4. Remove the locator tool from the clutch disc.

5. Installation of the clutch release bearing

follows the removal procedure in reverse,
observing the following requirements:

S Lubricate the hub bore with a high melting point

grease.

S Tighten the release shaft fork pinch bolt to

47 Nm (35 lbf.ft).

S After installation ensure the release bearing

assembly operates correctly when the clutch
pedal is depressed and released.

6. Reconnect the engine to the transmission

assembly as described in the ‘SEPARATING
THE TRACTOR’ section 90 of this Repair
Manual.

7. Check and adjust the clutch pedal free play as

previously described in this Chapter.

604.55.041.00 - 01 - 1998
8 SECTION 18 -- CLUTCHES -- CHAPTER 1

CLUTCH PILOT BEARING

A pre--lubricated ball bearing assembly is installed

at the rear end of the engine crankshaft, within the
flywheel. The bearing is located in the PTO drive
plate.

OVERHAUL (Op No. 10 103)

Removal

1. Remove the clutch as described in either

Section D or E.

2. Use slide hammer, Tool No. 943--S (2) and

puller, Tool No. 943 (1) to remove the PTO
drive plate bearing (3) as shown in Figure 6.
6

Installation

1. Lightly tap the bearing, shield side facing

outwards, into the PTO drive plate.

2. Use Step Plate Adaptor, Tool No. 630--12 (1),

to fully install the bearing (3) into the flywheel
(2) as shown in Figure 7.

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 9

18 104 CLUTCH OVERHAUL -- HYDRAULIC OPERATION

REMOVAL

1. Separate the tractor between the engine and

transmission, refer to the section,
‘SEPARATING THE TRACTOR’.

2. Remove the bolts securing the clutch pressure

plate and cover assembly to the flywheel and
remove the pressure plate assembly together
with the clutch disc.

NOTE: The bolts must be slackened evenly and

diagonally across the clutch to prevent distortion of
the cover assembly.
8
3. At the front of the transmission, remove the two
tubes (2) from the hydraulic release bearing
(1), Figure 9. Remove the three bolts securing
the release bearing assembly to the
transmission front plate and withdraw the
release bearing assembly.

4. To remove the clutch pedal, remove the left

hand side panel from the instrument console
and disconnect the rod to the master cylinder.
Carefully lever off the pedal return spring,
remove the clutch pedal shaft retaining snap
ring, withdraw the shaft and pull the pedal from
the tractor.
9

INSPECTION AND REPAIR

Friction Disc

1. Inspect the clutch disc to ensure the linings are

not loose, cracked, worn or contaminated with
oil. Check that the rivets are secure. If signs of
overheating due to clutch slippage or
excessive wear are evident, the disc must be
discarded and a new one installed.

IMPORTANT: Investigate the source of any oil or

grease on the facings and rectify before installing 10
Clutch Components -- Hydraulic Operation
a new disc.
1. Hydraulic Oil Reservoir
2. Clutch Pedal
3. Interlock Cable
4. Slave Cylinder Bleed Tube
5. Slave Cylinder Assembly
6. Slave Cylinder Oil Supply Tube
7. Master Cylinder

604.55.041.00 - 01 - 1998
10 SECTION 18 -- CLUTCHES -- CHAPTER 1

Pressure Plate

1. Examine the pressure plate assembly, ensure

NOTE: The diaphragm type clutch has no

serviceable components. A new assembly will be
required if any faults are found during inspection.

Hydraulic Release Bearing / Slave Cylinder

Assembly

1. Inspect the release bearing for the following, oil

leakage, weak or broken return spring and
wear or damage to the release bearing. Repair
kits are available should seals or the bearing
assembly require servicing.

Hydraulic Release Bearing / Slave Cylinder

Assembly Overhaul.

With reference to Figure 11

1. Remove bearing retaining snap ring, item 4,

and withdraw the bearing assembly.

2. Carefully pry the bearing cage claws open and

withdraw the piston assembly.

3. Remove the snap ring from the rear of the

housing and withdraw the guide sleeve

4. In the dismantled condition it is wise to replace

the seals with new items as a precautionary
measure against future failure. Inspect the
remaining components for wear or damage
and replace as necessary.

5. Reassembly is the reversal of the disassembly.

Coat all seals with clean brake oil of the correct
specification as they are installed and
assembled.

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 11

Release Bearing / Slave Cylinder Assembly 11

1. Housing 6. ‘O’ Ring 11. Snap Ring
2. Protective Cap Assembly 7. Guide Ring 12. Guide Sleeve
3. Bearing Assembly 8. Piston 13. Seal
4. Snap Ring 9. Guide Ring 14. Back Up Seal
5. Wiper Seal 10. Seal Ring 15. ‘O’ Ring

Master Cylinder

1. Remove the left hand instrument panel side

cover, if not previously removed.

2. Disconnect the two hoses from the reservoir

and plug to prevent excessive oil loss.

3. Disconnect the outlet tube to the slave cylinder

and plug.

4. Disconnect the push rod from the clutch pedal.

Clutch Components 12
5. Remove the two bolts securing the cylinder 1. Clutch Pedal Pin
assembly to the tractor bulkhead and withdraw 2. Master Cylinder Retaining Nut
the cylinder. 3. Cable Adjustment Nuts
4. Interlock Cable
5. Bleed Screw
6. Installation is the reversal of the removal 6. Master Cylinder to Slave Cylinder Tube
procedure. 7. Master Cylinder
8. Oil Supply from Reservoir

604.55.041.00 - 01 - 1998
12 SECTION 18 -- CLUTCHES -- CHAPTER 1

Master Cylinder -- Exploded View 13

1. Master Cylinder Body 5. Nylon Holder 9. Circlip
2. Valve Rubber Seal 6. Spring 10. Gland Seal
3. Rod 7. Retainer 11. Spool
4. Wavy Spring Washer 8. Push Rod and Boot Assembly

Master Cylinder -- Overhaul Reassembly

Disassembly 1. Reassembly is the reversal of the disassembly

procedure.
1. Roll back push rod rubber boot, remove the
circlip retaining the push rod and spool
assembly. System Bleeding
2. Gently tap the cylinder, spool end downwards, 1. Ensure the reservoir is filled up to the maximum
onto a firm surface to remove the spool line with the specified brake oil.
assembly.
2. Install a suitable rubber tube over the bleed
3. Withdraw the oil inlet adaptors and carefully screw. Immerse the tube into a jar of clean and
hook out the seals. correct specification brake oil. Position the jar
4. From the spool and spring assembly, bend above the bleed screw, this will prevent
back the locking tab of the retainer and possible air ingress at the bleed screw.
withdraw the spring assembly. Unhook the rod
and disassemble. 3. Open the bleed screw and fully depress the
clutch pedal, close the bleed screw with the
Inspection and Repair pedal depressed and then release the pedal.
Repeat this procedure until ‘air free’ oil is
1. Inspect the cylinder bore for wear, score marks entering the jar.
or burrs. If the bore is not in perfect condition
replace the cylinder assembly. Do not attempt
to repair. NOTE: Regularly inspect the oil level in the reservoir
during bleeding. Do not allow it to empty.
2. A seal kit is available in Service. When
overhauling the master cylinder obtain a kit and
replace ALL seals. Clutch Pedal
3. Coat all seals in clean brake oil prior to fitment.
1. Inspect the clutch pedal ensuring there are no
IMPORTANT: Use only the specified type of brake cracks in the pedal assembly and that there is
oil, Ambra brake LHM (NH610A). The oil used in this no excessive free play between the bushes and
system is a ’Mineral’ based oil. Use of a non specified pedal shaft when installed in the pedal. Discard
oil will cause seal damage and a resultant failure. and replace any worn or damaged parts.

604.55.041.00 - 01 - 1998
SECTION 18 -- CLUTCHES -- CHAPTER 1 13

INSTALLATION 5. Installation of the clutch release bearing

follows the removal procedure in reverse,
IMPORTANT: When installing a new pressure observing the following requirements:
plate assembly, the pressure plate friction face S Tighten the release bearing retaining bolts to
must be wiped clean with white spirit to remove the 25 Nm(18 lbf.ft).
protective coating.
S Install the two hydraulic tubes and bleed the
1. Lightly lubricate the hub splines of the system of air as previously described.
transmission input shaft with a suitable S Check the operation of the slave cylinder. Push
non--fibrous lithium base grease.
and hold the release bearing ‘IN’ by hand, ob-
2. Position the clutch disc on the flywheel with the tain an assistant to depress and release the
marked face and damper springs towards the clutch pedal. The release bearing should be
flywheel, use locator, Tool No. SW 14, to forced out with the pedal depressed and return
centralise the disc. ‘IN’ with the pedal released while still applying
3. Locate the pressure plate assembly onto the hand pressure.
flywheel and tighten the retaining bolts to a 6. Reconnect the engine to the transmission
torque of 35 Nm (26 lbf.ft). assembly as described in the ‘SEPARATING
4. Remove the locator tool from the clutch disc. THE TRACTOR’ section 90 of this Repair
Manual.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 1

SECTION 21 -- TRANSMISSION SYSTEMS

Chapter 1 -- 16 x 16 Transmission

CONTENT

Section Description Page

21 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault Finding, Calibration, Pressure Testing and Limp Home . . . . . . . . . . . . . . . . . . . . . . . 37
Overhaul Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
21 152 Dismantling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
21 114 Transmission Housing General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
21 152 Component Dismantling, Inspection and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 117
Clutch 1, 2 and Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Synchronisers, Forward/reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1--4/5--8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
High/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Clutch 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4 Wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Transmission Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
21 133 Operating Lever Cables, Removal, Replacemet and Adjustment . . . . . . . . . . . . . . . 184
Synchroniser Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
21 133 Control Valve Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

604.55.041.01 - 10 - 1998
2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

21 000 SPECIFICATIONS

Transmission Type 16 forward and 16 reverse speeds using straight cut

gears, four multi--plate wet powershift clutches, one
forward reverse friction cone synchroniser and one main
range friction cone synchroniser
Control System Electro--hydraulic with Electronic Management System
Clutch Hydraulic Operating Pressure 18--20 bar (260--290 lbf.in2) supplied from the CCLS
Hydraulic Piston Pump
Hydraulic Control Valve
Type Separate Casting, multi spool with internal cast--in
galleries
Control By electrically operated Pulse Width Modulated solenoid
coils signalled by Electronic Management System
Hydraulic Accumulator
Type Diaphragm type, nitrogen charged with 0.7 litre hydraulic
oil capacity
Charge Pressure 10 bar (145 lbf.in2)
Multi--Plate Wet Clutches
Type Constant running, pressure lubricated, pressure applied,
spring released
C1 and C2 clutches
Number of Friction Plates 4 in each clutch
Number of Steel Plates 4 in each clutch
C3 and C4 clutches
Number of Friction Plates 8 in each clutch
Number of Steel Plates 8 in each clutch
Number of Belleville Washers 4 pairs in each clutch
Belleville washer stack height 24 mm
Pressure Lubrication Maximum 7 bar (100 lbf.in2) supplied by the steering gear
pump

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 3

Lubricant Capacity U.S. Gallons 16.0

Transmission/Rear Axle Imp. Gallons 13.3
Litres . . . . . . 60.6

Lubricant Ambra Multi--G (NH 410 B)

Lubricant operating temperature 65!C (150!F)

Output Shaft Component End Float 0.004--0.012 in. (0.10--0.30 mm)

Output Shaft ‘D’ Shaped Shim Washer Sizes 0.079--0.080 in. (2.00--2.04 mm)
0.085--0.086 in. (2.15--2.19 mm)
0.091--0.092 in. (2.30--2.34 mm)
0.097--0.098 in. (2.45--2.49 mm)
0.102--0.104 in. (2.60--2.64 mm)

C3 Clutch Output Shaft to Transmission Rear Buckle Up Face:

Calculated Distance Washer Thickness

‘B’ (mm) Required (mm)
58.82--59.15 6.20--6.25
59.16--59.40 5.95--6.00
59.41--59.65 5.70--5.75
59.66--59.90 5.45--5.50
59.91--60.17 5.20--5.25
60.18--60.52 4.85--4.90

Synchroniser Wear Check

Main Synchroniser (1--4, 5--8)

Minimum Gap Between Friction and Outer Cone 0.032 in 0.8 mm

High--Low Range Synchroniser

Minimum Gap Between 0.060 in 1.50 mm

Clutch 3 and 4 Piston Travel 0.10--0.12 in 2.50--3.05 mm

Clutch 3 and 4 Separator Plate Thickness 0.089--0.091 in 2.26--2.3 mm

0.109--0.114 in 2.76--2.8 mm

Forward/Reverse and Range Synchroniser

Support Shaft Running Clearance 0.016--0.024 in 0.40--0.60 mm

Forward/Reverse Synchroniser Support Front

Bearing Retainer Plate Shim Sizes: F0NN--7Z478--AA 0.040 in. 1.00 mm

F0NN--7Z478--BA 0.012 in. 0.30 mm
F0NN--7Z478--CA 0.004 in. 0.10 mm
F0NN--7Z478--DA 0.002 in. 0.05 mm

604.55.041.01 - 10 - 1998
4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Gear Ratios 40 Km/hr Transmission

30 Km/hr Transmission

Forward Forward
Gear Range Transmission Gear Range Transmission
Ratio Ratio
1 Creeper 43.20 1 Creeper 43.42
2 Creeper 35.36 2 Creeper 35.36
3 Creeper 28.91 3 Creeper 29.06
4 Creeper 23.66 4 Creeper 23.66
5 Creeper 18.30 5 Creeper 18.39
6 Creeper 14.98 6 Creeper 14.98
7 Creeper 12.24 7 Creeper 12.31
8 Creeper 10.02 8 Creeper 10.02

1 L 8.51 1 L 8.55
2 L 6.97 2 L 6.97
3 L 5.69 3 L 5.72
4 L 4.66 4 L 4.66
5 L 3.30 5 L 3.62
6 L 2.95 6 L 2.95
7 L 2.41 7 L 2.42
8 L 1.97 8 L 1.97

1 H 2.74 1 H 2.08
2 H 2.25 2 H 1.69
3 H 1.84 3 H 1.39
4 H 1.50 4 H 1.13
5 H 1.16 5 H 0.88
6 H 0.95 6 H 0.72
7 H 0.78 7 H 0.59
8 H 0.64 8 H 0.48

Reverse Reverse
1 Creeper 43.60 1 Creeper 43.82
2 Creeper 35.68 2 Creeper 35.68
3 Creeper 29.17 3 Creeper 29.32
4 Creeper 23.88 4 Creeper 23.88
5 Creeper 18.46 5 Creeper 18.55
6 Creeper 15.11 6 Creeper 15.11
7 Creeper 12.36 7 Creeper 12.42
8 Creeper 10.11 8 Creeper 10.11

1 L 8.59 1 L 8.63
2 L 7.03 2 L 7.03
3 L 5.75 3 L 5.78
4 L 4.70 4 L 4.70
5 L 3.64 5 L 3.66
6 L 2.98 6 L 2.98
7 L 2.43 7 L 2.45
8 L 1.99 8 L 1.99

1 H 2.77 1 H 2.10
2 H 2.27 2 H 1.71
3 H 1.85 3 H 1.40
4 H 1.52 4 H 1.14
5 H 1.17 5 H 0.89
6 H 0.96 6 H 0.72
7 H 0.78 7 H 0.59
8 H 0.64 8 H 0.48

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 5

Low Pressure Hydraulic Circuit 18--20 bar (260--290 lbf/in2)

Pressure Regulating Valve

Low Transmission Oil Pressure Switch Closes @ 210--220 lbf/in2 (14.5--15.2 bar)
transmission oil pressure warning light comes ‘On’
Opens @ 240--250 lbf/in2 (16.5--17.2 bar)
transmission oil pressure warning light goes ‘Off’

Maximum Operating Pressure Low pressure circuit safety valve operates 400--415
lbf/in2 (27.6--28.6 bars)

SPECIAL TOOLS
DESCRIPTION TOOL NUMBER
(V.L. Churchill Ltd.) (FNH--A No.)
16 x 16 Transmission Overhaul Kit 4FT500 FNH--00865
Comprising of:--
Handle (for use with resizer tool) 4FT501 FNH--00866
Tapered Sleeve, C3/C4 Piston Seal Expander 4FT502 FNH--00867
Tapered Sleeve, C1/C2 Piston Seal Expander 4FT503 FNH--00868
Piston Installer (Pusher) 4FT504 –
Tapered Sleeve C3/C4 Piston Seal Installer 4FT505 FNH--00869
Tapered Sleeve C1/C2 Piston Seal Installer 4FT506 FNH--00870
Seal Resizer C1/C2/C3/C4 Piston Seal 4FT507 FNH--00871
Clutch Piston Return Spring Compressor 4FT508 FNH--00872
FWD Transfer Tube Remover 4FT509 FNH--00873
Transmission Stand Bracket 4FT510 –
Gauge Rolled In Tube Replacement 4FT511 –
Gauge Rolled In Tube Expander 4FT512 –
Diagnostic Switch 4FT950 FNH--00874

Additional tools required not supplied in the above kit:

Limp Home Harness 4FT952 –
Adaptor 80265235 –
Slide Hammer 954C –
Puller 951 or 9190 --
Pulling Attachment 1002 or 9198 –
Pressure Testing Switch Bypass Plug NH.21--115 --

THREAD SEALANT

Thread Sealant New Holland Thread Seal 82995768

Gasket Sealant New Holland Flexible Sealant 82995770 (50 ml)

82995771 (300 ml)

604.55.041.01 - 10 - 1998
6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Tightening Torque Values

Side Cover (External View)

Side Cover (Internal View)

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 7

604.55.041.01 - 10 - 1998
8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DESCRIPTION AND OPERATION

ELECTRO SHIFT TRANSMISSION

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 9

Introduction
The Electro Shift transmission is available in 30 or
40 kph, with 16 forward and 16 reverse gears, 2 or
4WD and with a creep option giving an additional
eight gears.

Four electro-hydraulic clutches provide four The High/Low synchroniser provides field or road
powershift (without clutch pedal) gear changes. speeds for the above 1 to 8 gears.
The main range mechanical synchroniser enables The mechanical synchroniser for
electro-hydraulic gears, 1 up to 4, or 5 up to 8, to Forward/Reverse, combined with the dump button
be selected. which disengages drive to the electro-hydraulic
clutches, provides a clutchless shuttle.

604.55.041.01 - 10 - 1998
10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

The transmission has a flywheel damper and no

conventional clutch.

3
Electro-hydraulic control of a piston (1) which
activates a coupler (2) provides an optional creep
range. This only operates in Low range, giving a
total of 24 x 24 gears.

4
The processor gives accurate control, via Pulse
Width Modulated (PWM) valves, of the four wet
multiplate clutches.
This also enables clutchless shuttle operations,
speed matching of gears, sequential powershifting
and high range gear logic.

5
Operation
Downshifting or Upshifting is achieved by pressing
the required button.
The clutch or inching pedal is used for all
synchroniser changes and must be depressed
when operating the High/Low, main shift (1--4 to
5--8) and the Forward/Reverse levers.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 11

However, the Forward/Reverse lever also has a

dump button which performs the same function as
the interrupt button (1) when depressing the
clutch/inching pedal.

7
Creeper gear engagement (1) must only be
undertaken with the tractor stopped, low range
selected and inching pedal depressed.

Clutchless shuttle/drive off

The dump button enables gear engagement and
drive off, without using the clutch pedal and is
particularly useful for shuttle operations.
When the dump switch button is depressed, drive
is instantly disengaged. When the button is
released, transmission output speed and clutch
pack engagement are automatically monitored to
take up the drive smoothly.
NOTE: To prevent inadvertent shuttle lever 8
engagement, an electronic interlock is provided. If
the tractor is stationary with the shuttle lever in
neutral the following procedure must be used to
drive away.:
Depress and release the dump switch then, within
one second, depress and hold in the switch. Move
the shuttle lever into gear. The drive will engage
when the button is released. If this sequence is not
followed a warning ‘bleeper’ will sound and the fault
code ‘CP’ will appear in the digital display.
To change from forward to reverse motion, press
the dump button, apply the brakes to slow the
tractor, move the shuttle lever fully rearward,
release the button and control tractor speed by
means of the throttle.
IMPORTANT: To reduce clutch damage caused by
shuttle shifting in too high a gear or at too high a
speed, a warning ‘bleeper’ will be heard and a
symbol ‘N’ will appear in the instrument cluster
under the following condition:
S In high range: ratios 5--8 and Shuttle shifting
while the tractor is still rolling.

604.55.041.01 - 10 - 1998
12 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Speed Matching
When travelling on the road in high range and the
main shift lever is in the 5--8 position, the
transmission will automatically select a gear ratio
to match engine speed to road speed when up
shifting or down shifting using the following
procedure:
To Upshift
S Depress shuttle dump switch or inching pedal
S Decrease engine speed with foot throttle
S Release shuttle dump switch or inching pedal

9
The microprocessor will then automatically select
a higher gear ratio to approximately match road
speed with engine speed.
To Downshift
S Decrease engine speed
S Depress shuttle dump switch or inching pedal
S Increase engine speed with foot throttle
S Release shuttle dump or inching pedal
The microprocessor will then automatically select
a lower gear ratio to approximately match road
speed with engine speed.
10
Low -- High Range Change
(Main Shift Lever in 5--8 Position)
When it is necessary to start under load in LOW
RANGE and change to HIGH RANGE an
additional microprocessor feature provides
automatic selection of 5H (13th speed) when the
range lever is moved from low (8L) to high range.

11
Sequential Powershifting
If the Powershift button is held depressed, the
transmission will make sequential ratio changes at
1.75 second intervals until the button is released.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 13

TRANSMISSION CONTROL/OPERATION

12
The operator controls the transmission using the The speed that the clutches hydraulically engage
gear levers and electrical buttons on these levers and disengage is controlled by the processor
(3). Signals are then sent to the processor (1) from through the PWM valves and is dependant upon all
the status switches (2) which inform the processor the signals received from the operator and the
which mechanical synchronisers are selected. sensors. The two clutches at the front of the
The operator also controls the clutch/inching pedal transmission C1/C2 can be considered as
(4) which has a potentiometer (B) and a disconnect ON/OFF clutches. However, a degree of gradual
switch (A) attached to it. engagement/disengagement exists during gear
changes. The two clutches at the rear of the
The processor takes a signal from the alternator (8) transmission C3/C4 are much larger and can be
which gives the engine speed. The transmission considered as the feathering or gradual
speed sensor (9) gives the output speed of the engagement clutches. It is these clutches that
transmission, and thus the wheel speed, to the permit smooth gear changes and take--offs by
processor. progressively engaging until fully locked.
The transmission oil temperature is measured by Whilst operating in any one gear, one of the C1/C2
the oil temperature sensor (6) adjacent to the and one of the C3/C4 clutches is always fully
transmission control valves. This gives an engaged.
indication of oil viscosity to the processor.
The processor then controls the four Pulse Width
Modulated (PWM) valves (7) which regulate the
Low Pressure Oil (18--20 bar) to operate the four
clutches within the transmission.

604.55.041.01 - 10 - 1998
14 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION HYDRAULIC CONTROL

Mounted on the side of the transmission is the

control valve assembly.
The control valve pack is supplied with Low
Pressure Oil (8) (18--20 bar) from an accumulator
(Fig. 11). This is necessary to ensure minimum
drop in oil pressure when changing gear,
particularly when changing two clutches at once.
Oil for lubrication enters at point 9.
The control valve pack incorporates four PWM
valves (3,4,5,7), a transmission oil temperature
sensor (10) and optional 4WD (2) and creep
solenoids (1) and a creep interlock piston (6).

Mounted on the rear of the control valve pack is the

lubrication combining valve pack. This
incorporates the lubrication regulating valve (1),
the lubrication combining valve (2) with valve spool
and spring (4) and the lubrication shuttle valve (3).
This valve pack combines lubrication oil at 5 bar
with low pressure/transmission control oil at 18--20
bar to increase clutch lubrication during clutch
feathering.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 15

TRANSMISSION GEAR DESCRIPTION

Number of teeth
Gear Description
40 Kph 30 Kph
A C1 Clutch Output Gear 34
B C2 Clutch Output Gear 26
C Creeper Driven Gear 55
D Front Bottom Shaft Gear 42
E Front Bottom Shaft Gear 48
F Front Bottom Shaft Gear 20
(Creeper only)
G Reverse Gear 33
H Forward Gear and/or Coupler 37
J Low Main Gear 53
K Intermediate Bottom Shaft Gear 37
L Intermediate Bottom Shaft Gear 41
M Intermediate Bottom Shaft Gear 25
N C4 Clutch Output Gear 42 37
O C3 Clutch (High) Output Gear 46 41
P C3 Clutch (Low) Output Gear 22
R Output Gear 37 43
R1 Reverse Idler Gear 31
S Output Gear 33 39
T Low Range Output Gear 65
U Output to FWD 29
V FWD Internal Shaft Rear Gear 26
X FWD Internal Shaft Front Gear 26
Y FWD Transfer Assembly Driven Gear 37 or 38

releases clutch 4.
S POWER FLOW: Input shaft -- clutch 1 -- gears
A--D--E--B-- F/R synchroniser -- Gears
H--L--M--J-- Main synchroniser -- clutch 3 --
Gears P--T-- High/Low synchroniser -- output
shaft.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 21

POWER FLOWS -- 5TH GEAR

Hydraulic clutches engaged

C1 C2 C3 C4

1--5 9--13

2--6 10--14

3--7 11--15

4--8 12--16

31
Gear lever positions

S 4th to 5th Change:

Synchroshift (1--4) to (5--8) with main shift lever
using inching pedal. Automatic
micro-computer controlled clutch sequence
engages clutches 2 and 4, releases clutch C1
and C3.
S Main Synchroniser:
Main synchroniser in (5--8) position provides
direct drive in centre section.
S POWER FLOW: Input shaft -- clutch 2 --
F/R synchroniser -- main synchroniser -- 32
Clutch 4 -- Gears N--R--S--O--P--T-- High/Low
synchroniser -- output shaft.

604.55.041.01 - 10 - 1998
22 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

POWER FLOWS -- 8TH GEAR

33
Hydraulic clutches engaged
C1 C2 C3 C4

1--5 9--13

2--6 10--14

3--7 11--15

4--8 12--16

34
Gear lever positions

S Power flows for 6th, 7th and 8th are similar to

2nd--3rd--4th except for the main synchroniser
which provides a direct drive in (5--8) position.
S The four wheel drive clutch is shown engaged.
S Drive is transmitted from the output shaft to the
four wheel drive transfer assembly by gears
U--V--X--Y.

reverse drive for all forward speeds (1--16 and
creeper 1--8).
S Moving the synchroniser into reverse engages
gear G, output from the C1--C2 clutches will be
transmitted through gears G--R1--K--M--J
reversing the drive line to clutches 3 and 4.

604.55.041.01 - 10 - 1998
26 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

NOTES

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 27

KEY TO TRANSMISSION HYDRAULIC CIRCUIT SCHEMATIC ILLUSTRATIONS

1. Regulated Pressure Supply from CCLS Pump Symbols

18--20 bar
2. Lubrication Supply from Steering Motor Return Regulated Pressure Supply
3. Supply from Creeper Solenoid to FWD Clutch
4. Supply from FWD Solenoid to FWD Clutch Regulated Pressure Line either to
5. Lubrication Combining Valve Reservoir or at Zero Pressure

6. Lubrication Shuttle Valve

Lubrication Oil
7. Lubrication Supply to PTO Clutch
8. Lubrication Supply to Transmission Shafts and Line Joining Points
Synchronisers
9. Lubrication Proportioning Valve C3/C4 Line Restriction
Clutches
10. Lubrication Proportioning Valve C1/C2 Pressure Operated Valve
Clutches
11. Accumulator 10 bar/0.7 litres Pulse Width Modulated Solenoid Valve
12. Lubrication Relief Valve
Solenoid Operated Valve
C1 Clutch 1
C2 Clutch 2 Positive Voltage Applied
C3 Clutch 3
C4 Clutch 4 Reservoir

PWM Pulse Width Modulation Valve Spring Assisted

604.55.041.01 - 10 - 1998
28 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION HYDRAULIC CIRCUIT SCHEMATIC -- START UP

S Regulated pressure oil at 18--20 bar

(260--290 lbf/in2) is supplied to the
transmission side cover assembly by the
CCLS piston pump (1).
S Lubrication oil is supplied to the transmission
side cover assembly from the steering
motor/cooler return (2). Maximum pressure is
limited by the lubrication relief valve (12) to 7
bar (100 lbf/in2).
S Regulated pressure oil is directed to:--
C1 PWM Valve
C2 PWM Valve
C3 PWM Valve
C4 PWM Valve
Creeper Solenoid Valve (3)
FWD Solenoid Valve (4)
Lubrication Combining Valve (5)
Since the PWM and solenoid valves are not
energised there is no flow of regulated pressure oil.
S Lubrication oil is directed to the lubrication
combining valve, spring pressure moves the
valve to the left.
S The lubrication oil from the lubrication
combining valve is directed to:--
C1/C2 Clutches
C3/C4 Clutches
Transmission Shafts and Synchronisers
PTO Clutch

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 29

604.55.041.01 - 10 - 1998
30 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION HYDRAULIC CIRCUIT SCHEMATIC --

SPEED 1 SELECTED, INCHING PEDAL PARTIALLY RAISED

S As the inching pedal is partially raised C2 PWM

valve opens fully, allowing full pressure
(18 bar) into clutch C2.
S C1/C2 lubrication proportioning valve (10) is
moved to the left by C2 clutch pressure,
increasing C2 clutch lubrication, reducing C1
clutch lubrication.
S As the inching pedal is released further, C4
PWM valve is progressively energised. As C4
clutch apply pressure increases from zero to 2
bar, oil flows past the lubrication shuttle valve
(6) to the left end of the lubrication combining
valve (5), moving it right to its central position.
Pressure regulated oil is combined with
existing C3/C4 lubrication oil to increase
lubrication oil flow during clutch apply.
Lubrication to transmission and PTO is
reduced during clutch apply.
S C3/C4 lubrication proportioning valve (9) is
moved to the left by C4 clutch apply pressure
to increase C4 clutch lubrication.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 31

604.55.041.01 - 10 - 1998
32 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION HYDRAULIC CIRCUIT SCHEMATIC --

SPEED 1 SELECTED, INCHING PEDAL FULLY RELEASED

S As the inching pedal is fully released C4 PWM

valve is fully energised.
S When C4 clutch apply pressure increases
above 15 bar the lubrication combining valve is
moved fully to the right. Pressure regulated oil
is no longer combined with lubrication oil.
Transmission and PTO lubrication is restored.
S Clutch apply pressure increases to full
pressure 17--19 bar.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 33

604.55.041.01 - 10 - 1998
34 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION GEAR DESCRIPTION

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 35

R F

(5--8) (1--4) H L

C3 C4
C1 C2 C J
O
N
A G H
B
P

RI U

F
M
K L
D
E
S
R

X T

5--8
8
7
6
Y N 5
SHG21124 N N
4
3
2
1

1--4

604.55.041.01 - 10 - 1998
36 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

NOTES

ELECTROSHIFT TRANSMISSION
GEAR IDENTIFICATION

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 37

21000 -- TROUBLE SHOOTING, LIMP HOME, CALIBRATIONS AND PRESSURE TESTING

The transmission / EDC electronic management

system has an inbuilt self diagnostic facility which
is able to store up to 30 different errors with the
hours of occurence. This facility utilises the digital
display of either the EIC or AEIC instrument panels
to indicate, in coded format, any malfunction in the
electrical and electronic circuitry and in the
processor.

It should be noted that the self diagnostic capability

is generally limited to diagnosis of the electrical and
electronic circuitry and related components,
however, there are some codes, which can be
generated if pressure switch circuits are not closed
because of an actual lack of hydraulic pressure.
45
Any malfunction of the mechanical and hydraulic
components must be diagnosed using
conventional techniques, performance
characteristics and tooling, such as pressure
testing equipment. Full guidance for both electrical
self diagnosis and conventional diagnosis is
contained within this section.

Trouble--shooting and fault finding should always

be carried out in a logical and planned sequence,
many apparent faults associated with electronic
components are often hastily diagnosed and result
in the replacement of expensive components. An
extra few minutes confirming the apparent fault will
result in a more positive and cost effective repair.

Prior to detailed fault finding, items like the earth

points and Battery should be cleaned and tested to 46
ensure that they are functioning correctly.
With the use of micro--processors it is often that
this item is blamed for any malfunction but the real
truth is that this item is usually sound and that the
fault is due to poor contacts in the associated
connectors.

Each connector illustrated and identified in the

wiring diagrams in Section 55 and referred to in the
following fault finding procedure, has the same
identification reference. For example, the main
processor connectors are referred to as
Connectors C127 and C128 in the illustration and
also referred to as C127 and C128 in the fault
finding procedure. Often in the fault finding flow
chart the connector and pin are abbreviated and
will read, for example, C127--10. The C127 refers
to the connector and the 10 to the pin number.
Section 55 contains complete wiring diagrams,
connector identifications and a list of circuit 47
numbers as used within the circuit diagrams.

604.55.041.01 - 10 - 1998
38 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Where the fault finding procedure requires checks

for continuity a visual inspection of the wiring
should be made prior to conducting tests to ensure
that obvious ‘mechanical’ damage has not
occurred to the harness or the connectors.

Where possible the inbuilt tractor diagnostics

should be utilised to determine the area of the fault.
The ’H’ menu mode, described in Section 55,
provides several modes to aid diagnosing faults.
One particular mode which should be used, before
any connections are split, is the H5, switch
diagnostics mode. This will provide testing of many
switch circuits, including the switch itself. If this
mode highlights a fault within a circuit then more
detailed fault finding can be directed towards a 48
particular circuit.

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

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high
range and work downwards to avoid damaging the
instrument.
Where possible it is recommended that connectors
are probed from the rear, certain connectors like
C079, C080 and C081, instrument panel
connectors, should always be probed from the
rear. Connector terminals should only be removed
using the special tools supplied in electrical repair
kit, Tool No.4FT.953 and the wires should not
require excessive pulling efforts to remove.
49
Where only front probing is practical it is
recommended that Connector test probe kit, Tool
No NH.55--125 is obtained. This provides all
connector terminal attachments for use with most
multi--meters.
IMPORTANT: Care should be used when using
the multi--meter, only use the instrument as
instructed to avoid damage to the internal elements
of the micro--processor. When checking the
continuity of wiring, sensors or switches it is
necessary to isolate the electronic
micro--processor and ensure the keystart is turned
off to prevent possible further damage. The
keystart should only be switched on and the
processor connected where specifically instructed
in the fault finding procedure.
TA60--21--01
4
If it is found necessary to clean the connectors a 50
contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains
Trichloro--ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 39

Limp Home Procedure

In the unlikely event of an electrical fault developing
within the powershift transmission that renders the
tractor immobile, for example, failure of the wiring
or supply voltage to the PWM valves, the
emergency ‘Limp Home Harness’, Special Tool No.
4FT 952A, is available to enable the tractor to be
driven onto a transporter or hard standing, in order
that the repair can be carried out in a suitable
location. The Limp Home device is not and must
not be used as a means to continue operating the
tractor in its work environment.
To engage and operate the ‘Limp Home Harness’
proceed as follows:--

1. Apply the parking brake.

2. Stop the engine and turn keystart off

3. Disconnect all of the PWM valve connectors.

Connect the Limp Home harness extension
connectors to the C2 (1) and C3 (2) PWM
valves.
4. Connect the other end of the Limp Home
harness to the ‘D1’ diagnostic plug (1) located
adjacent to the fuse box.
5. Place the range lever into Low Range and the
main lever into the 1--4 Range. Ensure the
forward/reverse lever is in Neutral.
NOTE: It is important that only the lowest ranges
are used when operating with the Limp Home
Harness due to the feathering capability of the
transmission being inoperative. 51

6. Start the vehicle.

7. Select forward or reverse.

8. Operate the momentary switch (2) of the Limp

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

9. When the tractor has been delivered to the

repair area, disconnect the Limp Home
Harness and reconnect the PWM valve
connectors and proceed with diagnosing and
repairing the fault.

604.55.041.01 - 10 - 1998
40 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

PRESSURE TESTING
Pressure ports are provided on the transmission
control valve cover, detailed in Figure55, to enable
the transmission clutches, the creeper and the four
wheel drive systems to be tested to determine the
correct function of a number of system
components. Components such as solenoids,
clutch pedal operation and micro--processor can
be seen to be operating correctly by the results of
pressure testing.

NOTE: Prior to pressure testing, make certain that

all the points detailed under the tractor preparation
are carried out to ensure maximum safety.

Tractor Preparation

1. Start the tractor and run until the transmission

oil has reached its normal operating
temperature of at least 40!C (104!F).

2. Apply the handbrake and remove the FWD

shaft.
3. Raise the right hand rear wheel and place a
suitable support under the axle casing.
Remove the right hand wheel.

4. Disconnect the grey connector to the low range

switch and install ‘Switch By--Pass Connector’,
Tool No. NH.21--115, into the tractor harness
end. By installing the connector, the processor
receives a signal indicating that low range is
selected, although the RANGE LEVER
remains in NEUTRAL throughout the testing.

5. Disconnect the differential lock solenoid

connector (1).

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 41

C1/C2 and C3/C4 Clutch Engagement and Four Wheel Drive Pressure Testing (Follow
Disengagement previous tractor preparation. The FWD shaft
must be removed).
1. Install the pressure gauges. Ideally four
gauges should be used, however, the testing 1. Install gauge into FWD test port.
can be carried out with two gauges using the
2. Disengage FWD, DO NOT TOUCH FOOT
following procedure:
BRAKES, shift all levers to neutral. Start
S Connect to C1 and C2 test ports and carry out and run engine at 1500 rev/min. Pressure
tests from powershift one through to four. reading should be 18--20 bar.
S Connect to C3 and C4 test ports and carry out 3. Engage FWD, pressure reading should drop to
tests from powershift one through to four. zero.

S Connect to C2 and C3 test ports and carry out Creeper Pressure Testing (Follow previous
clutch feathering test. tractor preparation
2. Position the shuttle lever in Forward, the main 1. Install gauge into creeper test port.
lever into the 1--4 range and leave the
High/Low lever in Neutral. Set the engine 2. Shift all levers into neutral. Start engine and
speed to 1500 rev/min. Observe the reading run at 1500 rev/min.
on the gauges and compare with those in Table 3. Depress the clutch pedal, engage low range
1 as the gears are shifted and with those in and select creeper. The pressure reading
Table 2 for the feathering tests. should be between 18--20 bar.

Figure55
Pressure Test Ports
All Pressure Test Ports Accept 7/16 inch JIC Fitting
1. C4 Pressure 8. Creeper Pressure 14. C2 PWM Solenoid Valve
2. C3 Pressure 9. FWD Pressure 15. C1 PWM Solenoid Valve
3. C3/C4 Lube Pressure 10. Lube Inlet Connector 16. Creeper Solenoid Valve
4. Lube Supply Pressure 11. Regulated Pressure Inlet 17. FWD Solenoid Valve
5. C2 Pressure 12. C4 PWM Solenoid Valve 18. Transmission Bearing / Syn-
6. C1/C2 Lube Pressure 13. C3 PWM Solenoid Valve chroniser Lube Pressure
7. C1 Pressure

604.55.041.01 - 10 - 1998
42 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Table 1 -- Pressure Testing -- Clutch PWM Solenoid Operation

Clutch
C1 C2 C3 C4 Observations
Gear

1 C2 and C4 at Full Pressure

C2 Full Pressure
1 2 C3 0 to 2 bar : 2 to 18 bar
C4 18 to 17 bar ; 17 to 0 bar

C2 and C3 at Full Pressure

C1 0 to 2 bar : 2 to 18 bar
C2/C3 18 to 17 bar : 17 to 0 bar
2 3 C4 0 to 18 bar

C1 and C4 at Full Pressure

C1 Full Pressure
C3 0 to 2 bar : 2 to 18 bar
3 4 C4 18 to 17 bar : 17 to 0 bar

C1 and C3 at Full Pressure

Table 2 -- Powershift 2 Selected -- Clutch Feathering Tests

Clutch
Pedal C2 C3 Observations

When clutch pedal is initially depressed Pressure in both

C2 and C3 reduce from the fully engaged pressure by
approximately 2 bar.

Fully depressing clutch pedal should zero C2/C3 pres-

sures.

Releasing clutch pedal from fully depressed position

should restore clutch 2 to full pressure, minus approx.
2bar and clutch 3 to feathering pressure.

Pressure in C3 should progressively increase as clutch

pedal is released indicating PWM valve and clutch poten-
tiometer are functioning correctly.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 43

Table 3 -- Forward/Neutral/Reverse Shuttle Switch -- 1st Powershift Selected

Switch
C1 C2 C3 C4 Observations
Position

C2 and C4 at Full Pressure

C2/C4 17 to 0 bar

C2 Immediate full Pressure

restored
C4 Controlled engagement to
full pressure

Table 4 -- Powershift 1 Selected -- Clutch Lube Tests

Clutch C1/2 C3/4

C2 C4 Observations
Pedal Lube Lube

C2/C4 Zero pressure

C1/C2 Lube Approx 0.5 bar
C3/C4 Lube Approx 0.5 bar

C2 Full pressure
C4 0--2 bar
C1/C2 Lube Approx 0.75 bar
C3/C4 Lube Approx 2 bar

C2 Full pressure
C4 Rising to Full pressure
C1/C2 Lube Approx 0.75 bar
C3/C4 Lube Approx 2 bar

C2 Full pressure
C4 Full pressure
C1/C2 Lube Approx 0.75 bar
C3/C4 Lube Reduced to 1 bar

604.55.041.01 - 10 - 1998
44 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

TRANSMISSION CLUTCH CALIBRATION

Required when any of the following items have

been performed or noticed:--

S The microprocessor has been replaced.

S The non volatile memory of the processor has
been reset (Mode H8 Performed).
S A clutch PWM solenoid valve has been
replaced.
S The shift quality or clutch featherability has
noticeably deteriorated.

Set Up Procedure:

Prior to conducting a transmission clutch

calibration, the following points should be checked.

S The temperature of the transmission oil is at

normal working temperature.
S The parking brake is applied
S The air conditioning, if fitted, is switched off.
S All electrical and hydraulic services are
deselected.

WARNING: The calibration procedure is controlled

by the electronic management system. To prevent
inadvertent movement of the tractor. Park the
tractor away from any obstacles, firmly apply the
parking brake and block the wheels, front and rear.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 45

SPRING PRESSURE CALIBRATION

Entering the calibration mode :
Press and hold both the upshift and downshift
buttons whilst starting the tractor.

56
Alternative method :
Install diagnostic tool 4FT950 into the Black
diagnostic connector, located by the fuse box.

Start the tractor.

Enter mode H1.

57
The word CAL should appear on the instrument
cluster display. This will be replaced after a few
seconds by the oil temperature, in degrees
Celsius.

Set the engine speed to 1200 +/-- 100 rpm.

58
C3 and C4 Calibration
Place all gear levers in the forward position.

604.55.041.01 - 10 - 1998
46 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

C3 calibration :
Press and hold the Upshift button.
If the start up procedure was incorrect, a U code
will be displayed (see page 47).

60
The display will change to show a number.
This number will flash and begin to scroll up, as
the clutch is calibrated.
When the processor detects a decrease in
engine rpm of 50, the calibration stops. This is
indicated by a fixed, non flashing number.
Release the Upshift button.

61
C4 calibration :
Use the downshift button to calibrate the C4
clutch in the same manor as the C3 clutch.

62
The display is similar to the C3 calibration.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 47

C1 and C2 calibration :
Depress the clutch pedal.

Place the range lever in neutral, leaving the

shuttle lever and the main lever in the forward
position.

Release the clutch pedal.

Set the engine speed to 1200 +/-- 100 rpm.

64
Press and hold the Upshift button to calibrate the
C1 clutch.
Press and hold the Downshift button to calibrate
the C2 clutch.
The procedure is the same as that for the C3 and
C4 clutches.

65
Spring Pressure Calibration Error Codes :

U20 -- Correct start up sequence was not used.

U21 -- Engine rpm too low
U22 -- Engine rpm too high
U23 -- Forward / Reverse shuttle lever is not in Forward
U24 -- Main lever is not in 5--8 range
U25 -- Range lever is not in high range
U26 -- Clutch pedal is not fully released
U27 -- C3 calibration too low
U28 -- C3 calibration too high
U29 -- C4 calibration too low
U30 -- C4 calibration too high
U31 -- Wheel motion detected during calibration
U32 -- C1 calibration too low
U33 -- C1 calibration too high
U34 -- C2 calibration too low
U35 -- C2 calibration too high

604.55.041.01 - 10 - 1998
48 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

CLUTCH FILL TIME CALIBRATION

Set up procedure:
S Warm the oil to normal operating temperature,
at least 60!C.
S Park the tractor on a level surface. Allow some
space as the tractor will move when testing
clutches 3 and 4.
S with a diagnostic tool installed start the engine
and set engine speed to 1200 +/-- 100 rpm.

66
Entering the calibration mode :
Place the 4--5 (main) and range levers in neutral,
place the shuttle lever in forward and release the
clutch pedal.
Using diagnostic tool 4FT950 select mode HE.

If the oil temperature is less than 60!C ’F1’ will

be displayed, alternating with the display of oil
temperature. This will NOT stop until the oil
reaches 60!C.

67
CLUTCH SELECTION:
While the 4--5 lever is in neutral, the display will
indicate which clutch is selected.

To select C1 or C2 the range lever must be in

neutral.
To select C3 or C4 the range lever must be in the
high range

To switch between C1 and C2 or C3 and C4,

press the upshift or downshift switch while the
4--5 lever is in neutral.

68
ADJUST AND TEST C1 OR C2
Shift the 4--5 lever into 5 (forward).
This display will show C1 or C2 and to the left of
this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on the C3 and
C4 clutches to prevent output rotation of the C1
and C2 clutches.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 49

The display will then change to a single digit

number which is indicating the quickfill time in 10
millisecond units.
This can be adjusted using the upshift and
downshift switches.

70
To test the quickfill setting, press and release the
dump switch. The display will show ’Fill’ and then
return to the quickfill setting.
Listen to the clutch engagement ’Slap’.
Increase the value to a point where a ’slap’ is just
audible and then reduce the value by 2.

71
ADJUST AND TEST C3 OR C4

Ensure that the handbrake is OFF.

Shift the range lever into the high range.

Shift the 4--5 lever into 5 (forward) and release

the clutch pedal.

72
This display will show C3 or C4 and to the left of
this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on C1 clutch to
connect C3 and C4 to the engine.

604.55.041.01 - 10 - 1998
50 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

The display will then change to a single digit

number which is indicating the quickfill time in 10
millisecond units.This can be adjusted using the
upshift and downshift switches.

74
To test the quickfill setting, press and release the
dump switch. The display will show ’Fill’ and then
briefly to the clutch selected then the quickfill
setting.
As the dump switch is released the tractor should
be felt to ’rock’ as the clutch fills.

75
Adjust the fill time until the rock is barely noticeable,
then reduce the value by 2.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 51

NOTES

604.55.041.01 - 10 - 1998
52 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

ERROR CODES
The transmission / EDC processor is able to create
and store up to 30 error codes with the hours at
which they occured and with the number of
incidences that a particular error code has
occured. Only error codes that prevent the tractor
from driving will be displayed to the operator, other
non disabling errors will be retreivable by a
technician through the H menu mode of the tractor
diagnostics.
It should be noted that the hours displayed is not
related directly to the hour meter. For example if the
occurence hours shows ’10’ this indicates that the
error occured 10 hours ago, not at 10 hours of
operation. 77
The following ’H’ menu mode routines are provided
to allow access to Error codes:
Hb -- Retrieve error codes for viewing.
Hc -- Clear processor memory of stored error codes
Hd -- View error codes live. This allows normal
operation of the tractor with error codes able to
display as they occur.

A full description of the ’H’ menu routines can be

found in Section 55.

78
It should also be noted that after installation of a
new processor or after a non volatile memory reset
operation (’H’ menu mode, H8), that the processor
defaults to a ’display all codes’ mode for 6 minutes.
If no error codes occur during this 6 minute period
the processor then reverts to normal operation. If
an error occurs during this period the processor will
continue to display ’live’ error codes until all the
errors are removed.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 53

16x16 Electroshift Transmission Error Codes

Error Fault Condition Priority Enabled/ Error

Disable? Displayed?

E21 Chassis harness disconnected 1 Disable Yes

E53 5 Volt Reference failed, shorted to 12 volts 2 Disable Yes
E54 5 Volt Reference failed, shorted to ground 3 Disable Yes
E12 Clutch pedal potentiometer signal too high 4 Disable Yes
E11 Clutch pedal potentiometer signal too low 5 Disable Yes
E39 C4 clutch solenoid open circuit 6 Disable Yes
E38 C4 clutch solenoid short circuit 7 Disable Yes
E41 C3 clutch solenoid open circuit 8 Disable Yes
E40 C3 clutch solenoid short circuit 9 Disable Yes
E43 C2 clutch solenoid open circuit 10 Disable Yes
E42 C2 clutch solenoid short circuit 11 Disable Yes
E45 C1 clutch solenoid open circuit 12 Disable Yes
E44 C1 clutch solenoid short circuit 13 Disable Yes
C Wheel speed too high for creeper gear 14 Recover Yes
HC Range shift to high with creeper engaged 15 Recover Yes
E37 Clutch disconnect switch open circuit 16 Disable Yes
E48 Clutch disconnect switch short circuit
misadjusted, always closed 17 Disable Yes
CP Depress clutch pedal to enable transmission 18 Recover Yes
N Clutchless shuttle operation attempted at too
high a speed and in too high a gear 19 Enabled Yes
E46 Fuse 12 blown 20 Enabled No
E47 Clutch disconnect switch misadjusted high 21 Enabled No
E51 Transmission temperature sensor open circuit 22 Enabled No
E52 Transmission temperature sensor short circuit 23 Enabled No
E24 All clutches not calibrated 24 Enabled No
EC4 C4 clutch not calibrated 25 Enabled No
EC3 C3 clutch not calibrated 26 Enabled No
EC2 C2 clutch not calibrated 27 Enabled No
EC1 C1 clutch not calibrated 28 Enabled No
E16 Creeper solenoid open/short circuit, or
attempt was made to engage creeper after
prior creeper error 29 Enabled No
E15 High/low range lever switches both on 30 Enabled No
E14 1--4/5--8 Range lever switches both on 31 Enabled No
E55 No output speed signal 32 Enabled No
E56 Differential lock switch error 33 Enabled No
E49 Wheel speed sensor circuit open or short
circuit 34 Enabled No
E26 Engine rev/min speed too high 35 Enabled No
E27 Engine rev/min speed too low 36 Enabled No

604.55.041.01 - 10 - 1998
54 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Key to Fault Finding Diagrams

Diagrams 1 to 10 -- Not related to error codes

1. Tractor Does Not Drive In Any Gear

2. Incorrect Gear Shift Sequence or Gears Missing
3. Powershifts Jerky / Loss of Drive
4. Poor Clutch Feathering
5. Clutch Potentiometer Calibration Check
6 Holding in Gear / Jumping Out of Gear / Clashing
7. Creeper Does Not Disengage
8. Clutches Squeal / Whine During Inching
9. Transmission is Noisy in Operation
10. Transmission ‘Clunks’ During Inching
Diagrams 11 onwards, error code related:
11. Error Code E11
12. Error Code E12
13. Error Codes E53 and E54
14. Error Codes E37, E47 and E48
15. Error Codes E38,E39 / E40,E41 / E42,E43 / E44,E45
16. Error Codes C and E16 -- Creeper Does Not Engage in Low Range
17. Error Code HC
18. Error Code CP
19. Error Code E46
20. Error Codes E51 and E52
21. Error Codes E24, EC4, EC3, EC2 and EC1
22. Error Code E15
23. Error Code E14
24. Error Code E55
25. Error Code E56
26. Error Code E49
27. Error Code E26
28. Error Code E27
29. Error Code Symbol ‘N’

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 55

DIAGRAM 1 -- Tractor does not drive (in any gear)

Key OFF
Key ON
recheck

Key ON. Is the Instrument Are any error Are the Remove
Cluster providing ‘Normal’ codes connectors refit/
Display in the transmission displayed C127 & repair
and EDC areas? C128 of as
processor required
Refer to error okay?
code listing
Reset ’H8’ and recalibrate the
processor. Recheck the
CCLS system operation. If still no drive
Install flow meter into
remote, is flow indicated fault refer to reolace processor.
when operated? hydraulic module.

Charge pump warning Does the Go to pressure

light illuminated engine stall or testing clutches
lug down?

Check pressure in Inspect operation of levers Inspect

low pressure circuit. for correct preparation. switch
Is pressure 18--20 Enter mode H5, is Neutral/ and wiring
bar? start inhibitor switch okay?

Pressure reducing valve

fault, or leak in low
pressure circuit. Refer to
Section 35, hydraulics.
Pressure test the
Suspect PWM
transmission clutches.
valves. Clean or
Are pressures okay?
replace valves in
circuits with
incorrect pressures

Suspect a mechanical
failure within
transmission. Seized
clutches, synchronisers
or broken gear in shaft.

604.55.041.01 - 10 - 1998
56 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 2 -- Tractor drives in ranges but has following fault:

-- Powershift function operates but the shift sequence is incorrect or gears missing
Key OFF
Key ON
recheck

Are the PWM solenoid Using the wiring diagram

connectors on the correct PWM ensure the correct harness
valves connector is on the
appropriate PWM solenoid.
Establish the missing gears.
From the table below determine
the affected clutch. Pressure test Suspect mechanical
the clutch. (Using the procedure failure of clutches shafts
detailed in pressure testing or gears
section.) Is the pressure 18--20
bar?

Substitute the affected clutches Install a new PWM valve

PWM valve and retest for to the affected clutch
pressure. Is pressure okay

Suspect internal leakage within

the transmission example, side
plate gasket, Clutch pack
housing, clutch supply tubes.

C1 C2 C3 C4

1--5 9--13

2--6 10--14

3--7 11--15

4--8 12--16

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 57

DIAGRAM 3 -- The powershifts are not smooth or the tractor loses drive between
powershifts (in work tractor stops or could be jerky)

Key OFF
Key ON
Perform complete transmission recheck
calibration.
1) spring calibration Tractor okay
2) fill time adjustment
is transmission still performing
poorly?

Is feathering
performance poor?

Suspect PWM valves 3 or 4.

Clean or replace and repeat
spring calibration.
Is powershift performance poor?

Are only double swap shifts poor?

(ie, 2 to 3 or 6 to 7 gear changes.
3 to 2 or 7 to 6 gear changes)

Suspect PWM valves 1 or 2.

Clean or replace. Repeat spring
calibration and fill time adjustment.
Is powershift performance still
poor?

Repair/replace
Remove and test accumulator accumulator
(see testing section) perform fill time
Is accumulator okay? adjustment

Suspect damaged clutch plates.

Inspect and replace as required.
(See overhaul) recalibrate after
assembly

604.55.041.01 - 10 - 1998
58 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 4 -- The tractor drives in all gears but has the following fault
Poor clutch pedal feathering/inching performance.
Key OFF
Key ON
recheck

Perform spring pressure

calibration and fill time Tractor okay
adjustment. Feathering/inching
still poor?

Is the clutch pedal

feathering/inching performance Refer to diagram 5
poor in only:
A) 1st (5th)/3rd (7th) gears
or
B) 2nd (6th)/4th (8th) gears

A B
Suspect PWM valve 4. Suspect PWM valve 3.
Clean or replace. Clean or replace
Recalibrate after recalibrate after
installation. installation.
Is feathering still poor? Is feathering still poor?

Suspect clutch Suspect clutch

plate damage. plate damage

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 59

DIAGRAM 5 -- Clutch pedal potentiometer calibration check

Tractor
okay

Ensure clutch pedal can travel

through its whole stroke. Inspect Repair or replace
linkage and potentiometer linkage as required
operating shaft. Are these okay?

Using diagnostic switch, select mode

HA to display the clutch pedal
position. Does the transmission
display value change smoothly from Clutch pedal
0--99 when the clutch pedal is Potentiometer and
depressed and released. calibration is okay

With the key start switch OFF,

disconnect the potentiometer
connector. Turn the key start switch Clutch pedal
ON to produce error code E11. Turn potentiometer is
the key start switch OFF and okay
reconnect the potentiometer. Retest in
HA mode. Does the display value Remove
change smoothly from 0 to 99? connectors
C127 and C128
Inspect to the processor,
Replace the potentiometer. connector inspect clean
Retest in HA. Is operation C077 and and refit .
correct? wiring. Recheck
Okay? potentiometer
Repair or replace operation, if still
as required incorrect replace
processor

Clutch pedal potentiometer

and calibration is okay.

604.55.041.01 - 10 - 1998
60 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 6: The tractor drives in all gears and ranges but has the following fault:
Transmission jumps out of gear, holds in gear or gears clash when shifting

Key OFF
Key ON
recheck

Is the gear fully

engaging? Inspect
and adjust shift lever
linkage as required.
Fault cured?

Using the service

diagnostic switch,
select mode HA, Check operation and inspect
Clutch pedal display. wiring of clutch pedal switch
Does display go to and check operation of
zero with the pedal potentiometer, Diagram 5
depressed?

Pressure test all Test affected clutch pack Remove, inspect and
clutches. Is pressure PWM with the PWM valve refit processor
dumped when the coil removed from the connectors, C127 and
clutch pedal is valve. Is pressure C128, if fault still exists
depressed? indicated? replace processor.

Suspect a mechanical Swap the PWM with one

fault within the of known performance. If
transmission, inspect pressure still exists
the detents in the shift suspect internal leakage
cover, if no fault found or faulty side plate
suspect either worn gasket.
synchronisers or
excessive end float of
transmission
components

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 61

DIAGRAM 7 -- The creeper does not disengage.

Key OFF
Key ON
recheck
Does transmission display (EIC Remove, inspect
only) or switch lamp indicate and refit processor
creeper is selected? connectors, C127
and C128. If
creeper still does
Verify that the FWD and creeper not disengage
solenoids or connectors have not replace processor
been interchanged. If
solenoid/wiring is correct
Pressure test at Mechanical
proceed
creeper port. Does fault.
pressure gauge Disassemble
Disconnect creeper indicate 18--20 bar transmission
connector at solenoid. Does when creeper and inspect
battery voltage exist at the switched on and creeper
solenoid connector with key zero pressure with components
start ON, creeper OFF? creeper switched for sticking and
off? damage.

Disconnect processor Change or

connector. Is battery clean creeper
voltage present at creeper solenoid
solenoid, key ON.
Remove, inspect and refit
Inspect wiring for short to processor connectors, C127 and
battery voltage. C128. If creeper still does not
Repair/replace wiring as disengage replace processor
required.

604.55.041.01 - 10 - 1998
62 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

FLOW DIAGRAM 8: The tractor drives in all gears and ranges but has the following fault:
Clutches squeal/whine during inching

In 1st (5th) In 2nd (6th)

and 3rd (7th) and 4th (8th)
gears only? gears only?

Pressure test C4 Pressure test C4

clutch. Is pressure clutch. Is pressure
250--280 lbf.in2 250--280 lbf.in2
(17--19 bar)? (17--19 bar)?

Suspect Suspect
leaking clutch leaking clutch
seals or leak seals or leak
in circuit to Suspect worn in circuit to
clutch clutch plates clutch

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 63

DIAGRAM 9: The tractor drives in all gears and in all ranges but has the following fault:
Transmission is noisy in operation

Is the Fault in the lube supply

transmission to transmission. Refer to
lube warning light Section 35, Hydraulics.
illuminated? Is the transmission noisy
after lube system repair?

Adjust as required and

Is the oil level investigate reason for
correct? oil loss (leakage)

Is the correct grade Drain and refill with

of oil used? correct grade of oil

Suspect failure
within
transmission, worn
bearings, worn or
failed parts

DIAGRAM 10: The tractor drives in all gears and ranges but has the following fault:
Transmission clunks during inching

Perform Clutch spring calibration

on C1 and C2 Clutches. Does
Transmission still clunk?

Tractor okay
Perform manual clutch fill time
calibration, HC and HD menu
modes, on C1 and C2 clutches.
Does transmission still clunk after
fill time calibration?

Perform clutch pressure test

procedure, observing the operation of Suspect faulty or
the C1 and C2 Clutches. Does the contaminated PWM Valves,
operation compare with that described clean or replace as required
in the pressure testing section?

Suspect worn clutches.

Examine and replace as
required

604.55.041.01 - 10 - 1998
64 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 11 -- Error Code E11

C077

1 C2--7
G Y/R/B Y/R/B
C128--19
O 2
C4--6
LN LN +5 Volt
C127--5
B 3
C4--5 B
B
C127--1

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 65

DIAGRAM 11 -- Error Code E11 -- Clutch potentiometer voltage below valid range
Key OFF
Enter Diagnostic Mode H9 In Mode H9 Key ON
channel 0. Operate the clutch channel 0.Does Recheck
pedal. Is the value continuously the value ever
less than 14? drop below 14 Inspect wiring for
during cycling of intermittent fault
the clutch pedal whilst in H9
mode channel 0
Are the connectors to the
potentiometer and processor Replace
okay? potentiometer

Reconnect/repair
as required
Disconnect processor
connectors C127 & C128 and
potentiometer connector C077.
Check for continuity between
Repair wiring as
the processor and
required
potentiometer connectors as
per the circuit diagram is
continuity correct for all wires?

With processor and

potentiometer connectors Locate and
disconnected. Is there an open repair short to
circuit to chassis between chassis
C077--1 and C128--19

Check operation of potentiometer. Remove left hand side panel below instrument
cluster to expose potentiometer and wiring. Disconnect plug to potentiometer and
check operation of potentiometer:
Between the orange and green wires. With pedal released, is resistance 0.32K",
gradually changing to 2.5k" as the clutch pedal is depressed
and
Between the green and black wires With pedal released, is resistance 3.6K",
gradually changing to 1.5k" as the clutch pedal is depressed?

Replace
potentiometer

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

604.55.041.01 - 10 - 1998
66 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 12 -- Error Code E12

C077

1 C2--7
G Y/R/B Y/R/B
C128--19
O 2
C4--6
LN LN +5 Volt
C127--5
B 3
C4--5 B
B
C127--1

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 67

DIAGRAM 12 -- Error Code E12 -- Clutch potentiometer voltage above valid range
Key OFF
Key ON
Recheck
Enter Diagnostic Mode H9 In mode H9
channel 0. Operate the clutch channel 0. Does Inspect wiring
pedal. Is the value continuously the value ever for intermittent
greater than 95. rise above 95 fault whilst in
during cycling of H9, Channel 0
the clutch pedal?

Replace potentiometer
Disconnect potentiometer
connector C077. Between pin 1 Locate and
and chassis. Is the voltage 0 repair short
volts? between C077--1
and C128--19

Disconnect potentiometer Locate and repair

connector C077. Between pin 3 short between
and chassis. Is the voltage 0 C077--3 and
volts? C127--1

Replace
potentiometer
With the key OFF is
Locate and repair open
there continuity
circuit between
between C077--3 and
C077--3 and C127--1
chassis?

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

604.55.041.01 - 10 - 1998
68 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 13 -- Error code E53 -- 5 volt reference failed, shorted to battery voltage
Error code E54 -- 5 volt reference failed, shorted to earth.

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 69

DIAGRAM 13 -- Error code E53 -- 5 volt reference failed, shorted to battery voltage
Error code E54 -- 5 volt reference failed, shorted to earth.

Key OFF
Key ON
Recharge
Disconnect the clutch pedal Refer to E11 & E12 fault
potentiometer. Is the error code finding charts
still displayed?
NOTE: Error code E11 will
display if either E53 or E54 is
cleared.

Leave the clutch pedal

potentiometer disconnected
during the following checks:

Disconnect the EDC control Replace the EDC

panel connectors. Is the error still control panel
displayed?

Disconnect the EDC rocker shaft Refer to EDC error

potentiometer. Is the error still codes 27 & 28 in the
displayed? hydraulics section

Disconnect the quadrant Refer to EDC error

potentiometer. Is the error still codes 25 & 26 in the
displayed? hydraulics section

Replace the processor with a Clear the processors

unit of known performance is the memory using mode H8.
error still displayed? Recalibrate the
transmission and EDC
systems.

Trace and repair a short circuit to

chassis or battery voltage
between C127--5 and either the
clutch potentiometer, EDC
control panel, EDC, rocker shaft
or quadrant potentiometers.

604.55.041.01 - 10 - 1998
70 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 14 -- Error Codes E37, E48 and E47

FS--13
C4--9
15A 7000D
C127--35
U/R/B U/R/B

C076

3 C2--12
R/U/B R/U/B
C127--30
7660
C076

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 71

DIAGRAM 14 --

Error Code E37 displayed -- Clutch disconnect switch open circuit

Check switch adjustment and switch operation,

if okay trace break in wiring (open circuit).

Error Code E48 displayed -- Clutch disconnect switch short circuit

Check switch adjustment and switch operation,

if okay trace short circuit in wiring.

Error Code E47 displayed -- Clutch disconnect maladjusted high

Check switch adjustment and operation of switch.

NOTE: With each of these error codes also check that the clutch potentiometer
operates over the full range using Service mode HA. If the range is not 0--99
then refer to ‘Clutch Potentiometer calibration’ Diagram 5.

604.55.041.01 - 10 - 1998
72 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 15 -- PWM Solenoids

CO20--5
7810 -- K/N/B
C127--11 A
C020--6 C028
7815 -- K/O/P
C127--36 B

C020--10
7820 -- K/P/B
C127--14 A
C020--11 C027
7825 -- K/R/B
C127--13 B

C020--12
7830 -- K/S/B
C127--18 A
C020--13 C026
7835 -- K/U/B
C127--26 B

C020--3
7840 -- K/W/B
C127--17 A
C020--4 C025
7845 -- K/Y/B
C127--12 B

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 73

DIAGRAM 15 -- PWM Solenoids

Error Code E38 displayed -- C4 (C25) PWM solenoid wiring short circuit
Error Code E39 displayed -- C4 (C25) PWM solenoid wiring open circuit
Error Code E40 displayed -- C3 (C26) PWM solenoid wiring short circuit
Error Code E41 displayed -- C3 (C26) PWM solenoid wiring open circuit
Error Code E42 displayed -- C2 (C27) PWM solenoid wiring short circuit
Error Code E43 displayed -- C2 (C27) PWM solenoid wiring open circuit
Error Code E44 displayed -- C1 (C28) PWM solenoid wiring short circuit
Error Code E45 displayed -- C1 (C28) PWM solenoid wiring open circuit

Error codes E38 through to E45 indicate either a short or open circuit in the wiring
of one of the PWM solenoids. Using a suitable multi--meter check the wiring from
the PWM solenoid back to the processor module. Locate the short/open circuit
and repair or replace wiring as necessary.

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

If wiring and PWM solenoids are okay, replace the microprocessor with one of
known performance.

604.55.041.01 - 10 - 1998
74 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 16 -- The creeper does not engage in low range -- possibly error code E16 or
Symbol ‘C’ displayed

7590 -- O/W/B
C127--3 2
5200 -- N/R/B 1003 G or 1031 R/N
C079--6 1

F12 C192
10A 7070 -- R/LG/B
A

2200 G/N/B
C128--22 B

C020--44
7005 -- U/P/B 7005 -- U/P/B
C127--15 2
C222
1

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 75

DIAGRAM 16 -- The creeper does not engage in low range -- possibly error code E16 or
Symbol ‘C’ displayed

Start tractor, depress With creeper switch and

clutch, select low range, Is error code E16 clutch pedal depressed,
engage creeper. Is ‘C’ displayed? does +12v exist at
displayed on C127--3?
transmission display? NO
Check wiring between
transmission harness Check continuity
Engage main lever in and processor. Does between fuse 12 and
5th gear and release continuity exist between switch (colour R/LG/B)
clutch to move tractor. C127--15 (U/P/B) and and between switch and
Is creeper mechanically C222--2 (U/P/B)? C127--3 (colour O/W/B)
engaged? NO

Is there continuity
Drive tractor, does error between C222--1 (B)
code ‘C’ reappear? Repair or replace
and earth? harness
NO
System
okay

Check for intermittent

connection at wheel
speed sensor or creeper
solenoid

Restart tractor, re--engage

creeper. Pressure test at Check pressure in Repair system
creeper port. Is pressure low pressure circuit. pressure fault, then
Is pressure 265--295 re--check creeper.
265--295 lbf. in2 (18--20
bar)? lbf. in2 (18--20 bar)?

Clean or replace
Mechanical fault.
creeper solenoid.
Disassemble transmission
and inspect creeper
components. Inspect
creeper piston for sticking,
coupling for damage,
internal leakage.

604.55.041.01 - 10 - 1998
76 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 17 -- Code HC displayed

1. High range switch

2. Low range switch

F12
10A C020--12
7070 -- R/LG/B
C167--A

C020--37 7220 -- S/N/B

C128--1 C167--B

7220 -- S/N/B
C104--8

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 77

DIAGRAM 17 -- Code HC displayed

Was shift lever moved to YES Is hydraulically actuated

high range? interlock damaged or
NO missing?
Electrical/mechanical high range
switch fault, perform switch Remove control valve
diagnostic routine. Enter mode and replace or repair as
H5, switch diagnostics, d83, required.
Replace/investigate high/low
switches. If switch okay suspect
a harness short to +12v of high
range switch. Note that the high
range switch circuit is also
connected to the dynamic gear
lamp display through connector
C104--8 (S/N/B).

604.55.041.01 - 10 - 1998
78 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 18 -- Error code CP displayed -- depress clutch pedal to re--enable

transmission

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 79

DIAGRAM 18 -- Error code CP displayed -- depress clutch pedal to re--enable

transmission

Has tractor been shifted Depress clutch pedal or

from neutral with clutch depress shuttle dump
pedal released. switch with FNR lever in
NO neutral to re--enable
transmission.

Inspect for loose harness

connectors at C127, Inspect connector and Test drive tractor to
C128, C020 and C001. ensure a tight fit. Is error ensure error code
Are all connections tight? code still displayed? does not re--appear.

Check for an intermittent open circuit on the neutral/start

inhibitor switch wiring:
With the key start OFF and the FNR lever in N, connect a
Locate and repair
continuity meter between connector C128--27 (W/R) and
open circuit.
C1--E (W/R). Continuity should be indicated.
Twist the harness from C128 down to C001.
Is there always continuity.

Check for an intermittent fault in battery supply to processor.

Locate and repair
Check for continuity between fuse 13 output and C127--34
open circuit.
(U/R/B) and C127--35 (U/R/B). Is there always continuity?

Check for an intermittent fault in ground wiring to processor.

Check for continuity between C128--32 (LN/O/B), C128--33 Locate and repair
(LN/LG) and C127--9 (B) and ground. open circuit.
Is there always continuity.

Remove and inspect the start inhibitor switch. Replace with a Discard removed
switch of known performance. Test drive tractor. switch
Is error code still displayed?

Suspect fault with rail in transmission top cover.

Remove top cover and inspect.

604.55.041.01 - 10 - 1998
80 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 19 -- Error code E46 displayed -- Fuse 12 blown.

FS--12
7070 -- R/LG/B 10A
C128--6

C020--12
C104--6
C165--2

C103--1 C164--1

C167--1
C196--1
C166--1

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 81

DIAGRAM 19 -- Error code E46 displayed -- Fuse 12 blown.

No power to switches, 1--4/5--8/shuttle dump/high range/low range/powershift up--down and
gearshift display module.
Key OFF
Key ON
Recheck

Disconnect C128 from the processor and confirm

Is fuse 12 blown? continuity between fuse 12 and C128--6 (R/LG/B). If
no continuity exists, trace and repair the open
circuit.

Replace fuse 12 (10 amp). Fuse may have failed through fatigue, check wiring
Operate tractor. to ensure there is no intermittent fault.
Does fuse blow again?

Ensure key start is OFF

and fuse 12 is removed. Inspect harness, twist harness with meter still
Disconnect C128 from the connected to ensure no intermittent fault. If no
processor. With a suitable intermittent fault is found, check with meter between
multi--meter check C128--6 (R/LG/B) and other C127/C128 terminals. If
between C128--6 (R/LG/B) an open circuit is indicated, trace and repair the
and earth. Is a short circuit fault in the harness.
indicated?

Disconnect connector C184, is a short circuit still indicated

between C128--6 and earth?
NO
With the multi--meter still Connect meter between Inspect connector,
connected between C184--13 and earth. Is ensure it is clean
C128--6 and earth, and continuity indicated? and undamaged.
C184 disconnected,
disconnect connectors Trace and repair
C104, C103 and the Disconnect C20 short circuit
shuttle dump switch connector. Is continuity between C20--12
connector C196. Observe still indicated? (U/LG/B) and
the meter while switches.
disconnecting, if continuity
Trace and repair short
to earth is broken after a
between C184--13
connector is disconnected
(R/LG/B) C20--12
the fault lies within that
(U/LG/B) and fuse 12.
circuit. If continuity still
exists, fault lies in harness.
Inspect harness, repair or
replace faulty wiring.

604.55.041.01 - 10 - 1998
82 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 20 -- Error Codes E51 or E52

7500 -- B/G C020--42 7500 -- B/G

C128--18 C023

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 83

DIAGRAM 20 -- Error Codes E51 or E52

Transmission oil Temperature wiring open circuit or short circuit
NOTE: E51 may be generated in extreme cold conditions, i.e, less than --30!C
E52 may be generated in extreme hot conditions, i.e, greater than 130!C
Key OFF
Key ON
recheck
For error E51 check connector,
C023 at sensor, is connector Refit connector
connected?

Inspect wiring between

Enter diagnostic mode H9. oil sensor and C128--18
Channel 1. Is the value outside for an intermittent
the range of 7 -- 89? short/open circuit, with
H9 channel 1 still
selected.

Is there a Locate and

Is the value less short circuit repair short
than 7 on wiring? circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 " at 20!C or
300 " at 40!C?

Is the value Is there an Locate and

greater than 89 open circuit on repair open
wiring circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 " at 20!C or
300 " at 40!C?

604.55.041.01 - 10 - 1998
84 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

NOTES

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 85

DIAGRAM 21 -- Error Code E24 -- all clutches not calibrated

Error Code EC4 -- clutch 4 not calibrated
Error Code EC3 -- clutch 3 not calibrated
Error Code EC2 -- clutch 2 not calibrated
Error Code EC1 -- clutch 1 not calibrated

Perform spring calibration procedure to clear error.

Note: These errors will only occur after installation of a new processor or after a ’H8’ (clear processor
memory operation)

604.55.041.01 - 10 - 1998
86 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 22 -- E15 -- High/Low switches both ON

1. High range switch

2. Low range switch

C020--26 7230 -- S/O/B

C128--2 C166--B

7030 -- U/LG/B
C166--A

F12
10A C020--12
7070 -- R/LG/B
C167--A

C020--37 7220 -- S/N/B

C128--1 C167--B

7220 -- S/N/B
C104--8

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 87

DIAGRAM 22 -- E15 -- High/Low switches both ON

Key OFF
Key ON
Enter Diagnostic mode H5 If d82 is not recheck
operate the range lever. Is d82 displayed remove
displayed when lever is shifted to low range switch and
low range and d83 displayed check operation In Replace
when lever is shifted to high situ. If d83 is not faulty
range displayed remove switch
high range switch
and check operation
in situ. are switches
functioning
Disconnect the dynamic correctly?
gear lamp display is the
error still displayed?

At the harness Locate

connector of the and
affected switch repair
check for battery short to
voltage on one battery
terminal only. Is voltage.
voltage correct?
Remove, inspect and refit
processor connectors, C127
and C128. Key OFF, Key
ON and recheck, if fault still
occurs replace processor.
Remove processor Trace
connector C128. and
Check for voltage at repair
either C128--1 (High short to
Range) or C128--2 battery
(Low Range) (with voltage.
switch
disconnected). Is
zero volts indicated?

Replace the gear

display module

604.55.041.01 - 10 - 1998
88 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 23 -- E14 -- 1--4/5--8 switches both ON

7010 -- U/N/B C020--39 7010 -- U/N/B

C128--3 C164--A

7030 -- U/LG/B
C164--B

F12
10A C020--12
7070 -- R/LG/B 7030 -- U/LG/B
C165--A

7020 -- U/W/B C020--40

7020 -- U/W/B
C128--4 C165--B

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 89

DIAGRAM 23 -- E14 -- 1--4/5--8 switches both ON

Key OFF
Key ON
Enter Diagnostic mode H5 If d77 is not recheck
operate the range lever. Is d77 displayed remove
displayed when lever is shifted to 5--8 range switch
5--8 range and d81 displayed and check operation Replace
when lever is shifted to 1--4 In situ. If d81 is not faulty
range displayed remove switch
1--4 range switch
and check operation
in situ. are switches
functioning
Disconnect the dynamic correctly?
gear lamp display is the
error still displayed?

At the harness Locate

connector of the and
affected switch repair
check for battery short to
voltage on one battery
terminal only. Is voltage.
voltage correct?
Remove, inspect and refit
processor connectors, C127
and C128. Key OFF, Key
ON and recheck, if fault still
occurs replace processor.
Remove processor Trace
connector C128. and
Check for voltage at repair
either C128--4 (5--8 short to
Range) or C128--3 battery
(1--4 Range) (with voltage.
switch
disconnected). Is
zero volts indicated?

Replace the gear

display module

604.55.041.01 - 10 - 1998
90 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 24 -- ERROR CODE E55 No Signal From Output Speed Sensor

Mechanical fault within

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

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 91

NOTES

604.55.041.01 - 10 - 1998
92 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 25 -- ERROR CODE E56 Differential Lock Switch Error

C219--10
5030--LN/R 5030--LN/R
C127--2 C183--6

C219----9
7170--B/W 7170--B/W
C128--25 C183--1

5010--B C219--12
5010--B
C127--1 C183--3

604.55.041.01 - 10 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 93

DIAGRAM 25 -- ERROR CODE E56 Differential Lock Switch Error

Key OFF
Key ON
recheck

Enter Diagnostic mode H5 Remove switch and

operate the diff lock switch. Is Replace
check operation. Is faulty
d91 displayed in Manual position switch functioning
and d99 displayed in auto switch
correctly?
position?

Disconnect switch connector

Remove, inspect and refit C183 and processor connectors
processor connectors, C127 and C127 and C128. Inspect wiring to
C128. Key OFF and ON and switch for damage. Using a
recheck. If fault still occurs use suitable multimeter check for a
Mode H8 to reset the processor. short circuit to earth, short to
Recalibrate the tractor. If E56 still +12V and a short circuit between
occurs replace the processor. the switch wires. Repair or
replace wiring as necessary.

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DIAGRAM 26 -- Error Code E49

C020--23
5010--B 5035--LN/G 5035--LN/G 5140--TQ/N
C127--1 C046--2

C020--43
5135--T/Q 5135--T/Q
C127--6 C046--1

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 95

DIAGRAM 26 -- Error Code E49

Wheel speed sensor open or short circuit.

Key OFF
Key ON
recheck
Enter diagnostic mode H9 Inspect wiring between
channel 20. Is the value outside speed sensor and
the range of 46--83? C127--6. For an
intermittent short/open
circuit with H9 channel
20 still connected
Is the value less Is there a short
than 46 Locate and repair
circuit on wiring short circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

Is the value
greater than 89 Is there an open Locate and repair
circuit on wiring open circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

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DIAGRAM 27 -- Error Code E26 displayed -- ERPM signal too high

C001--F
2015--W/S 2015--W/S 2015--W/S
C128--34 C013--W/S

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DIAGRAM 27 -- Error Code E26 displayed -- ERPM signal too high

Connect a volt meter between

the alternator speed connector
and ground. Is there Repair or replace
approximately 7 volts? With the alternator.
engine running.

The following checks must be carried out with the engine

stopped and key start switched OFF.

Suspect an intermittent fault. With an ohm meter connected Locate and repair
between C128--34 (W/S) and the alternator speed connection, intermittent short
twist the wiring harnesses along their length, especially near to circuit to ground.
the connectors. Does the resistance stay the same?

Suspect an intermittent fault to ground. With an ohm meter

connected between C128--34 (W/S) and ground and the Locate and repair
alternator speed connector disconnected, twist the wiring intermittent short
harnesses along their length, especially near to the connectors. circuit to ground.
Does the meter indicate a short to ground?

Remove, inspect and refit

connectors C127 and
C128 of the processor. If
the error still occurs
replace the processor.

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98 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 28 -- Error Code E27 displayed -- ERPM signal not present

C001--F
2015--W/S 2015--W/S 2015--W/S
C128--34 C013--W/S

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DIAGRAM 28 -- Error Code E27 displayed -- ERPM signal not present

Wheel speed sensor open or short circuit.

Key OFF
Is the instrument Key ON
cluster displaying recheck
engine RPM

Is the alternator drive

Replace drive belt
belt okay

Establish if there is a speed output from the

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

The following checks must be carried out with

the engine stopped and key start switched OFF.

Check alternator Check for short circuit Locate and repair

wiring for continuity: in wiring. With C128 short circuit to
Disconnect connector disconnected and ground referring
C128 from processor alternator wire to circuit diagram.
module and check disconnected, check
resistance to ground Remove, inspect
between C128--34
and refit
(W/S) and alternator from pin C128--34
connectors C127
speed sender (W/S). Is resistance
less than 10 ohms? and C128 of the
connection. Is an
processor. If the
open circuit error still occurs
indicated?
replace the
processor.
Check for continuity Locate and repair
between C128--34 open circuit in main
(W/S) and C001--F harness.
(W/S). Is wire okay?

Check for continuity Locate and repair

between alternator open circuit in engine
connector and C001--F harness.
(W/S). Is wire okay?

Is there continuity
between C128--34 Locate and repair
and alternator speed open circuit in main
connection. rear harness.

Remove, inspect and refit

connectors C127 and C128 of
the processor. If the error still
occurs replace the processor.

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100 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

DIAGRAM 29 -- Error Code N displayed

Clutchless shuttle operation attempted at too high a speed and in too high a gear
A warning bleeper and symbol ‘N’ are activated under the following conditions:

# In high range 5--8 gears, shuttling while tractor is still rolling.

# In high range 2--4 gears, shuttling while tractor is rolling faster than 9 Km/h (5.5 mph)

Important: The clutchless shuttle will still operate under the warning conditions. Clutch
damage may occur if the shuttle operation is carried out.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 101

TRANSMISSION OVERHAUL
IMPORTANT: Cleanliness during overhaul is
important. Ensure during the rebuilding stage that all
contaminant is eliminated, that working conditions
are clean and that all tools used do not introduce
contaminant into the previously cleaned
components. Pay particular attention to the control
valve when this is removed during this overhaul
stage.

The transmission must be removed from the tractor

before commencing overhaul. Should any single
component be identified as requiring removal refer
to the relevant area within the overhaul procedure
and consider if replacement of this single item can be
achieved without complete disassembly.

Note that the transmission uses hydraulically

actuated components and that cleanliness and the
removal of any contaminant is paramount to a
successful overhaul.

Separating the tractor between the engine and

transmission will not permit any component
replacement other than the lubrication transfer
tubes. Removal of the PTO/input shaft is not
recommended unless the tractor is separated at the
transmission to rear axle.

During disassembly and re--assembly it is necessary

to place the transmission in the horizontal and
vertical positions, therefore a secure suitable stand,
Figure 1, is a necessity. See Section under ‘Special
Tools’ for details.

Alternatively an engine stand of sufficient strength

together with a suitable bracket may be used. Shown
in Figure 2 are constructional details that will allow
local fabrication of a bracket, if required.

The following procedure, under component

headings, details the disassembly process to initially
remove each of the transmission component groups
from the housing. The procedure then deals with the
further disassembly of these groups, overhaul and
inspection and re--assembly.

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2 1

2
Transmission to Stand Attachment Bracket -- Constructional Detail

1. Main Bracket (made from 19mm mild steel plate) 2. Centre spigot (locally adjust to suit base stand --
thread detail suits V. L. Churchill engine stand)
NOTE: Strengthening gussets should be of similar
plate and welds should be secure, preferably
continuous.

IMPORTANT: It is recommended that boxes or COMPONENT REMOVAL

containers are made available to collect and store
the various components as they are disassembled.
Before overhaul of the main transmission internal
Each box or container should be identified and as
components can proceed, the following items must
each group of components is removed and
be removed:--
disassembled the components should be stored in
the relevant box. This procedure will readily identify
at the completion of the overhaul or re--build, if a # Remove the gearshift control cables, as detailed
small component such as a bearing or thrust washer on page 183 of this section.
remains, that an error in the assembly has occurred.
# Remove the gearshift cover, as detailed on page
If parts are replaced with new items remember to 104 of this section.
maintain stock control on the contents of the boxes
or containers.
# Remove the control valve assembly, as detailed
on page 187 of this section.
Within this overhaul section there is reference to
thrust washers under the description ‘polyimide’.
These washers are sometimes referred to as
VESPELR washers. The word VESPELR is the
trademark for parts produced by DUPONT from their
SP21 polyimide resin.

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21 152 TRANSMISSION DISASSEMBLY SEQUENCE

It is recommended that the transmission is Removal of components of the transmission with the
disassembled in the sequence indicated. transmission oriented as shown in the colour
diagram will facilitate operations.

SHG21130

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104 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

The output speed sensor, Figure 4, may be

unscrewed from the housing if required.

4
Unscrew and remove the two high (1) and low (2)
range sensor switches from the housing, Figure 5.
Note that the switches have differing thread sizes
and cannot be interchanged.

5
Remove gear linkage top cover.

6
Remove transmission control valve pack.

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C1/C2 Clutch Assembly, Front Bottom Shaft and

Creeper Components (where fitted) -- Removal

8
C1/C2 Clutch Assembly, Front Bottom Shaft and Bearings and Thrust Washers -- Exploded View

1. C1/C2 Clutch Support Shaft 10. PTO/Input Shaft to Forward/Reverse Synchroniser

2. ’O’ Ring Seal Support Shaft Needle Roller Bearing
3. Clutch Annular Sealing Rings 11. C2 Clutch 26 Tooth Output Gear
4. Polyimide Thrust Washer 12. Needle Roller Bearing
5. Needle Roller Bearing 13. Polyimide Thrust Washer
6. C1 Clutch 34 Tooth Output Gear 14. Front Bottom Shaft (with Creeper shown)
7. C1/C2 Clutch Assembly 15. Roller Bearing
8. Needle Roller Bearings 16. Lube Oil Baffle
9. Steel Washer 17. Front Cover Plate

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9
Creeper Transmission -- Coupler Components, Gear, fork, Actuating Piston and Rail Assembly

1. ’O’ Ring Seal 9. Steel Washer

2. Creeper Engagement Piston 10. Needle Roller Bearing
3. Actuator Rod 11. Creeper Gear
4. Creeper Fork Rail 12. Steel Washer
5. Creeper Disengagement Adjustment Lock Screw 13. Snap Ring
and lock Nut 14. Sliding Coupler
6. Coupler Fork 15. Coupler
7. Creeper Engagement Adjuster and Locknut 16. Plate
8. Fork Return Spring

Remove the oil transfer tube retaining brackets,

Figure 10.

1. C2 Clutch Pressure Supply Tube

2. Bottom Front Shafts Lube Supply Tube
3. Retaining Bracket
4. Retaining Bracket
5. Top Shaft Lube & Supply to Bottom Shafts Tube
6. C1 Clutch Pressure Supply Tube
7. Clutch C1 & C2 Lube Tube

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 107

Ease the oil transfer tubes back into the front cover
distribution block, Figure 11. Ease the bottom shaft
oil transfer lube tube from the C1/C2 support shaft
and remove it from the casting.

Position the transmission in a vertical plane.

11
Loosen the C1/C2 clutch support shaft (4) retaining
bolts (1) and remove the eight front cover bolts.
Screw two of these bolts evenly and fully into the two
jacking holes (3) to loosen and free the front cover
plate (2), Figure 12.

12
Remove the C1/C2 clutch support shaft retaining
bolts and pry the shaft away from the cover plate,
and remove the shaft support, Figure 13.

13
Remove the cover plate (1), Figure 14. Note that if
the transmission is equipped with creeper the
creeper rail and fork will become disengaged, see
component identification in Figure 9.

1. Front Cover Plate

2. C1 Clutch Output Gear
3. Lube Tube ‘O’ Ring Seals

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108 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Front Cover Removed

1. Lube Oil Baffle
2. C1 Clutch Output Gear Needle Roller Bearing
3. Front Bottom Shaft
4. Front Roller Bearing

15
Grasp the C1/C2 clutch assembly (3) and the front
bottom shaft (1), Figure 16, and remove these from
the housing. Recover the bottom shaft lubrication oil
baffle from the front bearing recess in the front cover.
Remove the C2 clutch 26 tooth output gear if this has
remained on the PTO/input shaft.
NOTE: If the transmission is equipped with creeper,
recover the creeper coupler components.

1. Front Bottom Shaft

2. C1 Clutch 34 Tooth Output Gear
3. C1/C2 Clutch Assembly
4. Creeper Fork
16
On transmissions not fitted with creeper remove the
coupler that connects the C2 clutch 26 tooth output
gear to the forward/reverse synchroniser support
shaft, Figure 17.

1. Coupler (C2 Clutch Output Gear to Forward/Re-

verse Synchroniser Support Shaft)
2. Forward/Reverse Synchroniser Support Shaft
3. Steel Thrust Washer
4. PTO/Input Shaft

17
Remove the PTO/input shaft (4), Figure 18. As the
shaft is pulled out the steel thrust washer (2)
separating the C2 clutch 26 tooth output gear (1) and
the forward/reverse support shaft (1) will normally
come with the shaft.
Note the lubrication seal (3).

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 109

Collect the PTO support shaft needle roller bearing

(2) from inside the nose of the Forward/Reverse
synchroniser support shaft (1), Figure 19.

19
Creeper Transmissions Only
Pull out the fork and rail together with the coupler
assembly from the forward/reverse synchroniser
support shaft. An exploded view of these
components is shown in Figure 9. Note that when
the front cover was removed the operating piston
may have remained in the cover and some of the
creeper components may have disengaged.

Remove the creeper gear retaining snap ring, (2),

Figure 20 and remove the steel washer(3), the gear
(1) and bearing and the second steel washer behind
the gear. Collect the PTO/input shaft needle roller
bearing from the nose of the forward/reverse
synchroniser support shaft (4).

20
Forward/Reverse and Main Range
Synchronisers -- Removal

Remove the snap ring (1) retaining the four wheel

drive gear, (2), Figure 21, and slide the gear from the
spline on the shaft (4).
To provide clearance for the removal of the inner
cover plate, the FWD output assembly (where fitted)
must be removed.

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110 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Remove the FWD output cover plate (3) retaining

snap ring (1). The snap ring is heavy duty and the
use of suitable heavy duty pliers is recommended,
Figure 22.
Removing FWD Output Shaft Cover Snap Ring
1. Snap Ring
2. FWD Output Shaft
3. Cover Plate

Using 2 levers prise out the 4WD cover plate (3).

22
Grasp the output shaft and pull the FWD transfer
assembly (2) Figure 22, from the transmission case,
Figure 23. If necessary, bump the assembly to free
it from the casing.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 111

24
Forward/Reverse and Main Range Synchroniser Assemblies -- Sectional View

1. Forward/Reverse Synchroniser Support Shaft 12. Polyimide Thrust Washer

2. Reverse Driving Gear 13. Driven Gear -- Low
3. Polyimide Thrust Washers x2 14. Needle Roller Bearing
4. Forward/Reverse Synchroniser 15. Polyimide Thrust Washers x2
5. Steel Thrust Washer 16. Main Range and Forward/Reverse Synchroniser
6. Driving Gear High Support Shaft(s) to PTO/Input Shaft Needle Roller
7. Main Range Synchroniser Bearings
8. Main Range Synchroniser Support Shaft 17. Forward Gear to Support Shafts Needle Roller
9. Needle Roller Bearing (press fit) Bearings
10. Needle Roller Bearing (press fit) 18. Forward/Reverse Synchroniser Steel Spacers
11. Main Range Synchroniser Support Shaft Rear 19. Reverse Gear Needle Roller Bearing
Bearing 20. Polyimide Thrust Washer

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112 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Remove the six bolts that retain the forward/reverse

synchroniser support shaft (3) front bearing retainer
plate (1) to the inner cover plate, Figure 25, and
remove the retainer. Collect and note the shims (2)
positioned behind the retainer, these will be re--used
during reassembly provided certain components are
suitable for re--use.

25
Remove the intermediate bottom shaft (1) front
bearing to bottom shaft retaining snap ring (2),
Figure 26, and collect the steel ‘D’ shaped washer
and the loose roller bearing thrust washer.

Intermediate Bottom Shaft Front Bearing Snap Ring

(inset shows loose thrust washer, ‘D’ shaped
washer, snap ring and needle roller bearing)

26
Remove the eight inner cover plate retaining
bolts,(2) Figure 27, and using two of these bolts in
the jacking holes provided, (1), evenly jack the plate
from the transmission casing. Withdraw the cover
plate (3) from the housing.
NOTE: The forward/reverse synchroniser support
shaft will be removed with the cover plate. During re--
assembly this shaft will be installed after the cover
plate is installed. Also note that the reverse idler gear
is attached to the inner face of the cover plate.

27
The forward/reverse synchroniser (1), (without the
support shaft), intermediate bottom shaft (3) and
main range synchroniser (2) are now exposed,
Figure 28.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 113

Grasp the forward/reverse synchroniser (1) and the

intermediate bottom shaft (2) and lift the assemblies
from the casing, Figure 29. The main range
synchroniser and its support shaft will remain in the
casing. Refer to Figure 24 sectional view, for the
position of the bearings and washers and collect
those items.

29
Remove the high range driving gear from the main
range synchroniser support assembly, Figure 24.
Collect the needle roller bearings from the support
shaft (note that this gear in forward acts simply as a
coupler, in reverse it becomes a driven gear).

Pull off the main range synchroniser assembly from

the support shaft and collect the polyimide thrust
washers positioned each side of the synchroniser.
Slide off the low range gear, needle roller bearing
and collect the polyimide thrust washer from behind
the gear, refer to Figure 24.

Release the main range synchroniser support shaft

(2), (also the C3/C4 clutch input) bearing (1), from
the casing by expanding the exposed ends of the
retaining ring (3) to move the ring into the groove in
the housing and at the same time grasping and lifting
the support shaft (2), Figure 30. The support shaft
will come out of the housing once the ring is in the 30
groove in the housing.

Figure 31 shows the support shaft and ring

removed. Note that the two needle roller bearings, in
the rear end of the main range synchroniser support,
items 13 and 14 in the sectional view Figure 24, are
a pressed fit in the shaft.

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114 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Output Shaft, High/Low Range Synchroniser

and Rear Top Shaft Removal

Rotate the transmission 180! so that the rear of the

transmission is now uppermost.

Remove the four bolts (5) retaining the output shaft

(3) rear bearing/hydraulic pump idler gear support
(4) and the four bolts (1) retaining the top shaft rear
bearing, (2), Figure 32. Remove the idler gear
support and the top shaft bearing retainer.
32
Lever up the output shaft assembly, (1 & 5) to reduce
the weight on the snap ring (2) and remove the
output shaft rear bearing retaining snap ring, the
steel ‘D’ shaped washer (3), and the loose roller
bearing thrust washer, (4), Figure 33.

33
Remove the 10 rear cover retaining bolts and gently
tap the output shaft (1) downward to free the rear
bearing from the output shaft, at the same time
easing the rear cover plate (2) upwards then remove
the cover plate, Figure 34.

34
Through the valve cover opening, unscrew the
high/low synchroniser fork to rail locknut and remove
the screw from the rail, (2) Figure 35. Slide the rail
(3) rearwards from the transmission leaving the fork
still engaged with the coupling. Align the fork to rail
boss with the cut out in the right--hand side of the
housing rear buckle--up face.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 115

Lift the output shaft and high/low synchroniser as an

assembly, complete with the shift fork, from the
housing, Figure 36.

36
Collect the high/low range synchroniser fork shaft
locking pin (1), Figure 37.

37
Collect the spacer washer (3) from the top shaft (2),
Figure 37, and lift out the shaft (C3 clutch output
shaft) assembly, Figure 38.

If the high/low range synchroniser fork shaft oil seal

is in doubt remove the shaft from inside the
transmission housing. If the shaft actuating lever
was left on the shaft during transmission removal,
remove the lever.

38
C3/C4 Clutch Assembly -- Removal

Grasp the C3/C4 clutch, support shaft and manifold

assembly and carefully remove it from the housing,
Figure 39.

Removing C3/C4 Clutch Assembly

1. Oil Manifold Assembly
2. Oil Transfer Tubes
3. C4 Clutch Output Gear
4. C3/C4 Clutch Assembly

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116 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Front Wheel Drive Internal Transfer Shaft

Assembly -- Removal

Rotate the transmission 90! so that the transmission

is now horizontal.

With FWD front gear fitted, gently tap the FWD

internal shaft (3) rearwards and remove it from the
housing, Figure 40. Collect the washer positioned
between the front gear and the bearing.

All components have now been removed from the

transmission housing with the exception of some 40
bearings that are positively retained in the housing, Removing FWD Internal Shaft
and the oil transfer tubes. Detail of these items
1. Roller Bearing
follows under the heading ‘Transmission Housing’
2. Snap Ring
which appears later in this section.
3. FWD Internal Shaft

The high/low synchroniser fork selector shaft,(1),

slides inwards to remove. If necessary lever out the
shaft lip type oil seal,(2), Figure 41, and carefully
install a new item using a suitable hammer and
punch. Grease the seal lip.

41
21 114 Transmission Housing -- General

After removal of the major assemblies the

transmission housing now contains the FWD shaft
rear bearing, the output shaft front bearing and the
oil transfer tubes.

The bearings may be removed after removing the

retaining snap rings, either by sliding them out or
using a suitable adaptor or slide hammer to drive
them out.

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21 152 C1/C2 DISMANTLING, INSPECTION, REASSEMBLY

42
Drive Line Components -- Clutch C1/C2
1. Clutch 1 Output Gear -- A 5. Creeper Gear -- C
2. Clutch 1 6. Creeper Coupler
3. Clutch 2 7. Lower Shaft
4. Clutch 2 Output Gear -- B 8. Lower Shaft Bearing

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118 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

43
Cross Sectional View -- Clutch C1/C2
1. Clutch Support 6. Creeper Gear -- C
2. Clutch 1 7. Creeper Coupling
3. Clutch 2 8. Clutch 2 Output Gear B
4. Coupling (less Creeper) 9. Clutch 1 Output Gear A
5. Forward/Reverse Input Shaft 10. Input PTO Shaft

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44
Front Section Components -- with Creeper Gear -- Exploded View
1. C1/C2 Clutch Support 15. Creeper Gear -- C
2. Polyamide Thrust Washer 16. Steel Thrust WasherC1 Clutch Hub
3. Needle Roller Bearing 17. Circlip
4. C1 Output Gear -- A 18. Creeper Sliding Coupler
5. C1--C2 Housing 19. Coupler Hub
6. Needle Roller Bearing 20. Steel Thrust Washer (PTO Shaft)
7. C2 Output Gear -- B 21. C2 Output Gear Adaptor
8. Needle Roller Bearing 22. Needle Roller Bearing
9. Creeper Piston 23. Polyamide Thrust Washer
10. Push Rod 24. Lower Shaft
11. Creeper Shift Rail 25. Roller Bearing
12. Spring 26. Lube Oil Baffle
13. Steel Thrust Washer 27. Front Cover Plate
14. Needle Roller Bearing

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120 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

COMPONENT DISASSEMBLY
C1/C2 Clutch Assembly, Front Lower Shaft and
Creeper Components (where fitted) --
Disassembly
Remove the C1 clutch driven gear (34 tooth), (3),
and the needle roller bearing (2) from the centre of
the clutch, (1), Figure 45.

45
Remove the C1 clutch hub (1) from the centre of the
clutch, (2), Figure 46.

46
Remove the now exposed C1 clutch hub steel thrust
washer (1), Figure 47. Note that the inner face of the
thrust washer has a raised face (2), to provide
clearance for the piston return spring assembly.

47
Using hand pressure, depress the clutch pressure
plate and remove the clutch pressure plate retaining
snap ring (1), Figure 48 and remove the pressure
plate.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 121

Remove the four friction plates, the four wavy

springs and the four separator plates, (1), Figure 49.

49
From the C2 clutch (6), remove the output gear (26
tooth), (1), and its bearings (2), Figure 50 and the
clutch hub (4).
Remove the pressure plate retaining snap ring and
remove the four friction plates, the four wavy springs
and the four separator plates following the same
procedure as used for C1 clutch.

50
Place the C1/C2 clutch assembly on a press and
using Tool No. 4FT 508 (1), compress the piston
return spring retainer assembly sufficiently to
release the snap ring from its groove, Figure 51.

Compressing Clutch Piston Return Spring

1. Special Tool No. 4FT 508
2. Press
3. Snap Ring
4. Piston Return Spring Assembly

51
Remove the piston return spring retainer snap ring,
Figure 52.

Release the press and remove the piston return

spring assembly.

Repeat the above procedure on the second clutch.

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122 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

NOTE: The piston in each clutch consists of three

separate items. The main part carries the outer pis-
ton seal. Adjacent to this main part of the piston is a
belleville spring and a secondary piston. The belle-
ville spring and the secondary part of the piston act
as a cushioning device during the application of the
clutches. See Figure 54 .

Remove the pistons by applying air pressure of not

more than 50 lbf/in2 (3 bar) to the respective piston
oil feed ports, Figure 53. Temporarily installing the
C1/C2 support shaft will aid the application of air.
Note that the secondary part of the piston and the
belleville washer may separate from the main part of 53
the piston during handling. Removing Clutch Piston Using Air Pressure
to Expel Piston
1. C2 Clutch Piston Oil Feed Port
2. C1/C2 Clutch Support Shaft Assembly
3. C1/C2 Clutch Assembly
4. Air Nozzle
(applied to C1 clutch piston oil feed port)
5. Lube Oil Port

54
Piston and Return Spring
1. Clutch Housing 5. Circlip
2. Piston 6. Return Spring Assembly
3. Belleville Washer 7. Outer Seal
4. Piston Adaptor

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 123

C1/C2 Clutch Assembly, Front Lower Shaft and

Creeper Components (where fitted) --
Inspection and Reassembly

Use the sectional view in Figure 54 to aid

identification of components.

Remove the PTO/input seal,(1), in the C1/C2 clutch

support shaft,(2), Figure 55, by carefully levering it
from the shaft. Install a new seal by gently pressing
it into the centre of the support shaft, ensure the seal
lip is facing inward towards the oil.

55
Remove and discard the four annular groove sealing
rings from the C1/C2 clutch support shaft,(3)
Figure 55, and carefully inspect the shaft for wear
and damage.

Install new sealing rings to the support shaft annular

grooves. Ensure the seal ends are correctly
positioned.

Inspect the PTO/input shaft for damage, evidence of

binding, pick--up etc. Check that the splined areas
are undamaged and free of any fretting. Ensure all
oil ways are free and thoroughly clean.

Renew the lube seal,(2), adjacent to the main input

spline, Figure 56.

NOTE: It is important that the seal is held down in

its groove during re--assembly. If the seal is dam-
aged lube oil will not be correctly distributed.

56
Inspect all snap rings and their grooves for Lubrication Seal on PTO/Input Shaft
deformation and damage. 1. Shaft
2. Lube Seal
3. Steel Washer
Remove the piston outer seals from the clutch
pistons and the piston inner seals and seal
energisers from the clutch housing.

Inspect the pistons, both inner and outer

components for scoring or damage. Check that the
piston belleville washer is not deformed. Compare
with a new item if in doubt.

Check the clutch housing for scratches, scores,

excessive wear and piston scuffing.

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Install the piston outer seal (1), by hand, ensuring the

lip on the seal is facing the inner or rear face of the
piston (2), Figure 57.

57
Repeat the process on the second clutch piston.
Install the clutch piston inner seal energiser into the
groove on the clutch housing, Figure 58. Ensure that
the seal is correctly seated and has not ‘rolled’ in the
groove. Use an inspection light to ensure correct
seating of this seal.
Repeat the above step on the second clutch piston
inner seal energiser.

59
Using Special Tool to Expand, Install and Resize the Piston Inner Seals on the C1/C2 Clutch Housing
1. Special Tool No. 4FT 503 (Tapered Sleeve) 5. Seal Positioned in Groove on top of Seal Energiser
2. Special Tool No. 4FT 501 (Handle) 6. Seal Positioned on Expander
3. Special Tool No. 4FT 507 (Re--sizer) 7. Seal Groove with Energiser already installed
4. C1/C2 Clutch Housing Assembly

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60
Installing Pistons into C1/C2 Clutch Housing using Special Tools
1. Piston Guide Sleeve Special Tool No. 4FT 506
2. Piston
3. Piston Pusher Special Tool No. 4FT 504
4. Piston Outer Seal

Install the clutch piston inner seals on the clutch Install the piston and seal assemblies into the clutch
housing as shown in Figure 59 and as follows:-- housing as shown in Figure 60 and as follows:--
a) Lubricate the piston inner seal and the a) Lubricate the piston inner seal inside the
Special Tool No. 4FT 503 (tapered sleeve clutch housing and check that the seal is
expander) with petroleum jelly and position resized.
the expander sleeve on the clutch housing b) Position the piston guide sleeve Special Tool
centre and the seal on the sleeve as shown. No. 4FT 506,(1), on top of the clutch housing
b) Push the piston inner seal up the taper, and lubricate the inside of the tool.
dropping the seal on top of the seal c) Position the piston,(2), in the guide sleeve
energiser, already in position on the clutch and using the piston pusher Special Tool No.
housing. 4FT 504,(3), evenly and firmly, using hand
Perform this operation quickly so that the pressure only, push the piston into the
seal is not subjected to the stretching action housing. Remove the guide sleeve and
for too long. pusher.
c) Ensure the seal is fully lubricated. Assemble IMPORTANT: If more than hand pressure is re-
the resizer, Special Tool No. 4FT 507, to the
quired to install the piston, this is indicating that the
handle, Special Tool No. 4FT 501, so that
piston inner or outer seal is proud and will be dam-
the smaller diameter is at the opening.
Lubricate the resizer and with the handle, aged if the piston is forced into the clutch housing.
firmly push the resizer over the seal to Stop the procedure, remove the piston, reset the
compress and resize the seal. Allow the seal, add more lubricant and try again.
tool to remain on top of the seal for at Position the piston cushioning belleville spring on top
least 30 minutes. of the main piston so that the outer edge of the
IMPORTANT: As the tool is positioned over the seal, belleville is uppermost and that the inner diameter is
ensure that the tool slides smoothly and squarely resting on the piston and install the outer part of the
over the seal. Upon completion of the process in- piston, see Figure 54.
spect the seal to ensure that no damage has oc- Repeat the piston installation process on the second
curred. clutch piston.
Repeat the installation and resizing process on the
second clutch piston inner seal.

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Assemble the clutch return spring assembly,(4),

onto the clutch housing and using a press,(2), and
spring compressor Special Tool No. 4FT 508,(1),
compress the spring assembly and install the snap
ring,(3), Figure 61. Release the press and remove
the tool.

Repeat the process for the second clutch.

61
Check the clutch friction and separator plates for
excessive wear, the friction plate material should
have a clear distinctive pattern to be considered
suitable for further service. All plates should be flat
without warping and there should not be excessive
discolouration.

The clutch separator springs (waved) should not be

discoloured or distorted. Check each spring’s shape
and height, comparing with a new item, if in doubt
renew the separator springs.

Inspect the clutch driven hubs for wear or damage.

62
1. Load Spreader (flat disc)
Inspect the front lower shaft gears, examining the 2. Weight (or load)
teeth for wear or pitting. 3. Piston Return Spring Assembly
4. Base Plate
Inspect the clutch engagement spring assemblies
for cracked coils or deformation. Check the spring
assemblies loaded height as shown in Figure 62, or
compare with a new item. If in doubt renew the spring
assembly.

The C1/C2 clutch assembly support shaft,(1),

contains the lube proportional selector valve,(5). If
the function of this valve is suspect, remove the end
plug retaining pin,(2), and remove the plug,(4) and
valve spool,(5). Carefully inspect the components
for wear or damage, thoroughly clean and
re--assemble using a new quad seal,(3), on the end
plug. The valve spool should move freely in its bore
as the support shaft is moved from side to side.
Figure 63 shows an exploded view of the assembly.

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The support shaft also contains rubber adaptors,(1

& 5), that accept the C1/C2 clutch oil transfer tubes
and the front lower shaft lube oil supply tube.

64
C1/C2 Clutch Support Shaft Oil Transfer Tube
Rubber Adaptors
1. Rubber Adaptor x 1 (small)
2. Annular Seals
3. Support Shaft
4. ‘O’ Ring Seal
5. Rubber Adaptors x 4 (large)
The front cover,(3), contains similar rubber adaptors
and plugs for the C1/C2 clutch oil transfer tubes and
the front lower shaft lube oil supply tube. Similarly,
these can be carefully removed and new items
installed by removing the plug retaining pins,(2), and
plugs,(1), removed and the plug quad seal renewed,
Figure 65.

Carefully inspect all bearings for wear and damage,

if necessary remove the bearings from the front
lower shaft and install new components.

65
The operation of the clutch pistons may be checked
by applying air pressure to the clutch piston oil
supply port, Figure 66. Use an air pressure not
exceeding 50 lbf/in2 (3 bar) and check that the piston
moves over its full travel and that there is no
excessive leakage. Coating the inner and outer
peripheries of the pistons with transmission fluid will
serve to indicate any leakage.
NOTE: For clutches C1 and C2 it is not necessary
to make specific piston movement calculations.
However this is necessary for clutches C3 and C4 as
described later.

66
Applying Air Pressure to C1/C2 Clutch Pistons
1. Lube Oil Port
2. C1/C2 Clutch Support Shaft Assembly
3. C1/C2 Clutch Assembly
4. Air Nozzle (applied to C1 clutch piston oil feed port)
5. C2 Clutch Piston Oil Feed port

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Install the separator plates, friction plates and

separator springs followed by the pressure plates in
the order shown in Figure 67. Note that care must be
used when installing the last separating spring in that
it does not get hooked in the snap ring groove.
Apply hand pressure to the clutch plate pack and
install the retaining snap ring.
Repeat the operation on the second clutch.
Carefully install the C2 clutch hub to the C2 clutch,
using a twisting motion to feel the hub through the
clutch plate teeth, Figure 68.
Install the washer with its relieved face against the
piston return spring assembly of the C1 clutch and
carefully install the C1 clutch hub. Again, use a
twisting motion to feel the hub through the clutch
plate teeth, Figure 68
Tie the assembly together to avoid separation of the
components prior to installation in the transmission.

67
C1/C2 Clutch Friction Plate, Separator Plate and Separator Spring Assembly Order -- Exploded View
1. Snap Ring 7. Inner Piston Half
2. Pressure Plate 8. C1/C2 Clutch Housing
3. Friction Plate x 4 9. Piston Outer Seal
4. Separator Plate x 4 10. Belleville Washer
5. Snap Ring 11. Piston Return Spring Assembly
6. Outer Piston Half 12. Wavy Spring x 4

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68
C1/C2 Clutch Hubs and Gears -- Exploded View
1. Needle Roller Bearing 5. Needle Roller Bearings
2. C1 Clutch Output Gear 6. C2 Clutch Output Gear
3. C1/C2 Clutch Housing 7. Steel Washer (note step on inner face)
4. C2 Clutch Hub 8. C1 Clutch Hub

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FORWARD/REVERSE AND MAIN RANGE SYNCHRONISERS

DISMANTLING, INSPECTION AND REASSEMBLY

69
Drive Line Components
1. Forward/Reverse Synchroniser Support Shaft 6. Main Low Gear -- J
2. Reverse Gear -- G 7. Lower Shaft
3. Forward Gear -- H 8. Forward/Reverse Synchroniser
4. Main Range Synchroniser 9. Reverse Idler Gear -- R1
5. Main Range Synchroniser Support Shaft

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70
Cross Sectional View
1. Forward/Reverse Synchroniser Support Shaft 5. Low Main Gear -- J
2. Forward/Reverse Synchroniser 6. Forward Gear -- H
3. Main Range Synchroniser 7. Forward/Reverse Synchroniser Cones
4. Main Range Synchroniser Support Shaft 8. Reverse Gear -- G

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71
Output Shaft and High/Low Range Synchroniser
1. C3 Clutch Output Shaft 15. Output Shaft
2. Polyimide Thrust Washer 16. Retainer/Pump Idler Gear Support
3. Two Gear Cluster 17. ’D’ Shaped Steel Washer
4. Roller Bearing 18. Bearing Loose Thrust Washer
5. Needle Roller Bearings 19. Roller Bearing
6. Low Range Gear 20. ’D’ Shaped Steel Washer (various thicknesses)
7. Spacer 21. Polyimide Thrust Washer
8. Rear Cover Plate 22. High/Low Range Synchroniser
9. Top Shaft Bearing Retainer 23. Polyimide Thrust Washers
10. Roller Bearing 24. Needle Roller Bearings
11. PTO Input Shaft 25. Snap Ring
12. Polyimide Thrust Washer 26. Roller Bearing
13. Snap Ring 27. Lube Tube Cup Plug
14. Snap Ring 28. Lube Tube

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Forward/Reverse and Main Range

Synchronisers -- Disassembly

If necessary the reverse idler may be removed from

the inner cover plate,(1), remove the snap ring,(6),
thrust washer,(5), gear,(3), and needle roller
bearing,(4), and the second thrust washer,(7),
Figure 72. The idler gear shaft,(8), is stepped and
may be pressed from the cover plate.

72
The forward/reverse synchroniser Figure 73 and
main range synchroniser Figure 76 will separate into
their component parts. Refer to Figure 75 and to
Figure 78 for exploded views of these two
synchronisers.

74
Forward/Reverse Synchroniser Support Assembly
1. Synchroniser Support Shaft
2. Snap Ring
3. Needle Roller Bearing
4. Polyimide Thrust Washer

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75
Forward/Reverse Synchroniser
1. Clutch Body Ring 6. Hub
2. Spring 7. Sliding Collar
3. Peg 8. Ring Gear
4. Detent 9. Inner Cone
5. Cone Locating Peg 10. Outer Cone

Main Range Synchroniser and Related Parts

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77
Main Synchroniser and Support Shaft
1. Synchroniser 4. Polyimide Thrust Washer
2. Lower Main Driven Gear -- J 5. Needle Roller Bearing
3. Synchroniser Support Shaft 6. Polyimide Thrust Washer

78
Main Range Synchroniser
1. Outer Cone/Coupling 7. Spring
2. Friction Cone 8. Polyimide Thrust Washer
3. Polyimide Thrust Washer 9. Friction Cone
4. Sliding Coupler 10. Outer Cone/Coupling
5. Detent Pin 11. Centre Hub
6. Detent Guide

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Output Shaft, High/Low Range Synchroniser

and Rear Upper Shaft -- Disassembly

Remove the low range output gear retaining snap

ring,(3), the end float controlling shim (steel washer
-- available in various thicknesses),(2), and the
polyimide thrust washer,(1), Figure 79. Retain the
shim from the output shaft,(4), for possible re--use.
Slide the gear and the needle roller bearings from the
shaft.
Remove the polyimide thrust washer and high/low
synchroniser followed by the second polyimide
thrust washer.
79
The two gear cluster may now be removed from the
shaft together with the two needle roller bearings
and the front polyimide thrust washer. An exploded
view of the output shaft and high/low range
synchroniser is shown in Figure 80.

80
Output Shaft and High/Low Range Synchroniser -- Exploded View
1. Low Range Output Gear 7. High/Low Synchroniser
2. Needle Roller Bearings 8. Polyimide Thrust Washer
3. Polyimide Thrust Washer 9. Output Shaft
4. Snap Ring 10. Needle Roller Bearings
5. ‘D’ Shaped Steel Washer (various thicknesses) 11. Polyimide Thrust Washer
6. Polyimide Thrust Washer 12. Two Gear Cluster

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15 14 13 12 11

81
High/Low Range Synchroniser -- Exploded View
1. End Plate 9. End Plate
2. Inner Powdered Metal Friction Cone 10. Inner Powdered Metal Friction Cone
3. Sliding Coupler 11. Spring x 3
4. Polyimide Washer 12. Pin x 3
5. Drive Lugs x 3 13. Centre Hub
6. Polyimide Washer 14. Inner Blocker Ring
7. Inner Blocker Ring 15. Outer Steel Blocker Ring
8. Outer Steel Blocker Ring

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Output Shaft Components

82
Output Shaft Assembly
1. Output Shaft/Four Wheel Drive Gear Assembly -- U 5. Bearing Assembly
2. Needle Roller Bearings 6. Needle Roller Bearings
3. High/Low Synchroniser 7. Cluster Gear: R--S
4. Low Range Gear -- T

Output Shaft Component End Float

Position the output shaft assembly vertically on the
splined end.
Measure the gap between the fixed gear (FWD
gear)(1) and the cluster gear (3) (gap equals end
float).
The gap should be 0.10 -- 0.30mm (0.004 -- 0.020in).
The ’D’ washer is available in 5 thicknesses to
provide adjustment if component parts are replaced.

83
Measuring End Float
1. Fixed Gear
2. Feeler Gauge
3. Cluster Gear

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Output Shaft Disassembly

’D’ Washer thicknesses:

2.00 -- 2.04mm 0.007 -- 0.080in
2.15 -- 2.19mm 0.085 -- 0.086in
2.30 -- 2.34mm 0.091 -- 0.092in
2.45 -- 2.49mm 0.097 -- 0.098in
2.60 -- 2.64mm 0.102 -- 0.104in

84
Removing Low Range Output Gear
Retaining Snap Ring
1. Polyimide Thrust Washer
2. Steel ’D’ Washer
3. Output Shaft
4. Snap Ring

Synchroniser Inspection

Inspect the main range and forward/reverse

synchroniser components for wear and damage as
follows:--
a) Inspect the cone (1) for wear and damage
and discolouration, if excessive renew the
synchroniser.
b) Check the gap between the cone and end
plate,(2) Figure 85, if the gap is less than
that specified renew the synchroniser.

85
Measuring Main Range Synchroniser
for Servicable Life
1. Friction Cone
2. Outer Cone/Coupling
3. Feeler Blade

Minimum Gap
Main Synchroniser mm inches
1--4, 5--8 0.8 0.032
High/Low Synchroniser 1.5 0.060

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C3/C4 DISMANTLING, INSPECTION AND

REASSEMBLY

86
Drive Line Components -- Rear Section
1. Clutch 3 6. Output Shaft
2. Clutch 4 7. Low Range Gear
3. Clutch 4 Output Gear 8. High--Low Synchroniser
4. Clutch 3/4 Support Assembly 9. Cluster Gear
5. Clutch 3 Output Shaft 10. Four Wheel Drive Gear

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87
C4 Clutch Driven Gear, Gear Bearing, C3 Driven Gear Bearing and Polyimide Thrust Washer
1. Manifold 6. Support Shaft
2. Polyimide Thrust Washer 7. C3 Driven Gear to Support Shaft Rear Bearing
3. C4 Driven Gear 8. C4 Driven Gear Rear Bearing
4. C3/C4 Clutch Assembly 9. Manifold Retaining Screws and Washers
5. C4 Driven Gear Front Bearing

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142 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

1. Retaining Ring Screw 12. Belleville Washer Snap Ring Retainer

2. C3 Piston 13. Belleville Washers
3. Piston Outer Seals 14. Inner Piston Seals
4. C4 Piston 15. Snap Ring
5. Steel Washer 16. Snap Ring
6. C4 Pressure Plate 17. Clutch Plate Retaining Ring
7. C4 Output Gear Needle Roller Bearing 18. Snap Ring
8. C3 Output Gear Needle Roller Bearing 19. Polyimide Thrust Washers
9. Oil Transfer Manifold 20. Support Shaft Annular Retaining Rings
10. Polyimide Thrust Washer 21. Support Shaft Needle Roller Bearing
11. Needle Roller Bearings 22. Roller Bearing

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C3/C4 Clutch Assembly -- Disassembly

Remove the four screws (2) that secure the manifold
(7) to the C3/C4 clutch support shaft and remove the
manifold and polyimide thrust washer (4) from the
shaft, Figure 89. Collect the screw lock washers (1)
and the support shaft inner needle roller bearing.

89
NOTE: Do not, at this stage, attempt to slide the sup-
port shaft from the clutch assembly.
Remove the two split pins (3) from the C3 clutch (1)
outer plate locking screws, Figure 90, and remove
the four locking screws (2).

90
Using hand pressure, depress the clutch pressure
plate, to free the loading on the retaining ring (1)
(note that only a small amount of movement is
available).
Rotate the locking ring,(1), one tooth until the outer
teeth align with the stamped grooves in the housing
(2), Figure 91. Remove the retaining ring.

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92
C3 Clutch Friction and Separator Plates -- Assembly Order
1. C3/C4 Clutch Housing 6. Pressure Plate
2. Steel Plates x 8 7. Polyimide Thrust Washer (one each side of hub
3. Friction Plates x 8 located in stepped recesses)
4. Pressure Plate locking Ring 8. C3 Clutch Hub
5. Locking Ring retaining Screws and Split Pin

Remove the C3 clutch pressure plate, the hub, the

friction and separator plates, Figure 92. Collect the
two polyimide thrust washers positioned either side
of the hub. The support shaft inner front needle roller
bearing is a pressed in fit and will remain in the shaft.

Turn the assembly 180! and slide the C4 output gear

from the C4 clutch, Figure 93. Collect the C4 gear
rear needle roller bearing.

93
Removing C4 Clutch Output Gear
1. Output Gear Needle Roller Bearing
2. C4 Clutch Output Gear
3. Output Gear Front Needle Roller Bearing
4. C3/C4 Clutch Body
5. Support Shaft

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Repeat the friction and separator plate removal

process for the C4 clutch. Note that the outer plate
is retained by a conventional snap ring. Also note
that a lube oil seal is positioned in the clutch hub,
sealing against the pressure plate, Figure 94. An
exploded view of the C4 clutch components is shown
in Figure 95.

94
Removing C4 Clutch Pressure Plate Retaining Snap
Ring
1. C3/C4 Clutch Support Shaft
2. Pressure Plate
3. Snap Ring
4. Output Gear Front Needle Roller Bearing

95
C4 Clutch Pressure Plate, Hub, Friction and Separator Plates -- Exploded View
1. C3/C4 Clutch Housing 5. Pressure Plate
2. Steel Washer 6. Snap Ring
3. Friction Plates x 8 7. Lubrication Seal
4. Steel Plates x 8 8. Clutch Hub

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146 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Collect the C4 output gear front needle roller bearing

(1), the steel thrust washer (2) and the C4 clutch to
support shaft needle roller bearing (3), Figure 96,
from the support shaft (6).

96
Remove the clutch support shaft front ball bearing
(4) retaining snap rings (2) & (3), Figure 97.

97
Carefully push or bump the support shaft,(1),
through the bearing,(5), (push fit) so that the support
shaft is removed from the rear, C4 end, of the
housing, Figure 98. Note that removing the shaft
from the C4 end of the housing will prevent damage
occurring to the annular sealing rings,(2).

98
Place the clutch housing assembly on a press,(2),
and using Tool No. 4FT 508,(1), depress the clutch
piston return belleville washers and remove the
retaining snap ring,(3), Figure 99. Release the press
and collect the belleville washers and snap ring
retainer. Note that the retainer is shaped to provide
a ‘lock’ for the snap ring.
Repeat the process on the second clutch piston
return belleville washers.

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Remove the clutch pistons by applying air pressure

of not more than 50 lbf/in2 (3 bar) to the clutch piston
oil feed ports, Figure 100. Temporarily replacing the
support shaft will make the application of air
pressure easier. Note that each piston is fed by two
longitudinal drillings in the support shaft, apply air to
one of these and plug the other.

100
Removing Clutch Piston Using Air Pressure to Expel
Piston
1. Stopper (to prevent air escape from second port)
2. Clutch Piston Oil Feed Ports
3. Support Shaft
4. Air Nozzle (applying air to C4 clutch oil feed ports)
5. Piston

101
Piston Return Spring and Retainer -- Exploded View
1. C3/C4 Clutch Body 5. Belleville Washers
2. Snap Ring Groove 6. Snap Ring
3. Piston 7. Snap Ring Retainer
4. Flat Washer 8. Piston Outer Seal

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148 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Inspect each of the belleville spring washers for

cracks and deformation. Assemble the springs to
form a stack (2), as though they were in the clutch
and measure the height as shown in (1), Figure 102.
This should be approximately 24mm, alternatively
compare the measured height with that of new
items. If in doubt renew the spring washers.

102
The C3/C4 clutch assembly support shaft manifold
contains the lube proportional selector valve. If the
function of this valve is suspect, remove the end plug
retaining snap rings and remove the plugs, springs
and valve spool. Carefully inspect the components
for wear or damage, thoroughly clean and
re--assemble using new seals on the end plugs.
Ensure that the valve spool moves freely in its bore.
Figure 103 shows an exploded view of the
assembly.

103
C3/C4 Clutch Support Shaft Manifold Assembly --
Exploded View
1. Manifold
2. Plug
3. Snap Ring
4. Quad Seal
5. Spring
6. Lube proportional Valve Spool
7. Spring
8. Plug
9. Snap Ring
10. Quad Seal

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C3/C4 Clutch Reassembly

Lubricate the piston,(2), and install the piston outer
seal,(1), by hand, ensuring the lip on the seal is
facing the inner or rear face of the piston and that the
seal is perfectly seated, Figure 104.
Repeat the process on the second clutch piston.

104
Install the clutch piston inner seal energiser into the
groove on the clutch housing, Figure 105. Ensure
that the seal,(1), is perfectly seated and has not
‘rolled’ in the groove. Use an inspection light to
ensure correct seating of this seal.

105

106
Using Special Tool to Expand, Install and to Resize the Piston Inner Seals on the C3/C4 Clutch Housing
1. Special Tool No. 4FT 502 (Tapered Sleeve) 5. C3/C4 Clutch Housing
2. Special Tool No. 4FT 507 (Re--sizer) 6. Piston Inner Seal on Tapered Sleeve Expander
3. Special Tool No. 4FT 501 (Handle) 7. Seal Energiser in Position in Groove
4. Piston Inner Seal in Groove

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Install the clutch piston inner seals on the clutch

housing as shown in Figure 106 and as follows:--

a) Lubricate the piston inner seal and the

Special Tool No. 4FT 502 (tapered sleeve
expander) with petroleum jelly and position
the expander sleeve on the clutch housing
centre and the seal on the sleeve as shown.
b) Push the piston inner seal carefully up the
taper, dropping the seal on top of the seal
energiser already in position on the clutch
housing. Perform this operation quickly so
that the seal is not subjected to the
stretching action for too long.
c) Ensure the seal is fully lubricated. Assemble
the resizer, Special Tool No. 4FT 507, to the
handle, Special Tool No. 4FT 501, so that
the larger diameter is at the opening.
Lubricate the resizer and with the handle,
firmly push the resizer over the seal to
compress and resize the seal. Allow the
tool to remain on top of the seal for at
least 30 minutes.

IMPORTANT: As the tool is positioned over the seal,

ensure that the tool slides smoothly and squarely
over the seal. Upon completion of the process in-
spect the seal to ensure that no damage has oc-
curred.
Repeat the installation and resizing process on the
second clutch piston inner seal.

107
Installing Pistons into C3/C4 Clutch Housing using Special Tools
1. Piston Guide Sleeve Special Tool No. 4FT 505 3. Piston Pusher Special Tool No. 4FT 504
2. Piston 4. Piston Seal

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Install the piston and seal assemblies into the clutch

housing as shown in Figure 107 and as follows:--

a) Lubricate piston inner seal inside the clutch

housing and check that the seal is resized.
b) Position the piston guide sleeve Special Tool
No. 4FT 505,(1), on top of the clutch housing
and lubricate the inside of the tool.
c) Position the piston,(2), in the guide sleeve
and using the piston pusher Special Tool No.
4FT 504,(3), evenly and firmly, using hand
pressure only, push the piston into the
housing. Remove the guide sleeve and
pusher.

IMPORTANT: If more than hand pressure is re-

quired to install the piston, this is indicating that the
piston inner or outer seal is misplaced and will be
damaged if the piston is forced into the clutch hous-
ing. Stop the procedure, remove the piston, reset the
seal, add more lubricant and try again.
Repeat the process on the second clutch piston.

With the clutch housing vertical and with the C4

clutch uppermost, Figure 108, very carefully
assemble the support shaft through the clutch
assembly from the C4 end so as not to damage the
annular sealing rings. When the shaft contacts the
front ball bearing, turn the assembly so that the shaft
rests on the bench and push the clutch housing
assembly downwards to enter the shaft through the
bearing. Install the bearing to shaft snap ring, item
18, Figure 88.

108
Installing C3/C4 Clutch Support Shaft into Clutch
Housing
1. Support Shaft
2. Annular Seals
3. Needle Roller Bearing
4. Ball Bearing
5. Clutch Housing

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The operation of the clutch pistons may be checked

by applying air pressure to the clutch piston oil
supply ports, Figure 109. Use an air pressure not
exceeding 50 lbf/in2 (3 bar) and check that the piston
moves over its full travel and that there is no
excessive leakage. Coating the inner and outer
peripheries of the pistons with transmission fluid will
serve to indicate any leakage. Note that each piston
has two oil supply ports and one must be plugged
during this test.

109
Applying Air Pressure to C3/C4 Clutch Pistons
1. Plug (applied to piston 2nd feed port)
2. Clutch Piston ports
3. Air Nozzle (applied to second clutch)
4. Support Shaft
5. Clutch Piston
Check that the splined areas of the input hub and the
output gear are undamaged and free of any fretting.
Inspect the clutch driven hubs for wear, damage or
pitting.
install a new lube seal in the groove of the C4 clutch
hub, ensure that it is correctly seated.
Ensure all oil ways are free and thoroughly clean.
Inspect all snap rings and their grooves for
deformation and damage.
Check the clutch friction and separator plates for
excessive wear, the friction plate material should
have a clear distinctive pattern to be considered
suitable for further service. All plates should be flat
without warping and there should not be excessive
discolouration.
Reassembly of the C3/C4 clutch assembly follows
the disassembly procedure in reverse.
NOTE: The C3/C4 clutches must be adjusted so that
a specified piston movement or running clearance of
the friction and separator plates is obtained. This
piston movement or running clearance must be the
same in both the C3 and C4 clutch packs. Pay
particular attention when following the relevant
re--assembly detail.
Ensure all components are lubricated with
transmission fluid prior to re--assembly.

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C3/C4 Clutch Piston Movement Adjustment

IMPORTANT: Each of the two clutch packs must be
adjusted to achieve optimum piston movement or
running clearance.
This is achieved by:--
a) assembling the friction plates, the separator
plates and the pressure plate with the
respective locking device (rotating ring for
C3 but without the locking screws installed
and snap ring for C4),
b) Installing a dial gauge with the anvil on the
pressure plate. Using a suitable air line,
supply air pressure through the piston oil
supply ports and determine the clutch pack
free movement.
The resultant reading will equate to the piston
movement to compress the clutch pack, as if the
piston was applied hydraulically. When this reading
is compared to the specification it will indicate the
variance in thickness of steel separator plates
required, to bring the clutch pack to optimum piston
movement. These separator plates are available in
two thicknesses 2.76--2.80mm and 2.26--2.30mm.
This measurement procedure must be performed
without the clutch hubs installed.
For the C3 clutch install the pressure plate into the
clutch housing and install the clutch plate retaining
ring, item 15, Figure 88, (see also Figure 110).
Do not install the four pressure plate retaining ring
locking screws as these could prevent movement of
the pressure plate during the following measuring
process.
If the dial gauge reading is between (2.40--4.10 mm)
the resultant piston movement is within
specification.
If the reading is outside the above figure, install one
or more of the alternate thickness plates to bring the
reading to specification.
Repeat the above procedure on the C4 clutch. With
this clutch, again the hub must not be installed and
note that the pressure plate is retained by a snap
ring. See the exploded view of this clutch in
Figure 110.
Disassemble both the C3 and C4 clutches, removing
the pressure plates, separator plate and friction
plates. Keep the C3 and C4 clutch components
matched to the respective clutches. Continue with
the following re--assembly procedure.

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110
C3 Clutch Friction and Separator Plates -- Assembly Order
1. C3/C4 Clutch Housing 6. Pressure Plate
2. Steel Plates x 8 7. Polyimide Thrust Washer (one each side of hub
3. Friction Plates x 8 located in stepped recesses)
4. Pressure Plate Locking Ring 8. C3 Clutch Hub
5. Locking Ring Retaining Screws and Split Pin

Assemble the polyimide thrust washers, item 19,

Figure 88, to the inner and outer stepped recesses
on the C3 clutch hub. Retain the washer with
petroleum jelly and install the clutch hub into the
clutch housing, Figure 111.
Install the separator plates and friction plates in
order as shown in Figure 110, to the C3 clutch.
Install the pressure plate into the clutch housing and
by hand press the pressure plate to compress the
separator springs sufficiently, so that the rotatable
locking ring, item 17, Figure 88, can be installed and
rotated into its location.

111
C3 Clutch Hub and Polyimide
Thrust Washer Installation
1. Polyimide Thrust Washer
2. Hub (note recess for polyimide thrust washer)
3. C4 Clutch End
4. C3 Clutch End

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Install the locking ring retaining screws and tighten

securely. Install the split pins through each pair of
screws, fold back the pins to secure, Figure 112. It
may be necessary to align the holes in the screws to
allow the split pins to assemble.

112
C3 Clutch Pressure Plate/Locking Ring Retention
1. C3 Clutch Hub
2. C3 Clutch End
3. C3 Clutch Pressure Plate and C3/C4 Clutch Drive
Input
4. C4 Clutch End
5. Retaining Screws
6. Split Pin
7. Locking Ring

Position the assembled C3 clutch and support

assembly, with the C3 clutch face down on the work
bench,(4) and slide onto the support shaft,(5), the
C4 clutch to support shaft needle roller bearing,(3),
and the polyimide thrust washer,(2) and the C4
driven gear to support shaft needle roller bearing,(1),
note that these two bearings are identical,
Figure 113.

113
Install the C4 clutch hub,(2), onto the support
shaft,(4), ensuring that the previously assembled
lube seal,(1), is in place, Figure 114.
Assemble the C4 clutch separator plates, friction
plates and pressure plate as shown in Figure 115.
Note that the C4 clutch pack is identical to the C3
clutch with the exception of the pressure plate
retention detail.

114

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156 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

115
C4 Clutch Pressure Plate, Hub, Friction and Separator Plates -- Exploded View
1. C3/C4 Clutch Housing 5. Pressure Plate
2. Steel Washer 6. Snap Ring
3. Friction Plates x 8 7. Lubrication Seal
4. Steel Plates x 8 8. Clutch Hub

Compress the pressure plate assembly sufficiently

to install the conventional locking snap ring,(3),
Figure 116.
Assemble the C4 clutch driven gear, the gear to
support shaft needle roller bearing, the support shaft
to C3 driven gear needle roller bearing and the
polyimide thrust washer, Figure 89.
Assemble the previously inspected manifold and
valve to the support shaft. Install the four securing
hex head screws and lock washers and tighten to
4.5--8.0 lbf ft (6--8N m).
Finally, ensure the clutch assembly is free to rotate
on its support shaft without binding and that a small
amount of axial end float for the C4 driven gear 116
exists. Installing C4 Clutch Pressure Plate
Retaining Snap Ring
1. C3/C4 Clutch Support Shaft
2. Pressure Plate
3. Snap Ring
4. Output Gear Front Needle Roller Bearing

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FWD Output Drive Assembly

117
Front Wheel Drive Output Assembly -- Sectional View
1. Output Shaft 17. Transmission Housing
2. Cover Plate 18. Plug (Pressure Supply)
3. Cover Plate Retaining Snap Ring 19. Oil Transfer Tube
4. Cover Plate ‘O’ Ring Seal 20. Oil Transfer Tube Seal
5. Engagement Spring Assembly 21. Pilot Valve Assembly
6. Inner Piston Seal 22. Bearing Retaining Snap Ring
7. Clutch Half/Gear 23. Steel Washers
8. Snap Ring 24. Transmission Drain Plug
9. Drive Gear (from transmission output) 25. Outer Piston Seal
10. Snap Ring 26. Sliding Clutch Half
11. Bearing Thrust Washer 27. Spring Keeper
12. Bearing Assembly 28. Output Shaft Front Bearing
13. Shaft (from transmission output) 29. Snap Ring
14. Output Shaft Rear Bearing 30. Oil Seal
15. Needle Roller Bearings 31. Dust Seal
16. Oil Pressure Supply Tube

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118
Front Wheel Drive Output Transfer Assembly -- Exploded View
1. Spacer 12. Spring Keeper
2. Needle Roller Bearing 13. Front Bearing
3. Needle Roller Bearing 14. Snap Ring
4. Gear/Clutch Half 15. ‘O’ Ring Seal
5. Spacer 16. Front Cover
6. Rear Bearing 17. Lip Type Oil Seal
7. Snap Ring 18. Dust Seal
8. Pilot Valve Assembly 19. Outer Piston Seal
9. ‘Oil Transfer Tube (with polyimide seal) 20. Clutch Half
10. FWD Output Shaft 21. Inner Piston Seal
11. Engagement Spring Assembly

Front Wheel Drive Transfer Assembly/Clutch

Disassembly
Remove the front cover plate by gently bumping the
output shaft to free the front cover from the bearing.
Remove the front bearing snap ring, item 29 in
Figure 117 and using Tool Nos. 951 or 9190,(2), and
1002 or 9198,(3), with a suitable shaft protector,(1),
pull off the front bearing,(4), Figure 119.

119

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Lift off the spring keeper,(1), and return spring

assembly,(2), and slide the front half of the
clutch,(3), from the shaft,(4), and gear/clutch half
(5), Figure 120.

120
Remove the rear bearing snap ring, item 22 in
Figure 118 and using Tool Nos. 951 or 9190,(2), and
1002 or 9198,(3), with a suitable shaft protector,(1),
pull off the rear bearing (4), Figure 121.

121
Remove the gear/rear half of the clutch and collect
the two bearings, items 2 and 3, together with the two
spacer washers, items 1 and 5, in the exploded view
of the FWD transfer output shaft assembly, shown
in Figure 118.
The oil transfer tube that connects the internal rolled
in tube channel to the output shaft, supplies pressure
oil to the FWD clutch. This transfer tube is a tight fit
in the transmission housing.
Remove the tube,(3), by threading an M10--1.5 bolt
into the centre of the tube. Extract using a
conventional slide hammer and suitable adapter
withdraw the tube, Figure 122. Alternatively use Tool
No. 4FT 509,(2), with slide hammer, part of Tool No.
954C,(1).

122

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160 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Front Wheel Drive Transfer Assembly --

Inspection
Use the sectional view in Figure 117 to aid
component identification.
Inspect all snap rings and their grooves for
deformation and damage.
Inspect the internal drive shaft gear, the shaft front
gear and the gear on the clutch half, examining the
teeth for wear or pitting.
Carefully inspect all bearings for wear, pitting and
damage.

Install new inner and outer seals, items 6 and 25,

Figure 117, to the output shaft.
Carefully pry out the output shaft lip seal, item 30,
Figure 117, from the cover plate and press in a new
seal using a suitable step plate or adaptor. Renew
the outer ‘O’ ring seal.
Inspect the clutch engagement spring assembly for
cracked coils or deformation. Check the spring
assembly loaded height as shown in Figure 123, or
by comparing it with a new item. If any doubt exists
renew the spring assembly.
Inspect the inner surfaces of the front half of the
clutch for damage, ensure that the sealing area is
unmarked. 123
Examine the clutch dog teeth for damage and wear. Checking Compressed Height of Clutch
Piston Return Spring Assemblies
Inspect the splined areas of the front half of the
1. Load Spreader (flat disc)
clutch, the output shaft and the internal drive shaft
2. Weight (or load)
for damage and fretting.
3. Piston Return Spring Assembly
Renew the seal on the oil transfer tube and ensure 4. Base Plate
the tube and the pilot valve assembly are
undamaged and functioning correctly.

Front Wheel Drive Transfer Assembly --

Inspection Ensure the two washers, item 23, Figure 117, are
Re--assembly of the front wheel drive output transfer positioned either side of the gear/clutch half. See
assembly follows the disassembly procedure in also items 1 and 5 in Figure 118.
reverse. In order for the dog clutch to perform correctly, it is
Coat the shaft seals with transmission fluid prior to essential that the pilot valve assembly, item 21,
re--assembly and allow the seals to resize before Figure 117, is assembled with the ball facing
assembling the sliding clutch half. rearwards. An exploded view of the FWD output
Use a suitable press and sleeve to install the front drive assembly is shown in Figure 118.
and rear bearings, ensure when installing the front Do not re--assemble the internal FWD shaft front
bearing that the sliding clutch half, the spring gear until the intermediate cover plate has been
assembly and the keeper plate do not become installed.
misaligned and damage the seals.

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Transmission Housing
Transfer Tubes
The tubes are ‘rolled in’ during manufacture. If
required the tubes can be removed but cannot be
re--used. Installation of new tubes requires a Special
Tool. The sealing durability of the tubes is dependent
upon the amount of rolling which expands the
outside diameter of the tube. Too little rolling will
allow leakage and too much will cause flaking of the
tube, stress and eventual premature failure of the
joint.

Remove and install the tubes as follows:--

Cut the tube with a hacksaw at a convenient distance

from the rolled in location.

Very gently tap the sawn end to drive the rolled in

area out of the housing.

Thoroughly clean the housing and install the new

tube easing it into its location points. The tube ends
should be flush with the bottom of the counterbore
in the transmission housing, as shown in Figure 124.

124

Using the special ‘rolled in’ tube rolling tool and

gauge, roll in the tube, shown in Figure 124, as
follows:--

a). Position the tool,(2), so that the rollers of the

tool are fully entered in the tube and using a
conventional tap wrench,(3) Figure 124,
‘screw in’ the centre portion until all
looseness is removed. Check that the tube
ends are still flush with the bottom of the
counterbore in the housing,(1) Figure 124.

b). Continue to turn the ‘centre screw’ of the tool 125

to expand the tube against the housing. Firm Using ‘Go’ and ‘No Go’ Gauge to Check Amount of
pressure will be required on the end of the Rolling
tool. Remove the tool. 1. Gauge Special Tool No. 4FT 511
2. ‘Go’ and Continue Rolling Diameter
3. ‘Go’ Stop Rolling
c). Use Special Tool No. 4FT511, ‘Go/No Go’ 4. Over Rolled Diameter (take new tube and start
Gauge,(1), Figure 125, and establish if the again)
‘Go’ portion (centre diameter) of the gauge
will enter the bore of the tube. The first
diameter indicates that rolling has begun.

d). Continue steps b and c until the ‘Go’ area

(middle diameter) of the Special Tool, just
enters the tube.

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162 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

IMPORTANT: Do not allow the tube to be over rolled

(last section of gauge will enter tube) as this could
lead to flaking and over stressing of the seal. If the
last diameter of the gauge enters the tube, the tube
has been over rolled and is not fit for use. Remove
the tube, use a new tube and repeat the process.

Repeat the process on the other end of the tube.

NOTE: The use of a 1/4 inch socket drive extension

reversed, will permit the tool to be ‘screwed’ con-
veniently with a conventional tap wrench.

Thoroughly clean the tube along its entire length.

INSPECTION

IMPORTANT: Cleanliness during overhaul is import-

ant. Ensure during the rebuilding stage that all conta-
minant is eliminated, that working conditions are
clean and that all tools used do not introduce conta-
minant into the previously cleaned components. Pay
particular attention to the control valve when this is
removed during this overhaul stage.

General

Before commencing a detailed inspection of the

transmission components, consider the history of
the transmission. If disassembly and overhaul has
been dictated by a specific failure at relatively low
service hours, a thorough examination of
components will identify salvageable bearing seals
and other such items. If, however, the transmission
has operated considerable service hours, then
replacement of all bearings and seals would be
recommended.

Wash all components, including the transmission

housing, in a suitable solvent and dry using a lint free
cloth or compressed air. During re--assembly of any
item in this Section use clean transmission fluid as
a lubricant unless otherwise stated.

Transmission Housing Inspection

Inspect the housing for damage especially bearing

bores and for any witness marks that may indicate
wear or damage in other components.

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INSTALLATION

IMPORTANT: Cleanliness during overhaul is import-

ant. Ensure during the rebuilding state that all conta-
minant is eliminated, working conditions are clean
and that all tools used do not introduce contaminant
into the previously cleaned components. Pay par-
ticular attention to the control valve when this is re-
moved during this installation stage.

C3/C4 Clutch Assembly -- Installation

Position the transmission in a vertical plane with the

rear uppermost.

Installation of the C3/C4 clutch and support shaft

assembly follows the removal procedure in reverse.

Ensure that the small distance pin on the rear

surface of the C3/C4 clutch assembly manifold is in
place, see inset Figure 126.

Carefully support the clutch assembly,(4), when 126

entering it into the transmission housing, Figure 126. Installing C3/C4 Clutch, Support Shaft and Manifold
Ensure the manifold,(1), locates with the removable Assembly (inset shows small pin on Manifold)
locating pin on the left hand side of the transmission 1. Manifold
housing, if not previously removed ensure the seal 2. Oil Transfer Tubes
of the locating pin is in good condition. Tighten the 3. C4 Driven Gear
locating pin to 40--60 lbf ft (55--80N m). 4. C3/C4 Clutch Assembly

Output Shaft and High/Low Range

Synchroniser -- Installation

Position the transmission in a vertical plane with the

rear uppermost.

Install the FWD internal shaft in the housing, passing

it through the front and rear bearings, Figure 127. Do
not install the front gear at this stage.

If the high/low range synchroniser operating fork

selector shaft assembly has been removed,
carefully install the shaft from the inside of the 127
transmission housing passing the shaft through the Installing FWD Internal Shaft
bore and the oil seal. Note that the shaft has a
1. Roller Bearing
keyway machined in the outer end, ensure that the
2. Snap Ring
sharp edges are removed. If necessary cover the
3. FWD Internal Shaft
keyway to prevent damaging the seal.

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Install the high/low synchroniser fork selector rail

shaft locking pin,(1), to retain the shaft in the
transmission housing, Figure 128.

Check that the C3/C4 clutch assembly has not come

out of engagement with the locking pin in the side of
the housing.

Installing High/Low Range Synchroniser Fork Shaft

Locking Pin
1. Shaft Locking Pin
2. Top Shaft (C3 Output)
3. Spacer
128
Carefully install the top shaft,(2), (C3 clutch output
shaft) assembly through the C3/C4 housing,(3), and
using a twisting motion feel in the engagement of the
splines on the C3 clutch, Figure 129. Gently tap the
shaft downward to seat the bearing.

Ensure the output shaft front bearing is in place and

retained by the snap ring.

129
Position the high/low range synchroniser operating
fork assembly onto the output shaft synchroniser.
With the output shaft and operating fork orientated
so that the fork aligns with the cutout in the
right--hand side of the housing, lower the output
shaft assembly into the housing, Figure 130.

130
Engage the fork with the finger of the operating shaft
and install the fork rail,(1), Figure 131. The high/low
synchroniser fork to rail relationship must be
adjusted to a neutral point. Refer to page 70. Tighten
the set bolt to 20--25 lbf ft (27--34 Nm) and the locking
nut to 15--19 lbf ft (20--26 Nm). Check the
engagement of the fork with the operating shaft
finger.

Installing the High/Low Synchroniser Fork Rail

1. Fork Rail
2. Output Shaft
3. Top Shaft (C3 Output)
4. Fork Assembly 131

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Install the rear cover plate, Figure 132 and locate

and install the top shaft bearing, gently tap the cover
to seat it.

132
Install the spacer,(2), and bearing,(1), (sliding fit) on
the rear end of the top shaft,(3), (C3 clutch output),
Figure 133.

Install the output shaft rear bearing (sliding fit), the

loose bearing roller thrust and the steel ‘D’ washer
to the shaft, Figure 134 inset.

133
Using a lever or pry bar positioned under the output
shaft front gear,(5), (FWD gear), raise the output
shaft assembly,(1), and install the thrust washer,(4),
’D’ washer,(3), and retaining snap ring,(2),
Figure 134.

134
Install the ten rear cover plate retaining bolts,(6),
Figure 135, and tighten to 35--48 lbf ft (45--67 Nm).

Install the top shaft bearing retainer,(2), Figure 135,

and tighten the four retaining bolts,(1), to 24--32 lbf
ft (32--44 Nm).

Install the output shaft,(3), bearing retainer

assembly,(4), Figure 135, and tighten the four
retaining bolts,(5), to 24--32 lbf ft (32--44 Nm).

135

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166 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Install the two high range,(1), and low range,(2),

sensor switches into the housing, Figure 136. Note
that the switches have differing thread sizes and
cannot be interchanged.

136
Forward/Reverse and Main Range
Synchronisers and Associated Gears and
Bearings -- Installation
Rotate the transmission so that the front end is
uppermost and position the polyimide thrust
washer,(3), on the front of the C3 clutch hub,(4),
Figure 137, retaining it with petroleum jelly.
Installing Polyimide Thrust Washer on the Front of
C3 Clutch Hub
1. C3 Pressure Plate
2. C3 Clutch Output Shaft
3. Polyimide Thrust Washer
4. C3 Clutch Hub
137
Position the range synchroniser support shaft rear
bearing retaining ring,(5), (retains bearing in
transmission housing) in the housing and whilst
expanding this ring, install the range synchroniser
support shaft,(2), and rear bearing assembly,(1),
Figure 138. Check that the retaining ring is correctly
positioned and the bearing is fully retained.
Installing Main Range Synchroniser Support Shaft
Retaining Ring
1. Ball Bearing
2. Support Shaft
3. C3 Clutch Output Shaft
4. Polyimide Thrust Washer (on C3 Clutch Hub)
5. Retaining Ring
6. C3 Clutch Pressure Plate (C3/4 Clutch Input)
138
Assemble to the support shaft the polyimide thrust
washer, the needle roller bearing and the gear,
Figure 139.
Main Range Synchroniser Support Shaft, and Gear
Assembly
1. Low Range Gear
2. Needle Roller Bearing
3. Range Synchro Support Shaft
4. C3 Clutch Output Shaft Needle Roller Bearing
5. Retaining Ring
6. PTO/Input Shaft to Range Synchro Support Shaft
Needle Roller Bearing
7. Ball Bearing
8. Polyimide Thrust Washer
139

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 167

Using petroleum jelly as a temporary adhesive, stick

the polyimide thrust washers, items 9, Figure 141, in
the recesses on each side of the range synchroniser.

Install the range synchroniser,(4), Figure 140, onto

the support shaft. Take great care to ensure that the
polyimide thrust washers are not displaced.

140

141
Forward/Reverse and Main Range Synchroniser Assemblies -- Sectional View
1. Forward/Reverse Support Shaft 10. Needle Bearing, (press fit)
2. Polyimide Thrust Washer 11. Needle Roller Bearing, (press fit)
3. Polyimide Thrust Washers x 2 12. Needle Roller Bearing
4. Forward/Reverse Synchroniser 13. Polyimide Thrust Washer x 2
5. Forward Gear to Support Shaft Needle Roller Bear- 14. Main and Forward/Reverse Synchroniser Support
ings x 2 Shaft to PTO Needle Roller Bearings x 2
6. Steel Thrust Washer 15. Driven Gear -- Low
7. Main 1--4/5--8 Synchroniser 16. Needle Roller Bearing
8. Polyimide Thrust Washer 17. Needle Roller Bearing
9. Main Range Synchroniser Support Shaft
Install on the nose of the range synchroniser support
shaft, Figure 140, the inner needle roller bearing,(3),

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168 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

(support shaft to PTO/input shaft) and the needle

roller bearing belonging to the 37 tooth high driven
gear,(1), items 19 and 22 in Figure 141.

Position the separating steel washer,(2), shown in

Figure 140 and item 7 in Figure 141, on top of the
range synchroniser support shaft and secure with
petroleum jelly.

NOTE: Bearings may be secured with petroleum

jelly.

If not already present, install the snap ring,(1), into

the bore,(2), of the high driven gear (6) (37 tooth).
Into this gear install the front needle roller bearing,
Figure 142. Cover the bearing with petroleum jelly
and push the bearing against the snap ring. (Note:
The second bearing in the 37 tooth gear has already
been placed on the range synchroniser support shaft
along with the separating washer, (5), see
Figure 140). See also preceding note.

142
High Driven Gear (37 Tooth) Bearings,
Washer and Snap Ring

Take the intermediate counter shaft and position in

the transmission housing alongside its final
assembly position. Do not locate it into the rear
bearing yet.

Install the forward / reverse synchroniser onto the

support shaft with steel spacers either side of the
synchroniser, item 15 Figure 141. Take great care to
ensure that the polyimide thrust washers are not
displaced.

143
High Driven Gear and Forward/Reverse
Synchroniser Forward Clutch Pack Half with Coupler
Installed on Range Synchro Support Shaft
1. Forward/Reverse Synchro Coupler
2. Range Synchroniser

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 169

Very carefully place this half of the synchroniser on

top of the centre coupler, Figure 144.

144
Install the intermediate cover plate,(2), and reverse
idler gear assembly,(1), Figure 145. Install the
retaining bolts and tighten systematically and evenly
to 34--44 lbf.ft (45--60 Nm).

Installing Intermediate Front Cover Plate

1. Reverse Idler Gear
2. Front Cover
3. Forward/Reverse Synchro
4. Intermediate Bottom Shaft

145
Position the intermediate bottom shaft front bearing
roller thrust washer (1) in front of the bearing and the
steel ‘D’ shaped washer and install the bearing to
bottom shaft retaining snap ring,(2), Figure 146.

Intermediate Bottom Shaft Front Bearing Snap Ring

(inset shows loose Thrust Washer, ‘D’ Shaped
Washer and Snap Ring)

146
Assemble the forward reverse synchroniser support
shaft (1), bearings,(2 & 3), and polyimide thrust
washer (5) Figure 147, retaining the front needle
roller bearing with the snap ring, (4), and using
petroleum jelly to retain the inner needle roller
bearing.

Forward/Reverse Synchroniser Support Shaft

Bearings

147

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170 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Very carefully install the forward reverse

synchroniser support shaft,(3), through the opening
in the cover plate, Figure 148. Feel the shaft through
the bearing and ensure it is correctly located. Ensure
polyimide thrust washer (5) is positioned.

NOTE: It is necessary to adjust the running clear-

ance of the components on the forward/reverse and
range synchronisers support shafts,(3), Figure 149.
The clearance is obtained by the placement of
shims(2) Figure 149, behind the forward/reverse
synchroniser support shaft front bearing retainer
plate.
148
Position shims,(2), of at least 0.040in (1.0 mm) Installing Forward/Reverse Synchroniser
thickness in position on the cover plate and install the Support Shaft into Synchroniser through the
bearing retainer,(1), and retaining screws, Intermediate Cover
Figure 149. Tighten the screws progressively and 1. Reverse Gear Needle Roller Bearing
evenly to 7--9 lbf. Ft. (9--13 Nm). 2. Support Shaft
3. Retaining Ring
Using a soft faced mallet, gently tap the
4. Ball Bearing
synchroniser support shaft bearing downward to
5. Polyimide Thrust Washer
seat the components. Be careful not to damage the
polyimide thrust washers.

IMPORTANT: The transmission must remain in the

vertical position during the next operation and the
rear end components must have been installed and
the rear top shaft rear bearing retainer must be in
position and fully secured.

Position a magnetic base dial indicator with the

anvil,(1), of the dial indicator positioned on the
forward/reverse synchroniser support shaft
bearing,(2). Ensure the gauge is vertical and
positioned to give a true reading. Calculate the
required shim value as follows:--
149
a) Grip the front of the forward/reverse
synchroniser support shaft,(3), and at the
same time lever or pry the shaft upwards. Do
this by using a pry bar under any of the
components accessible through the
gearshift cover opening.

b) Note the dial indicator reading.

c) Repeat the process and check the reading.

d) Calculate the shim pack value to obtain a

running clearance of 0.016--0.024in.
(0.4--0.6mm). 150

Position the selected shims, re--install the bearing

retainer and install the retaining screws. Tighten the
screws progressively and evenly to 7--9 lbf. ft.
(9--13Nm).

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Transmissions with and without Creeper

Setting and Adjusting C3 Clutch Output Shaft to

PTO Shaft Relationship

A polyimide thrust washer is positioned on the output

end of the PTO shaft against the C3 clutch output
shaft. This washer is available in various
thicknesses and selection of the correct thickness is
necessary to ensure that when the transmission is
reconnected to the rear axle assembly, adjustment
of the PTO shaft and gearing is possible within
specified limits. The selection of the correct
polyimide thrust washer is best done before the
PTO/input shaft is installed. Measuring the distance
between the C3 output shaft and the rear machined
face of the transmission housing will allow the
correct washer to be selected.

Select the correct thickness polyimide thrust washer

as follows:--
a) Position the transmission vertically with the
PTO output uppermost.
b) With the top shaft (C3 output shaft) rear
bearing retainer removed, from the rear
cover (5), tap the C3 shaft,(2), downwards
to seat it and tap the bearing outer track,(1),
to ensure that this has not risen. Place a
straight machine or uniform bar,(4), across
the C3 output shaft,(2).
c) Measure the distance between the rear
buckle--up face and the C3 clutch output
shaft as shown in Figure 151. Using a
vernier caliper,(3), measure the distance
both sides and calculate the average,
deduct the thickness of the bar (vernier 151
reading -- A = B). Establishing C3 Clutch Output Shaft
Relationship to Transmission Rear Buckle--up Face
1. Bearing Outer Track
From the following table select the washer thickness 2. C3 Output Shaft (Top Shaft)
that corresponds to the calculated distance:-- 3. Vernier Caliper
4. Straight/Uniform Bar
Calculated Distance Washer 5. Rear Cover (sectioned)
Thickness
58.82--59.15mm 6.20--6.25mm
59.16--59.40 . . . . . . . . . . . . . 5.95--6.00
59.41--59.65 . . . . . . . . . . . . . 5.70--5.75
59.64--59.90 . . . . . . . . . . . . . 5.45--5.50
59.91--60.17 . . . . . . . . . . . . . 5.20--5.25
60.18--60.52 . . . . . . . . . . . . . 4.85--4.90

The selected washer will be placed on the PTO/input

shaft and temporarily secured in place to prevent
loss prior to installation in the tractor when the shaft
has been installed.

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172 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

C1/C2 Clutch Assembly, Front Bottom Shaft and

Creeper Components (where fitted) --
Installation

If FWD is fitted, position the FWD transfer assembly

oil supply tube, complete with polyimide thrust seal,
in the transmission housing. The tube is a press fit
in the housing and should carefully be driven into its
location using a suitable drift.

Place the FWD clutch quick release check valve in

its bore with the ball end facing rearward. If the valve
is a new item, use a suitable driver and firmly strike
the end of the rear end of the valve to force the front
of the valve against the internal oil gallery in the FWD
shaft to seat or ‘coin’ the face. This will ensure an
effective oil seal during operation. Retain the valve
with petroleum jelly.

Install the FWD transfer assembly into the

transmission housing, Figure 152. Bump the
assembly to seat it in the casing.

152
Install the FWD output cover plate retaining snap
ring,(1). The snap ring is heavy duty and the use of
suitable heavy duty pliers is recommended,
Figure 153.

153
Position the FWD (where fitted) internal shaft (4)
front bearing thrust washer against the front bearing,
install the gear,(2), Figure 154, and the retaining
snap ring,(1).

154

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Install the PTO/input shaft to forward/reverse

synchroniser support shaft needle roller bearing, (3),
into the nose of the forward/reverse synchroniser
support shaft, (1), Figure 155.

155
Transmissions Without Creeper

The following steps relate to transmissions without

the creeper option. If the transmission has creeper,
refer to next page and follow the adjustment
procedure for creeper components and the differing
installation procedure.

Position the steel thrust washer (2), on the

PTO/input shaft (4), ensure that the lube seal (3), is
in place and correctly positioned and install the shaft
(4), carefully sliding it through the forward/reverse
synchroniser support shaft (1), Figure 156.

156

Place the previously selected polyimide thrust

washer on the rear of the PTO/input shaft and
temporarily secure in place to prevent loss prior to
installation of the transmission in the tractor.
Remember to remove the securing device just
before installation.

Position the C2 clutch to forward/reverse

synchroniser support shaft coupler,(1), on the
support shaft,(2), Figure 157.

157
Assemble the two needle roller bearings to the C2
clutch (26 tooth) output gear and position this gear
on the PTO/input shaft, Figure 68.

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Creeper Transmissions Only

Before continuing the installation process the

creeper components require setting and adjustment.

Position the creeper gear (3) onto the synchroniser

support shaft with steel thrust washers (2) &
(5)either side of the bearing (4). Secure with snap
ring (1), Figure 158.

158
Creeper Adjustment -- 1 (Creeper Engaged)

NOTE: Adjustment conducted in the transmission.

Loosen the fork to rail screw lock nut and loosen the
screw.

Install the creeper coupler components as shown in

Figure 160, together with the creeper coupler fork
and rail (3) & (4). Do not install the creeper return
spring at this point. It will be installed behind the
creeper fork when the setting and adjustment is
completed. 159

Using the square ended portion of the rail (4) screw

the rail through the fork until the stepped rear end of
the rail contacts and bottoms against the
intermediate cover plate (6) but does not lift the
creeper coupling. Do not allow any lifting of the
coupler.
Tighten the screw to 18--22 lbf.ft. (24--30 Nm).
Tighten the lock nut to 14--18 lbf.ft. (19--25 Nm).

NOTE: As the fork to rail screw is tightened the fork

will lift. This amount of lift equates to the designed
operating clearance.

Remove all the creeper components except the 55

tooth creeper gear, from the transmission housing.

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Creeper Adjustment -- 2 (Creeper Disengaged) Position the C1/C2 clutch support shaft through the
front cover opening without the ‘O’ ring seal and
without the shaft annular sealing rings (installing the
NOTE: Adjustment conducted on the bench.
shaft without these items during this adjustment
procedure will prevent unnecessary damage to the
Mount C1/C2 clutch components on the front seals). Install the support shaft retaining bolts and
cover. tighten evenly to 34--44 lbf. ft. (45--60 Nm).

160
Creeper Components Installed on Forward/Reverse Synchroniser Support Shaft for Adjustment
1. Creeper Gear 5. Retainer Screw and Locknut
2. Sliding Coupling 6. Intermediate Cover Plate
3. Creeper Fork 7. Forward/Reverse Synchroniser Support Shaft
4. Creeper Fork Rail

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176 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Position the C1 clutch output gear polyimide thrust Insert fabricated spacer
washer on the support shaft, followed by the C1/C2 Fabricate a 0.060 in. (1.50 mm) thick spacer from
clutch assembly and its output gears as shown in shim steel and insert it between the creeper gear
Figure 161. Ensure the components are installed sliding coupling and the C2 clutch output gear teeth
exactly as shown and that the output gears are (ensure the shim seats on the flat surface of the
correctly seated and engaged with the clutch hubs. teeth), Figure 161.

Mount creeper fork assembly Adjust actuator screw

Position the C2 clutch output gear to creeper gear Loosen the inner actuator rod adjuster lock nut and
coupler plate on the C2 output gear and taking the back out the adjusting screw. Screw in the adjuster
fork and rail with the inner actuator rod and the screw until the fork just begins to lift the coupler off
actuating piston and the creeper gear (55 tooth) the shim steel spacer (on no account interfere with
coupler, position the piston in the operating bore in the previously adjusted rail to fork relationship).
the front support plate as shown in Figure 161.

161
Creeper Components Installed on Front Cover for Adjustment
1. Adjuster 8. C1/C2 Clutch Assembly
2. Locknut 9. Front Cover Plate
3. Creeper Fork 10. C1/C2 Clutch Assembly Support Shaft
4. Sliding Coupling 11. Creeper Fork Rail Piston
5. Plate (part of Coupler) 12. Piston to Rail Actuator Rod
6. C2 Clutch Output Gear (26 tooth)
7. Shim (0.060in./1.50mm)

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NOTE: If after the adjustment is completed, the ad-

justment screw appears flush or level with the lock-
nut, this is indicating that the C1/C2 clutch assembly
is incorrectly positioned with probably one of the out-
put gears not seated. Investigate and repeat the ad-
justment. If the components are correctly positioned
the adjusting screw will be approximately 3/16 

1/16 in. (4  1 mm) above the lock nut.

162

Tighten the screw lock nut to 11--13 lbf.ft. (15--18

Nm).

Disassemble the components (including separating

the support shaft from the front cover), remove the
spacer shim and assemble the C1/C2 support shaft
‘O’ ring seal and the annular sealing rings.

Install the creeper fork rail return spring (5) on the rail
(4) and position the rail, spring and fork assembly in
the transmission housing. Take the creeper gear
coupler positioning this onto the creeper gear (2)
coupler teeth and at the same time engaging the rail
in its bore in the intermediate cover plate. Push the
rail against the return spring and using a suitable
wedge (1) secure the rail to prevent it pushing
upward.

Position the steel thrust washer (3) on the PTO/input

shaft (5), ensure that the lube seal (4) is in place and
correctly positioned and install the shaft, carefully
sliding it through the forward/reverse synchroniser
support shaft, Figure 163.

163

Use a twisting motion during the installation of the

shaft. Install the coupler plate to the centre of the Install the C2 clutch 26 tooth output gear with the two
sliding coupler, Figure 164. needle roller bearings, Figure 165.

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178 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

164

165
C1/C2 Clutch Assembly, Front Bottom Shaft and Bearings and Thrust Washers -- Exploded View
1. C1/C2 Clutch Support Shaft 10. PTO/Input Shaft to Forward/Reverse Synchroniser
2. ‘O’ Ring Seal Support Shaft Needle Roller Bearing
3. Clutch Annular Sealing Rings 11. C2 Clutch 26 Tooth Output Gear
4. Polyimide Thrust Washer 12. Needle Roller Bearing
5. Needle Roller Bearing 13. Polyimide Thrust Washer
6. C1 Clutch 34 Tooth Output Gear 14. Front Bottom Shaft (with Creeper shown)
7. C1/C2 Clutch Assembly 15. Roller Bearing
8. Needle Roller Bearings 16. Lube Oil Baffle
9. Steel Washer with Creeper (Polyimide Washer with- 17. Front Cover Plate
out Creeper)

All Transmissions

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Continue the installation as detailed in the following

steps:--

Position the front bottom shaft rear needle roller

bearing (2) in the front of the intermediate shaft (1),
Figure 166.

166
Position the polyimide thrust washer (3) on the rear
of the front bottom shaft (4), retaining the washer in
position with petroleum jelly, Figure 167. Ensure the
front bearing (2) is installed on the front bottom shaft.
Note the lube oil baffle (1) shown in Figure 167.

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167
The C1/C2 clutch assembly should be checked for
assembly detail prior to installation, the 26 tooth
gear, item 4 in Figure 168, has been positioned on
the shaft PTO/input shaft. Ensure that the C1 output
gear (2) (34 tooth) and the needle roller bearing is
installed in the C1 clutch assembly.

Position the front bottom shaft (1) inside the

transmission housing alongside its bearing bore.
Take the C1/C2 clutch assembly and slide it on to the
PTO/input shaft and at the same time position the
bottom shaft in the rear bearing, Figure 168.

For creeper transmissions only, the weight of the 168

installed C1/C2 clutch assembly will now hold the
creeper components in place. Remove the wedge.
Install new lube tube ‘O’ ring seals (3) to the ends of
the lube tubes and retain these in place using
petroleum jelly, Figure 169.

Position the lube oil baffle on the front bottom shaft

front bearing. Position a new front cover gasket on
the transmission housing and install the front cover
plate (1), Figure 169. Install the retaining bolts and
tighten sequentially and evenly to 34--44 lbf. ft.
(45--60 Nm).

NOTE: On creeper transmissions install the piston

to the creeper fork rail and ensure when installing the
cover that the piston enters the operating bore in the 169
front cover.

Install the polyimide thrust washer on top of the C1

clutch output gear through the C1/C2 support shaft
opening in the front cover.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 181

Ensure before fitting the C1/C2 clutch support shaft

that the oil transfer tubes, shown in Figure 170, are
in place in the front cover.

Coat the C1/C2 clutch support shaft clutch sealing

rings with petroleum jelly, check that the front shaft
oil seal and the shaft to cover ‘O’ ring are in place.
Check that the C1/C2 clutch oil transfer tube seals
and the front bottom shaft lube tube seal (rubber
covered inserts) are installed in the shaft.

Carefully slide the support through the front cover

and onto the PTO/input shaft, Figure 170. Install the
shaft retaining bolts and tighten evenly to 34--44 lbf. 170
ft. (45--60 Nm). Installing C1/C2 Clutch Support Shaft

Slide the C1/C2 clutch oil transfer tubes back into the
C1/C2 clutch support shaft, install the front bottom
shaft lube oil transfer tube and install the retaining
brackets, Figure 171. Tighten the retaining brackets
to 34--44 lbf. ft. (45--60 Nm).

Oil Transfer Tubes on Front Cover

1. C2 Clutch Pressure Supply Tube
2. Lower Front Shafts Lube Supply Tube
3. Retaining Bracket
4. Retaining Bracket
5. Top Shaft Lube & Supply to Bottom Shafts Tube
6. C1 Clutch Pressure Supply Tube
7. Clutch C1/C2 Lube Tube 171

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182 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

172
16 x 16 Electroshift Transmission Less Creep

Polyimide Washers Steel Washers

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 183

NOTES

173
16 x 16 Electroshift Transmission With Creep

Polyimide Washers Steel Washers

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184 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

21 133 GEARSHIFT CONTROL CABLE

The Forward/Reverse shuttle lever, the 1--4/5--8

main shift lever and the high/low lever each have a
cable link to the transmission casing.

Cable Removal and Replacement

Remove the securing screws and the knobs of all

the gear levers and the hand throttle.

Remove the screws retaining the lower gearshift

cover and remove the cover.

Remove the screws retaining the gear shift console

and the screws retaining the console for the
hydraulic remote valve levers. Lift the consoles high
enough to allow access to the three bolts retaining
the cable to lever connection box.

To remove a single cable, loosen the grub screw

retaining the lever to the box. Withdraw the lever
from the box. Remove the nuts from the three
through bolts and withdraw the bolts sufficient
enough to allow the cable box to come free of the
support.

If removing either the Forward/Reverse or 1--4/5--8 174

range control cables remove the rubber floor mat Shift Lever Console Removal
and the floor plate to gain access to the top of the
transmission.

Loosen the locknut of the cable to be removed so

that the locknut is free to slide up the cable outer
covering.

Loosen and remove the two bolts securing the cable

end sleeve flange to the transmission top cover.
Unscrew the sleeve sufficient to allow the cable to
shift rail connecting pin to be removed. The cable
assembly can now be removed from the tractor.

To remove the high/low control cable it is not

necessary to lift the cab floor. Disconnect the cable
to transmission operating link clip and withdraw the
pin to allow the cable to disconnect. Loosen and 175
remove from the thread the lower locknut of the Transmission Top Cover --
cable. Lift the cable until it is able to slide free of the 1--4/5--8 Cable Access
mounting bracket. The cable assembly can now be 1. Adjustment Sleeve Locknut
removed from the tractor. 2. Adjustment Sleeve
3. Sleeve Flange Locknut

Replacement is the reversal of the removal

assembly.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 185

Cable Adjustment

NOTE: To adjust the Forward/Reverse and 1--4/5--8

lever control cables it is necessary to gain access to
the transmission top cover. Remove the cab floor
mat and floor plate.

Forward/Reverse and 1--4/5--8 Cables

Ensure the transmission has all ranges in neutral.

With the cable installed and routed correctly, loosen

the bolts retaining the cable end sleeve flange just
sufficient to allow the sleeve to be rotated.

Rotate the sleeve until, initially, the lever in the cab

is positioned centrally in the console slot. Tighten the
sleeve flange bolts and the sleeve locknut. Operate
the lever and ensure that the synchronisers are fully
engaged. If the lever travel is too far one way, i.e. the 176
lever is contacting or almost contacting the end of 1--4 and 5--8 Shift Cable
the console slot, re--adjust the cable as previously
1. Cable, Shift Lever End
described until an equal gap is obtained between the
2. Shift Lever Retaining Screw
lever and console slot at both ends of its travel.
3. Cable End Connector to Shift Rail
4. Cable Outer Cover Adjustment Thread
5. Sleeve
6. Sleeve Locking Flange
7. Sleeve Locknut

High/Low Range Cable

The adjustment procedure is the same as detailed
for the forward/reverse and 1--4/5--8 lever cables,
except that it is not necessary to remove the cab
floor and the adjustment is carried out using the
locknuts either side of the cable mounting bracket
shown in Figure 177.

Synchroniser Centralisation
The forward/reverse, range and high/low
synchronisers must be centralised midway between
the movement limits. This adjustment is important as
a badly centralised synchroniser will tend to wear
and turn when in neutral. 177
High/Low Cable Adjustment
Adjustment of the High/Low Synchroniser
1. Upper Cable Locknut
Position the high/low synchroniser fork rail in neutral 2. Lower Cable Locknut
and install the rail detent ball, the ball actuator and 3. Cable Mounting Bracket
the spring.
Fabricate a simple plate from 0.125” (3mm) strip
steel so that the plate straddles the rail detent bore
and allows the stem of the detent ball actuator to
protrude (only the spring needs to be compressed).
Bolt the plate across the control valve retaining bolt
holes so that it compresses the detent spring and
holds the rail in neutral, Figure 178.

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186 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Ensure the rail to fork set screw and locknut are range position. Ensure that the point of
installed and tightened. Also ensure that the measurement on the fork is exactly the same as
adjustable high/low fork adjusting screw is when the fork was measured in the low range
tightened. position. Record this distance, Y in Figure 178.

Using an adjustable wrench to act on the high/low Adding measurement X and Y together and dividing
range selector shaft, shown at A in Figure 178, move by 2 will establish the mid--point. This resultant
the synchroniser backward and forward to engage measurement Z, shown in Figure 178, is the neutral
the high and low ranges several times, in order to position for the high/low synchroniser.
seat all the components.
Move the fork and rail so that the neutral detented
Using the lever, move the fork and synchroniser into position is selected.
the engaged low range position, shown at B in
Figure 178 and hold the lever fully hard in this Loosen the adjustable fork adjusting screw locknut
position (beyond the natural point of detent). and by rotating the screw, adjust the position of the
Establish a datum point and from that datum using fork relative to the rail to achieve the previously
a vernier caliper, measure the distance to the calculated mid--point position. Tighten the adjuster
selector fork in the low range position. Record the locknut to 43--59 lbf. ft. (58--80 Nm).
measured distance, X in Figure 178.
Move the fork and synchroniser in and out of high
Again using the lever move the fork and and low range several times and re--check the
synchroniser into the fully engaged high range adjustment.Installation of the internal transmission
position, shown at C in Figure 178 and hold hard in components is now complete. Install the control
that position (again possibly beyond the natural point valve assembly the gearshift cover and the gearshift
of detent) and from the previously established datum control mechanism as detailed later in this Section.
point, measure the distance to the fork in the high

178
Centralising High/Low Range Synchroniser Selector Fork
A. Adjustable Wrench 1. Adjuster Locknut
B. High/Low Fork Moved Fully Rearward 2. Adjuster Screw
C. High/Low Fork Moved Fully Forward 3. Detent Ball Spring Retainer (Note: hole to allow
D. High/Low Fork in Neutral and Adjusting Mid-- stem of detent to protrude)
Point

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 187

ADJUSTMENT OF FORWARD/REVERSE AND MAIN (1--4/5--8) SYNCHRONISERS

To gain access to the synchroniser forks and rails it

is necessary to remove the cab mat and floor.

Remove the transmission cover plate to expose the

shift rails (1) and forks (2). Remove the status
switches (4) and the detents (3).

179
The adjustment procedure is the same for both
synchronisers.

Using a suitable lever, fully position the synchroniser

in the engaged position and measure the distance A.

180
Now fully position the synchroniser in the opposite
fully engaged position and measure distance B.

Replace the detent and set the shift rail to neutral.

Adjust the fork to its neutral position.

Neutral N = A + B
2

181
Tighten the fork lock screws.

Re--install status switches and top cover.

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188 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

21 133 CONTROL VALVE -- OVERHAUL

The following procedure treats the transmission as

removed from the tractor. It is possible to remove the
control valve assembly from the transmission
without removing the transmission from the tractor.
Removal of the surrounding tubing, the accumulator
and other peripheral hardware is necessary.

It should be noted that unless contaminant is

suspected to be within the control valve cover oil
galleries or there is a suspected fault within the lube
control valve, it is not necessary to remove the valve
cover to remove any of the PWM solenoids or four
wheel drive and creeper solenoids.

NOTE: During removal of the control valve and the

connecting hardware, it is essential that outside con-
taminant is not permitted to enter the inside of the
transmission. If necessary steam clean the outside
of the control valve area before proceeding to re-
move the valve assembly.

Control Valve Removal

Drain the transmission/rear axle oil into a suitable

container.

Remove the 16 control valve cover retaining bolts (1)

shown in Figure 182. Use two of the removed bolts
in the jacking holes (2) provided in the cover and
carefully remove the control valve assembly from
the transmission housing.

182

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Control Valve Assembly Overhaul

Absolute cleanliness is essential during disassembly

and reassembly of the control valve. Ensure the
working area is clean and not likely to be
contaminated by other working operations being
performed alongside. It is recommended that only a
clean, dust free environment is used for the
overhaul.

Lube Valve Removal and Disassembly

Place the control valve face down on a clean surface 183

and remove the 12 bolts retaining the lube valve Side Cover Assembly Removal
assembly to the side cover. Carefully lift off the lube
1. Dowel
valve, noting the gasket between the two castings.
2. ‘O’ Ring
Remove the end plugs and withdraw the spools and 3. Dowel
springs as shown in Figure 184. 4. High/Low Detent
5. Side Cover
6. Lube Control Valve
7. C3/C4 Supply Tubes

Clean the valve body in a suitable cleaning solvent

and use pressure air to dry. Note during cleaning if
contaminant is expelled which may have caused an
oil blockage or stuck spool.

Examine the spools and bores for wear or damage,

replace as required.

Reassembly is the reverse of the disassembly. Coat

all components with clean transmission oil of the
correct specification just prior to assembly.

Prior to assembling the lube valve to the cover,

ensure the mating faces are clean and fit a new
gasket. Do not use a liquid gasket sealant
between these surfaces.

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190 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1

Lube Valve Inspection and Reassembly

184
Lube Valve Assembly
1. Lube Pressure Relief Valve 3. Lube Shuttle Valve Ball
2. Lube Control Valve Spool 4. Lube Valve Spool Spring (220 lb) and Plunger

Control Valve Cover Disassembly

Clean the complete PWM valve assemblies, less the
With reference to Figure 185 , remove the four PWM solenoids, in a suitable cleaning solvent. It is not
solenoid valves, the creeper interlock piston, the oil recommended to disassemble the PWM valves
temperature sender and the four wheel drive and further to clean. If the performance of the valve is
creeper solenoids, if fitted. suspect and no contaminant is found during
cleaning, but the solenoid is within specification, the
valve should be replaced with a new one.

Control Valve Cover Inspection and Reassembly

Clean the FWD and creeper valves in the same
manner as the PWM valves.
Clean the cover in a suitable cleaning solvent and
dry with pressure air. Note during cleaning if
Reassembly is the reverse of the disassembly.
contaminant is expelled which may have caused an
Ensure the ‘O’ rings of all the solenoid valve
oil blockage.
assemblies are in good condition prior to installation.
Coat the valve components with clean transmission
Carefully examine the cover for hairline cracks or oil of the correct specification prior to assembly.
other damage which may have caused oil leakage.
Replace the cover if any damage or cracks are
Tighten the 12 retaining bolts to a torque value of 27
found, do not attempt a repair.
Nm (20 lbf.ft).

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 1 191

185
Control Valve Assembly
1. Creeper Solenoid and Valve Assembly 6. Creeper Interlock Piston
2. Four Wheel Drive Solenoid and Valve Assembly 7. C4 PWM Solenoid and Valve Assembly
3. C1 PWM Solenoid and Valve Assembly 8. Regulated/Pressure Supply Inlet Connector
4. C2 PWM Solenoid and Valve Assembly 9. Lube Supply Inlet Connector
5. C3 PWM Solenoid and Valve Assembly 10. Transmission Oil Temperature Sender

Installation of Control Valve Cover onto

Transmission
Install cover assembly onto the transmission and
Before replacing the assembled control valve cover tighten the 16 retaining bolts to a torque value of 56
assembly onto the transmission, ensure that both Nm (41 lbf.ft). Reconnect the tubes, wiring etc
mating surfaces are clean and free from oil and disconnected during removal.
previous sealant. Apply a thin bead of sealant,
specification ESE--M4G234--A1 (Loctite 515), to the
transmission casing. Do not apply an excessive
quantity as the surplus may enter the transmission Fill the transmission/rear axle with the correct
oil and return to the control valve, causing blocked quantity and grade of transmission oil.
oil galleries or sticking spools.

Ensure the 6 ‘O’ rings seals, located to the right of the NOTE: After disassembly of the transmission
cover aperture, are in position in the transmission control system it will be necessary to recalibrate the
casing and the three tubes, located to the left, are in transmission clutches.
position with ‘O’ rings installed.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 1

SECTION 21 -- TRANSMISSION SYSTEMS

Chapter 2 -- 12 x 12 TRANSMISSION
Section Page
21 000 Specifications and Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction to Overhauling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
21 140 Transmission Installed -- Serviceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission Removed -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transmission Components Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

21 000 SPECIFICATIONS AND TIGHTENING TORQUE VALUES

Specifications
Lubricant Capacity U.S. Gallons 15
Transmission/Rear Axle Imp.Gallons 12.5
Litres 56.8
Lubricant Ambra Multi--G
Gasket Sealant New Holland Flexible Gasket Sealant
Part Numbers, 82995770 (50 ml)
82995771 (300 ml)
Output Shaft End Float 0.001 -- 0.003 in (0.0254 -- 0.0762 mm)
Shims Available for Output shaft 0.003 in (0.0762 mm)
End Bearing Retainer 0.005 in (0.1270 mm)
0.012 in (0.3048 mm)
0.030 in (0.7620 mm)

Gear Ratios Gear Ratios

30 Km/hr Transmission 40 Km/hr Transmission
F1 9.61 F1 9.61
F2 6.61 F2 6.56
F3 4.87 F3 4.59
F4 3.16 F4 3.16
F5 4.24 F5 3.83
F6 2.92 F6 2.61
F7 2.15 F7 1.83
F8 1.39 F8 1.26
F9 1.93 F9 1.58
F10 1.32 F10 1.08
F11 0.97 F11 0.76
F12 0.63 F12 0.52
R1 9.37 R1 9.37
R2 6.44 R2 6.40
R3 4.75 R3 4.48
R4 3.08 R4 3.08
R5 4.14 R5 3.73
R6 2.84 R6 2.55
R7 2.09 R7 1.78
R8 1.36 R8 1.23
R9 1.88 R9 1.54
R10 1.29 R10 1.05
R11 0.95 R11 0.74
R12 0.62 R12 0.51

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2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Tightening Torque Values

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 3

FAULT FINDING

GENERAL
The most important factor to consider in
transmission system fault finding is verification of
the problem by observing the system operation.
Therefore, if possible, operate the transmission
and note the operating characteristics.

PROBLEM POSSIBLE CAUSES REMEDY

1. Noisy Gearbox 1. Low oil level 1. Adjust as required

2. Incorrect oil grade 2. Determine oil grade, drain and

refill as necessary

3. Worn bearings 3. End float of output shaft out of

Note: Check the pressure specification.
lubrication feed to the Check and replace bearings as
transmission. Part 8, Chapter required, reset endfloat.
2.

2. Lubricant leak from split pin 1. Engine crankshaft rear oil 1. Replace rear seal/ gasket.
in transmission case bottom seal/housing gasket leakage Refer to Part 1 Engine System

2. Worn or damaged input shaft 2. Inspect and replace

oil seal, PTO drive shaft seal, seals/gaskets as necessary
transmission front plate
gasket, reverse idler bolt seal
leakage

3. Hydraulic release bearing seal 3. Replace seals in release

leakage (reservoir level bearing assembly
requires regular topping up)

3. Difficult / failure to engage 1. Incorrect linkage adjustment or 1. Adjust linkage, replace worn
gears worn linkage parts as required

2. Damaged linkage 2. Inspect, repair/replace as

required

3. Damaged/worn shift forks 3. Inspect shift forks and rails for

wear and distortion. Replace
as required.

4. Worn synchronisers 4. Inspect synchroniser ring

rubbing surfaces. Renew as
required if worn

5. Excessive output shaft end 5. Inspect bearings, replace as

float -- worn bearings required. Reset end float

6. Incorrect clutch operation 6. Air in hydraulic system, faulty

clutch cover plate

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4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

PROBLEM POSSIBLE CAUSES REMEDY

4. Failure to change between 1. Clutch interlock adjustment 1. Check cable adjustment

forward and reverse incorrect or assembly
inoperative 2. Inspect cable and lever
components.

5. Jumping out of gear 1. Gear not fully engaging 1. Check linkage adjustment

2. Detents in shift covers faulty 2. Remove shift covers and

inspect detent balls and
springs

3. Worn synchroniser 3. Inspect teeth of synchroniser

assy.

4. Excessive output shaft end 4. Check bearings and reset end

float (bearing wear) float to specification

6. Holding in gear 1. Worn sliding sleeve/ coupler 1. Inspect and replace as

required

2. Locked linkage 2. Adjust linkage and replace

worn parts as required.

DESCRIPTION AND OPERATION

GENERAL
The 12x12 transmission provides twelve forward
and twelve reverse speeds which are manually
selected by three levers. The basic transmission
can be specified with the following options:--
1. Four wheel drive (FWD) -- consisting of an
integral gear, clutch and output arrangement
that provides an engageable coupling between
the transmission and front axle. This four
wheel drive output is available with two ratios to
suit different tyre combinations. If two wheel
drive is specified the output arrangement is
deleted. Four wheel drive will automatically
engage when both brakes are applied,
providing 4 wheel braking.
2. 40 km/hr option may be specified in place of
the standard 30 km/hr.
F 1 3 L H
The transmission provides three selectable
ranges. Within each of these ranges a further four
ratios may be selected. This in effect provides a
three times four (3x4=12) transmission resulting in
12 ratios. All shifts except down shifting into low N N N
range are synchronised.
Gear Shift Pattern
F = Forward L = Low Range
N = Neutral M = Medium Range
R = Reverse H = High Range R 2 4 M

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 5

The three shift levers shown in Figure 2, control the

selection of the 12 forward and 12 reverse ratios.
Figure 1 shows the gear shift lever pattern. The
main shift lever, reference 4 Figure 2, operates in
a conventional H--pattern and, in conjunction with
the clutch pedal, is used to select any of four gear
ratios, whether the tractor is stationary or moving.
The range lever, reference 1, Figure 2, in
conjunction with the clutch pedal, is used to select
one of three ranges. The shuttle lever (3) is used
to select forward or reverse travel when any one of
the twelve ratios is engaged, provided that the
clutch pedal is depressed.

NOTE: An interlock mechanism prevents

movement of the shuttle lever, unless the clutch
pedal is depressed.

NOTE: A neutral start switch prevents operation of

the starting motor unless the shuttle
(forward/reverse) lever is in neutral.
Drive is transmitted from the engine to the
transmission by a conventional solid centre dry
plate clutch assembly.

IMPORTANT: If it is necessary to tow the tractor,

the range lever must be in the neutral position,
otherwise damage to transmission components
may occur.
It is permissible to tow start the tractor.
Oil supplied from the power steering motor, via the
PTO valve and oil cooler, provides pressure
lubrication for the synchronisers, bearings and
output shaft. The transmission shares a common
oil reservoir with the rear axle.

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6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Transmission Assembly 3
1. PTO Shaft 11. Input Shaft
2. Output Shaft 12. Forward/Reverse Synchroniser
3. Four Wheel Drive Front Axle Drive Shaft 13. Reverse Gear (free running on shaft)
4. Low Range Coupler 14. 1st Ratio Gear
5. High and Medium Range Synchroniser 15. 2nd Ratio Gear (splined to shaft)
6. First/Second Gear Synchroniser 16. 3rd Ratio Gear (free running on shaft)
7. Reverse Gear Cluster 17. Third/Fourth Gear Synchroniser
8. Four Wheel Drive Output Shaft 18. Range Cluster Gear
9. Four Wheel Drive Clutch 19. Range Cluster Shaft Bearing
10. Reverse Gear Idler

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 7

Gear Identification 12x12 Synchro Command

Gear Description Number of teeth

40 Kmph 30 kmph

A Reverse drive gear 33 33

B Reverse driven gear 39 39

C 1st gear drive 31 27

D 2nd gear drive 38 34

E 3rd gear drive 45 40

F High range gear drive 52 49

G Medium range gear drive 35 33

H Low range gear drive 19 19

J Low range gear driven 60 60

K F.W.D internal shaft rear gear 34 34

L FWD drive gear 38 38

M Medium range gear driven 44 46

N High range gear driven 27 31

P 3rd gear driven 34 39

Q 2nd gear driven 41 45

R 1st gear driven 49 52

S REverse cluster drive gear 40 40

T FWD Transfer driven gear 37 or 38 37 or 38

U FWD Internal shaft front gear 26 26

V Reverse cluster gear driven 33 33

W Reverse gear idler 35 35

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8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Power Flows Forward Low Range 4

Power Flows Forward Medium Range 5

Power Flows Forward High Range 6

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 9

Power Flows Reverse Low Range 7

Power Flows Reverse Medium Range 8

Power Flows Reverse High Range 9

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10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

21 140 INTRODUCTION TO OVERHAULING THE TRANSMISSION

GENERAL GROUP 3 Assemblies Serviced from

Transmission Rear End, Rear Axle Removed,
Transmission Removed -- Overhaul.
The arrangements of the procedures in this section S PTO shaft, Bearing and Seal
permit the servicing of the 12 x 12 transmission with
the minimum of disassembly. S High/Medium Range Synchroniser
S Low Range Coupler
The procedures are separated into five groups, S Range Cluster Gear and Bearing
detailed below, listing the components serviceable S Output Shaft Assembly
in each group.

GROUP 4 Assemblies Serviced with

Transmission Removed from Tractor --
Complete Overhaul. Refer to Section E.
GROUP 1 Assemblies Serviced with S Mainshaft Assembly, Including 3rd/4th
Transmission Installed. Serviceable Synchroniser
Components.
S Countershaft Assembly, Including 1st/2nd
S Gearshift Covers, Including Levers, Forks and Synchroniser
Mechanism.
S Four Wheel Drive Shaft and Bearings
S Neutral Start Switch.
S Four Wheel Drive Output Assembly and
Solenoid.
S Clutch Interlock.

GROUP 5 Component Inspection and Repair

(Sub--Assembly Overhaul). Transmission
Component -- Overhaul.

When servicing the transmission always work in

clean surroundings and with clean tools.
Thoroughly clean the transmission case to prevent
GROUP 2 Assemblies Serviced from entry of dirt. Use lint free cloths when wiping parts
Transmission Front End, Engine Removed, or your hands. Lay cleaned parts out on clean paper
Transmission Removed -- Overhaul. so a thorough inspection can be made.

S Release Bearing Assembly and Hydraulic

When installing the transmission components, do
Tubes
not use force. If parts do not assemble freely,
S Front Cover, including Seal and Reverse Idler. examine them for the cause of difficulty and coat
them with a film of clean petroleum jelly or
S Input Shaft and bearing transmission oil to facilitate assembly. Lubricate all
S Forward/Reverse Synchroniser shafts, bearings, oil seals and gears with a film of
clean transmission oil before installing them into the
S Reverse Cluster Gear transmission.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 11

TRANSMISSION INSTALLED -- SERVICEABLE COMPONENTS

Main Shift (Forward) Side Cover (Op No. 21 131)

Main Shift (Forward) Side Cover 1

1. 3rd/4th Synchroniser Fork 8. 1st/2nd Synchroniser Fork 12. 1st/2nd Shaft and Lever Assy.
2. 1st/2nd Synchroniser Fork Shaft 13. Cover Oil Seals
3. Fork Locking Bolt 9. Interlock Pin 14. Cover Body
4. Cover Gasket 10. 3rd/4th Synchroniser Fork 15. 3rd/4th Shaft Lever
5. Detent Cap Shaft 16. 1st/2nd Shaft Lever
6. Detent Spring 11. 3rd/4th Shaft and Lever Assy. 17. Locking Bolt
7. Detent Ball

Disassembly (Refer to Figure 1) Inspection

1. Remove the interlock cap, spring and ball and 1. Inspect and if necessary, install new seals into
remove the pin. the cover bores, lubricate seals with grease.
2. Remove one of the lever locking bolts. Punch 2. Inspect fork ends, shafts and levers for wear
the lever shaft out of the cover and remove the and damage replacing components as
lever. required.
3. Remove the corresponding fork locking bolt, Assembly
slide out the shaft and remove the fork. 1. Assembly of the cover is the reversal of the
4. Repeat the above operations on the other fork disassembly.
assembly.

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12 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Range Shift (Rear) Side Cover (Op No. 21 131)

Range Shift (Rear) Side Cover 2

1. Low Range Coupler Fork 7. Interlock Pin 11. Cover Oil Seals
2. Hi/Med. Synchroniser Fork 8. Low Range Coupler Shaft 12. Low Coupler Detent Assembly
3. Hi/Med. Shaft Lever 9. Hi/Med. Shaft and Lever Assy 13. Cover Gasket
4. Lever Locking Bolt 10. Low Coupler Shaft and Lever 14. Low Coupler Shaft Lever
5. Hi/Med. Detent Assembly Assembly 15. Fork Locking Bolt
6. Hi/Med. Shaft

Disassembly (Refer to Figure 2) Inspection

1. Remove the detent plug, followed by the ball
and spring for the low range fork, from the 1. Inspect and if necessary install new seals into
cover detent bore. bores of cover assembly. Lubricate seals with
grease.
2. Remove the low range fork locking bolt. Slide
out the rail and remove fork. 2. Inspect fork ends, shafts and levers for wear
3. Remove interlock pin. and damage, replace components as required.
4. Remove the detent plug, ball and spring from Assembly
the Hi--Med. fork cover detent bore.
5. Remove the locking bolt from the fork and slide 1. Assembly of the cover is the reversal of the
out the rail. Remove the fork. disassembly.
6. To remove the levers remove the locking bolts
and punch the shafts out of the cover
assembly. Remove levers from cover.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 13

Top Cover (Op No. 21 131)

Top Cover 3
1. Top Cover Body 7. Housing Retaining Bolt 13. Housing Gasket
2. Gasket 8. Operating Shaft Assembly 14. Neutral Start Switch
3. End Plug 9. Housing Seal 15. Seal
4. Fork Shaft 10. Operating Shaft/Lever Housing 16. Plunger
5. Fork Locking Bolt 11. Operating Lever 17. Detent Assembly
6. Fork 12. Cover Body End Plug

Disassembly (Refer to Figure 3) Inspection

1. Remove the detent plug, followed by ball and
spring. 1. Inspect the seals and replace where
necessary.
2. Remove the neutral start switch and operating
plunger. 2. Inspect the fork, levers and shaft for wear and
3. Remove the housing cover assembly. damage, replace components as required.
4. Remove the lever locking bolt and remove the
Assembly
lever from the shaft.
5. Using a suitable drift, punch the rail end plug 1. Assembly of the cover is the reversal of the
into the housing of the cover. disassembly.
6. Remove the fork locking bolts, and through the
bore of the removed plug punch out the rail and
remove the fork.

604.55.041.00 - 01 - 1998
14 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Gear Shift Levers and Linkage

WARNING: The bracket assembly is

heavy. Either obtain assistance or use suit-
able lifting equipment to aid removal.
Removal -- Less Cab

1. Remove the knobs from the levers.

2. Remove the trim from around the top of the
linkage.
3. Remove the locking screws from the main
shift and range levers, tap out the lever pivot
pins and remove the levers.
4. Remove the snap ring retaining the
forward/reverse lever and remove lever.
5. Disconnect the throttle pedal and remove the
platform securing bolts, Figure 4 and slightly
raise the platform.
6. Disconnect the links between the bracket
assembly and the transmission.

4
7. Remove the five bolts securing the bracket
assembly to the transmission casing, Figure 5.
Carefully remove the assembly. It may be
necessary to raise or lower the platform during
the removal procedure.

5
Removal -- With Cab
1. Remove the knobs from the levers.
2. Remove the trim from around the top of the
linkage.
3. Remove the locking bolts from the main shift
and range levers and tap out the lever pivot
pins.
4. Remove the protective rubber boot and
disconnect the links between the bracket
assembly and the transmission.
5. Remove the five bolts securing the bracket
assembly to the transmission casing. Carefully
remove the assembly.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 15

Gear Lever Linkage -- Top End 6

1. Forward/Reverse Lever 7. Operating Rod 13. Locking Screw
2. Snap Ring 8. Operating Arm Bush -- 4 off 14. Lever Return Spring
3. Nylon Washer 9. Nylon Washer 15. Main Shift Lever
4. Pivot Bracket Shaft 10. Pivot Bracket 16. Locking Screw
5. Support Assembly 11. Pivot Bracket Top Bush -- 4 off 17. Pivot Bracket Lower Bushes --
6. Operating arm 12. Range Lever 4 off

Disassembly

1. Remove the rods located between the lower 3. The operating arms and pivot bracket may be
bracket assembly and the upper arms. Note removed by withdrawing the shaft, reference 4,
their positions for re--assembly. Figure 6, secured by a single bolt.

2. Remove the support assembly, reference 5, 4. Removal of the bushes from the pivot bracket
Figure 6, by removing the 4 securing bolts. will allow the operating arms to be removed.

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16 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Gear Lever Linkage -- Bracket Assembly 7

(Shown off the vehicle and upside down for clarity)
1. Nylon Washer (Forward/Reverse) 10. Outer Shaft (3rd/4th Ratio)
2. Outer Shaft (Hi--Med. Range) 6. Nylon Washer 11. Nylon Washer
3. Nylon Washer 7. Bushing 12. Locking Screw
4. Inner Shaft (Low Coupler) 8. Inner Shaft (1st/2nd Ratio) 13. Nylon Washer
5. Centre Shaft 9. Nylon Washer 14. Locking Screw

1. Remove locking screws reference 14, Inspection And Repair

Figure 7.
1. Inspect the bushes, shafts and clevis pins, if
wear is evident or there is excessive play
between components, renew parts as
2. Remove the shaft assemblies references 2 and necessary.
10, Figure 7.
2. Ensure that the grease fittings and the bracket
channels are free of blockages to allow correct
lubrication.
3. Withdraw the inner shaft from the outer shaft.
Assembly

4. Remove the locking screw reference 12, 1. Assemble using the reverse of the disassembly
Figure 7, from the centre shaft operating arm procedure. Smear some grease onto the shafts
and withdraw the shaft. and bushes as they are being assembled.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 17

Installation
1. Replace the assembled bracket and linkage to
the tractor, using the reverse of the removal
procedure.
2. It will be necessary after disassembly to check
that the linkages are correctly adjusted.
Linkage adjustment should be conducted with
all transmission shift levers in neutral. Correct
adjustment is when all the operating arms are
in the vertical position and are perfectly
aligned, Figure 8 (1).

8
3. To adjust, disconnect the relevant link from the
transmission, this allows access to the clevis
pin which must be removed to allow the clevis
to be rotated, Figure 9.
4. Check operation of the levers after adjustment.

9
Neutral Start Switch Inspection
1. Inspect the conical ends of the switch plunger 1
for nicks and burrs. If either of these cannot be
removed by polishing, install a new plunger.
3
2. Check the switch (1) operation by connecting
to a suitable lamp (2) and battery (3) as shown 2
in Figure 10.
3. Operating the switch should illuminate the
lamp with the ball depressed and extinquish
when released. Replace switch if operation is
faulty.

10
Clutch Interlock
An interlock mechanism is provided on the
transmission top cover to prevent shifts between
forward and reverse travel, unless the clutch pedal
is depressed.
The interlock mechanism consists of a control
cable, which is connected at one end to the clutch
pedal assembly (1) and the other to the
transmission top cover (2) through a bore in the
housing, Figure 11.

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18 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

A plunger, connected to the control cable, engages

with a slot in the forward/reverse rail to prevent rail
movement. When the clutch pedal is depressed
the plunger is moved free of the slot to allow
shifting.

Adjustment
1. To ensure correct operation of the interlock,
adjust the cable using the adjusting nuts (3), so
that the pin (4) in the clutch pedal lever
contacts the upper end of the cable slot (5) and
provides 6--8mm of cable movement at the end
of the pedal stroke.

Front Wheel Drive Output Assembly --

Disassembly (Op No. 23 202)

1. Remove the front cover plate by gently

bumping the output shaft to free the front cover
from the bearing.

2. Remove the front bearing snap ring, reference

7 in Figure 17, and using Tool numbers 951 or
9190 (1) and 1002 or 9198 (2) with a suitable
shaft protector (4), pull off the front bearing (3),
Figure 12.

3. Lift off the spring keeper (4) and engagement

spring assembly (5) and slide the front half of
the clutch (3) from the shaft (1) and rear clutch
half (2), Figure 13.

13
4. Remove the rear bearing snap ring, reference
21 in Figure 17, and using Tool numbers 951 or
9190 (1) and 1002 or 9198 (2) with a suitable
shaft protector (4) pull off the rear bearing (3)
reference 3, Figure 14.

5. Remove the gear/rear half of the clutch and

collect the two bearings, references 15 and 17
with the two spacer washers references 16 and
19 in the exploded view of the FWD transfer
output shaft assembly shown in Figure 17.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 19

6. The oil transfer tube supplies pressure oil to

the FWD clutch. This transfer tube is a tight fit
in the transmission housing. It should be
removed and the polyamide thrust seal
renewed. Remove the tube (3) by threading an
M10--1.5 bolt into the centre of the tube and
using a conventional slide hammer and
suitable adapter, withdraw the tube, Figure 15.
Alternatively use Tool No. 4FT 509 (1) with
slide hammer, part of Tool No. 954C (2).

15
Front Wheel Drive Output Assembly --
Inspection
Use the sectional view in Figure 18 to aid
component identification.
1. Inspect all snap rings and their grooves for
deformation and damage.
2. Inspect the internal drive shaft gear, the shaft
front gear and the gear on the clutch half,
examining the teeth for wear or pitting.
3. Carefully inspect all bearings for wear, pitting
and damage.
4. Install new inner and outer seals, references
13 and 25, Figure 18, to the output shaft.

5. Carefully prise out the output shaft lip seal,

reference 19, Figure 18, from the cover plate
and press in a new seal using a suitable step
plate or adaptor. Renew the outer ‘O’ ring seal.

6. Inspect the clutch engagement spring

assembly for cracked coils or deformation.
Check the spring assembly loaded height as
shown in Figure 16, or by comparing it with a
new reference. If any doubt exists renew the
spring assembly.

16
7. Inspect the inner surfaces of the front half of
the clutch for damage, ensure that the sealing
area is unmarked.
8. Examine the clutch dog teeth for damage and
wear.
9. Inspect the splined areas of the front half of the
clutch, the output shaft and the internal drive
shaft for damage and fretting.

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20 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Front Wheel Drive Output Transfer Assembly -- Exploded View 17

1. Oil Transfer Tube 8. Oil Seal 15. Needle Roller Bearing
2. Pilot Valve Assembly 9. Front Cover 16. Spacer
3. Output Shaft 10. Inner Seal 17. Needle Roller Bearing
4. Engagement Spring Assembly 11. Outer Seal 18. Gear/Clutch Half
5. Spring Keeper 12. Quad Seal 19. Spacer
6. Front Bearing 13. Quad Seal 20. Rear Bearing
7. Snap Ring 14. Clutch Half 21. Snap Ring

Front Wheel Drive Output Drive Assembly -- 4. Use a suitable press and sleeve to install the
Re--Assembly front and rear bearings, ensure when installing
the front bearing that the sliding clutch half, the
spring assembly and the keeper plate do not
1. Use the sectional illustration in Figure 18 to aid become misaligned and damage the seals.
re--assembly and note the following
references, giving them special attention.
5. Ensure the two washers, reference 11,
2. Re--assembly of the front wheel drive output Figure 18, are positioned either side of the
transfer assembly follows the disassembly driven clutch half.
procedure in reverse.
6. In order for the dog clutch to perform correctly, it
3. Coat the shaft seals with transmission fluid is essential that the pilot valve assembly,
prior to re--assembly and allow the seals to reference 8, Figure 18, is assembled with the
resize before assembling the sliding clutch half. ball facing rearwards.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 21

18
Front Wheel Drive Output Assembly -- Sectional View
1. Shaft (from transmission output) 12. Transmission Drain Plug 23. Cover Plate Retaining Snap
2. Output Shaft Rear Bearing 13. Outer Piston Seal Ring
3. Oil Pressure Supply Tube 14. Sliding Clutch Half 24. Cover Plate ‘O’ Ring Seal
4. Transmission Housing 15. Engagement Spring Assembly 25. Inner Piston Seal
5. Plug (Pressure Supply) 16. Spring Keeper 26. Clutch Half/Gear
6. Oil Transfer Tube 17. Output Shaft Front Bearing 27. Snap Ring
7. Oil Transfer Tube Polyamide 18. Snap Ring 28. Drive Gear (from transmission
Seal 19. Oil Seal output)
8. Pilot Valve Assembly 20. Output Shaft 29. Bearing Thrust Washer
9. Bearing Retaining Snap Ring 21. Dust Seal 30. Snap Ring
10. Needle Roller Bearings 22. Cover Plate 31. Bearing Assembly
11. Steel Washers

604.55.041.00 - 01 - 1998
22 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

TRANSMISSION OVERHAUL
Transmission Stand Bracket

Transmission to Stand Attachment Bracket -- Constructional Detail 1

(Dimensions in millimetres unless stated)
1. Bracket Assembly 2. Stand Support Shaft

Although it is not necessary to mount the

transmission in a rotating stand to carry out an
overhaul, the bracket detailed above in Figure 1,
which is also suitable for 16x16 transmissions, may
be fabricated to mount the transmission to existing
stands to aid overhaul and transporting of the
transmission.
The stand support shaft reference 2, Figure 1, will
enable the bracket to be coupled to existing V.L.
Churchill Ltd stands. If a V.L. Churchill stand is not
available a suitable support shaft will have to be
fabricated.

DISASSEMBLY
Removal of Covers
1. Remove the tube from the side cover to the
FWD connector (1), Figure 2.
2. Place all transmission levers to neutral, shown
in Figure 2.
3. Remove the 8 securing bolts and withdraw the
range shift side cover, (3), Figure 2, from the
transmission.
4. Remove the 10 securing bolts and withdraw
the ratio shift cover, (2), Figure 2, from the
transmission.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 23

5. Remove the neutral start switch (1) to gain

access to one of the bolts and remove the 8
securing bolts from the top cover and withdraw
the top cover, Figure 3.

3
6. Remove the snap ring retaining the PTO shaft
bearing, pull out the PTO shaft and bearing,
Figure 4.

4
7. Remove the rear plate assembly, (10 bolts),
Figure 5.
8. Remove the 4 bolts securing the output shaft
retainer and remove the retainer and shims.

5
Removal of Transmission Rear End
Components

1. Remove bearing from the range cluster gear

assembly using a suitable puller, Figure 6.

604.55.041.00 - 01 - 1998
24 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

2. Remove the output shaft assembly (2) through

the rear of the transmission, Figure 7.
3. Remove the medium range gear and
synchroniser assembly (1) through the side of
the transmission.
NOTE: It may be necessary to move the FWD gear
rearward slightly, by removing the outer circlip from
the bearing.

7
4. Remove the range cluster gear assembly (2),
taking care not to damage the needle roller
bearing (1), Figure 8.

8
Removal of Transmission Front End
Components

1. At the front of the transmission, remove the two

tubes for the hydraulic release bearing,
Figure 9.

2. Remove the hydraulic bearing assembly (2).

(3 bolts), Figure 9.

9
3. Remove front plate assembly (1), (8 bolts),
Figure 9. To assist removal, use a suitable drift
through the top cover aperture onto the rear
face of the front cover. Progressively tap the
cover near to the dowels, until the cover is free.

NOTE: The reverse idler gear, front cover oil tube

and transmission input shaft are also removed in
this operation.

4. Remove snap ring from (top) mainshaft. Move

the reverse cluster forward slightly and slide off
the forward/reverse synchroniser assembly,
Figure 10.
10

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 25

5. Slide off reverse gear, Figure 11.

11
6. Remove the reverse cluster gear assembly,
Figure 12.

12
7. Lever out and remove the oil manifold,
Figure 13.

13
8. Remove snap ring from mainshaft front
bearing, Figure 14.

604.55.041.00 - 01 - 1998
26 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Removal of Transmission Centre Components

1. Remove snap ring from rear of mainshaft

assembly (retains 3rd/4th synchroniser).

2. Pull back and drop the countershaft (2) down

out of the way, Figure 15.

3. Remove mainshaft (1) from front of box

(countershaft moved out of way), Figure 15
and remove 3rd/4th synchroniser, 3rd ratio
gear and 2nd ratio gear (splined) (3), from the
side of the transmission.

15
4. Remove snap ring from countershaft front end.
5. Slide the countershaft assembly shaft (4) out
from the rear of the transmission casing,
Figure 16.
6. Remove the following as an assembly, (from
side window):--
3rd ratio gear, (5)
2nd ratio gear, (3)
1st/2nd synchroniser assembly, (2)
1st ratio gear. (1)
7. Remove the snap ring retaining the front
countershaft bearing into the casing and punch
out bearing.
16
FWD Output Assembly and Driveshaft
Removal
1. Remove the FWD output assembly cover snap
ring, Figure 17.

17
2. To assist removal, apply a suitable lever to pry
points on the cover and lever against the
transmission case to pull out assembly,
Figure 18.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 27

3. Remove snap ring from front end of shaft,

retaining front gear assembly (3), Figure 19.
4. Remove outer snap ring retaining rear bearing
(2) (if not already removed), Figure 19.
5. Remove snap ring from the groove in front of
the rear gear (1). Allow snap ring to hang loose
on shaft, Figure 19. Remove shaft and rear
bearing as an assembly.
NOTE: Remove FWD shaft from rear end.
6. To remove the front FWD shaft bearing,
remove the four bolts securing the FWD shaft
bearing support assembly to the transmission
casing. Remove the snap rings from either side
of the bearing and push out the bearing. 19

RE--ASSEMBLY
FWD Shaft Installation
1. Install the FWD shaft front bearing to the
support assembly and secure with snap rings
on either side.
2. Install the support to the transmission casing,
secure with the four retaining bolts.
3. Ensure the rear snap ring for the rear bearing is
installed into the transmission casing.
4. Position the front FWD gear between the shaft
support assembly and the casing.
5. Ensure the rear gear rear snap ring is installed
onto the shaft. Position and retain the rear
bearing onto the shaft. Feed the shaft and
bearing from the rear of the transmission
casing, picking up the rear gear and its front
snap ring, front bearing and front gear. Install
the front gear snap ring.

NOTE: Take care not to damage the front bearing

rollers when installing the shaft.

6. Retain the rear bearing with outer (casing)

snap ring.

Centre Components Installation

1. Install snap ring into groove of transmission
bore (front countershaft).
2. Install from the front the countershaft front
needle bearing into the transmission casing.

604.55.041.00 - 01 - 1998
28 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

3. Install through the transmission side window,

successively, the following parts, as shown in
Figure 20:--
i) 1st ratio gear, (1)
ii) 1st/2nd Synchroniser assembly, (2)
iii) 2nd ratio gear, (3)
iv) Splined 3rd ratio gear. (5)
Engage 1st ratio gear (i) and 2nd ratio gear (iii)
with splines of synchroniser.
4. Slide countershaft (4) from rear end, through
parts installed during previous operation.
Push shaft fully home, install washer and lock
with snap ring.
20
5. Install mainshaft (1), with front bearing
installed, from the front end of the
transmission, picking up the 3rd and 2nd ratio
gear assemblies and complete 3rd/4th ratio
synchroniser assembly, (3), Figure 21.

21
6. Align bearing on shaft to transmission bore and
push in sufficiently to allow snap ring to be
installed in casing bore, Figure 22.
7. Lock gears and synchroniser assembly to
mainshaft with the rear snap ring.
8. Pull the mainshaft assembly rearwards slightly
and locate the countershaft assembly into the
front bearing, install a wooden wedge between
the FWD shaft and a countershaft gear to hold
in position. Push the the mainshaft forward,
contacting the front bearing with the snap ring.
9. Install the needle roller bearing onto the rear of
the mainshaft assembly.
22
Rear End Components

1. Ensure the washer (1) is positioned onto the

range cluster gear assembly, Figure 23, and
install assembly, picking up mainshaft needle
bearing and engaging on splines of 3rd/4th
synchroniser. Ensure assembly is fully seated.
2. Assemble medium range gear with Hi/Med.
range synchroniser.
3. Insert gear/synchroniser assembly through
rear side window and engage with splines of
countershaft.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 29

NOTE: It may be necessary to move the FWD gear

rearward slightly, by removing the outer circlip from
the bearing. Ensure that the snap ring is replaced
before the output shaft is installed.
4. Install output shaft assembly (2) engaging gear
and synchroniser assembly previously
installed (1), Figure 24.
5. Install end bearing onto range cluster gear.
Heat bearing to a maximum temperature of
125!C (257!F) and push up to shoulder of gear.
6. Assemble rear cover assembly to
transmission case and secure (10 bolts).
7. Install retainer over output shaft to rear cover,
(temporarily, to keep output shaft in position). 24

Front End Components

1. Install oil manifold assembly over mainshaft
into casing bore, Figure 25. Align pegs with
transmission case bores, and ensure oil hole
alignment. Push fully home.
2. Install reverse cluster gear assy. DO NOT
push fully home.
3. Slide onto the mainshaft the reverse gear and
the forward/reverse synchroniser assembly.
4. With synchroniser engaged on mainshaft
splines, move synchroniser, together with
reverse cluster gear, into place.
25

NOTE: If necessary shift synchroniser to forward

position to allow assembly. Return to neutral when
correctly installed.
5. Retain components on mainshaft with snap
ring.
6. Apply a suitable gasket sealant (see
Specifications, to the front cover face and
locate the gasket. Apply sealant to the gasket
face to ensure an oil tight joint.

7. Install the input shaft assembly and the

reverse idler assembly into the front cover,
secure the idler shaft with the retaining bolt and
a new ‘O’ ring seal. Install the cover to the
transmission, Figure 26, ensuring that the oil
tube from the front cover to the transmission
casing is correctly located.

8. Secure the cover with the 8 retaining bolts.

9. Assemble the hydraulic release bearing

assembly to the front plate, secure with the 3
bolts.

10. Install hydraulic tubes. 26

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30 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

FWD Output

1. If FWD is fitted, position the FWD transfer

assembly oil supply tube, complete with
polyamide thrust seal, in the transmission
housing. The tube is a press fit in the housing
and should carefully be driven into its location
using a suitable drift.

2. Place the FWD clutch quick release check

valve in its bore, with the ball end facing
rearward. Using a suitable driver, firmly strike
the end of the rear of the valve to force the front
of the valve against the internal oil gallery in the
FWD shaft, this will seat or ‘coin’ the face, to
ensure an effective oil seal during operation.
Retain the valve with petroleum jelly.

3. Align the gear of the FWD output assembly

with the drive gear in the transmission casing
and install, Figure 27.

27
4. Install the FWD cover and secure with the snap
ring, Figure 28. The use of suitable heavy duty
snap ring pliers is recommended.

28
PTO Shaft

1. Grease and slide the PTO shaft assembly seal

up to the shaft shoulder.

2. Install the PTO shaft into the transmission,

Figure 29. Secure with snap ring.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 31

Output Shaft End Float

1. Check that the output shaft end float is

between 0.001 -- 0.003 in (0.0254 -- 0.0762
mm) using the following procedure:

2. Remove the retainer assembly held in position

with 2 bolts.

30
Install a number of shims (1), Figure 31, of
known dimensions, and re--install the retainer
(2), torque to correct specification.
Rotate the transmission several times to settle
assembly. Using a suitable lever (1) under the
FWD output gear and a dial indicator gauge (2)
on the output shaft end face (3), Figure 30,
measure the end float. From the figure read on
the gauge, deduct the required amount to
obtain an end float of between 0.001 -- 0.003 in
(0.0254 -- 0.0762 mm).

31
NOTE: Increasing shim thickness increases the
end float. Reducing shim thickness reduces end
float.
3. Install the output shaft bearing retainer
ensuring that the oil slot faces towards the top.
4. Check free running of:--
Input shaft,
PTO shaft,
Output shaft,
FWD shaft.
5. Verify that there is clearance between gears
and synchroniser cones.
6. Ensure all synchronisers are in neutral.
7. Install a new top cover gasket and install the
top cover, with forks in neutral position, to the
transmission assembly. Retain with 8 bolts.
Install the neutral start switch after the cover
has been tightened down.
8. Refit the ratio shifting cover using a new
gasket, ensuring forks are in neutral. Secure
with 10 bolts.
9. Refit the range shift cover, using a new gasket,
ensure forks are in neutral, secure with 8 bolts.
10. Assemble the FWD to shift cover tube
assembly.

604.55.041.00 - 01 - 1998
32 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

TRANSMISSION COMPONENT ASSEMBLIES

GENERAL INSPECTION AND REPAIR
Inspect oil seals for wear and damage. If any doubt
exists as to the condition of any seal, replace with
a new seal. Apply a film of clean transmission oil to
the sealing lip of any seal prior to installation.
Clean bearings in a suitable cleaning solvent and
inspect. If wear is evident or a bearing is not free
running, replace with a new bearing.
Inspect the gears for wear and chipped teeth.
Inspect the shafts for wear and ensure that oil
galleries are free from obstruction. Replace gears
or shafts that are damaged or worn. If any taper
roller bearings or cups are found to be
unserviceable these must be replaced in matching
sets.
If the transmission case has been completely
disassembled, clean the case internally and
externally. Inspect the case for damage or cracks.
Prior to assembly of components into the
transmission, ensure components are free from
dirt or other contamination. When assembling
components to the transmission casing lubricate
bearings and shafts with clean transmission oil.
NOTE: The following component assembly
instructions detail the level of assembly required
prior to transmission re--assembly.

RANGE CLUSTER GEAR ASSEMBLY

Assembly
1. Using a press with suitable adaptors install
front bearing and washer.

Range Cluster -- Figure 1

1. Rear Bearing
2. Cluster Gear
3. Washer
4. Front Bearing

1
MAINSHAFT ASSEMBLY
Assembly
1. Using a press with suitable adaptors install
bearing, reference 11, onto mainshaft
assembly.
Mainshaft -- Figure 2
1. Snap Ring
2. 3rd/4th Synchroniser
3. 3rd Ratio Gear
4. 2nd Ratio Gear
5. Bearing
6. Shaft
7. Snap Ring
8. Forward/Reverse Synchroniser
9. Reverse Gear
10. Oil Manifold 2
11. Bearing

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 33

FWD COUNTERSHAFT
Assembly
1. Install snap ring, reference 6, Figure 3 onto
shaft.
2. Install rear bearing, reference 9, Figure 3, and
retaining snap ring reference 7, Figure 3.
3. Install front bearing, reference 3, Figure 3, into
transmission casing.

FWD Countershaft Components -- Figure 3

1. Snap Ring
2. Output Drive Gear
3. Front Bearing (Installed into Front Support)
4. Snap Ring
5. Shaft Driven Gear 3
6. Casing Snap Ring
7. Snap Ring, Bearing To Shaft Retaining
8. Casing Snap Ring
9. Rear Bearing
10. Shaft

PTO DRIVE SHAFT ASSEMBLY

Assembly
1. Install snap ring, reference 5, Figure 4, to
shaft.
2. Press on bearing, reference 4, Figure 4, and
lock into position with snap ring, reference 3,
Figure 4.
3. Slide seal up to shoulder of shaft.

PTO Shaft Figure 4

1. Seal
2. Shaft
3. Snap Ring
4. Bearing
5. Snap Ring 4

REVERSE CLUSTER GEAR ASSEMBLY

Assembly
1. Install Hollow pin, reference 4, Figure 5. It is
important that this pin is installed correctly as it
supplies lubricating oil to the front bearing.
2. Press on the two end bearings using suitable
adaptors.

Reverse Cluster Gear Figure 5

1. Front Bearing
2. Gear Cluster
3. Rear Bearing
4. Hollow Pin

604.55.041.00 - 01 - 1998
34 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

REVERSE IDLER ASSEMBLY

1. Assemble the idler gear, reference 10,
Figure 6 and washers to the shaft and retain
with snap rings, references 5 and 8, Figure 6.
2. Secure the gear and shaft assembly to the
front cover using the bolt and washer with a
new ‘O’ ring seal.
Reverse Idler Components -- Figure 6
1. Bolt 7. Snap Ring
2. Washer 8. Idler Gear
3. ‘O’ Ring 9. Washer
4. Oil Transfer Tube 10. Snap Ring
5. Shaft 11. Front Plate
6. Washer
6

OUTPUT SHAFT ASSEMBLY

Assembly
1. Install onto the shaft the following components
in the sequence listed:--
Low range coupler, reference 6 Figure 7,
Low range gear, reference 5, Figure 7,
Washer, reference 4, Figure 7,
Spacer, reference 3, Figure 7,
Rear cone and roller bearing reference 2,
Figure 7.
Ensure that the coupler is a free sliding fit on
the shaft and that the gear is free to rotate.
2. Install the cone and roller bearing assembly on 7
the opposite end, reference 7, Figure 7.
Output Shaft Components -- Figure 7
1. Shaft
2. Rear Bearing
3. Spacer
4. Washer
5. Low Range Gear
6. Low Range Coupler
7. Front Bearing
8. Hi/Med. Range Synchroniser
9. Medium range Gear

MAIN COUNTERSHAFT
Assembly
1. Press on bearing, reference 6, Figure 8, using
suitable adaptors.
2. Press in the bearing cup, reference 5,
Figure 8.
Countershaft Assembly -- Figure 8
1. 3rd Gear
2. 1st Ratio Gear
3. 1st/2nd Synchroniser
4. 2nd Ratio Gear
5. Bearing Cup
6. Bearing
7. Shaft
8

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2 35

INPUT SHAFT
Assembly
1. Install bearing, reference 1 onto shaft,
reference 2, Figure 9.
2. Install seal, reference 3, Figure 9, into rear of
shaft. Grease lip prior to assembly.

Input Shaft Components Figure 9

1. Bearing
2. Shaft
3. PTO Shaft Seal

9
SYNCHRONISER ASSEMBLIES
The 12x12 transmission incorporates four baulk
ring type synchronisers, their locations shown in
Figure 3.

Synchroniser Assembly
1. Clutch Body
2. Synchroniser Ring
3. Sliding Sleeve
4. Synchroniser Body
5. Synchroniser Ring
6. Clutch Body
7. Spring
8. Guide
9. Plunger
10
Synchroniser operation:
In the neutral position the plungers are pressed into
the V--shaped recesses in the sliding sleeve. The
gears are free to rotate on the shaft. See ‘A’
Figure 11.
As the sliding sleeve is moved from neutral towards
the gear to be selected, the synchroniser ring is
pressed against the clutch body. Any difference in
speed of the parts to be engaged causes the
synchroniser ring rotate. This rotation, which is
limited by stops, causes the chamfered teeth of the
synchroniser ring to be pressed against those of
the sliding sleeve and prevent any further
movement of the sliding sleeve, see ‘B’ Figure 11.
Further shift pressure causes the synchroniser ring
and clutch body to eventually rotate at the same
speed and the shaft and gear speeds are
synchronised.
After synchronisation, no rubbing exists between
the clutch body and synchroniser ring. The force on
the chamfered teeth of these components is
relaxed, allowing the sliding sleeve to move past
the synchroniser ring and engage on the gear
driving tooth, See ‘C’ Figure 11.

604.55.041.00 - 01 - 1998
36 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 2

Synchroniser Operation 11
1. Synchroniser Body 4. Clutch Body
2. Sliding Sleeve 5. Plunger
3. Synchroniser Ring 6. Spring

Table 1
Synchroniser Inspection New Gap Minimum Gap
Synchroniser
1. Inspect the sliding sleeve, ensuring that wear mm (Inches) mm (Inches)
is even around the circumference of the
sleeve. If wear is uneven or there is evidence of Forward/Reverse 2.0 (0.079) 0.8 (0.032
fork pick up, replace the sleeve and inspect the
shift forks. High/Medium 1.8 (0.071) 0.8 (0.032)
2. Inspect the friction material on the 1/2
synchroniser ring. Replace the ring if friction 1.6 (0.063) 0.8 (0.032)
material is missing, there is visually uneven 3/4
wear or the material is excessively worn, as
determined in the following test:

Synchroniser Ring Wear

Place the synchroniser ring (3) over the
synchroniser clutch body (1). Rotate the ring
several times over the clutch body to ensure
correct seating.
Using a feeler gauge (2) determine the gap
between the ring and clutch body. Insert the gauge
at three equally spaced points around the
circumference, as shown in Figure 12. From Table
1 determine if the synchroniser ring is still
serviceable. Replace the synchroniser if the gap is
at or below the minimum specified.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 1

SECTION 21 -- TRANSMISSION SYSTEMS

Chapter 3 -- 8 ¢ 2 TRANSMISSION

Section Page

21 000 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmission -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 140 Introduction to Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear Shift Levers and Cover -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Front End -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission -- Complete Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS

Output Shaft End float 0.0015 -- 0.0034

(0.038 -- 0.086 mm)

Output Shaft End Float Shims Available 0.003 in (0.076 mm)

0.005 in (0.127 mm)
0.012 in (0.305 mm)

Oil Capacity Common With Rear Axle

Imp. gallons 14.5

U.S. gallons 17.4
Litres 66.0

Transmission/Rear Axle Oil Specification Ambra Multi--G (NH 410 B)

Ground Speed Charts

Rear tyre size Conversion factor
The charts on the two following pages show the
ground speeds in MPH and km/h. The charts are 13.6 -- 36 0.960
for tractors fitted with Dual Power and creeper 13.6 -- 38 0.993
gears. If your tractor does not have either of these
features, then the lines on the chart that are 16.9 -- 30 0.933
preceded by ‘C’ or ‘Power’ should be ignored. The 16.9 -- 38 1.067
road speeds in the charts relate to tractors with
16.9 -- 34 rear tyres. If the rear tyres of your tractor
are of a different size, then multiply each of the 18.4 -- 26 0.899
ground speeds shown in the printed charts by the 18.4 -- 30 0.966
following conversion factors: 18.4 -- 34 1.033
18.4 -- 38 1.101

20.8 -- 38 1.148

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2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

Ground Speeds in Miles per Hour (16.9 -- 34 Rear Tyres)

Main Range Dual Miles per hour Trans

Shift Lever Power Engine Speed (rev/min) Gear
L
Lever R ti
Ratio
1500 1900 2100 2200

1 C Power 0.16 0.20 0.23 0.24 67.08

1 C Direct 0.21 0.27 0.30 0.31 52.18
2 C Power 0.20 0.26 0.29 0.30 53.75
2 C Direct 0.26 0.33 0.37 0.38 41.81
3 C Power 0.36 0.46 0.50 0.53 30.63
3 C Direct 0.46 0.59 0.65 0.68 23.82
4 C Power 0.48 0.61 0.68 0.71 22.50
4 C Direct 0.63 0.80 0.88 0.92 17.50

1 L Power 0.93 1.18 1.31 1.37 11.74

1 L Direct 1.20 1.52 1.69 1.76 9.13
2 L Power 1.17 1.49 1.64 1.72 9.41
2 L Direct 1.51 1.91 2.11 2.21 7.32
3 L Power 2.05 2.60 2.88 3.01 5.36
3 L Direct 2.64 3.34 3.70 3.87 4.17
4 L Power 2.80 3.54 3.91 4.10 3.94
4 L Direct 3.59 4.55 5.03 5.27 3.06

1 H Power 3.35 4.25 4.69 4.92 3.29

1 H Direct 4.30 5.45 6.03 6.31 2.56
2 H Power 4.18 5.29 5.85 6.13 2.63
2 H Direct 5.38 6.81 7.53 7.89 2.05
3 H Power 7.34 9.29 10.27 10.76 1.50
3 H Direct 9.44 11.95 13.20 13.84 1.17
4 H Power 9.99 12.65 13.98 14.65 1.10
4 H Direct 12.84 16.26 17.98 18.83 0.86
R C Power 0.31 0.39 0.33 0.45 46.67
R C Direct 0.36 0.46 0.42 0.53 36.30
R L Power 1.35 1.71 1.89 1.98 8.17
R L Direct 1.73 2.19 2.42 2.54 6.35
R H Power 4.81 6.10 6.74 7.06 2.29
R H Direct 6.19 7.84 8.62 9.08 1.78

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 3

Ground Speeds in Kilometers per Hour (16.9 -- 34 Rear Tyres)

Main Range Dual Kilometers per hour Trans

Shift Lever Power Engine Speed (rev/min) Gear
L
Lever R ti
Ratio
1500 1900 2100 2200

1 C Power 0.27 0.34 0.37 0.39 67.08

1 C Direct 0.34 0.47 0.48 0.50 52.18
2 C Power 0.33 0.41 0.46 0.48 53.75
2 C Direct 0.42 0.54 0.59 0.62 41.81
3 C Power 0.58 0.73 0.81 0.85 30.63
3 C Direct 0.74 0.94 1.04 1.09 23.82
4 C Power 0.78 0.99 1.10 1.15 22.50
4 C Direct 1.01 1.28 1.42 1.48 17.50

1 L Power 1.51 1.91 2.11 2.21 11.74

1 L Direct 1.94 2.45 2.72 2.84 9.13
2 L Power 1.88 2.38 2.64 2.76 9.41
2 L Direct 2.42 3.07 3.39 3.55 7.32
3 L Power 3.31 4.19 4.63 4.85 5.36
3 L Direct 4.25 5.38 5.95 6.23 4.17
4 L Power 4.50 5.70 6.30 6.60 3.94
4 L Direct 5.78 7.32 8.10 8.84 3.06

1 H Power 5.39 6.83 7.55 7.91 3.29

1 H Direct 6.93 8.77 9.70 10.16 2.56
2 H Power 6.73 8.52 9.42 9.87 2.63
2 H Direct 8.65 10.96 12.11 12.69 2.05
3 H Power 11.81 14.96 16.63 17.32 1.50
3 H Direct 15.18 19.23 21.25 22.27 1.17
4 H Power 16.07 20.36 22.50 23.57 1.10
4 H Direct 20.67 26.18 28.93 30.31 0.86
R C Power 0.38 0.48 0.53 0.56 46.67
R C Direct 0.49 0.62 0.68 0.72 36.30
R L Power 2.17 2.75 3.04 3.18 8.17
R L Direct 2.79 3.53 3.90 4.09 6.35
R H Power 7.75 9.81 10.85 11.36 2.29
R H Direct 9.96 12.62 13.95 14.61 1.78

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4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

TIGHTENING TORQUES

Lbf.ft Nm

Clutch Release Bearing 49 67

Hub Support Bolts
Clutch Release Fork Bolt 35 47
Front Support Plate Bolts 32 44
Gear Shift Cover Assembly Bolts 41 56
Gear Shift Forks and Connectors 23 31
(Bolts and Locknuts)
Output Shaft Retainer Bolts 32 44
Rear Support Plate Bolts 32 44
Reverse Idler Shaft Retaining Bolt 17 24
Start Inhibitor Switch 30 40

SPECIAL TOOLS

DESCRIPTION V.L. CHURCHILL NUDAY LTD

TOOLS TOOLS

Heavy Duty Ratchet P61 9162

Slide Hammer MS.284 9567
Shaft Protectors 625A 9212
Step Plates 630S 9210
Puller Legs 930B 9521
Puller 938 9506
Internal/External Puller 943 9507
Slide Hammer 943S 9567
Pulling Attachments:
Small 951 9190
Large 952 9526
Pullers:
Small 1001 9196
Medium 1002 9198
Large 1003 9516

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 5

TRANSMISSION -- DESCRIPTION AND OPERATION

The non--synchromesh transmission is of a

constant mesh design and provides eight forward
and two reverse speeds which are manually 1--5 2--6 4--8 C
selected by two levers. The main gear lever
selects any one of four forward or one reverse L
speeds whilst a second shorter lever is used to
select an overall high or low ratio.

The transmission incorporates a start inhibitor N

switch which allows the tractor starter motor only to
be operated when the secondary (range) lever is in
the neutral position. 3--7 R1--R2 H

The gears are all in constant mesh and gear OM286 MT

connections are made by sliding couplings. The
1
transmission mainshaft is located in the top drive Gear Shift Lever Positions
line and the main countershaft and output shaft are (With Optional Creeper Gears)
located in the bottom drive line. The transmission L = Low Range
is available with Independent single or two speed N = Neutral
P.T.O., not shiftable. Refer to the “POWER C = Creeper gears
TAKE--OFF” --Section for further details of the H = High Range
R = Reverse
P.T.O. drive line.

The transmission features straight cut type gears

on all gears. Roller bearings are used throughout
the transmission, except on the output shaft
assembly where taper roller bearings are used.
Shims between the output shaft end cover and
bearing retainer provide the method of controlling
output shaft end float.

The low pressure hydraulic system oil is utilised to

effect pressure lubrication of the front
transmission. A proportion of the low pressure
hydraulic oil is fed, by means of external pipework,
to an oil cooler located at the front of the tractor
from which the cooled oil is directed to the front of
the transmission.

A hollow main countershaft and output shaft are

utilised to accept oil from the cooler. Cross drillings
in the main countershaft and output shaft allow the
oil to lubricate and cool the transmission gears.

The hydraulic return oil flows through the front

transmission back to the rear axle and tractor
hydraulic system. The front transmission, rear axle
and hydraulic system, therefore, form a common
oil reservoir.

A Dual Power option which consists of a planetary

gear set installed directly between the clutch and
input shaft of the standard transmission is
available. The planetary gear set provides either
a direct drive or an underdrive in each gear ratio of
the standard transmission. Refer to 8 ¢ 2 Dual
Power Section 21 Chapter 4.

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6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 7

21 140 INTRODUCTION TO TRANSMISSION OVERHAUL

To assist in overhauling the transmission, the S Front end oil seal

following notes on component accessibility should
be noted:--

Components Accessible With Transmission Components Accessible With Transmission

Installed: Removed:

S Gear shift Levers All items above, plus the following,

S Gear Shift Cover Assembly S Rear cover assembly

S Start inhibitor Switch S PTO drive shaft

Components Accessible With Engine S Selector rails, forks, detent components and
Removed Only: interlocks

All items above, plus the following, S Output shaft assembly

S Clutch assembly
S Range cluster gear

S Clutch release shaft, fork and bearing

assembly S Front upper shaft components

S Main Input Shaft S Front lower shaft components

S Front upper and lower shaft front bearings S Reverse idler components

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8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

GEAR SHIFT LEVERS AND COVERS -- OVERHAUL

REMOVAL 3. Use a hacksaw to partially cut the lever

retaining snap rings. If possible place the gear
shift lever into the jaws of a vice as close to the
snap ring as possible. Then using a chisel,
finally break off the rings. During this operation
1. If the tractor is equipped with a cab, lift up the ensure the retaining rings are not dangerously
floor mats and remove the floor panel in order to ejected from the grooves on the levers. Slowly
gain access to the shift cover. release the vice and remove the springs, ball
retainers and levers.

2. Place the gear shift levers in neutral. NOTE: There is no need to attempt to remove the
lever locating pins in the cover assembly as the
levers are slotted.

3. Disconnect the Battery negative cable.

INSPECTION

4. Disconnect the start inhibit switch wires from 1. Wash the shift cover and shift lever assemblies
the harness connection. in a suitable solvent and dry with a clean, lint
free cloth or compressed air.

5. Remove the gearshift cover retaining bolts and 2. Inspect the shift cover for cracks or other
partially lift the cover from the transmission damage. Renew the cover where necessary.
casing. With the cover raised, disconnect the
start inhibit switch wires from the switch and
remove the shift cover assembly from the
transmission. 3. Inspect the shift lever ball seats and ends for
wear and the lever locating pins in the cover.
Renew the pins if worn or damaged. New pins
should be pressed into the cover.
DISASSEMBLY

4. Inspect the lever retaining springs for cracks or

1. Remove the oil baffle plate retaining bolts from distortion, also inspect the retaining snap ring
the underside of the shift cover and remove the grooves on the levers.
plate and washers.

2. Unscrew and remove the gear shift lever 5. Inspect the safety start switch wiring harness
knobs. for damage. Renew the harness if damaged.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 9

Top Cover Assembly 3

1. Start inhibitor Switch Wiring Harness 13. Washer
2. Shift Cover Bolt 14. Washer
3. Washer 15. Range (High/Low) Lever
4. Cover 16. Main Gear Lever
5. Gasket 17. Pin, Start inhibitor switch
6. Pin 18. Dowel
7. Spring 19. Lever Locating Pins
8. Ball 20. Retainer
9. Spring 21. Lever Spring
10. Pin 22. Seal
11. Baffle Plate Retaining Bolt -- 3 off 23. Snap Ring
12. Baffle Plate 24. Gear Lever Knob

REASSEMBLY INSTALLATION

1. Lubricate the ball seats with a good quality 1. Install a new shift cover gasket to the cover
grease and pass the shift levers through the assembly, hold in place with a suitable grease
shift cover. to aid assembly. Re--install the cover following
the removal procedure in reverse, observing
2. Assemble the ball retainers and springs, the following points:
compress the springs and install new retaining
snap rings. S Ensure the start inhibit actuator housing is
aligned with the locating pin in the shift cover.
3. Reassemble the two oil baffle washers to the
underside of the shift cover, the oil baffle plate S Tighten the cover retaining bolts to 41 lbf.ft (56
and the retaining bolts. Nm).

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10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

START INHIBIT SWITCH

REMOVAL
1. Remove the shift cover as previously
described.
2. Unscrew the start inhibitor switch from the
housing.
INSPECTION
1. Inspect the start inhibitor switch for wear or
damage. Renew as necessary.

REASSEMBLY AND INSTALLATION

1. Reassembly and installation of the start
inhibitor switch follows the removal procedure
in reverse.
2. Test the switch operation by connecting a test
bulb in series with the switch terminals and a
battery. Move the switch actuator housing
along the high/low shift rail and away from the
centre line of the actuating dowel. The test bulb
should only light when the actuator housing is
centred over the actuating dowel.
NOTE: Do not move the actuator housing more
than 0.25 in (6 mm) from the actuating dowel centre
line or the dowel may come out of the shift rail.
5

TRANSMISSION FRONT END -- OVERHAUL

REMOVAL
1. Separate the engine from the transmission,
see “SEPARATING THE TRACTOR” .
2. Remove the gear shift levers and cover as
previously described in this Chapter.

DISASSEMBLY

1. Remove the clutch release fork retaining bolt

(3), Figure 6 and withdraw the clutch release
shaft (4) from the casing. Remove the clutch
release fork (2) from the transmission. Slide
the clutch release bearing and hub (1) from the
clutch release hub support.
6

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 11

2. Transmissions With Dual Power:

Disassemble the Dual Power unit as described
in 8 ¢ 2 Dual Power Section. Remove the
Dual Power housing retaining bolts and lift the
housing from the transmission casing. Take
care not to lose the anti--spin washer located
between the transmission mainshaft front gear
and front bearing if the bearing comes away
with the dual power housing.

7
Transmissions Less Dual Power: Disconnect
the low pressure lubrication lines from the
clutch release bearing hub support and the
front support plate. Remove the hub support
(1), Figure 7. Remove the snap ring (1)
retaining the main drive input shaft (2) to the
transmission mainshaft, Figure 8 and
withdraw the input shaft.

Input Shaft Retaining Snap Ring

1. Retaining Snap Ring
2. Main Drive Input Shaft

8
3. Remove the front support plate retaining bolts
(2), Figure 9 and withdraw the plate (1) from
the housing. If necessary, drive the plate from
the housing using a suitable drift inserted into
the main transmission compartment.

9
INSPECTION AND REPAIR
1. Inspect the clutch release components for
wear, see “CLUTCHES” -- Section 18.
Transmission Less Dual Power: Inspect the
mainshaft front oil seal located in the clutch
release bearing hub support, and if necessary,
use Slide Hammer, Tool No. 943S or 9567, to
remove the seal. Use a Step Plate, Tool No.
630S and sleeve of suitable diameter to install
a new seal, with the sealing lip facing
rearwards. Lubricate the sealing lip with a
suitable grease prior to installation.

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12 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

2. Examine the main drive input shaft and

retaining snap ring and replace if worn or
damaged.
3. Inspect the main countershaft front bearing
and if worn or damaged, use puller, tool No.
1001 or 9196 (2) and a shaft protector, tool No.
625A or 9212, (3) to remove the bearing (1)
from the shaft, Figure 10.
Use a sleeve of 1.25 in (32mm) internal
diameter and 1.62 in (41mm) external diameter
to install a new bearing onto the countershaft.

10
RE--ASSEMBLY
1. Install the front support plate to the
transmission case using a new gasket. If
necessary, lift the mainshaft and main
countershaft to align the countershaft front
bearing. Install the retaining bolts and tighten
to 32 lbf.ft (44 Nm).
Transmissions With Dual Power:
Re--assemble the Dual Power components as
detailed in the 8 ¢ 2 Dual Power Section.

NOTE: Ensure the anti--spin washer (2) is installed

between the mainshaft front gear (3) and front
bearing (1)if the bearing has come away with the
dual power unit during disassembly. If the bearing
has remained on the mainshaft, coat the outer
edge of the bearing with a suitable adhesive, such
as New Holland stud and bearing lock, Part
Number 82995772, (5), to ensure the bearing does
not rotate in the dual power housing, prior to
reassembly, Figure 11.

11
Transmission Less Dual Power: Install the
main drive input shaft into the forward end of
the transmission mainshaft and secure with the
snap ring. Place studs in two of the five bolt
holes to ensure correct alignment of the clutch
release hub on assembly. This will prevent
damage to the release hub oil seal. Position a
new gasket on the front support plate and slide
the clutch release hub support over the studs.
Drive the support into position with the drain
hole downwards. Remove the studs, install the
retaining bolts and tighten to 49 lbf.ft (67 Nm).
2. Install the clutch release bearing and hub
assembly onto the hub support.
3. Locate the release fork fingers into the slots in
the hub and install the release shaft through
the casing and release fork. Install the fork
retaining bolt and tighten to 35 lbf.ft (47 Nm).

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 13

COMPLETE TRANSMISSION OVERHAUL

DISASSEMBLY
1. Remove the clutch operating mechanism,
clutch release hub support, Dual Power
transmission (where fitted), front support plate
and main drive input shaft assembly as
previously described in this Chapter.
2. Remove the shift levers and cover assembly
as previously outlined in this Chapter, together
with the start inhibitor switch from the high/low
shift rail.
3. Remove the snap ring (4), the thrust washer (3)
and the hydraulic pump idler gear (2), located
on the output shaft retainer, Figure 12.
12

4. Remove the rear support plate retaining bolts

(1), Figure 12 and using a soft faced mallet
drive the forward end of the P.T.O. drive shaft
rearwards. This will separate the rear support
plate (1) from the transmission casing. If
necessary, lever the rear support plate from
the casing and withdraw the plate complete
with the P.T.O. drive shaft (4), Figure 13.
5. Remove the snap ring (2) retaining the P.T.O.
drive shaft rear bearing (5) and drive the shaft
and bearing out of the support plate.
6. Remove the bolts securing the output shaft
retainer to the rear support plate and withdraw
the retainer (3) Figure 13 and shims from the
rear support plate. 13

7. Partially withdraw the secondary countershaft

assembly (1) until the front bearing is out of the
location. Lift the secondary countershaft to
allow the output shaft assembly (2) to be
removed from the rear compartment,
Figure 14, followed by removal of the
secondary countershaft.

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14 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

8. Remove the high/low sliding coupling (2) from

the rear of the main countershaft, Figure 15.

15
GEAR SHIFT MECHANISM

1. Remove the four detent plungers (1) and

springs (2). The detent balls (3) located below
the springs should be collected as each shift
rail is removed, Figure 16.

16
2. Unscrew the start inhibitor switch (5) from the
housing. Loosen the locknut and remove the
bolt locking the high/low range fork (6) to the
shaft. Remove the range lever connector (4)
from the shaft and slide the rail out from the
rear of the gearbox. Place a clean cloth
beneath the start inhibitor switch actuator
housing. Take care to ensure the ball, spring
and actuating dowel are collected from the
housing and rail. Lift the high/low shift fork from
the rear compartment.

3. Unscrew the locknut and retaining screw from

the 1st--5th/3rd--7th shift fork (3) at the front of
the shift rail. Drive the rail forward from the
transmission casing pushing the sealing plug 17
out with the end of the rail. Remove the shift
connector and fork.

4. Unscrew the locknut and retaining screws from

the 4th--8th shift fork (8) and connector (1) and
push the shift rail rearwards from the
transmission case. Remove the fork and the
connector.

5. Unscrew the locknut and retaining screw from

the Reverse/2nd--6th shift arm (2) and
connector and slide the top rail out rearwards.
Lift the shift arm and the connector from the
transmission case.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 15

6. Remove the locknut and screw (1) retaining

the Reverse/2nd--6th shift fork to the lower
shift rail (4), Figure 18 and push out the rail
rearwards. Remove the shift fork from the
transmission casing.
7. Remove the interlock plungers from the cross
bore in the transmission case. If necessary,
remove the bore plug situated on the left--hand
side of the case to facilitate removal of the
plungers.

REVERSE IDLER ASSEMBLY

1. Bend down the locktab and remove the bolt (3) 18

retaining the reverse idler shaft to the
transmission case, Figure 18.

2. Drive the shaft out forwards and lift out the

reverse idler gear (2).

MAINSHAFT ASSEMBLY

1. Position a Step Plate, Tool No. 630S or 9210, in

the bore at the rear of the mainshaft.

2. Drive the shaft forwards, using a suitable drift,

from the transmission case and remove the
4th--8th coupling gear.

MAIN COUNTERSHAFT ASSEMBLY

1. If not previously removed, use puller, tool No.

1001 or 9196 and step plate, tool No. 630S or
9210, to remove the main countershaft front
bearing. remove the snap ring (4) located
behind the bearing, Figure 19 and remove the
thrust washer (2).

2. Withdraw the main countershaft (3) rearwards

removing the gears (1), couplings and thrust
washer. Store these components in the order
of removal to aid correct re--assembly.

NOTE: The inner and outer sections of the sliding 19

couplings are matched in manufacture and should
not be separated.

604.55.041.00 - 01 - 1998
16 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

INSPECTION AND REPAIR

REAR END COMPONENTS

1. Inspect the P.T.O. drive shaft and bearing

assembly. If the bearing is worn or damaged,
use Puller, Tool No. 1003 or 9516, Pulling
Attachment, Tool No. 951 or 9190 and Shaft
Protector, Tool No. 625A or 9212, to effect
removal. Use a convenient length of sleeve
1.44 in. (37 mm) internal diameter and 1.75
(44 mm) external diameter to install a new
bearing.

2. Inspect the output shaft retainer and rear

bearing cup for wear or damage. If necessary,
remove the cup from the retainer using a
suitable punch.
Use Step Plate, Tool No. 630S or 9210 and a
suitable punch to install the new bearing cup.

3. Examine the output shaft assembly for wear or

damage. If necessary, use Puller, Tool No.
1002 or 9198 (1), Puller Adaptor, Tool No. 951
or 9190 (2) and Shaft Protector, Tool No. 625A
or 9212 (4), to remove the front pilot bearing
cone and roller assembly (3), Figure 20.

4. Use Puller, Tool No. 1003 or 9516 (1) and Shaft

Protector, Tool No. 625A or 9212 (4), to
remove the gear (2), rear bearing (3) and thrust
washer in one operation, Figure 21.

5. Inspect the output gear bushing for wear and

replace the gear and bushing assembly if
necessary.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 17

6. Install the steel thrust washer aligning the flats

on the washer with the flats on the shaft and
position the rear bearing on the output shaft,
Figure 32, page 25. component E. Use Puller,
Tool No. 1003 or 9516 (1), Pulling Attachment,
Tool No. 952 or 9526 (3), Shaft Protector, Tool
No. 625A or 9212 (5) and a suitable sleeve of
1.5 in. (40 mm) internal diameter, 2.00 in. (50
mm) external diameter (2), to pull the bearing
(4) into position, Figure 22.

22
7. Inspect the secondary countershaft assembly
for wear or damage. If necessary, use Puller,
Tool No. 1003 or 9516, Pulling Attachment,
Tool No. 952 or 9526 and Step Plate, Tool No.
630S or 9210, to remove the rear bearing (4).
8. If necessary, remove the secondary
countershaft front bearing (2) using two steel
rods (5) 0.18 in. (48 mm) diameter and 2.0 in.
(50 mm) long inserted through the two holes in
the driving gear. Use Puller, Tool No. 1003 or
9516 (1), Pulling Attachment, Tool No. 951 or
9190 (3) and Step Plate, Tool No. 630S or 9210
(6), to push the bearing from the countershaft,
Figure 23.
9. Use Puller, Tool No. 1003 or 9516, Pulling 23
Attachment, Tool No. 951 or 9190 and Step
Plate, Tool No. 630S or 9210, to install both
front and rear bearings.

MAINSHAFT ASSEMBLY
1. Inspect the mainshaft assembly, the front and
rear bearings and P.T.O. drive shaft oil seal
located inside the forward end of the shaft.
2. If necessary, use Puller, Tool No. 1003 or 9516
(1), Pulling Attachment, Tool No. 951 or 9190
(2), to remove the mainshaft rear bearing (3),
Figure 24. If necessary, remove the front
bearing using two pieces of steel rod 0.18 in.
(4.8 mm) diameter and 2.0 in. (50 mm) long
inserted through the two holes in the main
driving gear together with Puller, Tool No. 1003
or 9516, Pulling Attachment, Tool No. 951 or
9190 and Step Plate, Tool No. 630S or 9210 24
(4).
3. Use Puller, Tool No. 1003 or 9516, Pulling
Attachment, Tool No. 952 or 9526 and Step
Plate, Tool No. 630S or 9210 to install a new
rear bearing. A new front bearing should be
installed using the above tools together with a
sleeve 2.5 in. (64 mm) internal diameter and
3.0 in. (76 mm) external diameter of
convenient length.

604.55.041.00 - 01 - 1998
18 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

4. When removing and installing the mainshaft

front bearing of transmissions installed with
Dual power, note that there is an anti--spin
washer between the mainshaft front gear and
bearing assembly. Ensure the washer is in
good condition prior to reassembly.
5. Inspect the P.T.O. drive shaft oil seal located
within the mainshaft and remove if worn or
damaged. Install a new seal, after lightly
greasing the sealing lip, with the sealing lip
facing rearwards. Use a Step Plate, Tool No.
630S or 9210 and sleeve of convenient size to
drive the seal into location.

MAIN COUNTERSHAFT ASSEMBLY

1. Inspect the main countershaft assembly and if

necessary, use Puller, Tool No. 938 or 9506
(1), puller legs, Tool No. 930B or 9521 (6),
Ratchet, Tool No. P61 or 9162 (2), Pulling
Attachment, Tool No. 952 or 9526 (3) and Shaft
Protector, Tool No. 625A or 9212 (5), to pull the
rear bearing (4) from the countershaft,
Figure 25.

25
2. Examine the output shaft pilot bearing cup
located in the end of the main countershaft (1).
If necessary, remove the bearing cup using a
suitable punch (2) inserted through the two
holes in the gear (3), Figure 26.

3. Use a suitable Step Plate, Tool No. 630S or

9210 and Puller, Tool No. 1003 or 9516, to
install a new output shaft pilot bearing cup into
the rear of the main countershaft.

26
4. Use Puller, Tool No. 1003 or 9516 (1), Pulling
Attachment, Tool No. 952 or 9526 (3), Step
Plate, Tool No. 630S or 9210 (5) and a sleeve
2.00 in. (50 mm) internal diameter and 3.21 in.
(58 mm) external diameter of convenient
length (4), to install a new rear bearing (2) onto
the main countershaft, Figure 27.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 19

5. Inspect all gears which are mounted on the

main countershaft for damage and wear.
Mount the gears on the countershaft and
check the bushings for free play. If any gear or
bushing is worn, a new gear and bushing
assembly must be installed. Similarly,
examine the reverse idler gear and bushing
assembly and replace if necessary.
6. Inspect the main countershaft rear bearing cup
(1) situated in the transmission case and if
damaged or worn, use Slide Hammer, Tool No.
943S or 9567 (2), to effect removal, Figure 28.
Install a new cup using a suitable drift.

28
7. Examine the countershaft front bearing,
previously removed from the front of the
countershaft, for wear and damage. If
necessary, install a new bearing on
re--assembly.

8. Inspect all components with internal splines,

external splines or gear teeth and if worn or
damaged, replace on re--assembly. Ensure
the lubrication oil drillings in the main
countershaft are free from obstruction.

604.55.041.00 - 01 - 1998
20 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

GEAR SHIFT MECHANISM a) 2nd--6th Gear (dog--teeth forward).

b) Reverse/2nd--6th sliding coupling and

connector.*

c) Phosphor--bronze thrust washer.

1. Check the gear shift forks, rails, arms and
connectors for wear or distortion. Examine the d) Reverse gear (dog--teeth rearward).
detent on the shift rails and replace the shift rail
if the detents are worn. e) Phosphor--bronze thrust washer.

f) 1st--5th Gear (dog--teeth forward).

g) 3rd--7th/1st--5th Sliding coupling and

connector.*
2. Renew all worn and damaged components.
h) 3rd--7th Gear (dog--teeth rearward).

i) Thrust washer

TRANSMISSION CASE j) Snap ring.

k) Front bearing.

* NOTE: These connectors have a chamfer on one

1. Wash out the transmission case with a suitable side of the inside diameter. This chamfer must face
solvent to remove all particles of metal and dirt. the rear of the transmission to allow the connector
Dry with a clean, lint free cloth or compressed to seat correctly on the main countershaft splines.
air. The sliding coupling and connector are matched in
manufacture and should be installed with the
etched marks aligned.

2. Inspect the case for cracks or other damage 2. Support the main countershaft during
and if beyond repair, re--assemble the reassembly and ensure the rear bearing is
transmission components into a new case. seated squarely in the bearing outer track.

3. Position the high/low sliding coupling on the

rear of the main countershaft.

RE--ASSEMBLY, Refer to Figure 32 during MAINSHAFT ASSEMBLY

transmission re--assembly unless otherwise
stated.
1. Ensure the snap ring retaining the mainshaft
rear bearing is in position in the transmission
casing.

2. Install the 4th--8th coupling gear on the rear of

MAIN COUNTERSHAFT ASSEMBLY the mainshaft with the shift fork groove to the
front.

3. Position the mainshaft assembly in the

transmission casing.

1. Pass the main countershaft through the rear 4. Drive the mainshaft assembly rearwards to
compartment and assemble the gears in the seat the rear bearing in the location within the
following sequence: casing.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 21

REVERSE IDLER ASSEMBLY

1. Position the reverse idler gear (1) between the

supporting lugs, Figure 29, with the extended
hub of the gear towards the front of the
transmission.

2. Install the reverse idler shaft from the rear

compartment with the retaining bolt hole
forwards. Install the retaining bolt (2) and
locktab, tighten the bolt to 17 lbf.ft (24 Nm) and
bend up the locktab.

29
GEAR SHIFT MECHANISM

1. Locate the Reverse/2nd--6th shift fork (4) onto

the appropriate sliding coupling on the main
countershaft and install the lower shift rail (5)
from the rear compartment with the fork
retaining hole to the rear of the shift rail,
Figure 30. Install the fork retaining screw and
lock nut then tighten the screw to 23 lbf.ft (31
Nm). Secure with the lock nut.

30
2. Insert the two interlock plungers into the bore
from the left--hand side of the transmission
case and install the screwed plug. Position
each plunger between the three shift rail bores.

3. Position the 4th--8th shift fork (10) on the

sliding coupling. Install the shift rail (1) from the
rear, with the oil relief groove rearwards and
pass through the bore in the shift fork. Install
the retaining screw and locknut and tighten to
23 lbf.ft (31 Nm).

NOTE: When installing the remaining top shift

rails, ensure the rails already installed are in the
neutral position so the interlock plungers do not
prevent the rail from entering the front support
bore.

4. Position the lower end of the Reverse/2nd--6th

shift arm (6) into the locating hole in the
Reverse/2nd--6th shift fork (4). Pass the
Reverse/2nd--6th top shift rail (9) in from the
rear with the oil relief groove rearwards. With
the shift rail correctly located in the shift arm,
install the retaining screw and locknut then
tighten to 23 lbf.ft (31 Nm).

604.55.041.00 - 01 - 1998
22 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

5. Position the 1st--5th/3rd--7th shift fork (3) in the

sliding coupling located at the front of the main
countershaft. Install the 1st--5th/3rd--7th shift
rail (2) from the front of the transmission.
Correctly locate the rail in the shift fork and
secure with the retaining screw. Install the shift
connector to the rear of the rail and secure with
the retaining screw. Tighten the retaining
screws and lock nuts to 23 lbf.ft (31 Nm).
Install the sealing plug at the front of the rail.
6. Position the high/low shift fork (7) in the groove
of the high/low sliding coupling located on the
output shaft. Install the high/low shift rail (8)
and correctly locate in the shift fork. Secure
the shift fork with the retaining screw and
tighten the screw and lock nut to 23 lbf.ft (31
Nm).
7. Install the four shift rail detent balls, springs
and plungers. Ensure the balls and plungers
slide freely in the bores.
NOTE: The shorter plunger is located in the
vertical bore above the high/low shift rail.
REAR END COMPONENTS
1. Ensure the snap ring located immediately in
front of the secondary countershaft front
bearing is in position in the transmission casing
bore.
2. Place the secondary countershaft assembly in
the approximate location and hold the
assembly at the top of the rear compartment
whilst the output shaft assembly is installed.
Align the secondary countershaft and drive
forwards until the front bearing seats against
the locating snap ring in the transmission case.
3. Locate the rear support plate, less the output
shaft retainer assembly, on the transmission
rear face. Drive the plate into position on the
dowels then install the retaining bolts and
tighten to 32 lbf.ft (44 Nm).
4. Install the P.T.O. drive shaft and rear bearing
through the transmission from the rear and use
a soft--faced mallet to drive the shaft and
bearing into position. Secure the rear bearing
with the snap ring.
5. To obtain the specified end play in the output
shaft taper roller bearings, shims of
appropriate thickness have to be installed
between the rear support plate and the output
shaft bearing retainer according to the
following procedure:
(i) Install shims to a thickness of approximately
0.06 in. (1.6 mm) and locate the output shaft
bearing retainer assembly on the rear support
plate.
(ii) Install the four retaining bolts and tighten to 32
lbf.ft (44 Nm).

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 23

(iii) Position the plunger of a dial indicator gauge

(3) against the end face of the output shaft (2),
Figure 31. Lever the shaft in and out and note
the end play reading. If no end play is
registered, add additional shims to produce a
gauge reading.

31
(iv) Remove the indicator gauge and the four
retainer bolts. Withdraw the retainer (1) and
shims.
(v) Remove a number of shims to obtain an end
float between 0.0015 in (0.038 mm) and
0.0034 (0.086 mm)

NOTE: Shims are available in thicknesses of

0.003 in., 0.005 in. and 0.012 in. (0.076 mm, 0.127
mm and 0.305 mm).

(vi) Having selected the correct shims, install the

bearing retainer, with the oil slot to the top,
shims and bolts. Tighten the bolts to 32 lbf.ft
(44 Nm). Re--position the dial indicator gauge
and re--check for end play.

6. Install the hydraulic pump idler gear, thrust

washer and snap ring.

Re--assembly of the front end components follows

the procedure detailed in the Section Transmission
Front End--Overhaul of this Chapter.

Installation of the shift levers and cover and the

start inhibitor switch follows the procedure detailed
in the Gear Shift Levers and Cover Overhaul
Section of this Chapter.

INSTALLATION

1. Re--connect the transmission to the engine

and rear axle, see “SEPARATING THE
TRACTOR”.

2. Refill the transmission/rear axle with the

correct grade and quantity of oil, Ambra
Multi--G meeting New Holland specification
NH 410 B.

604.55.041.00 - 01 - 1998
24 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

Key to 32
Transmission Components

A -- Input Shaft Assembly D -- Main Countershaft

1. Clutch Release Bearing Hub Support 1. Main Countershaft Front Bearing
2. ‘O’ Ring Seal 2. Snap Ring
3. Input Shaft Seal 3. Washer
4. Input Shaft Retaining Clip 4. 3rd -- 7th Gear
5. Seal 5. Coupling Matched With Connector, item 6
6. Input Shaft 6. Connector Matched With Coupling, Item 5
7. Seal 7. 1st -- 5th Gear
8. Washer
9. Reverse Gear
10. Washer
11. Coupling Matched With Connector, Item 12
12. Connector Matched With Coupling, Item 11
13. 2nd -- 6th Gear
14. Bearing Outer Cup
15. Taper Bearing
16. Countershaft
17. Bearing Outer Cup

B -- Top Shaft (Mainshaft) E -- Output Shaft Assembly

1. Input Cluster Gear Front Bearing 1. Taper Bearing
2. Anti--Spin Washer -- With Dual Power Only 2. Lube Oil Transfer Tube
3. Input Cluster Gear 3. High/Low range Coupling
4. Input Cluster Gear Rear Bearing 4. Output Shaft
5. Casing Snap Ring 5. Low Range Gear
6. 4th --8th Connector Gear 6. Thrust Washer
7. Taper Bearing

C -- Secondary Countershaft (Range F -- End Cover Assembly

Cluster) 1. Snap Ring
1. Casing Snap Ring 2. Snap Ring
2. Secondary Countershaft Front Bearing 3. P.T.O. Shaft Bearing
3. Secondary Countershaft Gear Cluster 4. Snap Ring
4. Secondary Countershaft Rear Bearing 5. P.T.O. Shaft
6. Bearing Outer Cup
7. End Cover
8. Shims
9. Output Shaft Retainer

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3 25

R5--1--01
Figure 32 604.55.041.00 - 01 - 1998
26 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 3

NOTES

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 1

SECTION 21 -- TRANSMISSION SYSTEMS

Chapter 4 -- 16×4 DUAL COMMAND TRANSMISSION

Section Page
21 000 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 168 Planetary Gear Set -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS

Planetary Gear Set Free Play 0.004--0.020 in

(0.10--0.51 mm)

Planetary Gear Set Free Play 0.013 in. (0.33 mm)

Shims Available 0.032 in. (0.81 mm)

Planetary Cover to Housing 0.046--0.060 in.

Shimming Gap (1.17--1.52 mm)

Planetary Gear Set Free Play Average Planetary cover Shim Thickness to
Shimming Chart to Housing Gap be added

0.001--0.013 in. (0.025--0.33mm) 0.045in. (1.14mm)

0.014--0.026in. (0.34--0.66mm) 0.032in. (0.81mm)
0.027--0.032in. (0.67--0.81mm) 0.026in. (0.66mm)
0.033--0.045in. (0.82--1.14 mm) 0.013in. (0.33mm)
0.046--0.0060in. (1.15--1.52mm) None

Dual Command System 220--260 lbf.in2

Pressures (15.2--17.9 bar)

Lubrication System Pressure Run lubrication pressure test, a pressure within the following range
should be recorded.
73--123 lbf.in2 (5.0--8.5 bar)

TIGHTENING TORQUES

Components lbf.ft Nm

Control Valve Spool Plug 28 38

Control Valve Body Retaining Bolts 32 44

Planetary Housing Retaining Bolts 77 105

Planetary Cover Retaining Bolts 35 47

Lubrication Tube Connector 13 17.5

Pressure Line Control Tube Connector 9 12

604.55.041.00 - 01 - 1998
2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

SPECIAL TOOLS

Description V.L. Churchill Ltd Nuday

Tools Tools

Slide Hammer MS.284 9567 (943S)

Step Plates 630S 9210 (630S)

PTO Clutch Compressor N--775 1312 (N--775)

Puller Legs 930B 9521 (930B)

Puller 938 9506 (938)

Internal / External Puller 943 9507 (943)

Slide Hammer 943S 9567 (943S)

Pulling Attachment
Small 951 9190 (6951)
Large 952 9526 (962)

Puller
Medium 1002 9198 (1002)
Large 1003 9516 (1003)

Spacer Gauge -- Dual Command FT.5000(SW523) 1303 (SW523)

Planetary Shaft Puller FT.5004 4721

Pressure Gauge FT.8616 FNH 06653

Adaptor FT.8503 FNH 00705

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 3

FAULT FINDING
IMPORTANT: Whenever effecting a repair the
reason for the cause of the concern must be
investigated and corrected to avoid repeat failures.
The following table lists problems and their
possible causes with recommended remedial
action.

PROBLEM POSSIBLE CAUSE REMEDY

Dual Command system 1. Direct drive clutch snap ring 1. Replace snap ring and other
pressure below specification displaced damaged parts
in normal drive only
2. Damaged or leaking control 2. Replace gasket
valve body gasket

3. Leaking sealing rings on direct 3. Replace sealing rings and/or

drive clutch housing hub or Dual Command housing
worn Dual Command housing

4. Leaking inner or outer seals on 4. Replace seals

direct drive clutch piston

5. Broken or cracked direct drive 5. Replace piston or housing

clutch piston or housing

Dual Command system 1. Damaged or leaking control 1. Replace gasket

pressure below specification valve body gasket
in power drive only
2. Leaking inner or outer seals on 2. Replace seals
under drive clutch piston

3. Broken or cracked underdrive 3. Replace piston

clutch piston

Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure below specification circuit Pressure Testing, Section 35,
in both normal drive and Chapter 5.
power drive

Dual Command system 1. Fault in low pressure hydraulic 1. Refer to Hydraulic Systems,
pressure above specification circuit Pressure Testing, Section 35,
in both normal drive and Chapter 5.
power drive

No power to rear wheels when 1. Low Dual Command system 1. Refer to first problem
normal drive engaged (power pressure in direct drive clutch
drive operative) circuit

2. Scorred, burred or binding 2. Replace piston

direct drive clutch piston

3. Control valve spool jammed in 3. Check control valve spool

underdrive position

4. Worn or defective direct drive 4. Replace clutch plates

clutch plates

5. Direct drive clutch pressure 5. Install snap ring correctly or

plate snap ring out of groove or replace
broken

604.55.041.00 - 01 - 1998
4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

PROBLEM POSSIBLE CAUSE REMEDY

No power to rear wheels when 1. Low Dual Command system 1. Refer to second problem on
power drive engaged (normal pressure in underdrive clutch page 3
drive operative) circuit

2. Scorred, burred or binding 2. Replace piston

underdrive clutch piston

3. Control valve spool jammed in 3. Check control valve spool

direct drive position

4. Worn or defective underdrive 4. Replace clutch plates

clutch plates

No power to rear wheels when 1. Low Dual Command system 1. Check system pressure
Dual Command is engaged in pressure
normal drive or power drive

2. Defective planetary gear set 2. Check components and

ring gear, planetary carrier, sun replace as necessary
gear, shaft or mainshaft splines

3. Main transmission or rear axle 3. Check and overhaul as

problem necessary

4. Clutch problem 4. Overhaul clutch

Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston

shifting from power drive to underdrive clutch piston
normal drive

2. Broken or defective underdrive 2. Replace springs

clutch piston return springs

3. Warped or defective 3. Replace clutch plates

underdrive clutch plates

Engine stalls or lugs when 1. Scorred, burred or binding 1. Replace piston

shifting from normal drive to direct drive clutch piston
power drive

2. Broken or defective direct drive 2. Replace springs

clutch piston return springs

3. Warped or defective direct 3. Replace clutch plates

drive clutch plates

Lubrication pressure below 1. Weak or broken cooler / 1. Overhaul cooler / lubrication

specification lubrication valve spring, or valve
valve stuck open

2. Blocked or restricted oil cooler 2. Replace oil cooler

Lubrication pressure above 1. Incorrect cooler / lubrication 1. Overhaul cooler / lubrication

specification valve spring or valve stuck valve
closed

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 5

DUAL COMMAND TRANSMISSION -- DESCRIPTION AND OPERATION

The Dual Command transmission consists of a

planetary gear set installed directly between the
clutch and the input shaft of the transmission.
The planetary gear set incorporates two
hydraulically operated clutches which lock an
element or elements of the planetary gear system
together to produce either a normal direct drive to
the transmission or a power underdrive which
lowers the speed but increases the torque.

Normal Direct Drive

With reference to Figure 1.

Locking any two members of a planetary gear

system together results in a direct drive with no
change in speed or direction of rotation.

Compressing the direct drive clutch plates locks

the sun gear (3) to the planetary carrier (2) which
is the output member of the system. Applying
power to the ring gear (1) results in a normal direct
drive.
1
Power Underdrive
With reference to Figure 2.
Compressing the underdrive clutch plate, locks the
sun gear (4) to the planetary housing. Applying
power to the ring gear (1) forces the pinions (2) to
rotate on their own axis and ‘walk’ around the sun
gear, taking the planetary carrier (3) with them.
The planetary carrier is the output members of the
system and turns in the same direction as the ring
gear but at a lower speed with a resultant increase
in torque. This condition produces a power
underdrive.

2
The Dual Command transmission is operated by a
two--position control valve, located on the side of
the planetary gear set housing, which directs oil
from the steering section of the tandem hydraulic
system pumps, to engage either the direct drive or
the underdrive clutch assembly. The oil pressure
is regulated by the low pressure regulating and
lubrication circuit relief valves housed within the
PTO valve assembly.

The ground speeds in normal direct drive are

unchanged from the previous 8--speed
transmission ground speeds.

The Dual Command transmission ratios and

3
corresponding gear shift lever positions are shown
in the Specifications of Chapter 3.

604.55.041.00 - 01 - 1998
6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

Oil Flow to the Direct Drive Clutch

With reference to Figure 5.

The control valve, which has no neutral position, is

moved by means of a solenoid operated pilot valve.
The solenoid is controlled by a switch located on
the instrument panel (1).
1

When the Dual Command control switch is moved

to the normal (direct drive) position, electric current 4
flows to the control valve solenoid and so energises
the solenoid coil.

The effect of energising the solenoid is to close the

pilot valve, thereby preventing the oil supplied at
port ‘A’ from acting on the top of the control valve.
Supply oil can, however, still pass through the
centre of the control valve and act under the control
valve spool.

The hydraulic pressure acting under the control

valve lifts the spool upwards, directing supply oil
between the lands to the gallery drilled in the
planetary housing which connects with the gap
between the second and third sealing rings on the
direct drive clutch hub. A drilled passage in the
clutch hub allows the oil to act behind the direct
drive clutch piston. The pressure moves the
piston, compresses the piston spring and locks the
direct drive clutch plate together so engaging the
direct drive clutch.

Hydraulic oil from the rear of the underdrive clutch

piston is exhausted and eventually returns to sump
via the control valve and the planetary housing.
Exhaust oil in the control valve also returns to the
planetary housing via a connecting passage in the
control valve housing.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 7

R5--4--03

Oil Flow to Direct Drive Clutch 5

Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil

1. Pilot Valve 8. Hub Support Plate 14. Pinion

2. Control Valve Spool 9. Direct Drive Clutch Plates 15. Planetary Carrier
3. Sealing Rings 10. Direct Drive Clutch Piston 16. Planetary Housing
4. Transmission Input Shaft Return Spring 17. Underdrive Clutch Plate
5. Direct Drive Clutch Piston 11. Sun Gear 18. Underdrive Clutch Piston
6. Transmission Countershaft 12. Centre Shaft Return Springs
7. Direct Drive Clutch Housing 13. Ring Gear and Input Shaft 19. Underdrive Clutch Piston

604.55.041.00 - 01 - 1998
8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

R5--4--04
Oil Flow to Underdrive Clutch 6

Reservoir and
Pressure Oil Lubrication Oil Exhaust Oil

1. Pilot Valve 8. Hub Support Plate 14. Pinion

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 9

Engaging the direct drive clutch locks the planetary and holding the sun gear, causes the pinions of the
carrier to the sun gear, which is splined to the direct planetary carrier to rotate on their own axis and
drive clutch housing. When any two members of ‘walk’ around the sun gear taking the carrier with
the planetary assembly are locked together a direct them.
drive results with no change in speed or direction of
rotation. Therefore, as the planetary carrier and the
sun gear are locked together, power input at the ring
gear is passed directly to the planetary carrier which The carrier, being the output member of the system,
is splined via a connecting shaft to the input shaft turns in the same direction but at a slower speed
of the transmission. than the ring gear, thereby producing an underdrive
with a resultant decrease in speed and increase in
torque.
Oil Flow to the Underdrive Clutch

Lubrication Oil Flow

With reference to Figure 6.

Lubrication oil is supplied by the low pressure

hydraulic system. This oil is directed via tubing
When the Dual Command control switch is moved through a transmission oil cooler, before entering a
to the power (underdrive) position, the electrical passage in the control valve body shown
connection to the solenoid is broken and the schematically at ‘B’ in Figure 5 and Figure 6.
solenoid becomes de--energised, which opens the
pilot valve.

The oil passes through a drilled passage in the

planetary housing between the first and second
Supply oil from port ‘A’ can now act on both the sealing rings on the direct drive clutch hub and
upper and lower surfaces of the control valve. through a drilled passage in line with the direct drive
However, the area of the top of the control valve is clutch plates. The oil flows around the clutch plates
greater than the area of the bottom, which results and through the planetary assembly. As the
in the control valve being pushed down by the members of the planetary assembly rotate, oil is
greater force acting on the top. thrown off to lubricate the bearings and other
components in the housing. Oil in the bottom of the
housing is directed through a tube connecting the
housing with the main countershaft bearing in the
Oil from port ‘A’ is now directed by the control valve hub support plate.
spool through a drilled passage in the planetary
housing to the underdrive clutch piston. The
pressure moves the piston, compresses the piston
return springs and locks the underdrive clutch Excess oil in the housing flows directly into the
plates together so engaging the underdrive clutch. transmission case to lubricate the transmission
gears and bearings. Oil entering the hub support
plate flows into the centre passage of the
countershaft and lubricates the bearings and gears
Hydraulic oil from the rear of the direct drive clutch through cross drillings in the shaft. As the
piston is exhausted and eventually returns to sump components on the countershaft and output shaft
via the control valve and the planetary housing. revolve, oil is carried to the input shaft and range
Exhaust oil in the control valve also returns to the cluster gear to lubricate the upper gears and
planetary housing via a connecting passage in the bearings in the transmission case. Excess oil in the
control valve housing. countershaft flows directly into the transmission
casing through a slot in the front support plate.

Engaging the underdrive clutch locks the direct

drive clutch housing to the planetary housing. As Oil collected in the transmission case is allowed to
the sun gear is splined to the inner hub of the direct flow into the rear axle centre housing, with which it
drive clutch assembly, it is also locked to the forms a common oil reservoir, through passages in
planetary housing. Applying power to the ring gear the transmission output shaft retainer.

604.55.041.00 - 01 - 1998
10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

21 186 PLANETARY GEAR SET -- OVERHAUL

REMOVAL
1. Drain the oil from the transmission and rear
axle centre housings.
2. Disconnect the wiring harness from the wire
assembly at the plug connector located above
the transmission bell--housing. It is not
necessary to take the wire assembly out of the
transmission plug.
3. Pull the large rubber plug free from the
transmission bell--housing and disconnect the
lubrication (1) and pressure (2) control lines
from the control valve body, Figure 7.

7
4. Unplug the wire assembly (2) from the Dual
Command solenoid (3).

5. Withdraw the bolts securing the valve body (4)

to the planetary housing and remove the valve
body.

6. Remove the gasket from the valve body.

8
7. Remove the pressure line connector (5) and
lubrication line connector (1) from the valve
body and remove the ‘O’ ring seals from the
connectors.

8. Separate the engine from the transmission as

described in “SEPARATING THE TRACTOR.

9. Disconnect the rod between the clutch pedal

and the clutch release cross--shaft lever by
removing the clevis pin at the lever end.

10. Remove the clutch release fork retaining pin

(5), Figure 9, support the fork (4) and withdraw
the clutch release cross--shaft (6).

11. Remove the fork (4) and release bearing

assembly (3).

12. Remove the bolts (1) from the planetary cover

(2).

13. Carefully remove the cover from the planetary

housing.

9
14. Remove the gasket from the cover.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 11

Planetary Gear Set Components -- Exploded View 10

1. Cover 8. Underdrive Clutch Assembly
2. Thrust Washer 9. Planetary Carrier
3. Sun Gear 10. Pilot Bearing
4. Direct Drive Clutch 11. Ring Gear and Shaft Assembly
5. Shaft 12. Shim
6. Thrust Washer 13. Ring Gear Bearing
7. Planetary Housing

15. Remove the ring gear and shaft assembly,

Fiugre 10, from the housing.

16. Carefully remove the planetary carrier, shaft,

sun gear and direct drive clutch assembly as a
complete unit.

NOTE: Removal of the ring gear may also

withdraw the Dual Command reduction gear set
and direct drive clutch unit (1) from the
transmission due to the shaft (2) being a tight fit in
the ring gear bearing. In these cases the shaft may
be extracted from the ring gear bearing by means
of a Slide Hammer, Tool No. MS.284 or 9567 (3)
and the Planetary Shaft Puller Tool No. FT.5004 or
4721 (4) placed over the rear of the shaft,
Figure 11.

11
17. If necessary, remove the pilot bearing from the
shaft using Puller, Tool No. 1002 or 9198,
Pulling Attachment, Tool No. 951 or 9190 and
Step Plate, Tool No. 630--S/4 or 9210/4.

18. Remove the shaft and separate the planetary

carrier from the direct drive clutch assembly.

19. Remove the sun gear from the inner splines of

the direct drive clutch assembly.

20. Carefully remove the bolts (2) securing the

planetary housing (1) to the transmission case,
Figure 12.
12

604.55.041.00 - 01 - 1998
12 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

21. Remove the planetary housing from the case.

NOTE: Take care not to lose the anti--spin washer

located between the transmission mainshaft front
gear and front bearing if the bearing comes away
with the Dual Command housing.

22. Remove and discard the gasket on the rear

hub of the planetary housing.

23. Remove the ‘O’ ring between the planetary

housing and the transmision front plate.

Direct Drive Clutch Assembly -- Exploded View

1. Steel Plates 7. Piston Return Spring

2. Pressure Plate 8. Sealing Rings
3. Snap Ring 9. Direct Drive Clutch Housing
4. Friction Plates 10. Piston Seals
5. Snap Ring 11. Piston
6. Spring Retainer

DISASSEMBLY

Direct Drive Clutch

1. Remove the sealing rings (8), Figure 13, from

the rear hub of the direct drive clutch housing
(9).
2. Depress the piston return spring and remove
the snap ring (3) from the inner hub using
Clutch Compressor, Tool No. N--775 or 1312
(4) and either Puller, Tool No. 1003 or 9516 or a
press (1), Figure 14.
3. Release the pressure and ensure the spring
retainer (2) does not enter the snap ring
groove. 14

4. Remove the spring retainer and spring.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 13

5. Remove the clutch pressure plate snap ring

(2), as shown in Figure 15.

6. Remove the pressure plate, the friction and

steel plates from the clutch housing (1).

IMPORTANT: Note the order in which the clutch

plates were removed.

7. Place an air hose nozzle in the hole between

the middle and rear sealing ring grooves in the
clutch housing hub and blow out the piston.
15

IMPORTANT: For safety, position the direct drive

clutch housing with the front face down on the
bench so the piston cannot cause injury when
expelled.

8. Remove the piston inner and outer seals.

Underdrive Clutch

1. Remove the large snap ring (1) from the inner

surface of the planetary housing (2).

NOTE: To remove the snap ring it is recommended

that four restraining clamps be made as shown in
Figure 16. Equispace the four clamps, Figure 17,
around the rim of the planetary housing (2) and
secure with the housing bolts.

604.55.041.00 - 01 - 1998
14 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

2. After removing the snap ring, gradually release

the restraining clamps.

3. Remove the spring retainer, pressure plate

and friction plate.

IMPORTANT: Note the order in which the clutch

plates were removed.

4. Remove the piston return springs, locating

dowel pins and rear plate.

5. Place an air hose nozzle in the pressure supply

port of the control valve housing and carefully Underdrive Clutch Assembly -- Exploded View 18
blow out the underdrive piston. 1. Piston Return Springs
2. Pressure Plate
3. Snap Ring
IMPORTANT: Position the planetary housing so 4. Spring Retainer
that the underdrive piston cannot cause injury 5. Friction Plate
6. Rear Plate
when expelled. 7. Piston Seals
8. Control Valve Body
9. Planetary Housing
6. Remove the inner and outer seals from the 10. Piston
piston. 11. Dowel Pins

Control Valve Assembly

With reference to Figure 19.

1. Remove the plug (2) located in the control

valve (3) at the opposite end to the solenoid
(1).

2. Remove the solenoid and pilot valve assenbly.

3. Remove the control valve spool (4).

INSPECTION AND REPAIR

1. Clean all parts in a suitable solvent and dry

thoroughly with a dry, lint--free cloth or
compressed air.

2. Examine the lubrication inlet tube, the

pressure inlet tube and the lubrication oil tube
for damage or distortion. Discard any
defective tubes.

3. Examine the control valve solenoid cable for

damage or loose connections.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 15

4. Examine the clutch release hub (2) and

bearing (4) for excessive wear or damage. If
necessary, remove the bearing from the hub
with Pulling Attachment, Tool No. 951 or 9190
(3), Step Plate, Tool No. 630--S/10 or 9210/10
(5) and either a press or Puller, Tool No. 1002
or 9198 (1), see Figure 20. Press a new
bearing onto the hub ensuring the thrust face of
the bearing faces away from the shoulder on
the hub.
5. Pack the recess in the bearing hub bore with a
high melting point grease.

20
6. Inspect the clutch release fork for cracks or
excessive wear and replace as necessary.

7. Examine the cross--shaft and lever for

distortion or excessive wear and install a new
assembly, if damage is evident. Inspect the
shaft bushings for excessive wear and replace
if found to be defective. Bushings should be
driven into the housing until they are flush with
the outside edges of the cross--shaft locating
bores.

8. Inspect the planetary cover for damage or

distortion. Check the face of the cover and the
mating surface for nicks or burrs and remove
any imperfections with an abrasive stone.

9. Inspect the planetary carrier and gears,

planetary shaft, pilot bearing and thrust washer
for damage or wear. Install new parts where
necessary.

10. Inspect the sun gear for excessive wear or

damaged teeth.

11. Inspect the sealing rings from the rear hub of

the direct drive clutch assembly for damage,
distortion or cracks.

If new seals are to be installed, insert the seals

in a 2.38 in. (60 mm) internal diameter test bore
for a period of 10 minutes prior to assembly.
This procedure ensures the seals obtain the
correct amount of pre--tension to avoid dam-
age on assembly. Install the new seals using
a suitable grease to hold the seals in position
during re--assembly and ensure the seals do
not protrude above the lands of the direct drive
housing.

12. Examine the bore in the hub of the planetary

housing where the direct drive sealing rings
locate. If wear or damage is evident the
planetary housing must be replaced.

604.55.041.00 - 01 - 1998
16 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

13. Examine the direct drive clutch housing both

externally for cracks or damage and internally
for wear and piston scuffing. Inspect the
housing external splines for cracked, broken or
missing teeth.
14. Inspect the direct drive clutch piston, friction
plates, steel plates, pressure plate and snap
ring and install new piston seals. Any defective
parts must be replaced during re--assembly.
15. Examine the direct drive clutch piston return
spring, spring retainer and snap ring for
damage.
16. Examine the thrust washer for damage or
distortion.

17. Inspect the planetary housing for cracks or

damage. Examine the underdrive clutch
piston, locating dowel pins, springs, rear plate,
friction plate, pressure plate, spring retainer
and snap ring and install new piston seals.
Discard and replace any cracked, damaged or
badly worn parts.
18. Examine the transmission input shaft front
bearing (4) in the hub of the planetary housing
(3), if removed with the Dual Command
housing assembly, for excessive wear or
damage. If necessary, use Puller, Tool No. 943
or 9507 (2) and Slide Hammer, Tool No. 943S
or 9567 (1) to remove the bearing, Figure 21.
Press in a new bearing. 21
19. Inspect the ring gear and shaft assembly for
damage or wear. Inspect the shaft splines for
damage. If necessary, install a new ring gear
and shaft assembly.

20. Examine the ring gear bearing (2) for wear or

damage. If necessary, remove the bearing
with Puller, Tool No. 938 or 9506 (6), Puller
Legs, Tool No. 930B or 9521 (5), Pulling
Attachment, Tool No. 952 or 9526 (4) and Step
Plate, Tool No. 630S/4 or 9210/4 (1), as shown
in 22. Take care not to damage the shim
located behind the bearing. Ensure the shim is
placed against the step on the ring gear shaft
(3) and then press the new bearing onto the
shaft, using a convenient length sleeve of 3.25
in. (82.6 mm) internal diameter and 3.75 in.
(95.3 mm) external diameter.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 17

IMPORTANT: The shim located behind the ring The free play should be between 0.004--0.020in
gear bearing governs the planetary gear set end (0.10--0.51mm). For free play available shims, see
play. If any of the major components of the Specifications.
planetary gear set are changed, refer to ‘Planetary Determine the shim required to give the specified
Gear Set Shimming Procedure’ in this Chapter, to free play as follows:--
determine the correct size shim to be installed.
1. Install the sun gear in the inner splines of the
direct drive clutch assembly.
21. Examine the valve spool bore in the valve body 2. Place the thrust washer in the planetary carrier
for damage or wear. and align the splines.

22. Inspect the valve spool lands for scratches, 3. Install the planetary carrier and thrust washer
wear or other damage. Minor burrs or onto the sun gear and ensure the splines of the
scratches may be removed with a fine abrasive planetary carrier are engaged with all of the
material but parts must be washed and dried direct drive clutch friction plates.
prior to re--assembly. 4. Hold the components tightly together and
install the planetary shaft from the rear. Tap the
23. Check the solenoid for cracks or damage. if shaft, if necessary, to ensure full engagement.
any doubt exists as to the serviceability of this
component, replace with a new solenoid 5. Press the pilot bearing onto the shaft using a
assembly. sleeve of 1.62 in (41.2 mm) internal diameter
and 1.88 in (47.8 mm) external diameter.
RE--ASSEMBLY 6. Position the planetary housing (with underdrive
clutch installed) on a bench.

Re--assembly of the direct drive clutch, the

underdrive clutch and control valve follows the NOTE: Support the housing on blocks so that the
disassembly procedure in reverse. rear of the planetary shaft does not foul the
workbench when the direct drive clutch and
planetary gear set is fully installed.

NOTE:
7. Place the thrust washer in the housing with the
(i) When re--assembling the solenoid to the tab up and towards the rear of the transmission.
valve, apply a proprietary thread sealant 8. Install the direct drive clutch and planetary gear
on the pilot valve assembly threads and set assembly in the housing. Ensure the
tighten the nut to 4 lbf.ft (5.4 Nm) assembly is fully seated in the housing.
9. Install the ring gear and shaft assembly
(ii) Ensure the gap of the underdrive clutch (without the ring gear bearing or shim) in the
retaining snap ring is placed in line with the housing. Place the Ring Gauge, Tool No.
lubrication port of the Dual Command FT.5000 or 1303, on the step of the ring gear
Housing. shaft.
10. Position the cover on the planetary housing
without the gasket.
PLANETARY GEAR SET SHIMMING
PROCEDURE
IMPORTANT: Ensure all components are properly
seated in the housing.

IMPORTANT: This procedure must be followed

11. Measure the distance between the face of the
whenever a new cover, bearing, ring gear, planetary
cover and the face of the housing at three
carrier, sun gear, direct drive clutch or planetary
conveniently spaced intervals. Average the
housing is installed.
three measurements. If the average
measurement is between 0.046--0.060in
(1.17--1.52mm) the free play is within the
required limits and no shims are necessary.
Free play among the components of the planetary 12. If the average measurement is less than the
housing is governed by means of a shim located range stated, determine the shim thickness
between the bearing and the step on the ring gear required by referring to the relevant chart in
shaft. Specifications Section.

604.55.041.00 - 01 - 1998
18 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

13. Remove the cover and the ring gear and shaft Installation of the planetary gear set and control
assembly from the planetary housing. Remove valve follows the removal procedure in reverse. Pay
the ring gauge and place the appropriate particular attention to the following important
shim(s) on the step of the ring gear shaft. Press points:
the bearing onto the ring gear using a
convenient length sleeve of 3.25 in. (82.6 mm)
internal diameter and 3.75 in. (95.3 mm)
external diameter). (i) If all components are correctly installed, the
14. Remove the components from the planetary cover should easily seat in the housing. Any
housing and retain in order for final installation. need for force indicates incorrect re--assembly.
(ii) Install new ‘O’ ring seals on the lubrication oil
INSTALLATION transfer tube.
(iii) Coat all tube joints with a proprietary sealing
compound.
NOTE: If it is necessary to install a new cover, (iv) Install new ‘O’ ring seals on the control valve
bearing, ring gear, planetary carrier, sun gear, direct pressure line and lubrication line connections.
drive clutch or planetary housing, refer to ‘Planetary
Gear Set Shimming Procedure’ in this Chapter, (v) Take care to avoid damage to the control valve
before installing the planetary components in the solenoid and wire and ensure the grommet is
transmission case. firmly in place to protect the solenoid wire.

PRESSURE TESTING

For the following tests ensure the tractor hydraulic

oil is at operating temperature, the transmission
and hydraulic system are in neutral and the power
take--off is disengaged.

Dual Command SYSTEM PRESSURE TEST

(Low Pressure Hydraulic Circuit Test)

1. Remove the pressure switch (1) for the low

pressure hydraulic circuit, Figure 23.

23
2. Install a 0--400 lbf.in2 (0--30 bar) pressure
gauge, FT.8616 (1), Figure 24 with adaptor
FT8503 or FNH 00705 (2) and test hoses, part
Nos 83936707 and 83926717 (3).

3. Set the engine speed to 2100 rev/min. and

observe the pressure reading. A reading of
15.2 --17.9 bar (220--260 lbf.in2) should be
recorded.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4 19

TRANSMISSION LUBRICATION PRESSURE

TEST

1. Operate the tractor and set the engine speed to

1000 rev/min. Stop the engine but do not
re--adjust the throttle.

2. Using a test hose (4), part number,

E1NN--F493--AA with adaptor FT.8503--8 and
a suitable 7/16 in. JIC adaptor (3), which must
be a tight fit inside the oil cooler inlet hose (1),
connect the 400 lbf.in2 pressure gauge,
25
FT.8616 (5), to the cooler inlet hose, Figure 25,
using a suitable hose clamp (2) to secure.

3. Using an assistant to start the engine, observe

the reading on the pressure gauge. Do Not run
the tractor longer than is necessary to observe
the pressure gauge reading.

The pressure recorded should be 73--123 lbf.in2

(5.3--8.5 bar), depending on engine speed. 73--123
lbf.in2 (5.0--8.5 bar) is the minimum operating
pressure of the lubrication circuit relief valve
located in the PTO valve and clutch assembly.

604.55.041.00 - 01 - 1998
20 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 4

NOTES

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5 1

SECTION 21 -- TRANSMISSION SYSTEM

Chapter 5 -- REDUCTION GEARBOX ASSEMBLY

Section Page
21 000 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reduction Gearbox -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reduction Gearbox -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS

Reduction Ratio 5.7:1

Output Shaft End Float with 0.0015--0.0034 in

Reduction Gearbox (0.038--0.086 mm)

Output Shaft Pre--Load with Pull required to turn the output shaft with string
Reduction Gearbox wound around output shaft splines
9.5--16 lbf. (1.0--1.8 N)

Output Shaft Pre--Load Shims 0.004 in. (0.10 mm)

Available for Reduction Gearbox 0.006 in. (0.15 mm)
0.020 in. (0.50 mm)

TIGHTENING TORQUES

Components lbf.ft Nm

Rear Support Plate Retaining Bolts 35 47

Output shaft Retainer Socket Head Screws 23 31

SPECIAL TOOLS

Description V.L. Churchill Ltd Nuday

Tools Tools

Step Plates 630S 9210 (630S)

Internal / External Puller 943 9507 (943)

Slide Hammer 943S 9567 (943S)

604.55.041.00 - 01 - 1998
2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5

REDUCTION GEARBOX -- DESCRIPTION AND OPERATION

The reduction gearbox, which is available as an The coupling is moved by means of the selector fork
option on the 8x2, with or less dual power, and gear shift rail.
non--synchromesh transmission, provides an extra
reduction ratio below the standard low range. The
reduction being obtained through the use of an
epicyclic gear set which is mounted on the
transmission output shaft.
In the neutral position, as shown in Figure 1 , the
coupling does not engage any component of the
When installed the reduction gearbox provides an reduction gear set and so the coupling and output
additional creep range of four forward and one shaft cannot be driven.
reverse speed, which increases the total number of
ratios available to twelve forward and three reverse.
On transmissions fitted with dual power, an
additional eight forward and two reverse speeds are
provided increasing the total ratios available to 24
forward and six reverse.
The transmission low range is selected by sliding
the gear shift rail rearwards to the detent position
adjacent to neutral. The movement of the rail,
The epicyclic gear set provides a reduction ratio through the selector fork, causes the coupling to
below the low range of 5.7:1. engage the reduction gear set carrier. Power is now
transmitted from the secondary countershaft, via
the carrier and coupling to the output shaft. The
All reduction gearboxes consist basically of an carrier has the same number of gear teeth on the
epicyclic gear set mounted in place of the outside diameter as the output shaft gear utilised on
transmission output shaft gear used on the standard transmission, therefore, the ground
standard transmission. speeds obtained in the low range are identical to
those of a standard transmission.

A cross section of the reduction gearbox is shown

in Figure 1.

The creep range is selected by sliding the gear shift

The epicyclic gear set consists of: rail and fork further rearward to the final detent
position. The coupling is moved by the selector fork
inside the carrier assembly to engage the
(i) An outer ring gear which is fixed in relation intermediate ring gear. Power is now transmitted
to the transmission housing. from the secondary countershaft to the coupling via
the planetary gear set.
(ii) Planetary gears mounted in the carrier, the
rear gear teeth engaging the outer ring
gear.

(iii) The carrier, which has teeth formed on the

outside diameter to act as the output shaft The planetary gear set is designed so that the
gear. carrier is driven and causes the planetary gears to
rotate with the rear teeth engaged in the stationary
(iv) Intermediate ring gear which engages the ring gear. The forward teeth of the planetary gears
front teeth of the planetary gears. engage and drive the intermediate ring gear at
reduced speed. The coupling, which now engages
(v) The coupling, which is splined to and drives the intermediate ring gear, therefore, drives the
the output shaft, which may engage the output shaft at a reduced speed to obtain the
carrier or intermediate ring gear. required creep range.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5 3

Reduction Gearbox 1
1. Roller Bearing 11. Support Plate
2. Thrust Washer 12. Intermediate Ring Gear
3. Needle Roller Bearing 13. Planetary Gear
4. Spacer 14. Carrier
5. Taper Roller Bearing 15. Coupling
6. Output Shaft Retainer 16. Output Shaft
7. Roller 17. Needle Roller Bearing
8. Socket Head Screw 18. Thrust Washer
9. Shim(s) 19. Selector Fork
10. Outer Ring Gear 20. Gear Shift Rail

604.55.041.00 - 01 - 1998
4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5

REDUCTION GEARBOX OVERHAUL

REMOVAL
1. Drain the oil from the transmission.
2. Separate the rear axle from the transmission,
see “SEPARATING THE TRACTOR” .
3. Remove the gear shift cover as described in
Chapter 3.
4. Remove the snap ring, thrust washer and
hydraulic pump idler gear, located on the
output shaft retainer.
5. Remove the rear support plate retaining bolts
(2) and lever the support plate (1) away from
the transmission, Figure 2.
2

6. Remove the rear support plate (2) and the

P.T.O. shaft (1) as an assembly, Figure 3.

7. Partially withdraw the secondary countershaft

assembly (1) until the front bearing is out of the
location. Lift the secondary countershaft to
allow the output shaft and reduction gear set
assembly (2) to be removed from the rear
compartment, Figure 4. Remove the
secondary countershaft.

8. Remove the high/low/creep coupling from the

rear of the transmission, or the output shaft, as
required.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5 5

DISASSEMBLY

1. Remove the output shaft retainer (1) from the

rear support plate (2), Figure 5.

2. Remove the outer ring gear (3) from the rear

support plate.

5
3. Remove the output shaft from the reduction
gear set assembly (2). If necessary, use a soft 3 1
faced hammer to drive the output shaft
forwards out of the assembly, Figure 6.
Ensure the intermediate ring gear (3) remains
inside the reduction gear set (1).

NOTE: Removal of the output shaft will push the

bearing off the rear of the output shaft.

6
4. Remove the thrust washer (3) and needle roller
bearing from the output shaft (or intermediate
ring gear (4) should these components remain
inside the gear set assembly).

5. Lay the epicyclic gear set on the bench with the

intermediate ring gear uppermost. Withdraw
the intermediate ring gear (4), Figure 7.

7
6. Remove the thrust washer, needle roller
bearing, spacer and second needle roller
bearing from the carrier.

7. Remove the planetary gears (2) from the

carrier (1). Take care to retain the bearing
rollers.

604.55.041.00 - 01 - 1998
6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5

INSPECTION AND REPAIR

1. Inspect the output shaft retainer and rear

bearing cup for wear or damage. If necessary,
use Pulling Attachment, Tool No. 943 or 9507
and Slide Hammer, Tool No. 943S or 9567 to
remove the cup from the retainer. Use a
suitable Step Plate, Tool No. 630S or 9210 to
install a new bearing cup.

2. Examine the rear support plate for wear or

damage and replace if necessary.

3. Inspect the output shaft and pilot bearing.

Replace worn or damaged components.

4. Check the secondary countershaft and P.T.O.

drive shaft bearings located in the rear support
plate. Replace any unserviceable bearing with
a suitable Step Plate, Tool No. 630S or 9210.

5. Examine all needle roller bearings and thrust

washers. Replace any unserviceable items.

6. Inspect the planetary gear set carrier, ring

gears and planetary gears and replace any
worn or damaged components on
re--assembly. However, if several components
are worn, the complete reduction gear set
should be replaced.

7. Examine the coupling and gear shift

mechanism. Replace any unserviceable
components.

RE--ASSEMBLY

1. Use high quality grease to position the thirteen

5 mm diameter rollers (3) and eleven 9 mm
diameter rollers (1) around the planetary gears
(2), Figure 8.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5 7

2. Install the planetary gears (3) with their rollers

(4) in the carrier (1) which must rest inside the
outer ring gear (2) which acts as an assembly
gauge, Figure 9.

IMPORTANT: During installation, turn each gear

until the master tooth (marked with a punched dot)
points towards the centre of the carrier.

Planetary Gear to Carrier Relationship

3. With reference to Figure 11 and viewed from

the front, four pairs of gear teeth are in
alignment. Identify the right--hand tooth of any
aligned pair on the 12 teeth gear as the master
tooth.

Identification of Master Tooth on 5.7:1 11

Reduction Ratio Planetary Gear
1. 16 Teeth Gear
2. 12 Teeth Gear
3. Master Tooth on 12 Teeth Gear
4. Rod Used to Establish Alignment of Gear Teeth

604.55.041.00 - 01 - 1998
8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5

4. Locate the smaller diameter thrust washer (2),

chamfered side up, on the carrier hub before
installing the intermediate ring gear (1) into the
carrier to fully engage with the planetary gears.

5. Place the gear coupling, groove to the front, on

the output shaft.

6. Position the larger diameter washer (1) on the

output shaft (2) with the chamfered side facing
the coupling (3) Figure 13.

(i) Lubricate the needle roller bearings with

high quality grease and install the narrow
needle roller bearing in the intermediate
ring gear. Install the two wide needle roller
bearings, with the spacer between them,
in the carrier.
(ii) Hold the previously assembled output
shaft vertically and locate the carrier
assembly on the output shaft.

NOTE: When the carrier is fully located, the output

shaft should protrude above the carrier rear thrust
face.
(iii) Push the output shaft rear bearing against
the output shaft shoulder (1).
(iv) Use feeler gauges (2) to check the
clearances between the bearing (3) and
the carrier. The gap should be
0.012--0.032 in. (0.3--0.8 mm), Figure 14.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5 9

INSTALLATION

1. Install the assembled carrier and output shaft

unit in the transmission. Ensure the coupling
engages the selector fork.

2. Remove the outer ring gear from the reduction

gear set assembly.

3. Install the rear cover plate on the transmission.

4. Install the support plate retaining bolts and

tighten to a torque value of 35 lbf.ft (47 Nm).

5. Locate the outer ring gear into the rear cover.

6. Replace the shims and bolt the output shaft

retainer to the support plate so that the ring
gear is also supported. Tighten the socket
head screws to a torque value of 23 lbf.ft (31
Nm).

7. Using a pull scale and string wound around the

output shaft, check the output shaft torque
pre--load. With the transmission in neutral the
pull scale should read between 9.5--16 lbf.in.
Add or subtract shims from between the output
shaft retainer to obtain the correct pre--load

Alternatively, if a pull scale is not available, add

or subtract shims to obtain an output shaft end
float of between 0.0015--0.0034 in.
(0.038--0.086 mm).

8. Install the hydraulic pump idler gear and thrust

washer and retain with the snap ring.

9. Replace the gear shift cover as described in

Chapter 3.

10. Reconnect the transmission and rear axle

assemblies, see “SEPARATING THE
TRACTOR” .

11. Fill the transmission with the correct grade and

quantity of oil, see Specifications.

604.55.041.00 - 01 - 1998
10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 5

NOTES

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 1

SECTION 21 -- TRANSMISSION SYSTEMS

Chapter 6 -- Dual Command Transmission (24 ¢ 24 Dual Command)

Section Page
21 000 Specifications, Special Tools and Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 168 Description and Operation Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dual Command Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Dual Command Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lubrication Valve Removal and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Transmission Control Valve Removal and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

SPECIFICATIONS, SPECIAL TOOLS AND TIGHTENING TORQUES

Control System Electro--hydraulic with electronic management system

Clutch Hydraulic Operating Pressure 15--18 bar (220--260 lbf.in2) at 2100 engine rev/min,
supplied from the low pressure side of pump

Pressure Lubrication Maximum 7.6 bar (110 lbf.in2) supplied by the steering
gear pump

Lubricant Capacity U.S. Gallons 15.4

Transmission/Rear Axle Imp. Gallons 12.8
Litres 58.5

Lubricant Ambra Multi -- G (NH 410B)

Lubricant operating temperature 65!C (150!F)

Hydraulic Control Valve

Type Separate Casting, with internal cast--in galleries

Control By electrically operated solenoid coils signaled by

electronic management system

Multi--Plate Wet Clutches

Type Constant running, pressure lubricated, pressure applied,

spring released.

Number of Friction Plates 5 in each clutch

Number of Steel Plates 5 in each clutch

Number of Separator Springs 5 in each clutch

604.55.041.00 - 01 - 1998
2 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

SPECIAL TOOLS

Description Tool Number

(V.L. Churchill Ltd.) (FNH--A No.)

Piston Installer (Pusher) 4FT504 --

Tapered Sleeve C1/C2 Piston Seal Installer 4FT505 FNH--00869

Clutch Piston Return Spring Compressor 4FT508 FNH--00872

Diagnostic Switch 4FT950 FNH--00874

M10 Studding (I metre) Purchase Locally

Silver Steel Rod 0.236 in (6mm)Dia x 6 in Purchase Locally

(152mm) long 3 off

TIGHTENING TORQUES

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 3

Description and Operation

General

The 24x24 transmission Dual Command assembly

consists of a dual, multi plate wet clutch assembly,
known as C1 and C2, located directly between the
flywheel damper and input shaft of the
transmission. The conventional clutch of the
standard 12x12 Synchro Command transmission
is not required.
The Dual Command unit provides an under drive to
all of the standard, direct drive ratios, reducing road
speed by 18% and increasing torque by 22%,
providing the transmission with 24 forward and 24
reverse gears. 2
Dual Command Switch Location
Selection of either under drive or direct drive 1. Direct Drive Switch
modes is by switches located on the main shift 2. Under Drive Switch
lever knob, Figure 2. The actual selection is 3. Main Shift Lever and Transmission Dump Switch
controlled by an electro--hydraulic system, the
operation of which is described in greater detail
later in this section.

Under Drive (UD) Operation--Mechanical

With reference to Figure 3 and Figure 4.

At tractor start up the transmission will
automatically default to under drive operation. Oil
pressure from the control valve assembly is
directed to the C1 (front) clutch assembly. The
drive is then taken down through the underdrive
gear assembly and onto the transmission input
shaft, the underdrive gear ratios providing the 18%
drop in input speed to the transmission.

Direct Drive (DD) Operation -- Mechanical

With reference to Figure 5 and Figure 6.

When the momentary switch on the main shift lever
knob is energised the oil pressure from the control
valve assembly is directed to the C2 (rear) clutch
assembly and drive is straight through the C2
clutch assembly to the transmission input shaft.

604.55.041.00 - 01 - 1998
4 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

Under Drive Power Flow -- Forward 3

Under Drive Power Flow -- Reverse 4

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 5

Direct Drive Power Flow -- Forward 5

Direct Drive Power Flow -- Reverse 6

604.55.041.00 - 01 - 1998
6 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

ELECTRICAL SYSTEM

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 7

Components Fig. 7 Ref. Function (In Dual Command Circuit)

Micro Processor 1 Controls engagement/disengagement of

C1/C2 clutches, via PWM and transmission
dump solenoids from inputs of various
switches and senders. Also monitors
system for electrical faults, providing error
codes for the instrument cluster.

Clutch Pedal Potentiometer 2 Provides information to micro processor to

determine current provided to PWM
solenoids.

Clutch Pedal Switch 2 Operates when the clutch pedal is fully

depressed, de--activating the transmission
dump solenoid and PWM solenoids.

Transmission Status Switches 8 Provides transmission status to micro

processor. Prevents tractor drive if levers
are accidentally engaged without depress-
ing the clutch pedal. Replaces the inter-
lock cable of standard 12x12 transmis-
sion. Forward/Reverse neutral switch pre-
vents tractor start up if not in the neutral
position.

Oil Temperature Sender 5 Provides the micro processor with oil

temperature information to compensate for
pressure changes with variation in oil
temperature within the PWM solenoid
operated hydraulic valves, this ensures a
consistent clutch engagement.

Transmission Speed Sensor 6 Measures tractor transmission output

speed.

Transmission Dump Solenoid 7A Deadheads pressure oil feed from the hy-
draulic pump to the PWM solenoids, when
transmission is in neutral or clutch pedal
fully depressed.

PWM Solenoid Valves 4 Directs and controls the oil from the hy-
draulic pump, via the dump solenoid, to
the C1/C2 clutches. Input is from the mi-
cro processor from information provided
by the clutch pedal potentiometer and shift
lever UD/DD switches.

Four Wheel Drive Solenoid 7B Directs oil from the pump to the FWD as-
sembly.

Instrument Panel Indicator Lights 3 Illuminates to indicate UD or DD selection.

604.55.041.00 - 01 - 1998
8 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

Electrical Operation Gear Shifting

Neutral As the clutch is depressed drive is disengaged

between the engine and transmission as the dump
The forward/reverse shuttle lever must be in valve is de--energised. Shifts are completed in the
neutral to allow engine start up. The other status normal manner and drive is gradually
switches, located on the Hi/Medium, 1/2 and 3/4 re--established as the pedal is raised as described
shift rails provide the micro processor with the in ‘inching /feathering.’ The system has an
transmission status. Drive will not be permitted if electronic override feature where if the clutch is
any of the shift levers are engaged without the released to quickly or accidentally the micro
clutch pedal being depressed. With the processor will take over and control the
transmission in neutral the dump valve solenoid is engagement speed of the clutch to prevent sudden
not energised and prevents pump oil from reaching and possibly damaging engagements.
the PWM valves. The electronics always default
the transmission to the Under Drive selection on
start up.

Gear Selection Drive

The clutch pedal must be depressed prior to any During continuous drive mode, clutch pedal fully
shift lever engagement, if not error code ‘CP’ will be released, the PWM 1 valve is fully open allowing full
displayed on the instrument cluster and drive will unrestricted pressure to the C1 clutch.
not be permitted by the micro processor. When the
clutch pedal is fully depressed and a
gear/range/direction selection is made, the dump
valve remains de--energised by action of the fully
depressed clutch pedal operating the switch. The
PWM solenoid operated valves are also
de--energised with the clutch pedal fully
depressed.

Inching/Feathering Under Drive to Direct Drive

As the clutch pedal is raised from the fully Operation of the direct drive switch, located on the
depressed position the dump valve solenoid main shift lever, deselects the PWM 1 solenoid and
becomes energised, allowing pressure oil from the energises the PWM 2 solenoid, pressure oil is
pump to the PWM solenoid valve. With the system switched to the C2 clutch. The clutch engagement
in the default, under drive mode, the PWM 1 time is still controlled by the micro processor during
solenoid becomes energised. As the clutch pedal this changeover to ensure a smooth shift.
is raised the clutch potentiometer provides
increased voltage to the micro processor, the micro
processor in turn provides increased current to the
PWM 1 solenoid which regulates the pressure to
the C1 clutch. As the clutch pedal and therefore
current, is raised the pressure to the C1 clutch is
raised correspondingly until full
pressure/engagement is achieved.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 9

HYDRAULIC SYSTEM

Dual Command Hydraulic System 8

1. Dual Command Assembly 8. Transmission Control Valve Feed from Pump
2. Lube Control Valve 9. Fixed Displacement Hydraulic Pump Assembly
3. Lube Control Valve, Lube Feed 10. Transmission Filter
4. Oil Cooler Tubes 11. Transmission Control Valve Assembly
5. Oil Cooler By--pass Valve 12. C1 Clutch Assembly Feed Tube
6. Four Wheel Drive Feed Tube 13. C2 Clutch Assembly Feed Tube
7. Oil Cooler By--pass Valve Feed from PTO Valve 14. C1/C2 Clutch Assemblies
Pack

Components Fig. 8 Ref. Function (In Dual Command Circuit)

Fixed Displacement Pump 9 Supplies pressure oil at 220--260 lbf.in2

(15.0--18.0 bar) at 2100 engine rev/min.
from the low pressure side of the pump to
the transmission control valve.
Transmission Control Valve 10 Receives oil from the pump. Houses PWM
solenoid valves, dump and four wheel drive
(where fitted) solenoids. Provides hydraulic
outlets to Dual Command assembly. Also
houses 1/2 shift rail staus switch and trans-
mission oil temperature sender.
Lube Control Valve 3 Proportions the transmission lube oil de-
pending on the operating state of the C1/C2
clutches. Ensures adequate lube to the
clutches especially during inching/feathering
mode.
C1/C2 Clutch Assembly 2 A dual multi plate wet clutch assembly pro-
viding either direct drive to transmission or
under drive via the under drive gear assem-
bly
Oil Cooler By--pass 5 Provides pressure regulated lube oil for the
C1/C2 clutches and the transmission bear-
ings and synchronisers.

604.55.041.00 - 01 - 1998
10 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

Hydraulic Operation Early production models incorporate a relief valve

Neutral within the lube control valve. This valve has no
function and was removed shortly after Job 1. The
Pressure oil supplied by the pump enters the relief valve for the transmission lubrication circuit is
transmission control valve. The oil is channeled located in the P.T.O. valve pack. The relief valve
directly to the dump valve solenoid, which, with the operates if the pressure in the lube circuit exceeds
transmission in neutral, is de--energised (closed), approximately 100lbf.in2 (6.9 bar).
preventing pressure oil from going through to the
PWM valves.
Neutral -- Diagram A
Inching/Feathering (Under Drive) The dump valve solenoid is de--energised,
therefore no oil pressure is in either the C1 or C2
With the clutch pedal depressed and the
clutches. The lube selector is held in its neutral
gear/range/direction selected the transmission is
state by the 20lb springs and both of the direct drive
still immobilised due to the dump valve remaining
and under drive cut--off valves are in the
de--energised by the action of the clutch pedal in
disengaged state. Oil from the oil cooler by--pass
the fully depressed position. As the clutch pedal is
valve passes through the selector valve and in this
raised the dump valve is energised allowing pump
neutral condition, restricted oil flows to both direct
oil to the PWM valves. Further lifting of the clutch
drive and under drive clutches. Unrestricted oil is
pedal provides a corresponding increase in oil flow
allowed to flow through the selector spool through
through the PWM 1 valve, in this case, and a
to the transmission synchronisers and bearings.
gradual engagement of the clutches in the C1
assembly.
Drive
With the clutch fully released full pressure is
allowed to operate on the clutches to provide direct
Inching/feathering (Direct Drive) -- Diagram B
drive.
As the clutch pedal is released and oil pressure to
Gear Shifting the C2 clutch assembly and subsequently the lube
selector valve, begins to increase, the lube selector
When shifting gear the action of fully depressing spool moves across against the neutralising
the clutch de--energises dump valve solenoid, the spring, at approximately 20lbf.in2 the selector
oil pressure to the PWM valves is cut, hence spool is fully engaged. In this position full
disconnecting drive between engine and lubricating oil flow is directed to the direct drive (C2)
transmission. As the clutch is raised hydraulic lube cut--off valve. The lube cut--off valve is in the
pressure is progressively restored to the clutch to open position until a pressure of 110--120lbf.in2 is
continue driving. attained in the C2 clutch line. Therefore between
20lbf.in2 and 110--120lbf.in2 the clutches in the C2
Under Drive to Direct Drive clutch receives the majority of the lube oil, which is
during the inching/feathering period when the oil is
Operation of the direct drive switch (hare symbol),
most required. During this period a small amount of
located on the main shift lever, deselects the PWM
1 solenoid and energises the PWM 2 solenoid, restricted lube oil is directed to the transmission
synchronisers and bearings and to the under drive
pressure oil is switched to the C2 clutch. The clutch
assembly.
engagement time is still controlled by the micro
processor during this changeover to ensure a
smooth shift.
LUBE CONTROL VALVE OPERATION Drive -- Diagram C
With reference to Figure 9. When the clutch pedal is raised sufficiently, to
provide the tractor with full drive, the oil pressure to
The lube control valve consists of a lube selector
the clutch assembly will exceed 120lbf.in2. At this
spool, a direct drive cut--off valve and an under
point the direct drive lube cut--off valve spool
drive cut--off valve. The lube selector spool is
moves across to the cut--off position, providing the
energised by oil pressure bled from either the C1
transmission synchronisers with unrestricted oil
or C2 supply oil and is centred neutral by springs.
flow and restricted oil to the now fully engaged C2
The direct drive and under drive cut--off valves are
clutch and disengaged C1 clutch.
also activated by pressure oil bled from C1 for the
under drive valve or C2 for the direct drive valve. The oil distribution is reversed when under drive
Both are held in the disengaged position by a is selected, i.e, C1 receives the unrestricted
central return spring. flow during inching/feathering.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 11

R5--6--42

9
Lube inlet from oil cooler Restricted lube oil Oil to dump
by--pass valve
C1/C2 clutch oil greater than C1/C2 clutch oil less than 120lbf.in2 (8.3 bar)
120lbf.in2 (8.3 bar) but greater than 20lbf.in2 (1.4 bar)

Lube Control Valve Operation

A -- Transmission in neutral B -- Direct drive, inching/feathering C -- Direct drive, driving

1. C1 Lube Cut off Valve Spool 7. C2 Lube Cut--off Valve Spool

2. C1 Lube Feed 8. Selector Spool Centralising Spring
3. Pressure Bleed from C1 Clutch 9. Lube Feed from Oil Cooler By--pass Valve
4. Spring -- 120 lb. 10. Transmission Bearing and Synchroniser Feed
5. Pressure Bleed from C2 Clutch 11. Selector Valve Spool
6. C2 Lube Feed

604.55.041.00 - 01 - 1998
12 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

DUAL COMMAND HYDRAULIC SYSTEM --TRANSMISSION IN NEUTRAL (FWD ENGAGED)

15 1

14 2

13 3

4
5
6
7
8

12 9

10
A. Transmission Control Valve B. Lube Control Valve 10
1. Regulated oil feed from low pressure side of the 8. Under drive (C1) clutch lube oil
fixed displacement pump. 9. Under drive lube cut--off valve
2. Dump solenoid 10. Lube oil feed from oil cooler by--pass valve
3. PWM 2 solenoid 11. Lube selector valve
4. Direct drive (C2) clutch pressure feed 12. Direct drive lube cut--off valve
5. Direct drive (C2) clutch lube oil 13. PWM 1 solenoid
6. Lube oil feed to transmission bearings and 14. Four wheel drive solenoid
synchronisers 15. Outlet to four wheel drive assembly
7. Under drive (C1) clutch pressure feed

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 13

DUAL COMMAND HYDRAULIC SYSTEM --

TRANSMISSION IN DIRECT DRIVE, INCHING/FEATHERING (FWD ENGAGED)

15 1

14 2

13 3

4
5
6
7
8

12 9

10
A. Transmission Control Valve B. Lube Control Valve 11

1. Regulated oil feed from low pressure side of the 8. Under drive (C1) clutch lube oil
fixed displacement pump. 9. Under drive lube cut--off valve
2. Dump solenoid 10. Lube oil feed from oil cooler by--pass valve
3. PWM 2 solenoid 11. Lube selector valve
4. Direct drive (C2) clutch pressure feed 12. Direct drive lube cut--off valve
5. Direct drive (C2) clutch lube oil 13. PWM 1 solenoid
6. Lube oil feed to transmission bearings and 14. Four wheel drive solenoid
synchronisers 15. Outlet to four wheel drive assembly
7. Under drive (C1) clutch pressure feed

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 17

21000 -- TROUBLE SHOOTING, LIMP HOME, CALIBRATIONS AND PRESSURE TESTING

The transmission / EDC electronic management

It should be noted that the self diagnostic capability

Any malfunction of the mechanical and hydraulic

components must be diagnosed using
conventional techniques, performance
characteristics and tooling, such as pressure
testing equipment. Full guidance for both electrical
self diagnosis and conventional diagnosis is
contained within this section.

Trouble--shooting and fault finding should always

Prior to detailed fault finding, items like the earth

points and Battery should be cleaned and tested to 16
ensure that they are functioning correctly.
With the use of micro--processors it is often that
this item is blamed for any malfunction but the real
truth is that this item is usually sound and that the
fault is due to poor contacts in the associated
connectors.

Each connector illustrated and identified in the

604.55.041.00 - 01 - 1998
18 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

Where the fault finding procedure requires checks

for continuity a visual inspection of the wiring
should be made prior to conducting tests to ensure
that obvious ‘mechanical’ damage has not
occurred to the harness or the connectors.

Where possible the inbuilt tractor diagnostics

should be utilised to determine the area of the fault.
The ’H’ menu mode, described in Section 55,
provides several modes to aid diagnosing faults.
One particular mode which should be used, before
any connections are split, is the H5, switch
diagnostics mode. This will provide testing of many
switch circuits, including the switch itself. If this
mode highlights a fault within a circuit then more 18
detailed fault finding can be directed towards a
particular circuit.

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

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high
range and work downwards to avoid damaging the
instrument.
Where possible it is recommended that connectors
are probed from the rear, certain connectors like
C079, C080 and C081, instrument panel
connectors, should always be probed from the
rear. Connector terminals should only be removed
using the special tools supplied in electrical repair
kit, Tool No.4FT.953 and the wires should not
require excessive pulling efforts to remove.
19
Where only front probing is practical it is
recommended that Connector test probe kit, Tool
No NH.55--125 is obtained. This provides all
connector terminal attachments for use with most
multi--meters.
IMPORTANT: Care should be used when using
the multi--meter, only use the instrument as
instructed to avoid damage to the internal elements
of the micro--processor. When checking the
continuity of wiring, sensors or switches it is
necessary to isolate the electronic
micro--processor and ensure the keystart is turned
off to prevent possible further damage. The
keystart should only be switched on and the
processor connected where specifically instructed
in the fault finding procedure.
TA60--21--01
4
If it is found necessary to clean the connectors a 20
contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains
Trichloro--ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 19

Limp Home Procedure

1. Apply the parking brake.

2. Stop the engine and turn keystart off

3. Disconnect both of the PWM valve connectors

and the dump solenoid connector. Connect the
Limp Home harness extension connectors to
the C1 (2) PWM and dump solenoid valve (1).
NOTE: The use of Limp home harness adaptor,
Tool No. NH.21--116 is required to enable the
connection of Tool 4FT--952 to the dump solenoid.
4. Connect the other end of the Limp Home
harness to the ‘D1’ diagnostic plug (2) located
adjacent to the fuse box.
5. Place the range lever into Low Range and the
main shift lever into 1st Gear. Ensure the
forward/reverse lever is in Neutral.
21
NOTE: It is important that only the lowest ranges
are used when operating with the Limp Home
Harness due to the feathering capability of the
transmission being inoperative.

6. Start the vehicle.

7. Select forward or reverse.

8. Operate the momentary switch (1) of the Limp

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

9. When the tractor has been delivered to the

repair area, disconnect the Limp Home
Harness and reconnect the PWM valve
connectors and proceed with diagnosing and
repairing the fault.

604.55.041.00 - 01 - 1998
20 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

PRESSURE TESTING
Pressure ports are provided on the transmission
control valve to enable the transmission clutches to
be tested to determine the correct function of a
number of system components. Components
such as solenoids, clutch pedal operation and
micro--processor can be seen to be operating
correctly by the results of pressure testing.

NOTE: Prior to pressure testing, make certain that

all the points detailed under the tractor preparation
are carried out to ensure maximum safety.

Tractor Preparation

1. Start the tractor and run until the transmission

oil has reached its normal operating
temperature of at least 40!C (104!F).

2. Apply the handbrake. 23

3. Disconnect the connector to the High/medium

status switch (1) and install a suitable bridging
wire between the two connector pins on the
harness side. With a bridging wire installed, the
processor receives a signal indicating that
either high or medium is selected, although the
HIGH/MEDIUM RANGE LEVER remains in
NEUTRAL throughout the testing.

24
C1/C2 Clutch Engagement and
Disengagement
1. Install pressure gauges into the C1 (1) and C2
(2), test ports.
2. Leave the High/Low/Medium range lever in
NEUTRAL, position the main shift lever into
1st GEAR and the shuttle lever in FORWARD.
Set the engine speed to 1500 rev/min.
Observe the reading on the gauges.
NOTE: For observing the system operation set the
engine speed to 1500 rev/min. For Testing for
maximum pressure in each clutch set the engine
speed to 2100 rev/min.
25

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 21

Table 1 -- Dual Power Pressure Testing

Clutch
Pedal C1 C2 Observations

Direct Drive Selected

Pressure on C1 and C2 should be zero. Indicates dump
valve solenoid operational

Releasing clutch pedal from fully depressed position

should smoothly and gradually restore clutch 2 to full
pressure. Clutch 1 should remain at zero. Indicates cor-
rect PWM 2 and clutch pedal potentiometer operation.

Depressing clutch pedal should progressively reduce

pressure in C2, until with pedal fully depressed zero pres-
sure should be indicated. Indicates correct PWM 2,
clutch potentiometer and dump valve solenoid operation.
Switch from Direct Drive to underdrive
C2 pressure should reduce to zero, C1 pressure should
rise to full pressure. This should appear to be an instanta-
neous operation with just a slight overlap of pressure be-
tween the clutches. Indicates correct operation of both
PWM valve solenoids

Under Drive Selected

Pressure on C1 and C2 should be zero. Indicates dump
valve solenoid operational

Releasing clutch pedal from fully depressed position

should smoothly and gradually restore clutch 1 to full
pressure. Clutch 2 should remain at zero. Indicates cor-
rect PWM 1 and clutch pedal potentiometer operation.

Depressing clutch pedal should progressively reduce

pressure in C1, until with pedal fully depressed zero pres-
sure should be indicated. Indicates correct PWM 1,
clutch potentiometer and dump valve solenoid operation.
Switch from Underdrive to Direct Drive
C1 pressure should reduce to zero, C2 pressure should
rise to full pressure. This should appear to be an instanta-
neous operation with just a slight overlap of pressure be-
tween the clutches. Indicates correct operation of both
PWM valve solenoids

Pressure Testing Notes:

1) Maximum pressure should be between 220--260 lbf.in2 (15.0--18.0 bar). If maximum pressure is
attained in only one of the clutches, suspect a fault in that clutch circuit, e.g. leaking clutch seals, faulty
PWM valve. The pressure at 1500 rev/min. should be between 200--240 lbf.in2 (13.8--16.5 bar).
2) If the pressure is low on both clutches this may indicate a faulty dump solenoid valve or a fault in the
hydraulic supply circuit.
3) Sudden, irregular rises or drops in pressure as the clutch pedal is operated may indicate a faulty clutch
potentiometer if it occurs in both underdrive and direct drive, or a faulty PWM valve if it occurs in only
one of the drives.
4) If the pressure comes on suddenly as the clutch pedal is raised this may indicate that the
clutch pedal switch is incorrectly adjusted.
5) If the pressure is not at absolute zero with the clutch pedal fully depressed this may also indicate a
maladjusted clutch switch or a possible fault with the dump solenoid valve.

604.55.041.00 - 01 - 1998
22 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

TRANSMISSION CLUTCH CALIBRATION

(CLUTCH BITE POINT)

Required when any of the following items have

been performed or noticed:--

S The microprocessor has been replaced.

Set Up Procedure:

Prior to conducting a transmission clutch

calibration, the following points should be checked.

S The temperature of the transmission oil is at

normal working temperature.
S The parking brake is applied
S The air conditioning, if fitted, is switched off.
S All electrical and hydraulic services are
deselected.

WARNING: The calibration procedure is controlled

by the electronic management system. To prevent
inadvertent movement of the tractor. Park the
tractor away from any obstacles, firmly apply the
parking brake and block the wheels, front and rear.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 23

CLUTCH SPRING PRESSURE CALIBRATION

Connect diagnostic test switch 4FT950.

26
Start the engine.
Select mode HF, using the test switch.

27
”CAL” will be displayed for a few seconds, then
the display will be controlled by clutch pedal
position as follows:
Pedal down (below 10%) -- Calibration value for
the selected clutch is displayed.
Pedal up (above 98%) -- Oil temperature is
displayed.
Pedal between 10% and 98% -- Pedal position is
displayed.

28
Set engine speed to 1200 +/-- 100 rpm.

604.55.041.00 - 01 - 1998
24 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

3. To select the clutch to be calibrated, shift the

main (1--4) lever to neutral and press the
upshift switch to select the high clutch, or press
the downshift switch to select the low clutch.
The selected clutch is indicated by the tortoise
and hare lamps.

30
4. Depress the clutch pedal, select a gear and
range, and slowly release the pedal to check
the engagement point.

Note 1: Releasing the pedal beyond 35% will not

further increase the clutch pressure.

Note 2: If the pedal is released above 90%, the

clutch pressure will dump after a few seconds.
Fully depress the pedal to restore operation.

Note 3: If the calibration value has previously been

set too high, the clutch may engage and move the
tractor, particularly if a low gear has been selected 31
and the brake is not firmly engaged. If calibration
is required because a PWM valve has been
replaced, the calibration number should be
reduced to 110 or less before releasing the clutch
pedal, as the old calibration value may be much too
high.

5. Use the upshift switch to increase the

calibration value or use the downshift switch to
decrease the calibration value as required to
move the clutch engagement point to 35%
pedal travel. The value can be adjusted even
when it is not being displayed.
6. After calibrating both clutches, turn off the key
switch for at least 1 second to store the
calibration values.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 25

CLUTCH QUICK FILL ADJUSTMENT

Warm the oil to normal operating temperature, at

least 60 degrees Celsius.

Park the tractor on a level surface. Allow some

space, as the tractor will move during testing.

With the diagnostic switch installed, start the

engine and set the engine speed to 1200 rpm.
Select diagnostic mode HE.

If the oil temperature is less than 60 degrees

Celsius, ”F1” will be displayed, Alternating with
display of oil temperature. This display WILL NOT
GO AWAY unless the oil temperature reaches 60
degrees.

604.55.041.00 - 01 - 1998
26 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

CLUTCH SELECTION:
While the 1--4 lever is in neutral, press the
downshift switch to select the Lo clutch or press the
upshift switch to select the Hi clutch. The selected
clutch will be indicated at all times by an L or an H
in the left digit of the transmission LCD display. The
number to the right of the L or H indicates the
quickfill duration for the selected clutch.

ADJUST AND TEST CLUTCHES

Shift the main shift lever into gear (no need to use
the clutch pedal, the clutches are all dumped), then
use the shuttle dump button or the clutch pedal,
shift the shuttle lever into gear, Release the hand
brake and SLOWLY release the clutch pedal until
the tractor “moves” (approx 20 % of pedal travel).
Observe whether the tractor nudges at the
beginning of clutch engagement. If there is no
nudge, the quickfill duration should be increased
until there is a slight nudge.
If the nudge is more of a jerk, the quick fill duration
should be decreased.
The factory setting is 3. 36

To adjust the quickfill duration, depress the clutch

pedal or shift the shuttle lever to neutral (but leave
the main shift lever in gear), then use the upshift
and downshift switches to increase or decrease the
number on the display.

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 27

The following ’H’ menu mode routines are provided

to allow access to Error codes:
Hb -- Retrieve error codes for viewing.
Hc -- Clear processor memory of stored error codes
Hd -- View error codes live. This allows normal
operation of the tractor with error codes able to
display as they occur.

A full description of the ’H’ menu routines can be

found in Section 55.

39
It should also be noted that after installation of a
new processor or after a non volatile memory reset
operation (’H’ menu mode, H8), that the processor
defaults to a ’display all codes’ mode for 6 minutes.
If no error codes occur during this 6 minute period
the processor then reverts to normal operation. If
an error occurs during this period the processor will
continue to display ’live’ error codes until all the
errors are removed.

604.55.041.00 - 01 - 1998
28 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

12x12 Dual Command Transmission Error Codes

Error Fault Condition Priority Enabled/ Error

Disable? Displayed?

E21 Chassis harness disconnected 1 Disable Yes

E36 Dump solenoid open circuit 2 Disable Yes
E35 Dump solenoid closed circuit 3 Disable Yes
E53 5 Volt Reference failed, shorted to 12 volts 4 Disable Yes
E54 5 Volt Reference failed, shorted to ground 5 Disable Yes
E12 Clutch pedal potentiometer signal too high 6 Disable Yes
E11 Clutch pedal potentiometer signal too low 7 Disable Yes
E39 Hi (C2) clutch solenoid open circuit 8 Disable Yes
E38 Hi (C2) clutch solenoid short circuit 9 Disable Yes
E41 Lo (C1) clutch solenoid open circuit 10 Disable Yes
E40 Lo (C1) clutch solenoid short circuit 11 Disable Yes
E37 Clutch disconnect switch open circuit 12 Disable Yes
E48 Clutch disconnect switch short circuit
misadjusted, always closed 13 Disable Yes
CP Depress clutch pedal to enable transmission 14 Recover Yes
N Clutchless shuttle operation attempted at too
high a speed and in too high a gear 15 Enabled Yes
E46 Fuse 12 blown 16 Enabled No
E47 Clutch disconnect switch misadjusted high 17 Enabled No
E51 Transmission temperature sensor open circuit 18 Enabled No
E52 Transmission temperature sensor short circuit 19 Enabled No
E24 Both clutches not calibrated 20 Enabled No
EHi Hi (C2) clutch not calibrated 21 Enabled No
ELo Lo (C1) clutch not calibrated 22 Enabled No
E55 No output speed signal 23 Enabled No
E56 Differential lock switch error 24 Enabled No
E49 Wheel speed sensor circuit open or short circuit 25 Enabled No
E26 Engine rev/min speed too high 26 Enabled No
E27 Engine rev/min speed too low 27 Enabled No

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 29

Key to Fault Finding Diagrams

Diagrams 1 to 6 -- Not related to error codes

1. Tractor Does Not Drive In Any Gear

2. Poor Clutch Feathering
3. Clutch Potentiometer Calibration Check
4. Holding in Gear / Jumping Out of Gear / Clashing
5. Transmission is Noisy in Operation
6. Transmission ‘Clunks’ During Inching
Diagrams 7 onwards, error code related:
7. Error Codes E35 and E36
8. Error Code E11
9. Error Code E12
10. Error Codes E53 and E54
11. Error Codes E37, E47 and E48
12. Error Codes E38,E39 and E40,E41
13. Error Code CP
14. Error Code E46
15. Error Codes E51 and E52
16. Error Codes E24, EHi and ELo
17. Error Code E55
18. Error Code E56
19. Error Code E49
20. Error Code E26
21. Error Code E27
22. Error Code N

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30 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 1 -- Tractor does not drive (in any gear)

Key OFF
Key ON
recheck

Key ON. Is the Instrument Are any error Are the Remove
Cluster providing ‘Normal’ codes connectors refit/
Display in the transmission displayed C127 & repair
and EDC areas? C128 of as
processor required
Refer to error okay?
code listing
Reset ’H8’ and recalibrate the
processor. Recheck the
Hydraulic system operation. If still no drive
Install flow meter into
remote, is flow indicated fault refer to reolace processor.
when operated? hydraulic module.

Hydraulic oil Pressure Does the Go to pressure

warning light illuminated? engine stall or testing clutches
lug down?

Check pressure in Inspect operation of levers Inspect

low pressure circuit. for correct preparation. switch
Is pressure 18--20 Enter mode H5, is Neutral/ and wiring
bar? start inhibitor switch okay?

Fault or leak in low

pressure circuit. Refer to
Section 35, hydraulics.

Pressure test the

Suspect PWM
transmission clutches.
valves. Clean or
Are pressures okay?
replace valves in
circuits with
incorrect pressures

Suspect a mechanical
failure within
transmission. Seized
clutches, synchronisers
or broken gear in shaft.

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 31

DIAGRAM 2 -- The tractor drives in all gears but has the following fault
Poor clutch pedal feathering/inching performance.
Key OFF
Key ON
recheck

Perform spring pressure

calibration and fill time Tractor okay
adjustment. Feathering/inching
still poor?

Suspect a PWM valve.

Clean or replace.
Recalibrate after
installation.
Is feathering still poor?

Suspect clutch
plate damage.

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32 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 3 -- Clutch pedal potentiometer calibration check

Tractor
okay

Ensure clutch pedal can travel

through its whole stroke. Inspect Repair or replace
linkage and potentiometer linkage as required
operating shaft. Are these okay?

Using diagnostic switch, select mode

With the key start switch OFF,

Clutch pedal potentiometer

and calibration is okay.

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 33

DIAGRAM 4: The tractor drives in all gears and ranges but has the following fault:
Transmission jumps out of gear, holds in gear or gears clash when shifting

Key OFF
Key ON
recheck

Is the gear fully

engaging? Inspect
and adjust shift lever
linkage as required.
Fault cured?

Using the service

Pressure test Test affected clutch pack Remove, inspect and

clutches. Is pressure PWM with the PWM valve refit processor
dumped when the coil removed from the connectors, C127 and
clutch pedal is valve. Is pressure C128, if fault still exists
depressed? indicated? replace processor.

Suspect a mechanical Swap the PWM with one

fault within the of known performance. If
transmission, inspect pressure still exists
the detents in the shift suspect internal leakage.
cover, if no fault found
suspect either worn
synchronisers or
excessive end float of
transmission
components

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34 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 5: The tractor drives in all gears and in all ranges but has the following fault:
Transmission is noisy in operation

Is the Fault in the lube supply

transmission to transmission. Refer to
lube warning light Section 35, Hydraulics.
illuminated? Is the transmission noisy
after lube system repair?

Adjust as required and

Is the oil level investigate reason for
correct? oil loss (leakage)

Is the correct grade Drain and refill with

of oil used? correct grade of oil

Suspect failure
within
transmission, worn
bearings, worn or
failed parts

DIAGRAM 6: The tractor drives in all gears and ranges but has the following fault:
Transmission clunks during inching

Perform Clutch spring calibration

procedure on Clutches. Does
Transmission still clunk?

Tractor okay
Perform manual clutch fill time
calibration, HE menu mode, on
C1 and C2 clutches. Does
transmission still clunk after fill
time calibration?

Perform clutch pressure test

procedure, observing the operation of Suspect faulty or
the Clutches. Does the operation contaminated PWM Valves,
compare with that described in the clean or replace as required
pressure testing section?

Suspect worn clutches.

Examine and replace as
required

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 35

Diaram 7 Error Code E35 displayed -- Dump Solenoid Closed Circuit

Error Code E36 displayed -- Dump Solenoid Open Circuit

Error codes E35 and E36 indicate either a short or open circuit in the wiring of the dump
solenoid. Inspect the connector of the dump solenoid and ensure it is in good condition and
correctly installed. If the fault persists use a suitable multi--meter to check the wiring from
the solenoid back to the processor module. Locate the short/open circuit and repair or
replace wiring as necessary.

If wiring is okay, disconnect the dump solenoid from the harness and check that the
resistance of the coil is approximately 10 ohms at 20!C. If not, replace the solenoid.

If wiring and solenoid are okay, remove, inspect and refit the processor connectors, C127
and C128, if the error continues to occur replace the microprocessor with one of known
performance.

2 C020--44
K/P/B K/P/B
C127--14
C163
C127--13
1 K/R/B K/R/B
C020--45

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36 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 8 -- Error Code E11

C077

1
G Y/R/B
C128--19
O 2
LN +5 Volt
C127--5
B 3
B
C127--1

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 37

DIAGRAM 8 -- Error Code E11 -- Clutch potentiometer voltage below valid range
Key OFF
Enter Diagnostic Mode H9 In Mode H9 Key ON
channel 0. Operate the clutch channel 0.Does Recheck
pedal. Is the value continuously the value ever
less than 14? drop below 14 Inspect wiring for
during cycling of intermittent fault
the clutch pedal whilst in H9
mode channel 0
Are the connectors to the
potentiometer and processor Replace
okay? potentiometer

With processor and

potentiometer connectors Locate and
disconnected. Is there an open repair short to
circuit to chassis between chassis
C077--1 and C128--19

Replace
potentiometer

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

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38 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 9 -- Error Code E12

C077

1 C2--7
G Y/R/B Y/R/B
C128--19
O 2
C4--6
LN LN +5 Volt
C127--5
B 3
C4--5 B
B
C127--1

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 39

DIAGRAM 9 -- Error Code E12 -- Clutch potentiometer voltage above valid range
Key OFF
Key ON
Recheck
Enter Diagnostic Mode H9 In mode H9
channel 0. Operate the clutch channel 0. Does Inspect wiring
pedal. Is the value continuously the value ever for intermittent
greater than 95. rise above 95 fault whilst in
during cycling of H9, Channel 0
the clutch pedal?

Replace potentiometer
Disconnect potentiometer
connector C077. Between pin 1 Locate and
and chassis. Is the voltage 0 repair short
volts? between C077--1
and C128--19

Disconnect potentiometer Locate and repair

connector C077. Between pin 3 short between
and chassis. Is the voltage 0 C077--3 and
volts? C127--1

Replace
potentiometer
With the key OFF is
Locate and repair open
there continuity
circuit between
between C077--3 and
C077--3 and C127--1
chassis?

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

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40 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 10 -- Error code E53 -- 5 volt reference failed, shorted to battery voltage
Error code E54 -- 5 volt reference failed, shorted to earth.

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 41

DIAGRAM 10 -- Error code E53 -- 5 volt reference failed, shorted to battery voltage
Error code E54 -- 5 volt reference failed, shorted to earth.

Leave the clutch pedal

potentiometer disconnected
during the following checks:

Disconnect the EDC control Replace the EDC

panel connectors. Is the error still control panel
displayed?

Disconnect the EDC rocker shaft Refer to EDC error

potentiometer. Is the error still codes 27 & 28 in the
displayed? hydraulics section

Disconnect the quadrant Refer to EDC error

potentiometer. Is the error still codes 25 & 26 in the
displayed? hydraulics section

Replace the processor with a Clear the processors

unit of known performance is the memory using mode H8.
error still displayed? Recalibrate the
transmission and EDC
systems.

Trace and repair a short circuit to

chassis or battery voltage
between C127--5 and either the
clutch potentiometer, EDC
control panel, EDC, rocker shaft
or quadrant potentiometers.

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42 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 11 -- Error Codes E37, E48 and E47

FS--13
C4--9
15A 7000D
C127--35
U/R/B U/R/B

C076

3 C2--12
R/U/B R/U/B
C127--30
7660
C076

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 43

DIAGRAM 11 --

Error Code E37 displayed -- Clutch disconnect switch open circuit

Check switch adjustment and switch operation,

if okay trace break in wiring (open circuit).

Error Code E48 displayed -- Clutch disconnect switch short circuit

Check switch adjustment and switch operation,

if okay trace short circuit in wiring.

Error Code E47 displayed -- Clutch disconnect maladjusted high

Check switch adjustment and operation of switch.

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44 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 12 -- PWM Solenoids

A C020--4
K/Y/B K/Y/B
C127--12

C162 (Hi)

B C020--3
K/W/B K/W/B
C127--17

C020--12
B K/S/B K/S/B
C127--18

C163 (Lo)

A C020--13
K/U/B K/U/B
C127--26

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 45

DIAGRAM 12 -- PWM Solenoids

Error Code E38 displayed -- C2 (C162) PWM solenoid wiring short circuit
Error Code E39 displayed -- C2 (C162) PWM solenoid wiring open circuit
Error Code E40 displayed -- C1 (C161) PWM solenoid wiring short circuit
Error Code E41 displayed -- C1 (C161) PWM solenoid wiring open circuit

Error codes E38 through to E41 indicate either a short or open circuit in the wiring
of one of the PWM solenoids. Inspect the connector of the solenoid and ensure it is in
good condition and correctly installed. If the fault persists use a suitable multi--meter to
check the wiring from the PWM solenoid back to the processor module. Locate the
short/open circuit and repair or replace wiring as necessary.

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

If wiring and PWM solenoids are okay, remove, inspect and refit the processor
connectors, C127 and C128, if the error continues to occur replace the microprocessor
with one of known performance.

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46 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 13 -- Error code CP displayed -- depress clutch pedal to re--enable

transmission

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 47

DIAGRAM 13 -- Error code CP displayed -- depress clutch pedal to re--enable

transmission

Has tractor been shifted Depress clutch pedal or

from neutral with clutch depress shuttle dump
pedal released. switch with FNR lever in
NO neutral to re--enable
transmission.

Inspect for loose harness

Check for an intermittent open circuit on the neutral/start

inhibitor switch wiring:
With the key start OFF and the FNR lever in N, connect a Locate and repair
continuity meter between connector C128--27 (W/R) and short circuit.
C001--E (W/R). Continuity should be indicated.
Twist the harness from C128 down to C001.
Is there always continuity.

Check for an intermittent open circuit on the neutral/start

inhibitor switch wiring:
With the key start OFF and the FNR lever in N, connect a
Locate and repair
continuity meter between connector C128--27 (W/R) and
open circuit.
C001--E (W/R). Continuity should be indicated.
Twist the harness from C128 down to C001.
Is there always continuity.

Check for an intermittent fault in battery supply to processor.

Locate and repair
Check for continuity between fuse 13 output and C127--34
open circuit.
(U/R/B) and C127--35 (U/R/B). Is there always continuity?

Check for an intermittent fault in ground wiring to processor.

Check for continuity between C128--32 (LN/O/B), C128--33 Locate and repair
(LN/LG) and C127--9 (B) and ground. open circuit.
Is there always continuity.

Remove and inspect the start inhibitor switch. Replace with a Discard removed
switch of known performance. Test drive tractor. switch
Is error code still displayed?

Suspect fault with rail in transmission top cover.

Remove top cover and inspect.

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48 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 14 -- Error code E46 displayed -- Fuse 12 blown.

C103--3

C103--4
FS--12 C196--1
10A 7070 -- R/LG/B
C128--6

C020--12

C197
C120--8
C178
C102--5
C177

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 49

DIAGRAM 14 -- Error code E46 displayed -- Fuse 12 blown.

No power to switches, 1/2, 3/4. Hi/Med, shuttle dump, powershift up--down, EDC panel and
raise/work/lower switch.
Key OFF
Key ON
Recheck

Disconnect C128 from the processor and confirm

Is fuse 12 blown? continuity between fuse 12 and C128--6 (R/LG/B). If
no continuity exists, trace and repair the open
circuit.

Replace fuse 12 (10 amp). Fuse may have failed through fatigue, check wiring
Operate tractor. to ensure there is no intermittent fault.
Does fuse blow again?

Ensure key start is OFF

Disconnect connector C020, is a short circuit still indicated

between C128--6 and earth?
NO
With the multi--meter still Connect meter between Inspect connector,
connected between C020--12 and earth ensure it is clean
C128--6 and earth, (transmission harness and undamaged.
disconnect connectors side). Is continuity
C104, C103 and the indicated?
shuttle dump switch
connector C196. Observe
the meter while Trace and repair short between C20--12
disconnecting, if continuity (R/LG/B) and connectors C197, C178 and
to earth is broken after a C177. Remove each connector and retest to
connector is disconnected establish if there is a faulty component.
the fault lies within that Ifcontinuity to earth is still indicated at C020--12
circuit. If continuity still inspect the transmission harness for signs of
exists, fault lies in harness. external damage and trace and repair fault in
Inspect harness, repair or harness wiring.
replace faulty wiring.

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50 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 15 -- Error Codes E51 or E52

7500 -- B/G C020--42 7500 -- B/G

C128--18 C023

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 51

DIAGRAM 15 -- Error Codes E51 or E52

Inspect wiring between

Enter diagnostic mode H9. oil sensor and C128--18
Channel 1. Is the value outside for an intermittent
the range of 7 -- 89? short/open circuit, with
H9 channel 1 still
selected.

Is there a Locate and

Is the value less short circuit repair short
than 7 on wiring? circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 " at 20!C or
300 " at 40!C?

Is the value Is there an Locate and

greater than 89 open circuit on repair open
wiring circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 " at 20!C or
300 " at 40!C?

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52 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 16

Error Code E24 displayed -- Both Clutches Not Calibrated

Perform spring pressure calibration on both clutches

Error Code EHi displayed -- Hi (C2) Clutch Not Calibrated

Perform spring pressure calibration on Hi (C2) clutch

Error Code ELo displayed -- Lo (C1) Clutch Not Calibrated

Perform spring pressure calibration on Lo (C1) Clutch

Note: These errors will only occur after installation of a new processor or after a ’H8’ (clear processor
memory operation)

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 53

DIGRAM 17 -- ERROR CODE E55

No Signal From Output Speed Sensor

Mechanical fault within

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

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54 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 18 -- E56 Differential Lock Switch Error

C219--10
5030--LN/R 5030--LN/R
C127--2 C183--6

C219----9
7170--B/W 7170--B/W
C128--25 C183--1

5010--B C219--12
5010--B
C127--1 C183--3

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 55

DIAGRAM 18 -- E56 Differential Lock Switch Error

Key OFF
Key ON
recheck

Enter Diagnostic mode H5 Remove switch and

operate the diff lock switch. Is Replace
check operation. Is faulty
d91 displayed in Manual position switch functioning
and d99 displayed in auto switch
correctly?
position?

Disconnect switch connector

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56 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 19 -- Error Code E49

C020--23
5010--B 5035--LN/G 5035--LN/G 5140--TQ/N
C127--1 C046--2

C020--43
5135--T/Q 5135--T/Q
C127--6 C046--1

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 57

DIAGRAM 19 -- Error Code E49

Wheel speed sensor open or short circuit.

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

Is the value
greater than 89 Is there an open Locate and repair
circuit on wiring open circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

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58 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 20 -- Error Code E26 displayed -- ERPM signal too high

C001--F
2015--W/S 2015--W/S 2015--W/S
C128--34 C013--W/S

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 59

DIAGRAM 20 -- Error Code E26 displayed -- ERPM signal too high

Connect a volt meter between

the alternator speed connector
and ground. Is there Repair or replace
approximately 7 volts? With the alternator.
engine running.

The following checks must be carried out with the engine

stopped and key start switched OFF.

Suspect an intermittent fault to ground. With an ohm meter

Remove, inspect and refit

connectors C127 and
C128 of the processor. If
the error still occurs
replace the processor.

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60 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 21 -- Error Code E27 displayed -- ERPM signal not present

C001--F
2015--W/S 2015--W/S 2015--W/S
C128--34 C013--W/S

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SECTION 21 -- TRANSMISSIONS -- CHAPTER 6 61

DIAGRAM 21 -- Error Code E27 displayed -- ERPM signal not present

Wheel speed sensor open or short circuit.

Key OFF
Is the instrument Key ON
cluster displaying recheck
engine RPM

Is the alternator drive

Replace drive belt
belt okay

Establish if there is a speed output from the

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

The following checks must be carried out with

the engine stopped and key start switched OFF.

Check alternator Check for short circuit Locate and repair

Check for continuity Locate and repair

between alternator open circuit in engine
connector and C001--F harness.
(W/S). Is wire okay?

Is there continuity
between C128--34 Locate and repair
and alternator speed open circuit in main
connection. rear harness.

Remove, inspect and refit

connectors C127 and C128 of
the processor. If the error still
occurs replace the processor.

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62 SECTION 21 -- TRANSMISSIONS -- CHAPTER 6

DIAGRAM 22 -- Error Code N displayed

Clutchless shuttle operation attempted at too high a speed and in too high a gear
A warning bleeper and symbol ‘N’ are activated under the following conditions:

# In high range 5--8 gears, shuttling while tractor is still rolling.

# In high range 2--4 gears, shuttling while tractor is rolling faster than 9 Km/h (5.5 mph)

Important: The clutchless shuttle will still operate under the warning conditions. Clutch
damage may occur if the shuttle operation is carried out.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 63

21 168 DUAL COMMAND REMOVAL

NOTE: To remove the dual command unit, the

tractor must be separated between front
transmission and the engine, refer to, ‘Separating
the Tractor.’
Disconnect the three dual command oil feed pipes
through the aperture at the right hand side of the
front transmission.

Remove the top two dual command attaching bolts

and install 2 off studs (M10) threads approximately
12 in (304mm) long, into the bolt holes, Figure 40.
NOTE: The gearbox top cover will require removal
to ensure the synchroniser and cone are not
dropped or damaged as they may fall loose from
the rear of the dual command unit during removal,
Figure 42.

40
NOTE: The oil lubrication tube is a tight fit in the
dual command body and may remain in position in
the dual command on removal from the vehicle. It
is recommended that this is removed to avoid
damage during disassembly of the dual command.
Remove the remaining 4 attaching bolts and pull
the dual command unit forward sufficiently to
attach a lifting strop and hoist, Figure 41.

41
Carefully remove the dual command unit (using the
hoist and strop) from the transmission.
Note the following components after the dual
command unit is removed
1. Reverse/Forward Cone
2. Reverse/Forward Synchroniser
3. Oil Lubrication Tube and ‘C’ Clip

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64 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

DUAL COMMAND OVERHAUL

Dual Command Components refer to, Figure 43

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 65

Dual Command Exploded View 43

NOTE: Items 1, 16 and 17 are located between the Dual Command Unit and the Gear Box Mating Parts

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66 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

With the Dual Command unit positioned on a work

bench remove the rear plate bolts (2), (Note
various bolt lengths) and remove the bearing
(1)/shim (3) assembly, Figure 44.

44
Place the unit on its rear face and remove the
support shaft bolts, from the outer housing.
Lift outer housing from backplate to expose clutch
pack assembly and underdrive gear, Figure 45,
note polyimide washer (1).

45
UNDER DRIVE GEAR ASSEMBLY

Overhaul

With the under drive gear cluster removed inspect

for damage, nicks or burrs to the gears. Heavy
damage or wear will result in fitting a new under
drive gear assembly.
Inspect the bearing for wear or damage and
replace with new if required. The bearing can be
pulled from the shaft using a suitable puller if it is
to be replaced.

SUPPORT SHAFT ASSEMBLY

To remove support shaft (3), install bolts (1) in the

end of the shaft and withdraw from the clutch pack
(2), Figure 46.

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 67

Overhaul

1. Remove the seal rings (2) from the support (1)

and inspect for wear and damage, renew parts
as required, Figure 47.
NOTE: The internal needle bearing (4) may be
damaged when removed for inspection. When
replacing push the bearing upto within 0.125in
(3.2mm) of the internal shoulder. Do not push
bearing upto to the shoulder as the bearing may be
distorted.

47
2. Refit new sealing rings (2) and ‘O’ Rings (3)
upon re--assembly.
Withdraw the following as per, Figure 48.
-- Needle roller bearing (1)
-- Underdrive Output Gear (2)
-- Centre Hub (3), with seal (4).

48
C1 -- CLUTCH PACK DISASSEMBLY (UNDER
DRIVE SIDE OF THE CLUTCH)

Lift the clutch housing from the backplate ensuring

clutch hub does not fall out and become damaged,
remove centre shaft and place clutch on a
workbench.
Disassemble the clutch pack by removing the ‘C’
Clip and remove all of the steel discs, friction discs
and spring separators.

Spring Pack

With the clutch pack removed, the piston spring

pack can be removed in the following manner:
Place clutch assembly (2) on press bench (1) and
using tool FT 508 (4), apply sufficient pressure to
allow removal of the clutch spring pack retaining
ring (3). Remove ring, ease pressure off and
remove spring pack, Figure 49.

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68 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

Overhaul

Inspect the spring assemblies for cracked coils or

deformation of the assembly, especially the
pressed steel endcap.
The spring tension can be checked by applying a
load to the assembly as in, Figure 50, or
comparison with a new one. If in doubt renew the
spring assembly.

50
Piston Removal

1. To remove the piston from the housing place

the support shaft back into the housing.
Position an air line nozzle (1) into an oil feed
hole in the support shaft and blanking the
exhaust port with a plug (2) apply sufficient air
pressure to push the piston from the housing,
Figure 51.

51
Overhaul

Ensure seal face is free of nicks or damage, repair

or renew the piston if damage is evident. Renew
inner and outer piston seals.
Re--Assembly

1. Lubricate the piston (2) with Transmission oil

(Ambra Multi G) and using guide tool 4FT 504
(1), push the piston into the guide body (4) and
on into the clutch housing, Figure 52.

52
C1 -- Overhaul

Check plates and discs for wear, damage, scoring,

flatness or discolouring renew if in doubt.
The spring separators can be checked by
measuring free height and compressed height by
application of weights on a parallel surface, as
shown in, Figure 53.
Spring Separators
1. Free Height = 0.200ins (5.08mm)
2. Load Height = 0.105ins (2.67mm)
With a weight of 40lbs (18kgs)
3. Load Height = 0.073ins (1.88mm)
With a weight of 95lbs (43kgs) 53

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 69

If the separators are not to specification as listed in,

Figure 53, they must be replaced.
1. Using press tool as previously described for
disassembly, re--assemble the spring pack into
housing (3) and refit the retaining clip.
2. Re--assemble discs (5 off each) in order: Steel
disc (2), friction disc (4) and spring separator
(1).

54
S Continue up to and including the fifth steel
Plate.
S Compress the plates by hand and hold in place
by inserting three rods (1) in the upper most lu-
brication outlet holes, Figure 55.

55
S Fit the the fifth friction disc separating spring
and end plate on top of rods and secure the as-
sembly with the retaining clip (1), Figure 56.
S Remove the rods.

56
Clutch Pack Setting Procedure

With the clutch pack re--assembled, the clearance

of pack to housing under load, will require
checking, as follows:--
1. Using a weight of 90--100 lbs (40--45kgs)
applied to the end pack, measure using a dial
indicator or depth gauge the distance from the
top face of the end plate to the edge of the
housing, Figure 57.

604.55.041.00 - 01 - 1998
70 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

2. Release the pack and measure the distance

again, the difference ‘C’ of these two readings
should be should be between 0.088--0.110 in
(2.25--2.8mm).
3. If not to specification disassemble the pack,
stack the 0.069 in (1.75mm) separator plates
and measure their combined thickness. Swap
them for 0.079 in (2.0mm) spring separators to
achieve the specification, depending on
original clearance.

C2 -- CLUTCH DISASSEMBLY
(DIRECT DRIVE SIDE OF THE CLUTCH)

Disassembly, re--assembly and setting of the

clutch pack is the same as for C1 clutch.
BACK PLATE ASSEMBLY

1. To disassemble the bearing assembly from the

end plate remove the circlip and push the
bearing assembly out, Figure 58.
2. The bearing can be fully disassembled by
using a suitable pulling attachment, Tool No.
951 or similar between the gear and bearings. Back Plate Assembly 58
Overhaul 1. Back Plate 5. External Bearing
2. External Bearing 6. Spacer
3. Needle Bearing 7. Circlip
1. Check the bearing assembly for signs of wear, 4. Bearing Support
scoring or damage and renew as required.
2. Check back plate for damage or distortion and
repair or renew as required.
Re--assembly

1. Rebuild the bearing assembly and push into

the back plate, refit the bearing retaining circlip.

CLUTCH PACK ASSEMBLY TO BACK PLATE

1. Fit a new seal and spacer and tap the input

shaft into the clutch spline until mating end
faces are flush. Support the assembly with the
C2 (DD) clutch facing upwards.
2. With the clutch assembly (2) supported on
wood place thrust washer (with oil lubrication
slot facing outboard) on piston face, fit a new
seal (3) to the hub (1) and insert into the clutch
plates, it may be necessary to rotate the hub
back and forth to locate the hub splines into the
clutch splines, Figure 59.
59

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 71

3. With the end plate assembly on its side,

position the clutch (1) onto the backplate (2) to
allow engagement between clutch hub and the
rear bearing gear spline, Figure 60.
Turn the entire assembly over onto the back plate
assembly.
4. Install the thrust washer over the spring pack
retaining ring (with the shoulder down),
Figure 63.

5. Fit seal to hub and place hub into clutch pack,

rotating back and forth to align the splines.
6. Refit the gear to hub, place needle bearing (3)
into gear and refit support shaft (1) (taking care
not to damage the support shaft seal rings (2)),
Figure 61.

7. Place the under drive gear cluster in position.

8. Fit 7 off new ‘O’ Rings (2) onto the support shaft
bolt hole counter bores, Figure 62.

Support Shaft Sealing

1. Polyimide Washer
2. ‘O’ Rings 7 off

9. Using grease to prevent movement place the

polyimide bearing washer (1) in position on the
(DD) gear face between the support shaft and
outer housing.

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72 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

Clutch Re--Assembly 63
1. Back plate 9. ‘O’ Rings -- 7 off
2. C2 Direct Drive Hub 10. Polyimide Washer
3. Clutch Housing 11. Needle Bearing
4. Thrust Washer (Oil Groove Facing Outboard) 12. Support Shaft Sealing Rings
5. C1 Underdrive Hub 13. C1 Hub Seal
6. Underdrive Output Gear 14. Thrust Washer (Lip to Clutch Face, oil groove
7. Roller Bearing facing outboard)
8. Support Shaft 15. C2 Hub Seal

DUAL COMMAND HOUSING

NOTE: It is recommended the output shaft seal in

the main cover be renewed upon re--assembly of
the cover.
1. To assist assembly of the cover orientate the oil
drain cutout in the support shaft to align as
close as possible to the oil slot in the main
casting.
2. Lower the main casting over the dowels lining
up the M6 bolt holes in the support shaft, then
fit and torque the 7 off M6 screws to, 7--10 lbs ft
(9--13Nm).
3. Install and tighten the M10 x 40mm bolt to,
25--33 lbs ft (33--45Nm) then carefully turn the
assembly over onto a support block, fit and
torque the remaining M10 x 55, 70 and 90mm
bolts, 25--33 lbs ft (33--45Nm).

604.55.041.00 - 01 - 1998
SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 73

BEARING AND SHIM ASSEMBLY

With the bearing retainer bolts torqued down, a pre

load should be achieved on the under drive cluster.
This pre load can be achieved in the following
manner.
1. Install bearing retainer with excess shims of
approximately, 0.040 in (1.0mm) and torque
the retainer bolts to 30--44 lbs ft (40--60Nm).

2. Attach a dial indicator (1) to the housing in a

position to contact the gear face and measure
end float (2), Figure 64.

Shim Thickness Required =

3. Calculate the shims required using the (Excess Shims -- End Float) -- Pre Load
following guide:--
Excess Shims = 0.047 in (1.19mm)
End Float = 0.015 in (0.38mm)
Minus
4. With the correct shims in place refit the bearing
assembly and torque the M10 X 20mm bolts to Average. Pre Load = 0.002 in (0.05mm)
30--44lbs ft (40--60Nm).
Shim Thickness Required = 0.030 in (0.76mm)

OIL LUBRICATION TUBE

1. Tap the oil lubrication tube into the dual

command housing until fully seated, or does
not protrude from the dual command end face
beyond 4.590 in (116.5mm).

IMPORTANT: If the oil lubrication tube is not fully

seated, once reassembled the tube may protrude
too far into the oil gallery in the gearbox and restrict
the oil flow.

604.55.041.00 - 01 - 1998
74 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

DUAL COMMAND ASSEMBLY INTO GEAR

BOX

NOTE: All ‘O’ Rings, seals and gaskets should be

renewed on re--assembly.

65
1. With the dual command re--assembled and
using a strop and hoist move the unit to the
gear box.

2. Apply vaseline to the three lugs on the forward

reverse gear synchroniser (3), Figure 66 and
place into position in the gear box, vaseline the
synchronizer cone (2), Figure 66 and position
on the dual command drive gear end.

3. Apply vaseline to the gear box mounting face

and adhere the gasket.

NOTE: The gearbox top cover will require removal

to ensure correct engagement of the reverse gear
cluster and to aid assembly of the oil lubrication
tube.

4. Carefully guide the dual command unit onto the

studs in the gear box aligning the rear gear
cluster and oil tube (1) with ‘C’ clip up to the
face of the gear box, Figure 66.

5. Install the attaching bolts and torque to

25--33 lbs ft (33--45Nm).

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 75

LUBRICATION VALVE REMOVAL AND OVERHAUL

Lubrication Valve 67
1. End Plug 7. End Plug
2. End Plug 8. Spring
3. Lubrication Cut Off Valve C1 9. Washer
4. Spring 10. Valve Spool
5. Lubrication Cut Off Valve C2 11. Washer
6. End Plug 12. Spring

Removal Re--Assembly

NOTE: The lubrication valve can only be accessed NOTE: All ‘O’ Rings, seals and gaskets should be
once the vehicle is separated between the engine renewed on re--assembly
and front transmission.
1. Re--assemble the lubrication valve as shown in,
Remove the valve 5 attaching bolts and withdraw Figure 67, ensuring all parts are clean and free
the valve from the dual command. of debris.
Overhaul
2. Tighten the end plugs to a torque of 11--16lbs ft
(15--22Nm)
With the valve disassembled as in, Figure 67,
inspect all parts for signs of wear or scoring and 3. Refit the valve to the dual command and torque
renew any suspect parts. attaching bolts 11--16lbs ft (15--22Nm).

604.55.041.00 - 01 - 1998
76 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

TRANSMISSION CONTROL VALVE REMOVAL AND OVERHAUL

Transmission Control Valve 68

1. 1/2 status Switch 8. Four Wheel Drive Oil Feed
2. Spring 9. Four Wheel Drive Valve
3. Plunger 10. Four Wheel Drive Solenoid
4. Pulse Width Modulation Solenoid C1 Clutch (UD) 11. Dump Valve
5. PWM Solenoid C2 Clutch (DD) 12. Temperature Sender
6. PWM Valve C2 Clutch (DD) 13. Oil Feed From Pump
7. Direct Drive Oil Supply 14. Oil Supply (UD)

Removal

1. To remove the transmission control valve

mounted on the right hand side of the
transmission, disassemble the oil tube
connections (3) and solenoid electrical
connections (2), Figure 69.

2. Remove the 5 attaching bolts (1) from the valve

body and withdraw from the transmission,
Figure 69.
69

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SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6 77

3. Withdraw the ‘L’ shaped plunger (1) from the

position in the transmission and check for
sticking, wear or damage, replace if in doubt,
Figure 70.

70
Re--Assembly

NOTE: All ‘O’ Rings, seals and gaskets should be

renewed, upon re--assembly.

1. Refit the valve with a new gasket, torque

attaching bolts to, 24--26lbs ft (33--35Nm

IMPORTANT: To avoid damage to the solenoid

body (coil) on reassembly it is recommended that
the valve is fitted independently of the coil, as
follows.

# Refit the solenoid valves (less body) to the

control valve and torque nut to 25--33lbs ft
(34--45Nm)

# Re--assemble the (solenoid body to valve) and

torque attaching nut to 1.3--1.4lbs ft
(1.7--1.8Nm).

1. Reconnect the solenoid valve harness

connectors.

2. Refit the oil tube connectors to the

transmission control valve body and torque to
24--26lbs ft (33--35Nm).

3. Attach the oil feed tubes to the connectors and

torque to 24--26lbs ft (33--35Nm).

604.55.041.00 - 01 - 1998
78 SECTION 21 -- TRANSMISSION SYSTEMS -- CHAPTER 6

NOTES

604.55.041.00 - 01 - 1998
SECTION 21– TRANSMISSIONS– CHAPTER 7 1

SECTION 21– TRANSMISSIONS

Chapter 7 – Electroshift (16 x 16) Power Shuttle Transmission

CONTENT

Section Description Page

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Cover Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

NOTE: The information contained in this Chapter is additional to that of Section 21, Chapter 1, 16x16
Transmission.Only items relevant to the Power Shuttle are detailed in this Chapter.

21 000 SPECIFICATIONS
Hydraulic Operating Pressure 18–20 bar (260–290 lbf.in2)
Synchroniser Position Potentiometer 0.9–1.0kΩ between pins 2 and 3 (Pot. fully rotated)
4.5–5.0 kΩ between pins 2 and 3 (Pot. at rest)

4.5–5.0kΩ between pins 1 and 2 (Pot. fully rotated)

1.4–1.5kΩ between pins 1 and 2 (Pot. at rest)

4kΩ between pins 1 and 3 (Pot. all positions)

Forward / Reverse PWM Solenoids 8–11Ω coil resistance.

604.55.041.02 –01–2000
2 SECTION 21– TRANSMISSIONS– CHAPTER 7

21 000 SECTION DRAWING

1
Top Cover Section view
1. End Plug x2 8. Piston
2. Synchroniser Position Potentiometer 9. 1–4/5–8 Shift Rail
3. Forward/Reverse Shift Fork 10. 1–4/5–8 Shift Fork
4. Forward/Reverse Detent Assy. 11. 1–4/5–8 Detent Assy.
5. Reverse PWM Solenoid 12. 5–8 Engaged Switch
6. Forward PWM Solenoid 13. 1–4 Engaged Switch
7. Forward/Reverse Shift Rail

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 3

21 000 – TIGHTENING TORQUES

604.55.041.02 –01–2000
4 SECTION 21– TRANSMISSIONS– CHAPTER 7

DESCRIPTION AND OPERATION

The 16 x 16 transmission with Left Hand Shuttle is
available as either a 30 Km/h or 40Km/h
configuration.
An optional Creeper is available providing an
additional 8 forward and 8 reverse speeds.
The transmission is also available with or less four
wheel drive.

3
The pressure oil to engage the clutches is supplied
from the Low Pressure Hydraulic Circuit, which is
maintained at 17 to 19 bar by the Low Pressure
Regulating Valve (1), located in the valve block on the
CCLS pump assembly.

4
Transmission lubrication oil is supplied via the
steering circuit and is controlled to a maximum
pressure of approximately 7 bar by the Lubrication
Relief Valve (4) located in the transmission side
cover.

5
An Oil Cooler By–pass Valve, located on the right
hand side of the transmission, ensures that
excessive oil generated at cold start up, or if the oil
cooler becomes blocked, bypasses the cooler until
the the oil warms up (above 62°C) or the pressure
drops.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 5

The Low Pressure Circuit incorporates a hydraulic

accumulator, located on the right hand side of the
transmission. This provides instant additional oil to fill
possible voids when shifts involving multiple clutches
are performed.

7
The transmission drive can be broken down into 3
groups as follows:

C1 and C2 clutches – located at the front of the

transmission to work in conjunction with C3 and C4
to give 4 basic ratios.

8
The Forward/Reverse synchroniser – located in the
mid section of the transmission to select forward or
reverse drive, electro–hydraulically operated by
PWM valves.

1–4/5–8 synchroniser – located just behind the

forward/reverse synchroniser for manual
mechanical range selection.

9
C3 and C4 clutches located in the rear section of the
transmission each supplying a single speed in
conjunction with C1 and C2 to give 4 basic ratios.

High and Low synchroniser located at the rear of the

transmission when combined with C1, C2, C3, C4
clutches and 1–4 / 5–8 synchroniser provide 16
forward and 16 reverse ratios.

604.55.041.02 –01–2000
6 SECTION 21– TRANSMISSIONS– CHAPTER 7

R F
1 2 3 4

(5–8) (1–4)

C3 C4

BSC0873A

11
FORWARD / REVERSE SYNCHRONISER
1. Synchroniser Fork 4. End Cap
2. Shift Rail 5. Reverse PWM Solenoid Valve
3. Forward/Reverse Actuating Piston 6. Forward PWM Solenoid Valve

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 7

MicroProcessor
When the shuttle lever is moved to either the forward
or reverse position, the microprocessor, via the top
cover potentiometer will determine if the
synchroniser is in the correct position.
If it is not the electro hydraulic system will move the
synchroniser before drive is engaged.
Then, unless the clutch pedal is depressed the
appropriate clutch PWM valves will be energised.

When the shuttle lever is moved to the neutral

position the control system will immediately
disengage all energised clutch PWM valves.
12
Forward selected R F
(5–8) (1–4)

C3 C4
C J
G H
B

F M
BSC0873C

13
Reverse selected R F
(5–8) (1–4)

C3 C4
C J
G H
B

RI
The forward / reverse synchroniser has no neutral
position, do not attempt to by–pass the shuttle lever
switch. F
BSC0873B M
14

604.55.041.02 –01–2000
8 SECTION 21– TRANSMISSIONS– CHAPTER 7

The engagement of the clutches is controlled by inputs from various sensors and switches:–

INPUT SENSORS

DESCRIPTION FUNCTION LOCATION

Transmission Output speed Provides a transmission output
sensor speed signal for the processor
when the radar is not present

Transmission oil temperature Measures the temperature of the

sensor oil to provide compensation for
hot/cold oil conditions.

Clutch pedal disconnect switch Disengages power to range

clutches (C3,C4) PWM valves,
thereby disengaging drive.

Clutch pedal potentiometer Provides operator controlled

engagement of the feathering
(C3,C4) clutches.

Shuttle lever Provides information to the

processor,via switches, for
forward, reverse and neutral
transmission drive selection.
Disengages power to all
transmission PWM valves when in
neutral.

Forward Reverse Potentiometer Provides information to the

processor about the position of
the forward and reverse
synchroniser

Gear shift switches Allows the operator to shift

between 4 basic ratios within a
range via push buttons switches
sending a signal to the processor,
without using the clutch pedal.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 9

INPUT SENSORS

DESCRIPTION FUNCTION LOCATION

Synchroniser Status switches Provides information to the
processor about the position of
the 1–4/5–8 and High/Low
synchronisers

Handbrake switch To be applied during calibration,

error code if not applied. Tractor
will drive if handbrake applied but
audible alarm sounds.

Creep engage switch Informs the processor when

creeper has been selected,
preventing selection of high
range.

Alternator Provides an engine speed signal

to the processor.

Seat Switch Seat switch must be operated, ie,

operator seated, before the
processor allows engagement of
forward or reverse drive. (Note, a
faulty switch can be over ridden
by the clutch pedal).

OUTPUT DEVICES

DESCRIPTION FUNCTION LOCATION

Clutch PWM valves,C1, C2, C3, Controls oil to the clutches to
C4 engage/disengage the clutches
via a signal from the processor.

604.55.041.02 –01–2000
10 SECTION 21– TRANSMISSIONS– CHAPTER 7

Forward and Reverse PWM Controls oil to the transmission

Valves top cover to operate the
synchroniser to select forward or
reverse via a signal from the
processor.

Instrument Cluster Display Provides operator information as

to which ratios are selected and
error code information.

CONTROL DEVICE –

DESCRIPTION FUNCTION LOCATION

MICRO PROCESSOR The transmission is controlled by
a micro processor, on the right
hand side under the EDC Control
Panel. The processor has 3 – 36
way connectors and in addition to
controlling the transmission it also
controls the Electronic Draft
Control system.
The trans mission has an inbuilt
diagnostic facility which can
interpret a number of system
faults and display an error code in
the transmission display.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 11

21 131 TOP COVER OVERHAUL

15
Top Cover Exploded View
1. 1–4/5–8 rail detent assembly 13. Forward/reverse fork rail
2. 5–8 range engaged switch 14. Forward/reverse shift fork
3. 1–4 range engaged switch 15. Forward/reverse piston and seal
4. Top cover 16. End cap
5. Potentiometer operating shaft 17. Circlip
6. Shaft spacer 18. 1–4/5–8 shift fork
7. ’O’ ring seal 19. 1–4/5–8 fork rail
8. Shaft support 20. Reverse PWM solenoid
9. Potentiometer spacer 21. Forward PWM solenoid
10. Forward/reverse detent assembly 22. ’O’ ring seal
11. ’O’ ring seal
12. Forward/reverse potentiometer

604.55.041.02 –01–2000
12 SECTION 21– TRANSMISSIONS– CHAPTER 7

REMOVAL
1. Remove the cab mat and floor.
2. Disconnect the wiring to the forward and reverse
PWM solenoids, the 1–4 and 5–8 status
switches and the synchroniser position
potentiometer.
3. Disconnect the 1–4/5–8 fork rail operating cable.
4. Disconnect the hydraulic feed tube.
5. Remove the four bolts securing the cover to the
transmission and carefully lift away.
WARNING
The Top cover assembly is awkward and heavy.
Obtain an assistant to help with removal. 16

DISASSEMBLY (REFERENCE FIGURE 15)

Disassemble the top cover using the the following
sequence:
6. Remove the 1–4 and 5–8 status switches.
7. Remove the 2 detent assemblies.
8. Remove the synchroniser position
potentiometer, shaft housing and operating
shaft.
9. Remove the 2 PWM solenoid valve assemblies.
10. Loosen the 1–4/5–8 fork to rail lock screws.
Carefully tap the rail out from the rear end,
pushing the end plug out in the process.
11. Remove the forward/reverse shift rail. Remove
the circlip and end cap of the forward/reverse rail.
Loosen the shift fork retaining screws. Through
the potentiometer housing orifice carefully pry
the forward/reverse shift rail from the top cover.

INSPECTION
1. Thoroughly clean the top cover, ensuring that the
oil galleries from the PWM valves to the shift rail
piston are free from any debris.
2. Inspect the shift rails and forks. Replace if bent
and in the case of the forks, the fork tips appear
excessively worn.
3. Inspect all the ’O’ ring seals. It is advisable to
replace all of the ’O’ rings as standard practice.
If the seal on the forward/reverse piston appears
in anyway damaged or suspect it should be
replaced.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 13

REASSEMBLY
Reassembly is the reverse of the disassembly,
noting the following items:
1. Coat the piston seal with transmission oil prior to
assembly.
2. After insertion of the 1–4/5–8 rail install the end
plug with New Holland flexible gasket sealant
(82995770) applied to the plugs outer edge.
3. Adjust the fork positions on their rails using the
following procedure.

ADJUSTMENT OF FORWARD/REVERSE
AND MAIN (1–4/5–8) SYNCHRONISERS
To gain access to the synchroniser forks and rails it
is necessary to remove the cab mat and floor.

Remove the transmission cover plate to expose the

shift rails (1) and forks (2). Remove the status
switches (4) and the detents (3).

17
The adjustment procedure is the same for both
synchronisers.

Using a suitable lever, fully position the synchroniser

in the engaged position and measure the distance A.

18
Now fully position the synchroniser in the opposite
fully engaged position and measure distance B.

Replace the detent and set the shift rail to neutral.

Adjust the fork to its neutral position.

Neutral N = A + B
2
Tighten the fork lock screws.
Re–install status switches and top cover.

604.55.041.02 –01–2000
14 SECTION 21– TRANSMISSIONS– CHAPTER 7

TRANSMISSION CLUTCH AND

SYNCHRONISER CALIBRATION
Required when any of the following items have been
performed or noticed:–
• The microprocessor has been replaced.
• The non volatile memory of the processor has
been reset (Mode H8 Performed).
• A clutch or synchroniser PWM solenoid valve
has been replaced.
• A clutch pack has been overhauled.
• The forward/reverse synchroniser potentiometer
has been replaced.
• The forward/reverse synchroniser has been
replaced.
• The shift quality or clutch featherability has
noticeably deteriorated.
• A delay or jerky drive engagement when using
the clutch pedal for inching operations also
during shuttle shifts or automatic take off without
using the clutch pedal.
• A delay in drive engagement when making
powershifts.
If, after the auto clutch calibration has been
performed, using H1 mode, the shift/shuttling is still
not as required, then the calibration may be fine
tuned manually, using the H2 mode.

Clutch fill time calibration (HE Menu Mode)

Required if the following has been noticed:–
• A clunk is heard when engaging the clutch during
inching operations.

Clutch and Synchroniser calibration set up

Procedure:
Prior to conducting a transmission clutch calibration,
the following points should be checked:
• The temperature of the transmission oil is warm,
at least 20°C (68°F).
• The parking brake is applied
• The air conditioning, if fitted, is switched off.
• All electrical and hydraulic services are
deselected.
WARNING
The calibration procedure is controlled by the
electronic management system. To prevent
inadvertent movement of the tractor, park the tractor
away from any obstacles, firmly apply the parking
brake and block the wheels, front and rear.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 15

SPRING PRESSURE AND SYNCHRONISER

CALIBRATION

Entering the calibration mode :

Press and hold both the upshift and downshift
buttons whilst starting the tractor.

20
Alternative method :
Install diagnostic tool 4FT950 into the Black
diagnostic connector, located by the fuse box.
Start the tractor.
Enter mode H1.

21
The word CAL should appear on the instrument
cluster display. This will be replaced after a few
seconds by the oil temperature, in degrees Celsius.
Set the engine speed to 1200 +/– 100 rpm.
NOTE: The engine RPM must be stable with no
noticeable surging. If necessary, adjust the throttle
position to achieve this, still remaining within the
1200 +/– 100 rpm range.

22
C3 and C4 Calibration
Place the two gear levers in the forward position.
NOTE: No need to use the clutch pedal.

604.55.041.02 –01–2000
16 SECTION 21– TRANSMISSIONS– CHAPTER 7

Move the shuttle lever into the forward drive position.

24
IMPORTANT: The shuttle synchroniser must be
calibrated before further calibration of the
transmission is attempted. Failure to observe this
procedure will result in error code U36 showing in the
gearshift display.

Forward/Reverse Synchroniser calibration:

Press and hold the upshift and downshift switches,
the display will show ’Soc’. Continue to hold the
upshift and downshift buttons.

25
The gearshift display will now sequence through
figures ’1’, ’2’, ’3’ and ’4’. When the display reads
’End’, calibration of the transmission synchronisers
has been completed, release the upshift and
downshift buttons.
The display then returns to CAL then temperature
display.

26
C3 calibration :
Press and hold the Upshift button.
If the start up procedure was incorrect, a U code will
be displayed. (see page 18).

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 17

The display will change to show a number.

This number will flash and begin to scroll up, as the
clutch is calibrated.
When the processor detects a decrease in engine
rpm of 30, the calibration stops. This is indicated by
a fixed, non flashing number.
Release the Upshift button.

28
C4 calibration :
Use the downshift button to calibrate the C4 clutch in
the same manor as the C3 clutch.

29
The display is similar to the C3 calibration.

30
C1 and C2 calibration :
Place the range lever in neutral, leaving the main
lever in the forward position. Leave the shuttle lever
in the forward drive position.

Set the engine speed to 1200 +/– 100 rpm.

604.55.041.02 –01–2000
18 SECTION 21– TRANSMISSIONS– CHAPTER 7

Press and hold the Upshift button to calibrate the C1

clutch.
Press and hold the Downshift button to calibrate the
C2 clutch.
The procedure is the same as that for the C3 and C4
clutches.

32
Spring Pressure Calibration Error Codes :

U20 – Handbrake not applied

U21 – Engine rpm too low
U22 – Engine rpm too high
U23 – Forward / Reverse shuttle lever is not in Forward
U24 – Main lever is not in 5–8 range
U25 – Range lever in low range
U26 – Clutch pedal is not fully released
U27 – C3 calibration too low
U28 – C3 calibration too high
U29 – C4 calibration too low
U30 – C4 calibration too high
U31 – Wheel motion detected during calibration
U32 – C1 calibration too low
U33 – C1 calibration too high
U34 – C2 calibration too low
U35 – C2 calibration too high
U36 – Synchroniser not calibrated – Must calibrate synchroniser first
U37 – Synchroniser reverse position outside limits
U38 – Synchroniser forward position outside limits
U39 – Reverse Synchroniser, no movement at maximum pressure
U40 – Forward Synchroniser, no movement at maximum pressure

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 19

H2 MENU MODE –

Display of Clutch/synchroniser calibration

values and C3/C4 manual adjustment
NOTE: The tractor is driveable in this mode.
Install the diagnostic switch, Tool No. 4FT 950, and
start the engine.
Select mode H2 using the diagnostic switch.

33
The calibration values are displayed in the following
sequence:
Range of Values
Clutch 1 101–240
Clutch 2 101–240
Clutch 3 101–240
Clutch 4 101–240
Synchro position signal reverse 655–963
Synchro position signal forward 61–376
Display then returns to Oil temperature.

34
After the values have been displayed it is possible to
adjust the C3 and C4 clutches.
The transmission oil temperature should be at least
40°C.
Depress the clutch pedal, select either gear 7L (C4
is used) or 8L (C3 is used), with the shuttle lever in
forward, release the clutch pedal and perform shuttle
shifts driving the tractor at between 1500–1800 rpm.
NOTE: The tractor can be driven in all gears but
Powershifts are not possible. The tests are
performed in the low range because this is more
sensitive to calibration changes.

35
If the shuttle shifts require fine tuning:–
While driving the tractor, with the clutch pedal fully
released, the clutch value is displayed and may be
adjusted using the up and down powershift switches.
Make only small adjustments and shuttle to test the
performance.
WARNING
Take care to remain observant to the outside
surroundings during these adjustments.

NOTE: If the shuttle lever is moved to neutral the

display will show either C3 or C4 depending on the
gear selected.
36

604.55.041.02 –01–2000
20 SECTION 21– TRANSMISSIONS– CHAPTER 7

CLUTCH FILL TIME CALIBRATION

Set up procedure:
• Warm the oil to normal operating temperature,
at least 60°C.
• Park the tractor on a level surface.
• with a diagnostic tool installed, depress the
clutch, start the engine and set engine speed to
1200 +/– 100 rpm.

37
Entering the calibration mode :
Using diagnostic tool 4FT950 select mode HE.
Place the 4–5 (main) and range levers in neutral,
place the shuttle lever in forward and release the
clutch pedal.
If the oil temperature is less than 60°C ’F1’ will be
displayed, alternating with the display of oil
temperature. This will NOT stop until the oil reaches
60°C.

38
CLUTCH SELECTION:
C1/C2 C3/C4
While the 4–5 lever is in neutral, the display will
indicate which clutch is selected.
To select C1 or C2 the range lever must be in neutral.
To select C3 or C4 the range lever must be in the high
range.
To switch between C1 and C2 or C3 and C4, press
the upshift or downshift switch while the 4–5 lever is
in neutral.

39
ADJUST AND TEST C1 OR C2
Shift the 4–5 lever into 5 (forward).
This display will show C1 or C2 and to the left of this
a sequence of horizontal lines will appear to indicate
a ramping up of pressure on the C3 and C4 clutches
to prevent output rotation of the C1 and C2 clutches.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 21

The display will then change to a single digit number

which is indicating the quickfill time in 10 millisecond
units.
This can be adjusted using the upshift and downshift
switches.
The factory default setting is 3.

41
To test the quickfill setting, press and hold both the
upshift and downshift buttons. The display will show
’FILL’ The transmission will automatically engage
and release appropriate clutches.
NOTE: If nothing appears to happen depress the
clutch, cycle the shuttle lever and release the clutch
to re–enable the transmission.
To adjust, reduce the value until no ’clunk’ is evident,
then increase the value until there is a distinct ’clunk’
evident.
Then reduce the value by 2.

42
ADJUST AND TEST C3 OR C4
Ensure that the handbrake is OFF.
If coming from C1/C2 testing, shift both the 4–5 and
range levers to neutral.
Shift the range lever into the high range.
Shift the 1–4/5–8 lever into 5–8 range).

43
This display will show C3 or C4 and to the left of this
a sequence of horizontal lines will appear to indicate
a ramping up of pressure on C1 clutch to connect C3
and C4 to the engine.

604.55.041.02 –01–2000
22 SECTION 21– TRANSMISSIONS– CHAPTER 7

The display will then change to a single digit number

which is indicating the quickfill time in 10 millisecond
units.This can be adjusted using the upshift and
downshift switches.
The factory default setting is 4.

45
To test the quickfill setting, press and hold both the
upshift and downshift buttons.
The display will show ’FILL’ while C3 or C4 is
engaged briefly. The display will then show the clutch
selected followed by the quickfill value.
NOTE: If nothing appears to happen depress the
clutch, cycle the shuttle lever and release the clutch
to re–enable the transmission.
To adjust, decrease the value until the tractor does
not move, then increase the quickfill just enough to
cause the tractor to move.
Then reduce the value by 2.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 23

21000 – TROUBLE SHOOTING, LIMP HOME, CALIBRATIONS AND PRESSURE TESTING

The transmission / EDC electronic management

It should be noted that the self diagnostic capability

is generally limited to diagnosis of the electrical and
electronic circuitry and related components,
however, there are some codes, which can be
generated if pressure switch circuits are not closed
because of an actual lack of hydraulic pressure.
1
Any malfunction of the mechanical and hydraulic
components must be diagnosed using
conventional techniques, performance
characteristics and tooling, such as pressure
testing equipment. Full guidance for both electrical
self diagnosis and conventional diagnosis is
contained within this section.

Trouble–shooting and fault finding should always

Prior to detailed fault finding, items like the earth

points and Battery should be cleaned and tested to 2
ensure that they are functioning correctly.
With the use of micro–processors it is often that
this item is blamed for any malfunction but the real
truth is that this item is usually sound and that the
fault is due to poor contacts in the associated
connectors.
Each connector illustrated and identified in the
wiring diagrams in Section 55 and referred to in the
following fault finding procedure, has the same
identification reference. For example, the main
processor connectors are referred to as
Connectors C127, C128 and C242 in the
illustration and also referred to as C127, C128 and
C242 in the fault finding procedure. Often in the
fault finding flow chart the connector and pin are
abbreviated and will read, for example, C127–10.
The C127 refers to the connector and the 10 to the
pin number.
Section 55 contains complete wiring diagrams,
connector identifications and a list of circuit 3
numbers as used within the circuit diagrams.

604.55.041.02 –01–2000
24 SECTION 21– TRANSMISSIONS– CHAPTER 7

Where the fault finding procedure requires checks

for continuity a visual inspection of the wiring
should be made prior to conducting tests to ensure
that obvious ‘mechanical’ damage has not
occurred to the harness or the connectors.

Where possible the inbuilt tractor diagnostics

A good quality multi–meter is an essential item to

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi–meter it is good practice to select a high
range and work downwards to avoid damaging the
instrument.
Where possible it is recommended that connectors
are probed from the rear, certain connectors like
C079, C080 and C081, instrument panel
connectors, should always be probed from the
rear. Connector terminals should only be removed
using the special tools supplied in electrical repair
kit, Tool No.4FT.953 and the wires should not
require excessive pulling efforts to remove.
5
Where only front probing is practical it is
recommended that Connector test probe kit, Tool
No NH.55–125 is obtained. This provides all
connector terminal attachments for use with most
multi–meters.
IMPORTANT: Care should be used when using
the multi–meter, only use the instrument as
instructed to avoid damage to the internal elements
of the micro–processor. When checking the
continuity of wiring, sensors or switches it is
necessary to isolate the electronic
micro–processor and ensure the keystart is turned
off to prevent possible further damage. The
keystart should only be switched on and the
processor connected where specifically instructed
in the fault finding procedure.
TA60–21–0
If it is found necessary to clean the connectors a 14 6
contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains
Trichloro–ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 25

ERROR CODES
The transmission / EDC processor is able to create
and store up to 30 error codes with the hours at
which they occured and with the number of
incidences that a particular error code has
occured. Only error codes that prevent the tractor
from driving will be displayed to the operator, other
non disabling errors will be retreivable by a
technician through the H menu mode of the tractor
diagnostics.
It should be noted that the hours displayed is not
related directly to the hour meter. For example if the
occurence hours shows ’10’ this indicates that the
error occured 10 hours ago, not at 10 hours of
operation. 7
The following ’H’ menu mode routines are provided
to allow access to Error codes:
Hb – Retrieve error codes for viewing.
Hc – Clear processor memory of stored error codes
Hd – View error codes live. This allows normal
operation of the tractor with error codes able to
display as they occur.

A full description of the ’H’ menu routines can be

found in Section 55.

8
It should also be noted that after installation of a
new processor or after a non volatile memory reset
operation (’H’ menu mode, H8), that the processor
defaults to a ’display all codes’ mode for 6 minutes.
If no error codes occur during this 6 minute period
the processor then reverts to normal operation. If
an error occurs during this period the processor will
continue to display ’live’ error codes until all the
errors are removed.

604.55.041.02 –01–2000
26 SECTION 21– TRANSMISSIONS– CHAPTER 7

16x16 Electroshift Power Shuttle Transmission Error Codes

Error Fault Condition Enabled/ Error
Disable? Displayed?

E21 Chassis harness disconnected Disable Yes

E53 5 Volt Reference failed, shorted to 12 volts Disable Yes
E54 5 Volt Reference failed, shorted to ground Disable Yes
E12 Clutch pedal potentiometer signal too high Disable Yes
E11 Clutch pedal potentiometer signal too low Disable Yes
E39 C4 clutch solenoid open circuit Disable Yes
E38 C4 clutch solenoid short circuit Disable Yes
E41 C3 clutch solenoid open circuit Disable Yes
E40 C3 clutch solenoid short circuit Disable Yes
E43 C2 clutch solenoid open circuit Disable Yes
E42 C2 clutch solenoid short circuit Disable Yes
E45 C1 clutch solenoid open circuit Disable Yes
E44 C1 clutch solenoid short circuit Disable Yes
C Wheel speed too high for creeper gear Recover Yes
HC Range shift to high with creeper engaged Recover Yes
E37 Clutch disconnect switch open circuit Disable Yes
E48 Clutch disconnect switch short circuit
misadjusted, always closed Disable Yes
CP Depress clutch pedal to enable transmission Recover Yes
N Clutchless shuttle operation attempted at too
high a speed and in too high a gear Enabled Yes
H Shuttle performed at too high a speed Enabled Yes
E46 Fuse 12 blown Enabled No
E47 Clutch disconnect switch misadjusted high Enabled No
E51 Transmission temperature sensor open circuit Enabled No
E52 Transmission temperature sensor short circuit Enabled No
E24 All clutches and synchroniser not calibrated Enabled No
EC4 C4 clutch not calibrated Enabled No
EC3 C3 clutch not calibrated Enabled No
EC2 C2 clutch not calibrated Enabled No
EC1 C1 clutch not calibrated Enabled No
E16 Creeper solenoid open/short circuit, or
attempt was made to engage creeper after
prior creeper error Enabled No
E15 High/low range lever switches both on Enabled No
E14 1–4/5–8 Range lever switches both on Enabled No
E55 No output speed signal Enabled No
E56 Differential lock switch error Enabled No
E49 Wheel speed sensor circuit open or short
circuit Enabled No
E26 Engine rev/min speed too high Enabled No
E27 Engine rev/min speed too low Enabled No
E59 Shuttle lever switch disagreement Disable No* (N)
E60 Forward synchroniser becomes disengaged Disable No* (N)
E61 Synchroniser Potentiometer voltage high Disable Yes
E62 Synchroniser Potentiometer voltage low Disable Yes
E63 Forward Synchroniser not engaging Disable No* (N)
E64 Reverse Synchroniser not engaging Disable No* (N)
E65 Forward synchroniser solenoid open circuit Enabled No

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 27

16x16 Electroshift Power Shuttle Transmission Error Codes (continued)

Error Fault Condition Enabled/ Error
Disable? Displayed?

E66 Reverse synchroniser solenoid open circuit Enabled No

E67 Forward solenoid circuit fault Enabled No
E68 Reverse solenoid short circuit Enabled No
E69 Reverse synchroniser becomes disengaged Disabled No* (N)
E70 Shuttle lever forward switch voltage too high Enabled No
E71 Shuttle lever forward switch voltage too low Enabled No
E72 Shuttle lever reverse switch voltage too high Enabled No
E73 Shuttle lever reverse switch voltage too low Enabled No

EC Output speed too high while in creeper Disabled Yes

EHC High range engaged while in creeper Disabled Yes
EC1 Clutch 1 not calibrated Enabled No
EC2 Clutch 2 not calibrated Enabled No
EC3 Clutch 3 not calibrated Enabled No
EC4 Clutch 4 not calibrated Enabled No

* Where a ’N’ type error is displayed, shown in the tables above with, “(N)”, the associated error
will be revealed in H–Menu mode HD (display errors).

604.55.041.02 –01–2000
28 SECTION 21– TRANSMISSIONS– CHAPTER 7

Key to Fault Finding Diagrams

Diagrams 1 to 10 – Not related to error codes
1. Tractor Does Not Drive In Any Gear
2. Incorrect Gear Shift Sequence or Gears Missing
3. Powershifts Jerky / Loss of Drive
4. Poor Clutch Feathering
5. Clutch Potentiometer Calibration Check
6 Holding in Gear / Jumping Out of Gear / Clashing
7. Creeper Does Not Disengage
8. Clutches Squeal / Whine During Inching
9. Transmission is Noisy in Operation
10. Transmission ‘Clunks’ During Inching
Diagrams 11 onwards, error code related:
11. Error Code E11
12. Error Code E12
13. Error Codes E53 and E54
14. Error Codes E37, E47 and E48
15. Error Codes E38,E39 / E40,E41 / E42,E43 / E44,E45
16. Error Codes C and E16 – Creeper Does Not Engage in Low Range
17. Error Code HC
18. Error Code CP
19. Error Code E46
20. Error Codes E51 and E52
21. Error Codes E24, EC4, EC3, EC2 and EC1
22. Error Code E15
23. Error Code E14
24. Error Code E55
25. Error Code E56
26. Error Code E49
27. Error Code E26
28. Error Code E27
29. Error Code E59
30. Error Code E60 and E69
31. Error Code E61 and E62
32. Error Code E63 and E64
33. Error Code E65 and E66
34. Error Code E67 and E68
35. Error Code E70 and E71
36. Error Code E72 and E73
37. Error Code Symbol ‘N’

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 29

DIAGRAM 1 – Tractor does not drive (in any gear)

Key OFF
Key ON
recheck

Charge pump warning Does the Go to pressure

light illuminated engine stall or testing clutches
lug down?

Check pressure in Inspect operation of levers Inspect

low pressure circuit. for correct preparation. switch
Is pressure 18–20 Enter mode H5, is Neutral/ and wiring
bar? start inhibitor switch okay?

Pressure reducing valve

Suspect a mechanical
failure within
transmission. Seized
clutches, synchronisers
or broken gear in shaft.

604.55.041.02 –01–2000
30 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 2 – Tractor drives in ranges but has following fault:

– Powershift function operates but the shift sequence is incorrect or gears missing
Key OFF
Key ON
recheck

Are the PWM solenoid Using the wiring diagram

Substitute the affected clutches Install a new PWM valve

PWM valve and retest for to the affected clutch
pressure. Is pressure okay

Suspect internal leakage within

the transmission example, side
plate gasket, Clutch pack
housing, clutch supply tubes.

C1 C2 C3 C4

1–5 9–13

2–6 10–14

3–7 11–15

4–8 12–16

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 31

DIAGRAM 3 – The powershifts are not smooth or the tractor loses drive between
powershifts (in work tractor stops or could be jerky)

Key OFF
Key ON
Perform complete transmission recheck
calibration.
1) spring calibration Tractor okay
2) fill time adjustment
is transmission still performing
poorly?

Is feathering
performance poor?

Suspect PWM valves 3 or 4.

Clean or replace and repeat
spring calibration.
Is powershift performance poor?

Are only double swap shifts poor?

(ie, 2 to 3 or 6 to 7 gear changes.
3 to 2 or 7 to 6 gear changes)

Suspect PWM valves 1 or 2.

Clean or replace. Repeat spring
calibration and fill time adjustment.
Is powershift performance still
poor?

Repair/replace
Remove and test accumulator accumulator
(see testing section) perform fill time
Is accumulator okay? adjustment

Suspect damaged clutch plates.

Inspect and replace as required.
(See overhaul) recalibrate after
assembly

604.55.041.02 –01–2000
32 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 4 – The tractor drives in all gears but has the following fault
Poor clutch pedal feathering/inching performance.
Key OFF
Key ON
recheck

Perform spring pressure

calibration and fill time Tractor okay
adjustment. Feathering/inching
still poor?

Is the clutch pedal

feathering/inching performance Refer to diagram 5
poor in only:
A) 1st (5th)/3rd (7th) gears
or
B) 2nd (6th)/4th (8th) gears

A B
Suspect PWM valve 4. Suspect PWM valve 3.
Clean or replace. Clean or replace
Recalibrate after recalibrate after
installation. installation.
Is feathering still poor? Is feathering still poor?

Suspect clutch Suspect clutch

plate damage. plate damage

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 33

DIAGRAM 5 – Clutch pedal potentiometer calibration check

Tractor
okay

Ensure clutch pedal can travel

through its whole stroke. Inspect Repair or replace
linkage and potentiometer linkage as required
operating shaft. Are these okay?

Using diagnostic switch, select mode

HA to display the clutch pedal
position. Does the transmission
display value change smoothly from Clutch pedal
0–99 when the clutch pedal is Potentiometer and
depressed and released. calibration is okay

With the key start switch OFF,

disconnect the potentiometer
connector. Turn the key start switch Clutch pedal
ON to produce error code E11. Turn potentiometer is
the key start switch OFF and okay
reconnect the potentiometer. Retest in
HA mode. Does the display value Remove
change smoothly from 0 to 99? connectors
C127 and C128
Inspect to the processor,
Replace the potentiometer. connector inspect clean
Retest in HA. Is operation C077 and and refit .
correct? wiring. Recheck
Okay? potentiometer
operation, if still
incorrect replace
Repair or replace processor
as required

Clutch pedal potentiometer

and calibration is okay.

604.55.041.02 –01–2000
34 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 6: The tractor drives in all gears and ranges but has the following fault:
Transmission jumps out of gear, holds in gear or gears clash when shifting

Key OFF
Key ON
recheck

Is the gear fully

engaging? Inspect
and adjust shift lever
linkage as required.
Fault cured?

Using the service

Suspect a mechanical Swap the PWM with one

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 35

DIAGRAM 7 – The creeper does not disengage.

Key OFF
Key ON
recheck
Does transmission display (EIC Remove, inspect
only) or switch lamp indicate and refit processor
creeper is selected? connectors, C127
and C128. If
creeper still does
Verify that the FWD and creeper not disengage
solenoids or connectors have not replace processor
been interchanged. If
solenoid/wiring is correct
Pressure test at Mechanical
proceed
creeper port. Does fault.
pressure gauge Disassemble
Disconnect creeper indicate 18–20 bar transmission
connector at solenoid. Does when creeper and inspect
battery voltage exist at the switched on and creeper
solenoid connector with key zero pressure with components
start ON, creeper OFF? creeper switched for sticking and
off? damage.

Disconnect processor Change or

604.55.041.02 –01–2000
36 SECTION 21– TRANSMISSIONS– CHAPTER 7

FLOW DIAGRAM 8: The tractor drives in all gears and ranges but has the following fault:
Clutches squeal/whine during inching

In 1st (5th) In 2nd (6th)

and 3rd (7th) and 4th (8th)
gears only? gears only?

Pressure test C4 Pressure test C4

clutch. Is pressure clutch. Is pressure
250–280 lbf.in2 250–280 lbf.in2
(17–19 bar)? (17–19 bar)?

Suspect Suspect
leaking clutch leaking clutch
seals or leak seals or leak
in circuit to Suspect worn in circuit to
clutch clutch plates clutch

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 37

DIAGRAM 9: The tractor drives in all gears and in all ranges but has the following fault:
Transmission is noisy in operation

Is the Fault in the lube supply

transmission to transmission. Refer to
lube warning light Section 35, Hydraulics.
illuminated? Is the transmission noisy
after lube system repair?

Adjust as required and

Is the oil level investigate reason for
correct? oil loss (leakage)

Is the correct grade Drain and refill with

of oil used? correct grade of oil

Suspect failure
within
transmission, worn
bearings, worn or
failed parts

DIAGRAM 10: The tractor drives in all gears and ranges but has the following fault:
Transmission clunks during inching

Perform Clutch spring calibration

on C1 and C2 Clutches. Does
Transmission still clunk?

Tractor okay
Perform manual clutch fill time
calibration, HE menu mode, on
C1 and C2 clutches. Does
transmission still clunk after fill
time calibration?

Perform clutch pressure test

Suspect worn clutches.

Examine and replace as
required

604.55.041.02 –01–2000
38 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 11 – Error Code E11

C077

1 C2–7
G Y/R/B Y/R/B
C128–19
O 2
C4–6
LN LN +5 Volt
C127–5
B 3
C4–5 B
B
C127–1

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 39

DIAGRAM 11 – Error Code E11 – Clutch potentiometer voltage below valid range
Key OFF
Enter Diagnostic Mode H9 In Mode H9 Key ON
channel 0. Operate the clutch channel 0.Does Recheck
pedal. Is the value continuously the value ever
less than 14? drop below 14 Inspect wiring for
during cycling of intermittent fault
the clutch pedal whilst in H9
mode channel 0
Are the connectors to the
potentiometer and processor Replace
okay? potentiometer

With processor and

potentiometer connectors Locate and
disconnected. Is there an open repair short to
circuit to chassis between chassis
C077–1 and C128–19

Check operation of potentiometer. Remove left hand side panel below instrument
cluster to expose potentiometer and wiring. Disconnect plug to potentiometer and
check operation of potentiometer:
Between the orange and green wires. With pedal released, is resistance 0.32KΩ,
gradually changing to 2.5kΩ as the clutch pedal is depressed
and
Between the green and black wires With pedal released, is resistance 3.6KΩ,
gradually changing to 1.5kΩ as the clutch pedal is depressed?

Replace
potentiometer

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

604.55.041.02 –01–2000
40 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 12 – Error Code E12

C077

1 C2–7
G Y/R/B Y/R/B
C128–19
O 2
C4–6
LN LN +5 Volt
C127–5
B 3
C4–5 B
B
C127–1

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 41

DIAGRAM 12 – Error Code E12 – Clutch potentiometer voltage above valid range
Key OFF
Key ON
Recheck
Enter Diagnostic Mode H9 In mode H9
channel 0. Operate the clutch channel 0. Does Inspect wiring
pedal. Is the value continuously the value ever for intermittent
greater than 95. rise above 95 fault whilst in
during cycling of H9, Channel 0
the clutch pedal?

Replace potentiometer
Disconnect potentiometer
connector C077. Between pin 1 Locate and
and chassis. Is the voltage 0 repair short
volts? between C077–1
and C128–19

Disconnect potentiometer Locate and repair

connector C077. Between pin 3 short between
and chassis. Is the voltage 0 C077–3 and
volts? C127–1

Check operation of potentiometer. Remove left hand side panel below instrument
cluster to expose potentiometer and wiring. Disconnect plug to potentiometer and
check operation of potentiometer:
Between the orange and green wires. With pedal released, is resistance 0.32KΩ,
gradually changing to 2.5kΩ as the clutch pedal is depressed
and
Between the green and black wires With pedal released, is resistance 3.6KΩ,
gradually changing to 1.5kΩ as the clutch pedal is depressed?

Replace
potentiometer
With the key OFF is
Locate and repair open
there continuity
circuit between
between C077–3 and
C077–3 and C127–1
chassis?

Remove, inspect and refit

processor connectors C127
and C128. If error still occurs
replace processor

604.55.041.02 –01–2000
42 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 13 – Error code E53 – 5 volt reference failed, shorted to battery voltage
Error code E54 – 5 volt reference failed, shorted to earth.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 43

DIAGRAM 13 – Error code E53 – 5 volt reference failed, shorted to battery voltage
Error code E54 – 5 volt reference failed, shorted to earth.

Leave the clutch pedal

potentiometer disconnected
during the following checks:

Disconnect the EDC control Replace the EDC

panel connectors. Is the error still control panel
displayed?

Disconnect the EDC rocker shaft Refer to EDC error

potentiometer. Is the error still codes 27 & 28 in the
displayed? hydraulics section

Disconnect the quadrant Refer to EDC error

potentiometer. Is the error still codes 25 & 26 in the
displayed? hydraulics section

Replace the processor with a Clear the processors

unit of known performance is the memory using mode H8.
error still displayed? Recalibrate the
transmission and EDC
systems.

Trace and repair a short circuit to

chassis or battery voltage
between C127–5 and either the
clutch potentiometer, EDC
control panel, EDC, rocker shaft
or quadrant potentiometers.

604.55.041.02 –01–2000
44 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 14 – Error Codes E37, E48 and E47

FS–13
C4–9
15A 7000D
C127–35
U/R/B U/R/B

C076

3 C2–12
R/U/B R/U/B
C127–30
7660
C076

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 45

DIAGRAM 14 –

Error Code E37 displayed – Clutch disconnect switch open circuit

Check switch adjustment and switch operation,

if okay trace break in wiring (open circuit).

Error Code E48 displayed – Clutch disconnect switch short circuit

Check switch adjustment and switch operation,

if okay trace short circuit in wiring.

Error Code E47 displayed – Clutch disconnect maladjusted high

Check switch adjustment and operation of switch.

NOTE: With each of these error codes also check that the clutch potentiometer
operates over the full range using Service mode HA. If the range is not 0–99
then refer to ‘Clutch Potentiometer calibration’ Diagram 5.

604.55.041.02 –01–2000
46 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 15 – PWM Solenoids

CO20–5
7810 – K/N/B
C127–11 A
C020–6 C028
7815 – K/O/P
C127–36 B

C020–10
7820 – K/P/B
C127–14 A
C020–11 C027
7825 – K/R/B
C127–13 B

C020–12
7830 – K/S/B
C127–18 A
C020–13 C026
7835 – K/U/B
C127–26 B

C020–3
7840 – K/W/B
C127–17 A
C020–4 C025
7845 – K/Y/B
C127–12 B

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 47

DIAGRAM 15 – PWM Solenoids

Error Code E38 displayed – C4 (C25) PWM solenoid wiring short circuit
Error Code E39 displayed – C4 (C25) PWM solenoid wiring open circuit
Error Code E40 displayed – C3 (C26) PWM solenoid wiring short circuit
Error Code E41 displayed – C3 (C26) PWM solenoid wiring open circuit
Error Code E42 displayed – C2 (C27) PWM solenoid wiring short circuit
Error Code E43 displayed – C2 (C27) PWM solenoid wiring open circuit
Error Code E44 displayed – C1 (C28) PWM solenoid wiring short circuit
Error Code E45 displayed – C1 (C28) PWM solenoid wiring open circuit

Error codes E38 through to E45 indicate either a short or open circuit in the wiring
of one of the PWM solenoids. Using a suitable multi–meter check the wiring from the PWM solenoid
back to the processor module. Locate the short/open circuit and repair or replace wiring as necessary.

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

If wiring and PWM solenoids are okay, replace the microprocessor with one of known performance.

604.55.041.02 –01–2000
48 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 16 – The creeper does not engage in low range – possibly error code E16 or
Symbol ‘C’ displayed

7590 – O/W/B
C127–3 2
5200 – N/R/B 1003 G or 1031 R/N
C079–6 1

F12 C192
10A 7070 – R/LG/B
A

2200 G/N/B
C128–22 B

C020–44
7005 – U/P/B 7005 – U/P/B
C127–15 2
C222
1

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 49

DIAGRAM 16 – The creeper does not engage in low range – possibly error code E16 or
Symbol ‘C’ displayed

Start tractor, depress With creeper switch and

clutch, select low range, Is error code E16 clutch pedal depressed,
engage creeper. Is ‘C’ displayed? does +12v exist at
displayed on C127–3?
transmission display? NO
Check wiring between
transmission harness Check continuity
Engage main lever in and processor. Does between fuse 12 and
5th gear and release continuity exist between switch (colour R/LG/B)
clutch to move tractor. C127–15 (U/P/B) and and between switch and
Is creeper mechanically C222–2 (U/P/B)? C127–3 (colour O/W/B)
engaged? NO

Is there continuity
Drive tractor, does error between C222–1 (B)
code ‘C’ reappear? Repair or replace
and earth? harness
NO
System
okay

Check for intermittent

connection at wheel
speed sensor or creeper
solenoid

Restart tractor, re–engage

creeper. Pressure test at Check pressure in Repair system
creeper port. Is pressure low pressure circuit. pressure fault, then
Is pressure 265–295 re–check creeper.
265–295 lbf. in2 (18–20
bar)? lbf. in2 (18–20 bar)?

Clean or replace
Mechanical fault.
creeper solenoid.
Disassemble transmission
and inspect creeper
components. Inspect
creeper piston for sticking,
coupling for damage,
internal leakage.

604.55.041.02 –01–2000
50 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 17 – Code HC displayed

1. High range switch

2. Low range switch

F12 C020–12
10A 7070 – R/LG/B
C167–A

C020–37 7220 – S/N/B

C128–1 C167–B

7220 – S/N/B
C104–8

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 51

DIAGRAM 17 – Code HC displayed

Was shift lever moved to YES Is hydraulically actuated

604.55.041.02 –01–2000
52 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 18 – Error code CP displayed – depress clutch pedal to re–enable

transmission

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 53

DIAGRAM 18 – Error code CP displayed – depress clutch pedal to re–enable

transmission

Has tractor been shifted Depress clutch pedal or

from neutral with clutch depress shuttle dump
pedal released. switch with FNR lever in
NO neutral to re–enable
transmission.

Inspect for loose harness

Check for an intermittent open circuit on the neutral/start

inhibitor switch wiring:
With the key start OFF and the FNR lever in N, connect a
Locate and repair
continuity meter between connector C128–27 (W/R) and
open circuit.
C1–E (W/R). Continuity should be indicated.
Twist the harness from C128 down to C001.
Is there always continuity.

Check for an intermittent fault in battery supply to processor.

Locate and repair
Check for continuity between fuse 13 output and C127–34
open circuit.
(U/R/B) and C127–35 (U/R/B). Is there always continuity?

Check for an intermittent fault in ground wiring to processor.

Check for continuity between C128–32 (LN/O/B), C128–33 Locate and repair
(LN/LG) and C127–9 (B) and ground. open circuit.
Is there always continuity.

Remove and inspect the start inhibitor switch. Replace with a Discard removed
switch of known performance. Test drive tractor. switch
Is error code still displayed?

Suspect fault with rail in transmission top cover.

Remove top cover and inspect.

604.55.041.02 –01–2000
54 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 19 – Error code E46 displayed – Fuse 12 blown.

FS–12
7070 – R/LG/B 10A
C128–6

C020–12
C104–6
C165–2

C103–1 C164–1

C167–1
C196–1
C166–1

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 55

DIAGRAM 19 – Error code E46 displayed – Fuse 12 blown.

No power to switches, 1–4/5–8/shuttle dump/high range/low range/powershift up–down and
gearshift display module.

Key OFF
Key ON
Recheck

Disconnect C128 from the processor and confirm

Is fuse 12 blown? continuity between fuse 12 and C128–6 (R/LG/B). If
no continuity exists, trace and repair the open
circuit.

Replace fuse 12 (10 amp). Fuse may have failed through fatigue, check wiring
Operate tractor. to ensure there is no intermittent fault.
Does fuse blow again?

Ensure key start is OFF

and fuse 12 is removed. Inspect harness, twist harness with meter still
Disconnect C128 from the connected to ensure no intermittent fault. If no
processor. With a suitable intermittent fault is found, check with meter between
multi–meter check C128–6 (R/LG/B) and other C127/C128 terminals. If
between C128–6 (R/LG/B) an open circuit is indicated, trace and repair the
and earth. Is a short circuit fault in the harness.
indicated?

Disconnect connector C184, is a short circuit still indicated

between C128–6 and earth?
NO
With the multi–meter still Connect meter between Inspect connector,
connected between C184–13 and earth. Is ensure it is clean
C128–6 and earth, and continuity indicated? and undamaged.
C184 disconnected,
disconnect connectors Trace and repair
C104, C103 and the Disconnect C20 short circuit
shuttle dump switch connector. Is continuity between C20–12
connector C196. Observe still indicated? (U/LG/B) and
the meter while switches.
disconnecting, if continuity
Trace and repair short
to earth is broken after a
between C184–13
connector is disconnected
(R/LG/B) C20–12
the fault lies within that
(U/LG/B) and fuse 12.
circuit. If continuity still
exists, fault lies in harness.
Inspect harness, repair or
replace faulty wiring.

604.55.041.02 –01–2000
56 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 20 – Error Codes E51 or E52

7500 – B/G C020–42 7500 – B/G

C128–18 C023

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 57

DIAGRAM 20 – Error Codes E51 or E52

Transmission oil Temperature wiring open circuit or short circuit
NOTE: E51 may be generated in extreme cold conditions, i.e, less than –305C
E52 may be generated in extreme hot conditions, i.e, greater than 1305C
Key OFF
Key ON
recheck
For error E51 check connector,
C023 at sensor, is connector Refit connector
connected?

Inspect wiring between

Enter diagnostic mode H9. oil sensor and C128–18
Channel 1. Is the value outside for an intermittent
the range of 7 – 89? short/open circuit, with
H9 channel 1 still
selected.

Is there a Locate and

Is the value less short circuit repair short
than 7 on wiring? circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 Ω at 20°C or
300 Ω at 40°C?

Is the value Is there an Locate and

greater than 89 open circuit on repair open
wiring circuit

Check the resistance of

the sender. Is the
resistance approximately Replace sender
600 Ω at 20°C or
300 Ω at 40°C?

604.55.041.02 –01–2000
58 SECTION 21– TRANSMISSIONS– CHAPTER 7

NOTES

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 59

DIAGRAM 21 – Error Code E24 – all clutches not calibrated

Error Code EC4 – clutch 4 not calibrated
Error Code EC3 – clutch 3 not calibrated
Error Code EC2 – clutch 2 not calibrated
Error Code EC1 – clutch 1 not calibrated

Perform spring calibration procedure to clear error.

Note: These errors will only occur after installation of a new processor or after a ’H8’ (clear processor
memory operation)

604.55.041.02 –01–2000
60 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 22 – E15 – High/Low switches both ON

1. High range switch

2. Low range switch

C020–26 7230 – S/O/B

C128–2 C166–B

7030 – U/LG/B
C166–A

F12 C020–12
10A 7070 – R/LG/B
C167–A

C020–37 7220 – S/N/B

C128–1 C167–B

7220 – S/N/B
C104–8

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 61

DIAGRAM 22 – E15 – High/Low switches both ON

At the harness Locate

connector of the and
affected switch repair
check for battery short to
voltage on one battery
terminal only. Is voltage.
voltage correct?
Remove, inspect and refit
processor connectors, C127
and C128. Key OFF, Key
ON and recheck, if fault still
occurs replace processor.
Remove processor Trace
connector C128. and
Check for voltage at repair
either C128–1 (High short to
Range) or C128–2 battery
(Low Range) (with voltage.
switch
disconnected). Is
zero volts indicated?

Replace the gear

display module

604.55.041.02 –01–2000
62 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 23 – E14 – 1–4/5–8 switches both ON

7010 – U/N/B C020–39 7010 – U/N/B

C128–3 C164–A

7030 – U/LG/B
C164–B

F12
C020–12
10A 7070 – R/LG/B 7030 – U/LG/B
C165–A

7020 – U/W/B C020–40

7020 – U/W/B
C128–4 C165–B

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 63

DIAGRAM 23 – E14 – 1–4/5–8 switches both ON

Key OFF
Key ON
Enter Diagnostic mode H5 If d77 is not recheck
operate the range lever. Is d77 displayed remove
displayed when lever is shifted to 5–8 range switch
5–8 range and d81 displayed and check operation Replace
when lever is shifted to 1–4 In situ. If d81 is not faulty
range displayed remove switch
1–4 range switch
and check operation
in situ. are switches
functioning
Disconnect the dynamic correctly?
gear lamp display is the
error still displayed?

At the harness Locate

connector of the and
affected switch repair
check for battery short to
voltage on one battery
terminal only. Is voltage.
voltage correct?
Remove, inspect and refit
processor connectors, C127
and C128. Key OFF, Key
ON and recheck, if fault still
occurs replace processor.
Remove processor Trace
connector C128. and
Check for voltage at repair
either C128–4 (5–8 short to
Range) or C128–3 battery
(1–4 Range) (with voltage.
switch
disconnected). Is
zero volts indicated?

Replace the gear

display module

604.55.041.02 –01–2000
64 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 24 – ERROR CODE E55 No Signal From Output Speed Sensor

Mechanical fault within

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

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 65

NOTES

604.55.041.02 –01–2000
66 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 25 – ERROR CODE E56 Differential Lock Switch Error

C219–10
5030–LN/R 5030–LN/R
C127–2 C183–6

C219––9
7170–B/W 7170–B/W
C128–25 C183–1

5010–B C219–12
5010–B
C127–1 C183–3

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 67

DIAGRAM 25 – ERROR CODE E56 Differential Lock Switch Error

Key OFF
Key ON
recheck

Enter Diagnostic mode H5 Remove switch and

operate the diff lock switch. Is Replace
check operation. Is faulty
d91 displayed in Manual position switch functioning
and d99 displayed in auto switch
correctly?
position?

Disconnect switch connector

604.55.041.02 –01–2000
68 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 26 – Error Code E49

C020–23
5010–B 5035–LN/G 5035–LN/G 5140–TQ/N
C127–1 C046–2

C020–43
5135–T/Q 5135–T/Q
C127–6 C046–1

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 69

DIAGRAM 26 – Error Code E49

Wheel speed sensor open or short circuit.

Key OFF
Key ON
recheck
Enter diagnostic mode H9 Inspect wiring between
channel 20. Is the value outside speed sensor and
the range of 46–83? C127–6. For an
intermittent short/open
circuit with H9 channel
20 still connected
Is the value less Is there a short
than 46 Locate and repair
circuit on wiring short circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500Ω

Is the value
greater than 89 Is there an open Locate and repair
circuit on wiring open circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500Ω

604.55.041.02 –01–2000
70 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 27 – Error Code E26 displayed – ERPM signal too high

C001–F
2015–W/S 2015–W/S 2015–W/S
C128–34 C013–W/S

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 71

DIAGRAM 27 – Error Code E26 displayed – ERPM signal too high

Connect a volt meter between

the alternator speed connector
and ground. Is there Repair or replace
approximately 7 volts? With the alternator.
engine running.

The following checks must be carried out with the engine

stopped and key start switched OFF.

Suspect an intermittent fault. With an ohm meter connected Locate and repair
between C128–34 (W/S) and the alternator speed connection, intermittent short
twist the wiring harnesses along their length, especially near to circuit to ground.
the connectors. Does the resistance stay the same?

Suspect an intermittent fault to ground. With an ohm meter

connected between C128–34 (W/S) and ground and the Locate and repair
alternator speed connector disconnected, twist the wiring intermittent short
harnesses along their length, especially near to the connectors. circuit to ground.
Does the meter indicate a short to ground?

Remove, inspect and refit

connectors C127 and
C128 of the processor. If
the error still occurs
replace the processor.

604.55.041.02 –01–2000
72 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 28 – Error Code E27 displayed – ERPM signal not present

C001–F
2015–W/S 2015–W/S 2015–W/S
C128–34 C013–W/S

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 73

DIAGRAM 28 – Error Code E27 displayed – ERPM signal not present

Wheel speed sensor open or short circuit.

Key OFF
Is the instrument Key ON
cluster displaying recheck
engine RPM

Is the alternator drive

Replace drive belt
belt okay

Establish if there is a speed output from the

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

The following checks must be carried out with

the engine stopped and key start switched OFF.

Check alternator Check for short circuit Locate and repair

wiring for continuity: in wiring. With C128 short circuit to
Disconnect connector disconnected and ground referring
C128 from processor alternator wire to circuit diagram.
module and check disconnected, check
resistance to ground Remove, inspect
between C128–34
and refit
(W/S) and alternator from pin C128–34
connectors C127
speed sender (W/S). Is resistance
less than 10 ohms? and C128 of the
connection. Is an
processor. If the
open circuit
error still occurs
indicated?
replace the
processor.
Check for continuity Locate and repair
between C128–34 open circuit in main
(W/S) and C001–F harness.
(W/S). Is wire okay?

Check for continuity Locate and repair

between alternator open circuit in engine
connector and C001–F harness.
(W/S). Is wire okay?

Is there continuity
between C128–34 Locate and repair
and alternator speed open circuit in main
connection. rear harness.

Remove, inspect and refit

connectors C127 and C128 of
the processor. If the error still
occurs replace the processor.

604.55.041.02 –01–2000
74 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 29 – Error Code E59 displayed – Forward/Neutral/Reverse Switch

disagreement (More than one or no switches applied)

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 75

DIAGRAM 29 – E59 – Forward/Neutral/Reverse Switch disagreement (More than one or

no switches applied)
EFFECTS – Transmission enabled

Key OFF
Key ON
recheck

Suspect
Using diagnostic Menu Mode H5 (switch intermittent fault.
diagnostics), operate shutttle lever, are Wiggle test wiring
switches functioning okay? from the shuttle
(forward = d22) lever switch to the
(reverse = d23) processor.

Disconnect shuttle switch assembly

connector, C075 and processor
connector, C128. Trace and repair
Is an open circuit indicated between fault in wiring
C075–4 (7420A–Y/P/B) and C128–27?

Clean/replace the switch assembly

604.55.041.02 –01–2000
76 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 30 – Error Code E60 displayed – Forward Synchroniser becomes disengaged

Error Code E69 displayed – Reverse Synchroniser becomes diisengaged

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 77

DIAGRAM 30 – E60 – Forward Synchroniser becomes disengaged

E69 – Reverse Synchroniser becomes disengaged
EFFECTS – Transmission is Disabled

Key OFF
Key ON
recheck

Ensure the tractor is test

’N’ is displayed. Cycle the shuttle lever to driven in different gears
re–engage. Is the fault re–occuring? and conditions to
determine if the error
was a one off occurence

Perform the synchroniser calibration

procedure. Test drive the tractor, does Tractor okay
the error re–occur?

Remove the cab floor and remove the top Adjust fork to rail position.
plate of the top cover. Are the fork to rail Tighten lockscrews and
locking screws tight? test operation

Is the fork to rail position adjustment Adjust as described in

correct? the overhaul section.

Remove the top cover and inspect the Replace damaged parts
detents, forks and rails. Are the top cover as required. Refit top
components serviceable? cover and test operation

Suspect a faulty synchroniser. Dismantle

the transmission and inspect the
synchroniser.

604.55.041.02 –01–2000
78 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 31 – Error Code E61 displayed – Synchro Potentiometer voltage too high
Error Code E62 displayed – Synchro Potentiometer voltage too low

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 79

DIAGRAM 31 – E61 – Synchro Potentiometer voltage too high

E62 – Synchro Potentiometer voltage to low
EFFECTS – Transmission is Disabled

Key OFF
Key ON
recheck

Remove floor pan and disconnect synchroniser

potentiometer connector.
Using a suitable multi–meter, is either a short Trace and repair
to +12V/+8V or to earth indicated between fault in wiring
potentiometer harness connector, C158–2,
(7960–P/K/B) and black processor connector
C128–17?

Check potentiometer operation. Replace

Is a short circuit indicated? potentiometer

Substitute processor with one of

known performance.

604.55.041.02 –01–2000
80 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 32 – Error Code E63 displayed – Synchroniser not fully engaging into forward
Error Code E64 displayed – Synchroniser not fully engaging into reverse

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 81

DIAGRAM 32 – E63 – Synchroniser not fully engaging into forward

E64 – Synchroniser not fully engaging into reverse
EFFECTS – Transmission is Disabled

Key OFF
Key ON
recheck

’N’ will be displayed. Cycle the shuttle lever to

attempt re–engagement. Synchroniser
possibly sticking, is the error still generated
after cycling the shuttle lever?

Repair fault as
Perform the Synchroniser calibration routine. indicated by the
Are any ’U’ codes displayed? ’U’ Code.

Remove the floor pan and remove the

synchroniser position potentiometer. Enter
menu mode H9, channel 27. Rotate the Replace
potentiometer manually and observe the potentiometer
cluster display. Is the potentiometer
functioning correctly?

Pressure test the synchroniser operating piston. Suspect a faulty PWM

Is the pressure approximately 16 bar when solenoid valve.
actuated? Clean/replace and retest

Suspect mechanical fault within transmission.

Possible synchroniser failure or sticking piston.
Remove top cover and inspect.

604.55.041.02 –01–2000
82 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 33 – Error Code E65 displayed – Forward Synchroniser solenoid open circuit
Error Code E66 displayed – Reverse Synchroniser solenoid open circuit

C242

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 83

DIAGRAM 33 – E65 – Forward Synchroniser solenoid open circuit

E65 – Reverse Synchroniser solenoid open circuit
EFFECTS – Transmission is Disabled

Key OFF
Key ON
recheck

Remove floor pan and disconnect affected solenoid.

Test across solenoid terminals with a suitable Replace solenoid
multi–meter. Is an open circuit indicated?

Disconnect processor connectors.

Test for an open circuit between C242–28 and
C157–RM8030–LG/O/S, and between C242–22
and C157–RM8035–R/N/S, for E65.
Test for an open circuit between C242–27 and
C156–RM8045–P/LN/S and between
C156–RM8040–LG/P/S and C242–23, for E66.
Trace fault and repair/replace wiring as required.

604.55.041.02 –01–2000
84 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 34 – Error Code E67 displayed – Forward Synchroniser solenoid short circuit
Error Code E68 displayed – Reverse Synchroniser solenoid short circuit

C242

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 85

DIAGRAM 34 – E67 – Forward Synchroniser solenoid short circuit

E68 – Reverse Synchroniser solenoid short circuit
EFFECTS – Transmission is Disabled

Key OFF
Key ON
recheck

Remove floor pan and disconnect affected solenoid.

Test across solenoid terminals with a suitable Replace solenoid
multi–meter. Is an open circuit indicated?

Disconnect processor connectors.

Test for an short circuit between C242–28 and
C157–RM8030–LG/O/S, and between C242–22
and C157–RM8035–R/N/S, for E67.
Test for an short circuit between C242–27 and
C156–RM8045–P/LN/S and between
C156–RM8040–LG/P/S and C242–23, for E68.
Trace fault and repair/replace wiring as required.

604.55.041.02 –01–2000
86 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 35 – ERROR CODES:

E70 – Shuttle lever forward switch voltage too high
E71 – Shuttle lever forward switch voltage too low
EFFECT – Tractor will operate normally, except there will be a short delay recognising that
forward has been selected.

Disconnect the transmission/EDC processor

connector C242, and disconnect connector,
C075 to forward/reverse/neutral switch Trace and repair
assembly. Using a suitable multimeter, check faulty wiring
between C242–32 & C075–2, (CM7250–S/R).
For: (1) Open Circuit (2) Short to earth. Is
either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

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

Trace and repair Reconnect forward/reverse/neutral

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

C242

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 87

DIAGRAM 36 – ERROR CODES;

E72 – Shuttle lever reverse switch voltage too high
E73 – Shuttle lever reverse switch voltage too low
EFFECT – Tractor will operate normally, except there will be a slight delay recognising that
reverse has been selected.

Disconnect transmission/EDC processor

connector C242, and disconnect connector, C075
to forward/reverse/neutral switch assembly. Using Trace and repair
a suitable multimeter, check between C242–33 & faulty wiring
C075–3 (CM7260–S/U). For: (1) Open Circuit (2)
Short to earth. Is either condition indicated?

Reconnect processor connectors. Leave forward/reverse/neutral

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

Trace and repair Reconnect forward/reverse/neutral

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

C242

604.55.041.02 –01–2000
88 SECTION 21– TRANSMISSIONS– CHAPTER 7

DIAGRAM 37 – Error Code N displayed

Clutchless shuttle operation attempted at too high a speed and in too high a gear

A warning bleeper and symbol ‘N’ are activated under the following conditions:

• In high range 5–8 gears, shuttling while tractor is still rolling.

• In high range 2–4 gears, shuttling while tractor is rolling faster than 9 Km/h (5.5 mph)

Important: The clutchless shuttle will still operate under the warning conditions. Clutch
damage may occur if the shuttle operation is carried out.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 89

PRESSURE TESTING

Forward / Reverse Synchroniser

Prepare the tractor for pressure testing:
1. Lift and remove the cab rubber mat and remove
the floor pan.
2. Start and run the tractor to warm the
transmission oil to a minimum temperature of
20°C (68°F).

ÏÏ
3. Obtain suitable pressure gauges, (0–40 bar,
0–600 lbf.in2), and hoses, Figure 48,

ÏÏ 2

ÏÏ
1. Pressure gauge, FT8503A, with adaptor 1
FT8503–8
2. Quick release adaptor, Pt No.291924
3. Adaptor, 297153 (7/16x20 JIC–1/4x18NPSF)
3
4. Hose, (Finis Code 3936707)

48
4. Install the transmission side quick release
couplers (part number 86502603 or special tool
No.297240) into the forward (F) and reverse (R)
test ports. The test ports have a 7/16 UNF
thread.

49
5. Install the gauges onto the forward and reverse
pressure test port couplers. Figure 49.

NOTE: Due to the operating characteristics of the

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

604.55.041.02 –01–2000
90 SECTION 21– TRANSMISSIONS– CHAPTER 7

Entering the calibration mode :

Press and hold both the upshift and downshift
buttons whilst starting the tractor.

51
Alternative method :
Install diagnostic tool 4FT950 into the Black
diagnostic connector, located by the fuse box.
Start the tractor.
Enter mode H1.

52
The word CAL should appear on the instrument
cluster display. This will be replaced after a few
seconds by the oil temperature, in degrees Celsius.
Set the engine speed to 1200 +/– 100 rpm.
NOTE: The engine RPM must be stable with no
noticeable surging. If necessary, adjust the throttle
position to achieve this, still remaining within the
1200 +/– 100 rpm range.

53
Place the two gear levers in the forward position.
NOTE: No need to use the clutch pedal.

604.55.041.02 –01–2000
SECTION 21– TRANSMISSIONS– CHAPTER 7 91

Move the shuttle lever into the forward drive position.

55
Press and hold the upshift and downshift switches,
the display will show ’Soc’. Continue to hold the
upshift and downshift buttons.

56
The gearshift display will now sequence through
figures ’1’, ’2’, ’3’ and ’4’. When the display reads
’End’, calibration of the transmission synchronisers
has been completed, release the upshift and
downshift buttons.
The display then returns to CAL then temperature
display.

57
The table (Figure 58) shows the synchroniser Pressures
calibration stages and at what stage pressure can be
expected to be seen. Stage Forward (F) Reverse (R)
Maximum pressure should be between 18–20bar SOC YES NO
(260–290lbf.in2).
1 NO NO

2 NO YES
3 4–5 bar NO
4 YES NO
END NO NO
58

604.55.041.02 –01–2000
92 SECTION 21– TRANSMISSIONS– CHAPTER 7

604.55.041.02 –01–2000
SECTION 23 -- DRIVE LINES -- CHAPTER 1 1

SECTION 23 -- FRONT AXLE

Chapter 1 -- Four Wheel Drive Axle Transfer Box

Tractors With 8 x 2 And 16 x 4 Transmission

Section Page
23 200 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transfer Box -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
23 202 Transfer Box -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

23 200 SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS:
Type Rear axle centralised mounting with
electro/hydraulic actuation of dog type non slip
clutch. Mechanically engaged/electro--hydraulic
release.
Transfer Box Ratio 0.930:1 and 0.907:1
Idler Gear Teeth 44
Driven Gear Teeth 40 and 39
Clearances And Adjustments
Idler Gear Bearings rolling resistance 0.45 -- 1 Kgf (1 -- 2.2 lbf)
Adjustable by shims
Idler Gear Bearing Shims Available 0.10, 0.25, 0.30, 0.50 mm
Output Shaft Bearings Rolling Resistance 1.9 -- 4.5 Kgf (4.2 -- 9.9 lbf)
Adjustable by shims
Output shaft Bearings Shims Available 0.10, 0.25, 0.30, 0.50 mm
Clutch Spring Free Length 48.0 mm (1.889 in)
Oil Capacity
Transfer Box Assembly Lubricated by Rear Axle Oil
Increase in Rear Axle Oil Capacity
With Transfer Box Installed
Litres 1.3
Imp. Pints 2.2
U.S. Pints 2.6
Thread Sealant New Holland Thread Lock and Seal
Part Number 82995773

604.55.041.00 - 01 - 1998
2 SECTION 23 -- DRIVE LINES -- CHAPTER 1

TIGHTENING TORQUES:

COMPONENTS lbf. ft Nm

Transfer Box to Rear Axle Retaining Bolts 49 66

Driveshaft Bolts 42 57
Idler Gear Retaining Bolt 59 80
Oil Drain Plug 59 80
End Plate Bolts 38 51

SPECIAL TOOLS:

DESCRIPTION V.L. CHURCHILL NUDAY

LTD TOOLS TOOLS

Idler Gear Bearing Fixture FT3169 --

Pulling Attachment:
Small 951 9190
Puller:
Large 1003 9516

DESCRIPTION AND OPERATION

The transfer box assembly of four wheel drive The lower shaft is supported in two taper roller
tractors installed with either 8x2 or 16x4 bearings and has a sliding dog clutch splined to its
transmissions is mounted under the rear axle centre central portion. The driven gear carries a mating dog
housing and through a universally jointed drive shaft clutch and when not engaging with the sliding
passing along the central axis of the tractor, component is free to rotate on the shaft. The clutch
connects the output from the transmission to the four is engaged by four radially positioned springs and
wheel drive axle. released by hydraulic pressure signaled by an
electrical switch on the control console.
The transfer box features a simple dog type clutch
to engage the drive to the front axle.
Engagement/disengagement of the dog clutch is An electrically operated solenoid valve directs oil
controlled by a combination of hydraulic pressure from the low pressure hydraulic circuit, via an
taken from the low pressure hydraulic circuit and external tube to the rear end plate of the transfer box.
return springs within the transfer box assembly. When four wheel drive is disengaged by the
operator, the solenoid is actuated and oil flow is
A helical gear mounted on the rear axle pinion shaft directed through the short transfer tube to the central
transmits the drive through a mating helical idler bore of the lower shaft.
gear, carried in two taper roller bearings in the
transfer box to a driven gear on the lower shaft.
A moving double check valve positioned in this
Two ratios of transfer box 0.93:1 (44/40) and 0.907:1 central bore moves forward and the pressurised oil
(44/39) are available to suit the various front and rear flow passes through the centre of the valve by lifting
tyre sizes. The ratio is stamped on a plate located on the inner check valve of its seat, Figure 2.
the top left hand side of the transfer box case. The Pressurised oil on entering Gallery ‘A’ moves the
ratio is determined by the number of teeth on the sliding clutch against the radially positioned springs,
driven, lower, gear. To change the ratio the driven disengaging the dog teeth on the driven gear. The
gear is replaced with either a 39 or 40 tooth gear as driven gear is now free to rotate on the shaft and
appropriate. drive to the front axle is disconnected.

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 3

Transfer Box Assembly -- Cutaway View 1

1. Sliding Clutch 5. Electrical Supply Connection 9. Double Check Valve
2. Coil Springs (4 off) 6. Hydraulic Oil Supply 10. Oil Transfer Tube
3. Output Shaft 7. Sealing Rings 11. Driven Gear
4. Solenoid Valve 8. External Oil Tube 12. Idler Gear

Clutch Operation -- Schematic View 2

(Inset Showing Clutch Engagement)
1. Driven Gear 4. Return Springs (4 off) 7. Oil Exhaust Route
2. Oil Transfer Tube (inlet) 5. Spring Keeper Plate 8. Check Valve (ball seated, valve
3. Check Valve (ball unseated) 6. Sliding Clutch moved rearwards)

604.55.041.00 - 01 - 1998
4 SECTION 23 -- DRIVE LINES -- CHAPTER 1

When the operator engages four wheel drive the

electrical circuit to the solenoid is broken and the
solenoid deactivated. Hydraulic pressure to the
check valve now collapses and spring pressure
forces the sliding clutch towards the driven gear. As
the sliding clutch moves, discharging oil slides the
whole check valve rearwards; the inner primary
check ball will not allow oil to pass through the valve
centre from gallery ‘A’, hence the whole valve
slides rearwards. This movement exposes a large
exhaust path, through radial drillings in both the
shaft and the gear to the rear axle reservoir,
permitting a rapid engagement of the clutch. A
small amount of oil is also initially exhausted
through the solenoid to allow the check valve to
move.

23 202 TRANSFER BOX -- OVERHAUL

REMOVAL

1. Park the tractor on a hard level surface and

block the wheels.

2. Remove the drive shaft guard and drive shaft.

3. Remove the rear axle/transmission drain plug

(2), Figure 3 and allow the oil to drain into a
suitable container capable of holding 66 litres
(14.5 Imp. Galls, 17.4 U.S. Galls).

4. Remove the solenoid cover plate, (3) Figure 3

and disconnect the wires (2, 3 & 4) Figure 4
from the solenoid (2), Figure 4.

5. Disconnect the wire protecting tube (4)

Figure 3 from the side of the transfer box
casing.

6. Disconnect the hydraulic oil feed pipe (5),

Figure 3 from the casing.

7. Support the transfer box with a suitable jack,

remove the retaining bolts (1), Figure 3 and
lower the transfer box assembly away from the
tractor.
4

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 5

DISASSEMBLY

1. Remove the external oil tube linking the

solenoid port to the transfer box rear end plate.

2. Remove the solenoid coil (1) and unscrew the

core and valve assembly (2), Figure 5.

5
3. Remove the socket head bolt (3) securing the
idler gear and bearing assembly (2), Figure 6.
If necessary, carefully apply heat to the nut end
(1) to soften and release the thread locking
compound applied during manufacture.

6
4. Mark the front of the idler gear (1) to aid
reassembly. Drive out the central shaft (2) and
lift out the gear and bearing assemblies. Keep
the bearings (3), spacers and shims together
for possible re--use, Figure 7.

7
5. Remove the output shaft end plate (2). Collect
and identify the shims (1) positioned between
the plate and the bearing outer track, Figure 8.

604.55.041.00 - 01 - 1998
6 SECTION 23 -- DRIVE LINES -- CHAPTER 1

6. Remove the rear end plate (1), Figure 9.

Remove the short oil transfer tube from the
shaft (3), if this remained in the shaft.

7. Gently drive the output shaft forward and

backward and remove the front and rear
bearing outer tracks (2).

9
8. With the aid of an assistant, lever the clutch
spring keeper (2) against the clutch springs (3),
Figure 10, to release the load on the snap ring
(1), remove the snap ring.

9. Remove the four clutch springs.

10
10. Position two suitable lengths of steel rod or
tube (4) between the drive gear and the front of
the casing so that the shaft (3) may be pressed
through the driven gear (2), Figure 11.
Remove the bearing (1).

11
11. Ease the shaft forward as far as the clutch will
permit and lift out the drive gear and thrust
washer.

12. With the shaft still eased forward remove the

front bearing (3).

Removing Output Shaft Front Bearing

1. Shaft Protector
2. Tool No.1003 (9516)
3. Bearing
4. Tool No.951 (9190)
5. Output Shaft

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 7

13. Remove the clutch snap ring, passing it along

the waisted section of the shaft and over the
short splined area.

14. Ease the shaft (3) rearwards and draw the

clutch (2) forwards to expose the clutch rear
sealing ring (1), Figure 13. Remove the sealing
ring.

15. Carefully ease the shaft (3) rearwards and lift

out the clutch (1) and spring keeper (2),
Figure 14.

16. Remove the check valve (2) from the central

bore (3) of the shaft (1), Figure 15. Applying an
air line to the cross drilling between the clutch
sealing rings will aid removal.

604.55.041.00 - 01 - 1998
8 SECTION 23 -- DRIVE LINES -- CHAPTER 1

16
Transfer Box Assembly -- Exploded View
1. Bolt 9. Thrust Washer 17. Shim 25. Casing
2. Shim 10. Check Valve 18. Front End Plate 26. Oil Tube
3. Spacer 11. Driven Gear 19. Seal 27. Retainer
4. Idler Gear 12. Output Shaft 20. ‘O’ Ring 28. Shim
5. Rear End Plate 13. Sealing Rings 21. Bearing 29. Bearing
6. Oil Transfer Tube 14. Sliding Clutch 22. Spring -- 4 off 30. Shim
7. ‘O’ Ring 15. Spring Keeper 23. Solenoid Cover 31. Bearing
8. Bearing 16. Snap Ring 24. Solenoid/Valve 32. Shaft

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 9

INSPECTION AND REPAIR

1. Remove the ‘O’ ring seals from the shaft end

plates (1) & (2), Figure 17 and the remaining
sealing ring on the central area of the shaft.

17
2. Remove and discard the felt/lip seal (2) from
the output end plate (1), Figure 18. Do not
install a new seal at this stage.

3. Wash all components, including the actuating

valve, the oil transfer tube and the check valve
from the centre of the shaft, in a suitable
solvent and allow to air dry.

18
4. From the tractor remove the transfer box
hydraulic feed pipe, Figure 3, and clean the
small filter/screen positioned inside the now
exposed adaptor.

5. Inspect the valve core (4) ‘O’ rings (1) & (3) and
back up seals (2), renewing if required,
Figure 19.

19
6. Carefully inspect the idler gear bearings. If
worn or damaged, renew both bearings. Slide
the outer tracks (2) from the gear, Figure 20.

7. Inspect the idler gear (1) and lower gear teeth

for wear or damage. If wear or damage is found
also inspect the driving gear on the rear axle
pinion.

604.55.041.00 - 01 - 1998
10 SECTION 23 -- DRIVE LINES -- CHAPTER 1

8. Inspect the clutch dog teeth on both the sliding

clutch component (1) and the gear (2). If the
clutch dogs show wear, or are not square, then
both parts should be renewed, Figure 21.

9. Inspect the clutch springs for deformity and

cracks, check that the spring free length is
48 mm (1.889 in).

10. Inspect the clutch and shaft splines. Ensure

the clutch slides smoothly on the splines.

21
11. Inspect the lower shaft bearing assemblies.
Renew where necessary.

12. Inspect the output shaft to driveshaft spline for

damage and wear.

RE--ASSEMBLY

1. Install new ‘O’ ring seals on the two end plates

and install a new clutch sealing ring on the
smaller diameter of the shaft. Do not install the
larger sealing ring until the shaft has been
positioned inside the casing.

2. Coat the check valve with grease to retain in

the shaft during assembly and install the valve
(2) in the shaft (1). Ensure the valve is entered
with the spring facing forward and the ball to
the rear, Figure 22.

3. Thoroughly lubricate the inside of the clutch

and lay the clutch in the casing with the spring
keeper plate.

22
4. Pass the shaft (4) through the rear bearing
bore and through the clutch and keeper plate
(2). Before fully assembling the clutch on the
shaft, install the larger diameter sealing ring
(1). Lubricate both sealing rings (1) & (3),
Figure 23.

5. Fully assemble the clutch onto the shaft

moving the clutch to the fully closed position.

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 11

6. With the shaft (4) eased fully forward,

assemble the driven gear (3) and thrust
washer onto the shaft.

7. Using a suitable spacer (1), press the rear

bearing (2) onto the shaft whilst supporting the
front of the shaft, Figure 24.

8. Position the snap ring on the shaft, adjacent to

the keeper plate in the waisted section.

24
9. Using a suitable sleeve drive on the front
bearing, ensure the sleeve only bears on the
inner track.

10. Install the four clutch springs (3) and following

the disassembly procedure in reverse,
compress the keeper (2) and springs to install
the snap ring (1). Ensure the snap ring is fully
seated in its groove, Figure 25.

25
11. Ensure the check valve is still in position inside
the shaft, slide in the bearing outer track (2)
and install the rear end plate (1) with the oil
transfer tube (3), Figure 26. Tighten the bolts
to a torque of 38 lbf.ft (51 Nm).

26
12. Slide in the front bearing outer track and install
the front bearing retainer without its felt/lip seal
and shims. Tighten the bolts to a torque of
38 lbf.ft (51 Nm).

13. Access the degree of end float by mounting a

dial indicator against the clutch assembly and
moving the shaft forward and backwards,
Figure 27.

604.55.041.00 - 01 - 1998
12 SECTION 23 -- DRIVE LINES -- CHAPTER 1

14. Select shims equivalent to this end float

assessment and add a further 0.1 mm
(0.004 in) shim to the result.

15. Remove the front bearing retainer (2), install

the shim pack (1) and plate and hand tighten
the retaining bolts, Figure 28.

28
16. Measure the rolling resistance of the shaft
within its bearing, using a length of string (1)
wrapped around the output shaft and a spring
balance (2). Progressively tighten the bolts to a
final torque of 51 Nm (38 lbf.ft) and ensure the
rolling resistance is within 18--44 Nf (4.2-- 9.9
lbf). Only read the spring balance when the
shaft is rotating and ensure that the string does
not over wrap on the shaft, Figure 29.

29
17. If the rolling resistance is not within the
specified limits adjust the shim pack
accordingly. Add shims to increase the rolling
resistance, subtract shims to decrease.

18. When the correct rolling resistance is obtained,

remove the end plate and install a new felt/lip
seal. Carefully replace the end plate, taking
care not to damage the seal and tighten the
end plate retaining bolts to a torque of 38 Nm
(38 lbf.ft ).

19. Install the solenoid valve and oil transfer tube.

20. The idler gear can now be re--assembled, but

requires the pre--load on its taper roller
bearings to be calculated by measuring the
rolling resistance using special Tool No.
FT3169, using the following procedure:

(i) Slide the bearing outer tracks into the idler gear
and assemble the inner bearings with the
spacer and one 0.3 mm (0.012 in.) shim
between them.

604.55.041.00 - 01 - 1998
SECTION 23 -- DRIVE LINES -- CHAPTER 1 13

(ii) Mount this assembly on the special tool and

tighten the tool bolt to a torque of 68 Nm (50
lbf.ft), Figure 30.

1. Idler Gear
2. Special Tool No. FT3169
3. Spacer
4. Shim
5. Vice Grip

30
(iii) With the tool stock (1) mounted in a vice,
measure the rolling resistance of the bearings
by wrapping a length of string (2) around the
gear and using a spring balance (3), Figure 31.
Make the reading as the gear rotates, not at the
point where rotation begins.

31
(iv) Increase the value of the shim placed between
the bearings (1) to reduce the rolling resistance
or decrease the value to increase the rolling
resistance. Adjust the shims (3) until the
resistance is between 4--10Nf (1.0--2.2 lbf).

(v) When the specified rolling resistance is

achieved, measure the distance (2) across the
bearing inner races as shown in Figure 32.

32
(vi) Measure the distance across the casing idler
gear mounting lugs, Figure 33.

(vii) Subtract the bearing width measurement from

the casing lug measurement and make up a
shim pack equal to this result. Divide the
resultant value by two where possible and
place half the value of shims on each side of
the bearing assemblies. It is not essential that
these shims be exactly equal as long as the
sum total of the two sets of shims equals the
required amount.

604.55.041.00 - 01 - 1998
14 SECTION 23 -- DRIVE LINES -- CHAPTER 1

Example:
Width of bearing races, Figure 32,
= 3.75 mm

Width of transfer case lugs, Figure 33,

= 3.95 mm

3.95 -- 3.75 = 0.2 mm

Therefore two shims are required, each of 0.1 mm.

Add one shim to each side of the bearing.

21. Remove the idler gear from the special tool.

Lightly lubricate and assemble the gear (1),
bearings, spacer (4) and predetermined shim
(2), (3) & (6) values to the transfer casing (5) as
shown in Figure 34. Apply a suitable thread
locking compound, New Holland Part Number
82995773 and tighten the idler gear retaining
bolt to a torque value of 80 Nm (59 lbf.ft).

34
INSTALLATION
1. Installation of the transfer box assembly
follows the removal procedure in reverse.

IMPORTANT: Use only the approved gasket

between the transfer box and rear axle housing.
Any variation in thickness and material from that
specified may result in excessive gear noise or
premature gear wear.

2. Tighten the transfer box retaining bolts to a

torque of 66 Nm (49 lbf.ft). Tighten the
driveshaft bolts to a torque of 57 Nm (42 lbf.ft).
Apply thread locking compound, New Holland
Part Number 82995773 to the drive shaft to
axle drive flange coupling bolts.

3. Fill the rear axle with the correct quantity and

grade of oil.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 1

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION

Chapter 1 -- FRONT AXLE FOUR WHEEL DRIVE

CONTENTS
Section Description Page

25 000 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 Removal -- Installation -- Overhaul of front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

25 000 -- MAIN DATA -- TIGHTENING TORQUES -- CROSS--SECTIONAL VIEWS -- TOOLS --

DESCRIPTION AND OPERATION -- FAULT DIAGNOSIS

SPECIFICATION

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steering, load bearing structure,

pivoting at centre

Bevel gear pair -- differential

Pinion--crown gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . 10/32 = 3.2:1

mm inches

Backlash between bevel gear pair . . . . . . . . . . . . . . . . 0.15--0.20 0.006--0.008

Thickness of pinion position adjustment spacer

(7), page 6 and (4), page 8 . . . . . . . . . . . . . . . . . . . . . . 2.5 up to 3.7 in 0.1 in- 0.098 up to 0.145
tervals in 0.004 intervals

Thickness of pinion bearing adjustment spacer (8), 2.5 up to 4.8 0.098 up to 0.189
page 6 and (5), page 8 . . . . . . . . . . . . . . . . . . . . . . . . . . in 0.05 intervals in 0.002 intervals

604.55.041.00 - 01 - 1998
2 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

SPECIFICATION

mm inches
Thickness of crown wheel position adjustment spacer 0.9 -- 1 -- 1.1 -- 1.2 -- 0.035 -- 0.039 -- 0.043 --
(3, page 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 1.4 -- 1.5 -- 1.6 -- 0.047 -- 0.051 -- 0.055 --
1.7 -- 1.8 -- 1.9 -- 2 0.059 -- 0.062 -- 0.067 --
0.071 -- 0.075 -- 0.079

Backlash between planet pinions and side gears . . . . . 0.15 0.006

Thickness of planet pinion thrust washers . . . . . . . . . . . . 1.470 -- 1.530 0.058 -- 0.060

Thickness of side gear thrust washers . . . . . . . . . . . . . . . 1.4 -- 1.5 -- 1.6 -- 1.7 -- 0.055 -- 0.059 -- 0.063 --
1.8 0.067 -- 0.071

Diameter of cross pin for planet pinions: 23.939 -- 23.960 0.9425 -- 0.9433

Diameter of cross pin bore in planet pinions: 24.040 -- 24.061 0.946 -- 0.947

Clearance between cross pin and bores ............ 0.080 -- 0,122 0.003 -- 0.005

Diameter of side gear hubs . . . . . . . . . . . . . . . . . . . . . . . . 43.961 -- 44.000 1.731 -- 1.732

Diameter of side gear hub bores in differential cage . . . 44.080 -- 44,119 1.735 -- 1.737

Clearance between side gears and bores . . . . . . . . . . . 0.080 -- 0,158 0.003 -- 0.006

Differential lock, self locking

Single sided friction plate New 2.8 0.110

Minimum thickness 2.7 0.106

Double sided friction plate New 1.6 0.063

Minimum thickness 1.45 0.057

Steel separator plates New 1.5 0.059

Minimum thickness 1.4 0.055

Differential lock, hydraulically operated

Free length of spring (1, page 6): ! 87 3.425

Spring length under load of:

1888 -- 2035 N (192.5 -- 207.5 kg) ! 48 1.890

Axle shafts and steering knuckles

Diameter of outer axle shafts (5 and 7) in correspon- 41,975 -- 42,000 1.652 -- 1.653
dence with bushes (8):
Inside diameter of installed bushes (8), page 7: 42.100 -- 42.175(1) 1.657 -- 1.660
Clearance between axle shafts and bushes . . . . . . . . . . 0.100 -- 0.200 0.004 -- 0.008
Interference fit between bushes and respective bores . 0.064 -- 0.129 0.003 -- 0.005

Thickness of swivel bearing shims (7), page 7 . . . . . . . 0.10 -- 0.15 -- 0.20 -- 0.004 -- 0.006 -- 0.008 --
0.25 -- 0.30 0.010 -- 0.012

Epicyclic final drives

Gear ratio: 15:(15:75) = 6:1
Thickness of driven gear shims (1, page 7) . . . . . . . . . . 0.77 -- 0.83 0.030 -- 0.033

(1) measurement to be obtained without reaming (continued overleaf)

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 3

SPECIFICATION

(continued)
mm inches
Axle pivot
Endfloat at pivot between axle casing and relative 0.3 -- 1.1 0.012 -- 0.043
supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0.078
Diameter of front pivot pin ...................... 52.652 -- 52,671 2.073 -- 2.074
Inside diameter of installed front bush . . . . . . . . . . . . . 52.720 -- 52.790(1) 2.076 --2.078
Clearance between pin and bush . . . . . . . . . . . . . . . . . 0.049 -- 0.138 0.019 -- 0.005
Outside diameter of rear bush installed in bevel pi- 99.020 -- 99.050 3.898 -- 3.900
nion support
Inside diameter of rear bush installed in axle pivot 99.146 -- 99.221(1) 3.903 -- 3.906
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between two bushes . . . . . . . . . . . . . . . . . . 0.096 -- 0.201 0.004 -- 0.008
Thickness of front and rear thrust washer of front 4.90 -- 5.00 0.139 -- 0.197
axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(1) measurement to be obtained without reaming

604.55.041.00 - 01 - 1998
4 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

TORQUE SPECIFICATIONS

360
265

294
217

360
265
50
37
113
83
19
26
lbf.ft
Nm

90
66
113
83

113
83
113
83

35--59
26--44
113

113
83

83
392
289
113
83

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 5

TOOLS

X 293665 Wrench for front differential case

Warning -- The tools marked below with an (X) are bearing adjustment nut (models 85
ESSENTIAL for the operations described in this hp and 95 hp).
section. To work in safety and obtain the best results
whilst saving time and energy, these essential tools
should be supplemented by the specific tools listed
below and other tools which are to be made from the X 293880 Wrench for front axle wheel hub
drawings provided in this manual. bearing retaining nut

List of specific tools required for the various X 293882 Pair of grips for removal of front axle
operations described in this section. hub bearings.

293460 Front axle overhaul stand. 292888 Dowels (M 12 x 1.25) for front axle
and cover.

291517 Hook for removal--installation of the

front differential assembly. 293812 Dowels (M 16 x 1,25) for removal/in-
stallation of front axle wheels.

293743 Overhaul support for front axle diffe-

X 293857 Front axle pivot pin removal tool.
rential casing.

X 292161 Front axle pivot bearing outer ring

X 293878 Wrench for threaded adjustment removal tool.
ring of front bevel drive pinion.

X 292220 Tool for measurement of rolling drag

X 293391 Pinion bearing adjustment tool. torque of front axle bearings.

X 293510 Universal gauge for pinion bearing 293889 Guide for installation of axle shafts
adjustment. on stub axle housing

293400 Universal gauge for positioning of 292870 Universal kit for testing oil pressure
front bevel drive pinion. for front axle diff. lock engagement.

LOCALLY FABRICATED TOOLS

Front pinion shaft holding tool --

fabricate from 4WD shaft coupling

604.55.041.00 - 01 - 1998
6 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Hydraulic Diff Lock 2

1. Diff lock return spring 8. Pinion depth shim
2. Diff lock hydraulic feed 9. Crown wheel preload adjusting ring
3. Backlash shim 10. Lock tab
4. Pinion oil seal 11. Crown wheel
5. Pinion nut 12. Dog clutch
6. Pinion 13. Piston oil seals
7. Pinion bearing preload shim

DESCRIPTION AND OPERATION

The front axle is centrally pivoting with the pivot and which do not require any maintenance.
the drive shaft coaxial with the longitudinal axis of the Two differential locks are available:
tractor. The drive shaft has no universal joints.
D Self locking with friction plates on units with 8×2
The differential has two planet gears; drive is
or 16×4 transmissions.
transmitted to lateral epicyclic final drive units
(installed in the wheel hubs) through universal joints D Electro--hydraulically engaged dog clutch.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 7

Hub 3
1. Driven gear shims 5. Axle shaft
2. Cassette oil seal 6. Axle shaft oil seal
3. Hub axle shaft oil seal 7. Swivel pin shims
4. Axle shaft securing bolt 8. Axle shaft bush

604.55.041.00 - 01 - 1998
8 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Auto Lock Diff Lock 4

1. Pinion oil seal 7. Lock tab
2. Pinion nut 8. Crown wheel
3. Pinion 9. Friction plate
4. Pinion bearing preload shim 10. Steel separator plate
5. Pinion depth shim 11. Crown wheel backlash adjusting ring
6. Crown wheel preload adjusting ring

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 9

Front differential lock operation

When energised the solenoid valve sends oil behind When de--energised the return spring disengages
the piston to engage the dog clutch the dog clutch.

604.55.041.00 - 01 - 1998
10 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

FRONT AXLE HYDRAULIC DIFFERENTIAL LOCK

FAULT DIAGNOSIS

Problems Possible causes Remedies

The diff. lock fails to engage. 1. Transmission oil level insufficient. Top up oil level.

2. Oil filter clogged. Replace filter.

3. Hydraulic pump defective. Overhaul or replace pump.

4. Diff. lock control switch defective. Replace switch.

5. Solenoid valve electrical fault: Make good electrical connections and

loose, damaged connections or replace defective parts.
defective contactor.

6. Diff. lock control solenoid valve Overhaul or replace the solenoid

stuck in discharge position. valve.

7. Oil leaking past seals with Replace all defective seals.

consequent loss of pressure:
piston seals or delivery pipe
seals.

Diff. lock fails to disengage. 1. Diff. lock solenoid valve stuck in Overhaul or replace the solenoid
delivery position. valve.

2. Diff. lock release spring broken. Replace spring.

3. Solenoid valve electrical fault: Make good electrical connections and

loose, damaged connections or replace defective parts.
defective contactor.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 11

COMPLETE FRONT AXLE

Removal-- installation (Op. 25 100 30)

DANGER
Lift and handle all heavy parts using suitable lifting
equipment with a sufficient lifting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.

Proceed as follows:
Note -- The front axle assembly can be removed
from the tractor either with or without previously
removing the drive shaft. The description below
refers to removal of the front axle with the drive
shaft installed on the tractor. For removal of the
drive shaft refer to sect. 23.
Depending upon the work to be conducted on the
axle it may be beneficial to slacken certain tight nuts
prior to removal of the axle from the tractor.
e.g.
— Wheel hub bearing nuts, left and right hand
— Pinion lock nut
— Track rod end nuts

1. Disconnect the negative battery lead (1).

6
2. Unscrew bolts (1) and remove the front
mudguard supports (2).

604.55.041.00 - 01 - 1998
12 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

3. Attach nylon slings to the front ballast, remove

the locking pin, lift the ballast clear of the
tractor and place it in a safe position.

8
4. Unscrew bolts (1) and remove the drive shaft
guard (2).

9
5. Remove the bolt, and slide the sleeve (1) in the
direction of the arrow and detach the drive shaft
from the front axle.

1 2

10
6. Insert wedges (1) into either side of the axle
pivot to stop the axle from oscillating and jack
(2) or hoist the tractor.

7. Lift the tractor and place a stand (3) under the

sump pan.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 13

8. Disconnect steering pipes.

12
9. Unscrew the union (1) of the front diff. lock and
detach the flexible hose (2).

13
10. Unscrew the wheel bolts and remove the front
wheels.

25582

14
11. Unscrew the front and rear retaining bolts (1) of
the front axle support.

604.55.041.00 - 01 - 1998
14 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

12. Using a lifting hook and two nylon cables (one

for each side) detach the front axle from the
tractor.

13. Refit the front axle following the instructions

below.

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.

— Refit the axle, and bolt the front and rear

supports in position.
16
— Reconnect the diff. lock pipe and the power
steering pipes.

— Fit the front wheels.

— Raise the front of the tractor using the hoist or

jack to remove stand.

— Reconnect the drive shaft and refit the drive

shaft guard.

— Refit the mudguards.

— Refit front weights to the tractor and secure the

lock pins. 1
2 3 4 5
— Reconnect the negative battery lead.
1. Front support pillar 17
— Adhere to the tightening torques indicated on 2. ‘O’ Ring
page 4. 3. Spacer
4. Seal
5. Rear support pillar
6. Seal

FRONT AXLE
Removal installation (Op. 25 100 38)

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.

Note -- For overhaul, the front axle should be

mounted on stand n. 293460.

2558
7
18

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 15

1. Unscrew plug (1) and drain off the oil from the
axle casing.

1
25588

19
2. Unscrew plug (1) on the left--hand epicyclic
final drive casing and drain the oil; repeat the 1
same operation on the right--hand casing.

25589

20
3. Remove the rear support (1) of the front axle;
remove the front support and retrieve the
washer.
1

25590

21
4. Unscrew the two track rod retaining bolts (1).

25591

604.55.041.00 - 01 - 1998
16 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Prior to removal of the track rod ensure that the

hubs will not rotate on their swivels, causing the
axle to fall from its stand.

5. Using a removal tool, withdraw the pins from

their bores in the stub axle housing, and
remove the track rod.

24080

23
6. Remove the circlips (2) from the cylinder rod
pivot pins, unscrew the pin retaining bolts of the
cylinder (1), withdraw the pins and detach the 1 2
two cylinders.
Recover the four pins, washers, spacers and
cylinders complete with hoses.

25593

24
7. Unscrew the retaining bolts of the left--hand
final drive casing cover (1). Screw in the two
studs 292888 (2) and, using a slide hammer 1 2
screwed into the oil drain plug, detach the
cover (1) from the casing.

25594

25
8. Remove the outer circlip (1) securing the
driving gear (2) and remove the gear.
1 2

25595

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 17

9. Remove the inner circlip (1) securing the

driving gear (2, fig. 28).
1

25596

27
NOTE: If desired it is possible to remove the hub
and stud axle housing together, without the need to
1 2
remove the wheel hub bearing lock nut.

10. Remove the staking (1) on the wheel hub

bearing lock nut (2).

25597

28
11. Remove the wheel hub bearing lock nut using
special tool 293880.
1

25598

29
12. Remove the wheel hub (1) with the ring gear
(2).
1 2

25599

604.55.041.00 - 01 - 1998
18 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

13. Unscrew the three retaining bolts (1) of the

lower pin of the stub axle housing. Recover the
lower pivot pin and the adjustment shims. 1

25600

31
14. Unscrew the four retaining bolts (1) of the
mudguard bracket (2) and remove the bracket.

32
15. Unscrew the three retaining bolts of the upper
pivot pin.
2
1
16. Withdraw the upper pivot pin (1) and detach the
stub axle housing (2).

25602

33
17. Unscrew the retaining bolt (2) of the axle shaft
(1).
1 2

25603

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 19

18. Remove the axle shaft from the casing (1,

fig. 15 ).

19. To disassemble the right--hand final drive unit,

follow the same procedure as the left hand final
drive unit.

35
20. Unscrew two of the bolts fixing the bevel
drive--differential support to the axle casing.
Screw in the two dowels292888 (1). Remove
1 2 3
the remaining bolts and separate the
differential support from the axle casing. Attach
a hoist (2) to the support and remove the
differential support (3) from the axle casing.

25606

36
21. Install tool 293743 (1) in the vice on the work
bench. Bolt the differential support on to the
tool detach the lifting hoist. 1 2

22. Unscrew bolt (2) and remove the ring nut lock
tab (3). Remove the internal diff. lock control 3
pipe.

25607

37
23. Remove the two bolts securing the external bell
housing (1) of the diff. lock, and fit in their place
two bolts with minimum length 70 mm.
Gradually unscrew the four remaining bolts
from the external bell housing of the diff. lock so
as to allow the diff. lock release spring to
gradually extend.

Note -- It is necessary to fit two bolts because the

normal bell housing bolts are not sufficiently long to
allow the spring to extend to its full free length.

604.55.041.00 - 01 - 1998
20 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

24. Unscrew the last two 70 mm bolts. Remove the

bell housing (1), the helical spring (2) and the
diff. lock piston. 1 2

25609

39
25. Remove circlip (2) and remove the diff. lock
sleeve.
1 2

25610

40
26. Remove the circlip securing the diff. lock
piston, and recover the sliding sleeve with the
two thrust washers.

24093

41
27. Gently tap the piston out of the clutch bell
housing.

24094

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 21

28. Unscrew the two bolts (2) of the crown

wheel--differential support caps (1).
1 2

25612

43
29. Remove the crown wheel--differential
assembly (2) from the housing (1).
1 2

25613

44
30. Straighten the locking tab on the splined shaft
lock nut (1).
1

2561
5
45
31. To loosen the pinion nut it is necessary to
manufacture a tool to hold the pinion shaft. This 1 2
can be manufactured by welding a suitable
20 mm nut to the end of a drive shaft coupling
81873108.

Locally Manufactured Pinion Shaft Tool

1. Coupler Part No 81873108
2. 20 mm Nut

604.55.041.00 - 01 - 1998
22 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

32. Unscrew the nut using wrench 293878 (1)

while holding the bevel drive pinion shaft
against rotation with the locally fabricated tool. 1

25616

47
33. Remove the locking ball from the sleeve.

48
34. Withdraw the pinion shaft (1) from the rear of
the casing and remove the spacer, the
adjustment shims and the bearing. 1

2561
8
49
35. Remove the dust seal, the oil seal (1) and the
rear bearing.
1

2561
9
50

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 23

FRONT AXLE DIFFERENTIAL

Overhaul (Op. 25 102 24)
Hydraulic Differential lock
In case of differential assembly overhaul it is
necessary to adjust the backlash between the
teeth of the planet pinions and side gears.

Proceed as follows:

1. Thoroughly clean the components of the

differential to remove any traces of oil which
would otherwise prevent accurate backlash
measurement.

2. Install the two side gears without thrust

washers.

3. Fit the planet gears complete with thrust

washers and pins and screw the pin retaining
bolts in by a few turns to hold the pins in place.

4. Position a dial gauge on the differential

housing.

5. Move the left--hand the side gear to bring it into

full contact with the planet pinion and then push
it up against the differential housing, reading
the endfloat (Gs) on the dial gauge.
24597

6. Repeat the above operations to measure the

endfloat on the right--hand side gear (Gd).

The endfloat should be 0.25 mm.

Therefore the shims to be inserted in the
differential housing are given by:

S L.H. = Gs -- 0.25 mm for the left--hand side

gear;

S L.H. = Gd -- 0.25 mm for the right--hand side

gear.
24598

7. Install shims as near as possible to the 52

calculated value, and, using a dial gauge and
following the procedure described above,
check that the endfloat of the left and
right--hand side gears is approximately 0.25
mm.

604.55.041.00 - 01 - 1998
24 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

8. Reassemble the front axle adhering to the the respective bolts. Finally fit the locking tab of
following instructions: the lock ring and the internal diff. lock pipe.
— Install the bevel drive--differential housing on
— Refer to the illustrations on pages 6, 7 and 8 to the front axle casing and fit the external diff. lock
check the orientation of the various pipe.
components.
— Install the axle shafts and securing bolt.
— Respect the tightening torques prescribed on
page 3. — Fit the stub axle, the adjustment shims, the
upper and lower pivot pins and the mudguard
— Carry out the adjustments described on pages brackets.
26--23.
— Fit the wheel hub, the ring gear of the final drive
— Install the rear bearing, the seal, the dust seal,
unit and the lock ring and tighten to the
the adjustment shims, the spacer and the bevel
prescribed torque value, whilst turning the
drive pinion shaft complete with front bearing.
wheel hub to ensure that the bearings are
— Insert the detent ball, tighten the bevel drive correctly seated.
pinion lock nut and secure in position by
staking. — Fit the securing and stop circlips, the driving
gear and the cover of the final drive unit.
— Install the crown wheel--differential assembly,
the support caps and tighten the relative bolts. — Fit the pins, washers, spacers and steering
cylinders.
— Install the diff. lock sleeve and the relative lock
ring. — Fit the track rod, the front and rear supports and
the oil drain plugs.
— Install the diff. lock control piston with new ‘O’
rings, the spring, the bell housing and tighten — Refill with oil.

1 2 3 4

5
16

14 13 12 11 10 9 8

Drive Pinion Components 53

1. Shim (Pinion depth) 7. Seal 12. Shim (Pinion bearing preload)
2. Bearing 8. Ball 13. Shim (Pionon bearing preload)
3. Bearing Cup 9. Sleeve 14. Spacer
4. Housing 10. Bearing 15. ‘O’ Ring
5. Nut 11. Bearing Cup 16. Pinion
6. Dust Cap

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 25

1. Differential assembly
2. Shim (Backlash)
3. Circlip
4. Dog clutch
5. Lock ring

1. Dog clutch
2. Thrust washer
3. Return spring
4. Piston ‘O’ rings ×2
5. Hub
6. Lock ring
7. Circlip

STEERING SWIVEL PINS AND BEARINGS

Replacement (Op. 25 108 46 or 25 108 47)

In the event that the steering swivel pins prove

difficult to remove, proceed as follows.

9. Remove the grease nipples and the steering

swivel pin retaining bolts.

10. Fit the bolts (1) of tool 293857.

11. Fit the plate (2) of the tool and fix it to the three
bolts with nuts (5).

12. Fit the central tie bolt (4) screwing it fully into
the grease nipple bore on the pin (6).

13. Screw in the nut (3) to drive the pin out of its
bore.
2459
6
56

604.55.041.00 - 01 - 1998
26 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

14. Using extractor tool 292161 (1) remove the

steering swivel bearings.
1

15. Re--install the steering swivel bearings using a

suitable drift.

24599

57
STUB AXLE ADJUSTMENT

WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e.
safety goggles, gloves and footwear.

Install the front axle on stand 293460 and proceed

as follows.

16. Smear grease AMBRA GR 75MD on the

outer races of the bearings and fit the upper
cover, without the shims, and with tool 1 2
292220 (2) attached. Tighten the retaining
bolts.

Note --To facilitate installation of the swivel pin, we

recommend that guide 293889 (1) is installed on
the axle shaft.

24076

58
17. Fit the lower cover without shims, lubricate the
three retaining bolts with engine oil.

18. Gradually,tighten the lower cover bolts equally

whilst rotating the casing to allow the excess
grease to escape.

24077

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 27

19. Using a torque wrench and tool 292220 (1),

check that the torque required to rotate the
casing is 15 -- 25 Nm. Adjust the three bolts
1
until the correct torque is achieved.

20. Measure the gap (H) created between the

lower cover and the casing in three places.

24078

21. Calculate the average of the three values

measured. The total thickness of the
adjustment shims to be fitted under the lower
cover is Shim S3= H -- 0.20 mm .
If necessary, round up the value to the next
0.05 mm.

22. Insert shims under lower swivel cover. Torque

to 113 Nm.

23. After having rotated the casing a few times to

allow the components to bed down, check that
the torque necessary to rotate the casing is 118
-- 147 Nm.

24. If the torque value measured is greater than the

prescribed value, increase the thickness of the
shims, if it is less than the prescribed value,
reduce the thickness of the shims.
2407
9
61

25. Remove tool 292220, fit the grease nipples in

the upper and lower covers and grease the
assembly.

604.55.041.00 - 01 - 1998
28 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Pinion Bearing Preload Shimming

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part
and another. Wear suitable safety clothing, i.e.
safety goggles, gloves and footwear.

Proceed as follows.

26. If necessary remove bearing from pinion.

27. Clamp tool 293391 (1) in the vice, fit the inner
races of the bearings (2 and 4) and the bearing
spacer (3) and secure the nut on the tool.

24584

62
28. Using a depth micrometer, measure distance
(H1) between the upper surface of the tool and 1
the central threaded pin of tool 293391 (1).
H1

29. Disassemble the above parts, lubricate the

bearings with oil and then re--assemble the 2
parts, excluding the bearing spacer, in the
differential housing. Hold the differential 3
housing in the vice using tool 293743.
4

5
63
30. Tighten a nut of tool 293391 (1), while turning
the tool to ensure that the bearings are seated 1
correctly. H2
31. Using a depth micrometer, measure distance
(H2).
32. The thickness of the adjustment shim required
is calculated by:
Shim S1 = H2 -- H1 + 0.05 mm
If necessary, round the value thus obtained up to
the nearest 0.05 mm.
1
Leave tool in differential housing for pinion depth
measurement.
64

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 29

Pinion To Crown Wheel Shimming Procedure

The pinion to crown wheel shimming procedure
calculates the thickness of shims S2,
positioned beneath the shoulder of the pinion
gear to ensure that the theoretical conical
point of the pinion aligns with the centre of the
differential crown wheel.
Pinion Shimming Dimensions
H4 Dimension from Pinion Bearing to Centre line
of Differential Casing
H3 115 mm Manufacturers Pinion DimensionC
(Correction Factor)
S2 Shim Thickness 65

The dimension H4 necessary in the calculation of

the shim thickness can be determined using either
New Holland pinion adjustment tool 293400 or VL
Churchill tool FT3135.

Both procedures are explained as follows.

Pinion Shimming using New Holland Pinion

Adjustment Tool 293400 1 2
1. Install pinion bearings in differential support
housing and clamp in position using New
Holland Tool No 293391 as used when
determining thickness of shims for bearing
preload.
1. Pinion Measuring Gauge Tool No 293400
2. Pinion Bearing Clamp. Use Tool No
293391
or alternative clamp 50048 as shown
3. Pinion Bearings 3
4
4. Micrometer (Part of Tool No 293400)
66
2. Install New Holland Pinion Setting Tool
No 293400 complete with bearing cup and
adjusting rings. Tighten bearing caps to
113 Nm (83 lbf).

If New Holland Tool No 293391 as described in

pinion bearing shimming procedure is not
available the Bearing Clamp Tool No 50048
may be used to clamp the bearings.

3. Adjust the cones of the tool so that the depth

micrometer tip touches the inner race of the
bearing and measure the dimension (H4).
67

604.55.041.00 - 01 - 1998
30 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Determine the thickness of shims to be

installed beneath the pinion gear as follows:
Shim thickness S2 = H4--H3
Where:--
H4 = Dimension measured using pinion
micrometer tool
H3 = 115 mm"C
115 mm is the nominal manufacturing
dimension from rear face of pinion gear to
conical point of pinion. (Supplied by
Manufacturer)

C= Manufacturing correction factor stamped

on face of pinion. 1

Example H4 = 118.27
C = +0.1 mm
H3 = 115 + 0.1 7 +0.1
= 115.1 mm
S2 = H4 --H3
= 118.27 -- 115.1
Shim Thickness S2 = 3.17 mm

68
Pinion Shimming using VL Churchill Tools
FT. 3135

1. Install bearing caps (less bearing cup) and

tighten to a torque of 113 Nm (83 lbf).

2. Measure internal dimension of bearing bore

and call this dimension ‘A’.

69
3. Install pinion bearings in the differential support
housing and clamp in position with Tool No FT
3135.
NOTE: Tighten the clamp so that the bearing
cones can just be turned by hand.
4. Locate the bar gauge, part of Tool No FT3135, H4
across bearing bore and measure dimension
‘B’.
1. Depth Gauge
2. Bar Gauge -- Part Of Tool No FT.3135
3. Pinion Shaft Bearings
4. Pinion Setting Gauge -- Tool No FT.3135
5. Differential; Support Casing 70

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 31

5. Calculate Dimension ‘H4’ using Formula

H4=B --25* + A
2
NOTE: *FT 3135 Bar Gauge is 25 mm
diameter.
6. Determine the thickness of shims S2 to be
installed beneath the pinion gear as
follows:
S2 = H4 -- H3
Where:--
H4 = Dimension Calculated in Step 5
above.
H3 = 115 mm"C
115 mm is the nominal manufacturing
dimension from rear face of pinion gear to
conical point of pinion. (Supplied by
Manufacturer)
C= Manufacturing correction factor
stamped on face of pinion.
Example A = 95 mm
B = 95.77 mm
H4=B --25* + A
2
95
H4 = 95.77--25* +
2

H4 = 118.27
C = 0.1 mm
H3 = 15 + 0.1
= 115.1
Shim Thickness S2 = 118.27 -- 115.1
= 3.17 mm

Pinion Shim and Bearing Installation

7. Install shim selected in pinion to crown wheel

shimming procedure between pinion head and
bearing. Ensure the chamfer on the shim faces
towards the pinion head.

604.55.041.00 - 01 - 1998
32 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

8. Install bearing onto pinion

72
NOTE: The use of a electronic induction heater will
assist in the installation of the bearings without the
need for a press.

73
Pinion Bearing Preload Rolling Torque

The pinion bearing preload is measured as the

torque or force required to rotate the pinion. The
shim selected in the Pinion Bearing preload shim
adjustment procedure on Page 28 ensures that the
correct preload is achieved when the pinion nut is
tightened to a torque of 294 Nm (217 lbf ft).

NOTE: If the special tool required to determine the

thickness of preload shim is not available install the
same shim as removed during disassembly.

1. Install the inner pinion bearing onto the pinion

and locate the pinion into the differential carrier.
Hold the pinion in position with a universal
puller.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 33

1 2 3 4

5
16

14 13 12 11 10 9 8

Drive Pinion Components

1. Shim 7. Seal 12.Shim
2. Bearing 8. Ball 13.Shim
3. Bearing Cup 9. Sleeve 14.Spacer
4. Housing 10.Bearing 15.‘O’ Ring
5. Nut 11.Bearing Cup 16.Pinion
6. Dust Cap

2. Install the spacer and shims onto the pinion

shaft. Lubricate and install the pinion outer
bearing.

604.55.041.00 - 01 - 1998
34 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

3. Install the sleeve. ball and pinion nut. Do not

install the ‘O’ ring, oil seal and dust shield at this
stage.

4. Tighten the pinion nut to a torque of 294 Nm

(217 lbf ft).

5. Screw an M12 bolt into end of the pinion shaft

or use the locally fabricated pinion holding tool.
Using a suitable low value torque meter
measure the rolling torque of the pinion.

The rolling torque should be 0.5--1.0 Nm

(4.5--8.5 lbf in) excluding breakaway torque.

6. If the values recorded during the adjustment

procedure are outside the specification adjust
the thickness of shim and recheck bearing
preload.

7. When the correct shim thickness has been

established remove the pinion nut, sleeve and
ball and install the ‘O’ ring and pinion oil seal.

8. Carefully reinstall the sleeve, ball and pinion

nut.

NOTE: Attempting to fit the oil seal with the sleeve

installed may damage the oil seal lip.

9. Tighten the pinion nut to a torque of 294 Nm

(217 lbf ft) and deform the locking tab.
Measure and record the pinion and seals
rolling resistance A1.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 35

CROWN WHEEL ADJUSTMENTS

Adjustment of the crown wheel bearings and

the backlash between the pinion and crown
wheel.

Hydraulic Dog Clutch

10. Install the differential assembly complete with

crown wheel and inner crown wheel bearing
rings in the differential housing.

24112

78
11. Insert the outer bearing rings in the differential
housing, fit the differential support caps,
ensuring correct orientation of the threaded
adjustment ring. Tighten the bolts to a torque of
59 Nm, then slacken them off and re--tighten to
a torque of 20 Nm.

79
12. Measure the thickness SP the adjustment shim
which was previously removed during the axle
overhaul procedure. Refit the shim and circlip.

13. With the bearings lubricated, rotate the crown

wheel and at the same time tighten the
threaded adjustment ring using wrench
293665 to a torque of 39 -- 59 Nm to take up
the axial play between the components.

24591

80
14. Measure the backlash between pinion and
crown wheel, using a dial gauge perpendicular
to the outer edge of a tooth on the crown wheel.

15. Repeat the measurement in a further two

positions 120# apart and compare the average
of the three values (Gm) with the specification
backlash: 0.15--0.20 mm, with an average of
0.18 mm. 1

2459
2
81

604.55.041.00 - 01 - 1998
36 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

If the measured backlash exceeds the

prescribed value, fit a thinner adjustment
shim.
The thickness of the adjustment shim to be fitted in
the differential housing is given by:
Shim S = Sp -- {(Gm -- 0.18 ) x 1.35}
where:

Sp = thickness of test shim installed in the

differential housing. i.e. original shim used as a test
shim.

Gm = average backlash measured between the

pinion and crown wheel
If the backlash measured is less than the
prescribed value, fit a thicker adjustment
shim, the value being given by:
Shim S = Sp + {( 0.18 -- Gm) x 1.35}
Recheck the backlash and adjust shim if
necessary.

Crown Wheel to Pinion Backlash

1
Self Locking Differential Lock

1. Locate the differential assembly into the

support casing and tighten bearing cap bolts to
a torque of 59 Nm (44 lbf ft).

NOTE: Ensure the stepped edge of the adjuster

ring (2) faces and touches the edge of the bearing.

2. Loosen bearing cap bolts and re--torque to 2

20 Nm (15 lbf ft)
82

3. Adjust the ring gears to remove all free play

between the crown wheel and pinion. 1 2

4. Position a dial indicator with the stylus at 90# to

the crown wheel teeth and adjust each ring nut
by equal amounts until crown wheel to pinion
backlash is 0.18--0.23 mm (0.007--0.009 in)

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 37

5. Tighten right hand ring nut (nut opposite crown

wheel) to obtain a torque of 39--59 Nm
(29--44 lbf ft) and recheck the crown wheel to
pinion backlash.

6. Re--tighten the bearing cap bolts to a torque of

113 Nm (83 lbf. ft)

84
Differential Bearing Preload
Self locking and hydraulically engaged
differential lock
The differential bearing preload is checked by
measuring the combined rolling torque of the crown
wheel and pinion assembly and comparing it to the
pinion and seals rolling torque value.

1. Attach a torque meter to the pinion shaft and

measure the rolling torque to rotate the pinion
and crown wheel A2.

85
2. Subtract from the rolling torque reading A2
described above, the pinion only rolling torque
A1. 1 2
The difference between the two values should
be 1 to 1.5 Nm, (9 -- 13 lbf in).
3
3. If the rolling torque of the pinion and differential
assembly is not to specification adjust the ring
‘opposite’ the crown wheel to increase or
reduce differential bearing preload. Recheck
the rolling torque as detailed above.
Refit the lock tabs to secure the adjusting 25607
ring(s). 86

EXAMPLE
Rolling torque of Pinion and Differential
A2 = 2.1 Nm (19 lbf in)

Rolling torque of Pinion

A1 = 0.7 Nm (6 lbf in)

Calculated Rolling Torque of Differential

= 2.1 -- 0.7 Nm (19 -- 6 lbf in)
=1.4 Nm (13 lbf in)

604.55.041.00 - 01 - 1998
38 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Refit the differential to the axle casing after

having carefully cleaned and degreased the
mating surfaces and applied a bead of gasket
sealer approx. 2mm wide along the line shown
in the figure below.

24591

87
Gasket sealer application diagram for
assembly of bevel drive unit and epicyclic final
drive unit.
The types of gasket sealer to use are listed on page
1, sect. 00.

24595

88
CHECKING THE ALIGNMENT OF
STEERING--DRIVE WHEELS (Op. 44 511 80)

When travelling forward in a straight path, the

wheels of four--wheel drive tractors must be
parallel to the longitudinal axis of the tractor,
alternatively a slight toe--in of the front wheels is
permissible up to a maximum of 6 mm as
measured at the edges of the wheel rims.

To check the exact value of the toe--in setting of

four--wheel drive tractors, proceed as follows.

1. Inflate the front tyres to the prescribed

pressure.

604.55.041.00 - 01 - 1998
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 39

2. Position the steering at half--lock with a

straight--edge along the longitudinal axis of the
tractor.

3. Check that the wheels are parallel to the

longitudinal axis of the tractor.

4. Measure the distance (1) between the front

inside edges of the wheel rims, at the height
of the wheel hub centres.

5. Turn both front wheels through 180o then

measure, again at the height of the wheel hub
centres, the distance (2) between the rear
inside edges of the wheel rims, checking that
1
this new measurement is equal to or greater
than the distance (1) by a maximum or 6 mm.
The rotation of the wheels through 180o is 2
necessary to eliminate the effect on the
measurement of any wear of the rims.

24666

6. If it is necessary to correct the wheel alignment,

remove nut (2) and pull the track rod end (1) out 1
of its housing. Slacken off locknut (3) and
screw the track rod end (1) in or out to increase
or decrease the distance (2, fig. 81).
Reposition the track rod end (1) in its housing
and re--check alignment as described in points
4 and 5.
After having adjusted the alignment to within
the prescribed limits, tighten locknut (3) to a
torque of 180 Nm (183 kgm) and nut (2) to 100
Nm (10.2 kgm). 3 2
24667

Note -- Self--locking nut (2) must be renewed each 90

time it is removed or partially unscrewed.

604.55.041.00 - 01 - 1998
40 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

NOTES

604.55.041.00 - 01 - 1998
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 1

SECTION 27 -- MECHANICAL REAR WHEEL DRIVE

Chapter 1 -- Rear Axle

Section Page
27 000 Specifications, Tightening Torques and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
27 120 Rear Axle Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
27 106 Planetary Gear Assembly and Axle Housing Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Differential and Differential Lock Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive Pinion Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

27 000 SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS

MODEL 8x2/16x4 12x12/24x24 16x16

(Transmission)

Rear Axle General :

Planetary Gears 3 3 3

Ratios Spiral Bevel 5.286 5.625

Planetary 4.5 6.0

Overall 23.786 33.75

Pitch Dia, Spiral Bevel 13.13 in

(333.5mm)

Axle Shaft Dia 2.7 in

(68.58mm)

Differential Lock Mechanical Electro Hydraulic

Draw Bar Pull lbs 9000 9500 9500

kgms (4082) (4309) (4309)

Load Capacity lbs 12000 13800 13800

kgms (5443) (6260) (6260)

Oil Specification Ambra Multi--G

Oil Quantity

Imp. Gallons 14.5 12.5 13.3

U.S. Gallons 17.4 15.0 16.0

Litres 66.0 56.8 60.6

604.55.041.00 - 01 - 1998
2 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Axle Shaft Pre--Load Differential Bearing Pre--Load

Differential Bearing Rolling Torque using a Spring
Axle Shaft Rolling Torque using a torque wrench
Pull Gauge: 15--67 lbf. (7--30 Kgf.)
8.03--20.8 lbf (11.6--28.2 Nm)
Table 2:
Table 1: GAP SHIM TO BE
MEASURED INSTALLED
RESULTANT SPACER TO BE
FIGURE INSTALLED 0.024--0.029 in 0.038--0.040 in
(0.61--0.74 mm) (0.97--1.02 mm)
0.049--0.052 in 0.045 in
(1.24--1.32 mm) (1.14mm) 0.030--0.035 in 0.044--0.046 in
(0.76--0.87 mm) (1.12--1.17 mm)
0.053--0.056 in 0.049 in
(1.35--1.42 mm) (1.24 mm) 0.036--0.041 in 0.050--0.052 in
(0.91--1.04 mm) (1.27--1.32 mm)
0.057--0.060 in 0.053 in
(1.45--1.52 mm) (1.35 mm) 0.042--0.047 in 0.056--0.058 in
(1.07--1.19 mm) (1.42--1.47 mm)
0.061--0.064 in 0.057 in
(1.55--1.63 mm) (1.45 mm) 0.048--0.053 in 0.062--0.064 in
(1.22--1.35 mm) (1.58--1.63 mm)
0.065--0.068 in 0.061 in
(1.65--1.73 mm) (1.55 mm) 0.054--0.059 in 0.068--0.070 in
(1.37--1.50 mm) (1.73--1.78 mm)
0.069--0.072 in 0.065 in
(1.75--1.83 mm) (1.65 mm) 0.060--0.065 0.074--0.076 in
(1.50--1.63 mm) (1.88--1.93 mm)
0.073--0.076 in 0.069 in
(1.85--1.93 mm) (1.75 mm) 0.066--0.071 0.080--0.082 in
(1.65--1.78 mm) (2.03--2.08 mm)
0.077--0.080 in 0.073 in
(1.96--2.03 mm) (1.85 mm)
Drive Pinion Pre--load
0.081--0.084 in 0.077 in (Rolling Torque)
(2.06--2.13 mm) (1.96 mm) Table 3:
0.085--0.088 in 0.081 in
(2.16--2.24 mm) (2.06 mm) Using Gauge, Tool No. FT.4602
10--17 lb.in (1.1--1.9 Nm)
0.089--0.092 in 0.085 in
(2.26--2.34 mm) (2.16 mm)
Using a Spring Pull Gauge
13--23 lbf. (5.9--10.5 Kgf.)

TIGHTENING TORQUES

Components lbf.ft Nm

Axle Shaft Housing Retaining Bolts 130--190 176--258

Axle Shaft Retaining Bolt 250--400 339--542
Differential Ring Gear Retaining Nuts 85 115
Differential Case Retaining Bolts 68--92 92--125
Differential Lock Fork Pivot Shaft Retaining Bolts 42--56 57--76
Differential Lock Hanger Retaining Bolts 42--56 57--76
Inner Brake Housing Retaining Bolts 65--89 88--121
Drive Pinion Bearing Retainer Bolts 100--125 136--170
Ring Gear Thrust Block 27--37 37--50
Wheel Nuts (Disc to Hub)
Manual Adjust Wheels 288 390
Power Adjust Wheels 525 712

604.55.041.00 - 01 - 1998
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 3

SPECIAL TOOLS

DESCRIPTION V.L. CHURCHILL NUDAY

LTD TOOLS TOOLS

Shaft Protectors 625A 9212

Step Plates 630S 9210
Step Plate Adaptor 630T 9211
Taper Base 370 --
Slave Ring CT.9056 --
Planetary Ring Gear Remover/Replacer FT.4500 (SW.6) 2122 (SW.6--48)
2123 (SW.6--56)
Differential Bearing Pre--Load Gauge FT.4501 (SW.7) 2141 (SW.505)
Drive Pinion Pre--Load Gauge T.4062 (Pull Scale)
Drive Pinion Pre--Load Gauge Adaptor T.4062A
Puller Legs 930B 9521
Puller 938 9506
Internal/External Puller 943 9507
Slide Hammer 943S 9567
Pulling Attachments:
Small 951 9190
Large 952 9526
Pullers:
Small 1001 9196
Medium 1002 9198
Large 1003 9516

FAULT FINDING

PROBLEM POSSIBLE CAUSE REMEDY

1. Rear Axle Noisy 1. Lack of oil 1. Top up as required

2. Incorrect oil specification 2. Drain and refill with oil of

correct specification

3. Worn axle bearings 3. Disassemble and inspect

bearings

2. No Drive 1. Operate the differential lock,

if the tractor drives this
(NOTE: Refer also to ‘Clutch indicates a failure within an
Systems’ fault finding. axle shaft housing assembly.
If the tractor does not drive
the fault may lie in the
differential unit. Ensure the
Clutch and transmission
systems are not at fault.

604.55.041.00 - 01 - 1998
4 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

PROBLEM POSSIBLE CAUSE REMEDY

3. Differential Lock not 1. External linkage damaged or 1. Replace/repair as required

engaging (mechanically broken
engaged)

2. Internal linkage, cross shaft 2. Remove the HPL top cover

rod, fork or pivot shaft and inspect
damaged/broken

3. Damaged or broken teeth on 3. Remove differential and

differential lock adaptor or inspect differential lock
coupling assembly

4. Differential Lock not 1. Spring broken between 1. Remove differential and

disengaging (mechanically adaptor and coupling replace spring
engaged)
2. Teeth of adaptor or coupling 2. Remove differential and
damaged/burred replace damaged parts

5. Differential Lock not 1. Fuse 15 blown 1. Replace fuse

engaging
(electro--hydraulic) 2. Faulty Relays, G or A. 2. Replace faulty relay

3. Brake switch activated 3. Ensure brake switches are

correctly adjusted and
operating correctly

4. Rocker switch faulty 4. Replace switch

5. Solenoid faulty 5. Replace solenoid

6. Faulty hydraulic oil supply to 6. Check low pressure

solenoid assembly hydraulic circuit. Refer to
Hydraulic Section

7. Wiring fault 7. Locate and repair faulty

wiring

8. Internal linkage 8. Remove HPL top cover and

damaged/broken inspect

9. Differential lock coupling / 9. Remove differential and

adaptor gear teeth damaged replace damaged parts

6. Differential Lock not 1. Faulty operating switch 1. Replace switch

disengaging (failed in ‘ON’ position)
(electro--hydraulic)
2. Solenoid Faulty (Seized) 2. Inspect solenoid, repair or
replace as required

3. Faulty wiring 3. Locate and repair fault in

wiring

4. Spring broken between 4. Remove differential and

coupling and adaptor replace spring

5. Damaged or broken coupling 5. Remove differential and

and adaptor gear teeth replace damaged
components

6. Faulty brake pedal switch 6. Ensure switches are

correctly adjusted and
operating correctly

604.55.041.00 - 01 - 1998
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 5

DESCRIPTION AND OPERATION

There are two basic types of rear axles. An

8×2/16×4 rear axle which has mechanically
operated brakes and a mechanical differential lock.
A 12×12 and 16×16 rear axle which has
hydraulically operated brakes,
hydraulic/electrically operated differential lock and
three planetary gears.

The rear axle assembly, attached to the rear of the

front transmission, connects the drive from the
engine and gearbox to the rear wheels. Housed
within the rear axle assembly are the following
components:--

-- Main Drive Pinion and Differential Ring Gear

-- Differential

-- Differential Lock Assembly

-- Brakes

-- Final Reduction Gears

-- Axle Half Shafts

-- P.T.O. Components

-- Transmission Handbrake

-- Hydraulic Pumps, variable displacement or

Tandem Gear Pumps.

The drive from the transmission output shaft is

transmitted to the spiral bevel pinion by the drive
coupling. The pinion is located in the front of the
rear axle housing by two pre -- loaded, opposed
tapered roller bearings, and meshes with the
differential ring gear.

The ring gear is riveted to the differential case

assembly which is supported between taper roller
bearings mounted in the rear axle housings.

NOTE: In service the ring gear rivets are replaced

by nuts and bolts.

604.55.041.00 - 01 - 1998
6 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

Rear Axle Assembly 1

1. Outer Brake Housing 13. Planet Gears
2. Axle Housing Outer Bearing 14. Axle Housing Inner Bearing
3. Axle Shaft 15. Sun Gear
4. Axle Shaft Oil Seal 16. Differential Lock Fork
5. Planet Gear Carrier 17. Drive Pinion
6. Axle Housing 18. Drive Pinion Locknut
7. Brake Torque Pin 19. Rear Axle Housing
8. Differential Assembly 20. Pinion Bearing Retainer
9. I.P.T.O Drive and Driven Gears 21. Differential Ring Gear
10. I.P.T.O Rear Shaft 22. Thrust Block
11. Differential Lock Assembly 23. Inner Brake Housing
12. Rear Wheel Brake Assembly

A thrust block is fitted to the heavy duty axle to

prevent the ring gear from flexing due to pre loading
from the drive pinion. The casting of the block also
ensures an adequate quantity of lubricating oil
flows to the drive pinion bearings.
The axle shaft housings operate with higher oil
levels than the centre housing. The left hand side
of the centre housing and the right hand axle shaft
housing both have restrictions to maintain the
increased levels, Figure 2 and Figure 3.
The differential case assembly forms two halves
which are bolted together to enclose the differential
spider and side gears.

604.55.041.00 - 01 - 1998
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 7

The drive from the pinion is transmitted via the ring

gear and differential case assembly to the arms of
the spider. Mounted on the spider are pinion gears
which are in constant mesh with the two side gears.
An intermediate shaft is splined into each side gear
and the brake assemblies are splined onto these
shafts.
The outer end of each intermediate shaft forms the
sun gear of an epicyclic final reduction gear set
mounted within each axle housing.

Left and Right Hand Axle Housings 2

1. Right Hand Axle Housing
2. Oil Restrictor
3. Left Hand Axle Housing

The drive to the wheels is transmitted from the

intermediate shaft to the outer shaft via the
reduction gear set.
The inner ends of the outer axle shaft are splined
into the planetary gear carrier. The axle shafts are
supported by a taper roller bearing mounted in
each axle housing.
The oil provided for the I.P.T.O. and hydraulic
systems is also used for lubricating the rear axle
components. The differential and ring gear
assembly is partially immersed in the oil to splash
feed the bearings and bushings.

Left Hand Oil Restrictor 3

1. Rear Axle Centre Housing
2. Plastic Plug

DIFFERENTIAL LOCK
When a tractor is fitted with a conventional
differential assembly is working in soft soil, and one
wheel starts to slip, all the drive is then transmitted
to that wheel and traction ceases.
To overcome this slippage a differential lock is fitted
to all models.

604.55.041.00 - 01 - 1998
8 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

The differential lock mounted to the left hand side

of the crown wheel can be engaged to connect one
of the side gears to the differential case assembly.
This action locks the differential assembly together
and provides a direct drive to both wheels.
The lock assembly consists of a sliding coupling
(3), an adaptor (2) and a fork and lever assembly.
The sliding coupling is splined onto the protruding
end of the side gear.
The adaptor is positioned between the coupling
and the left hand differential case (1). A spring (4)
positioned between the coupling and the adaptor
ensures the coupling only engages with the
adaptor when required and the dog teeth on the
adaptor and the differential case are not
permanently engaged.

OPERATION

The fork and lever assembly is operated by either

a spring controlled foot operated linkage
(mechanically engaged), or an electro hydraulic
system operated by a rocker switch mounted on
the right hand panel.

Mechanical Engagement/Disengagement

When actuated the fork forces the dog teeth of the

coupling to mesh with the adaptor and thereby lock
the side gear to the differential case. After the
differential lock, of the mechanically engaged
system, has been engaged, the foot pedal can be 5
released.
The mechanically operated differential lock will
automatically disengage when the spring pressure
overcomes the side forces acting on the coupling
teeth. This situation will only occur when the torque
to both wheels is equal.

Electrical Operation
NOTE: The rear axle differential lock engagement
is controlled by a rocker switch to the right of the
operator’s seat. If your tractor has a cab, refer to
Figure 6. On tractors without cab, the switch is
incorporated in a panel on the right--hand fender --
see Figure 7.
An electro--hydraulic, self--holding differential lock
is installed in the rear axle and may be operated in
the manual or automatic modes. The rocker switch
(1) has three positions, the central position being
off.

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 9

WARNING: Avoid using the differential

lock at speeds above 8 km/h (5 MPH) or
at any time when turning the tractor. When
engaged, the differential lock will make steering
the tractor very difficult.

IMPORTANT: If a rear wheel spins at speed,

reduce engine speed before engaging the
differential lock, to avoid shock loads to the
transmission.

Operating in Manual Mode NOTE: If the automatic mode is selected with the
fast raise switch already in the raised position, the
differential locks will engage but disengage when
the fast raise switch is subsequently used to raise
In conditions creating wheel slip press the front the 3--point linkage.
(yellow) part of the switch (1) Figure 6 or 7 fully in
to lock the rear wheels together. The differential
lock will be engaged, as indicated by the amber Either brake pedal temporary
warning light on the instrument panel. applied (single pedal disengagement
Braking

Disengagement will occur when one or both brake Return the rocker switch differential lock will
pedals are applied or if the rocker switch is returned to the central position disengage
to the central position. The lock will remain
engaged until traction at the rear wheels equalises.
The warning light on the instrument panel will go out NOTE: The lock will remain engaged until traction
when the differential lock has disengaged. at the rear wheels equalises.

Operating in Automatic Mode FINAL REDUCTION GEAR ASSEMBLY

(Planetary Gear Assembly)

Press the rear part of the switch (1) Figure 6 or 7 To increase the torque transmitted to the rear
fully in to lock the rear wheels together. The amber wheels, an epicyclic reduction gear assembly is
warning light on the instrument panel will illuminate located within each of the rear axle housings. The
when the differential lock is engaged. outer end of each intermediate shaft acts as the
planetary sun gear around which are located three
planet gears. The planet gears are mounted within
a carrier which is splined to the rear axle shaft.
Disengagement will occur as follows:

Fast raise switch (2) temporary The planet gears mesh with a ring gear which is
activated (to raise the disengagement (will mounted within the axle housing. As the
rear 3--point linkage re--engage when intermediate shaft gear revolves, the planet gears
3--point linkage is are forced to rotate and roll around the inside of the
lowered) fixed ring gear. This action causes the planet gear
carrier to rotate at a reduced speed and transmit
increased torque to the rear axle and wheels.

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10 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

27 120 REAR AXLE HALF SHAFT ASSEMBLY OVERHAUL

Rear Axle Half Shaft Assembly 8

1. Planetary Reduction Gears and Carrier 7. Sun Gear and Shaft
2. Carrier Retaining Bolt and Lock Tab 8. Axle Shaft
3. Inner Brake Housing 9. Axle Shaft Housing
4. Thrust Block 10. Axle Shaft Bearing
5. Brake Discs and Actuator 11. Shim
6. Outer Brake Housing

Operations or Repairs that can be performed Operations or Repairs that can be performed
with the left hand half axle removed. with the right hand half axle removed.

Right Hand Brake Plates Overhaul

Differential Operating Fork Overhaul

Sun Gear Assembly Overhaul

Left Hand Brake Plates Overhaul
Half Shaft Assembly Overhaul

Sun Gear Assembly Overhaul

Crown Wheel and Pinion Assembly Overhaul

Half Shaft Assembly Overhaul Differential Lock Assembly Overhaul

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 11

REMOVAL
IMPORTANT: Prior to removal ensure vehicle is
safely supported, the front wheels chocked to
prevent movement and the handbrake is released.
1. Drain the rear axle oil from the centre housing
and disconnect the hydraulic lift rods,
Automatic pick up hitch tie rods, handbrake
cables and either the hydraulic brake pipes or
footbrake linkage, depending on axle type.
2. Remove the rear wheels, replacing the nuts
onto the studs to prevent damage to the stud
threads during overhaul.

3. Support the rear of the cab or platform (1) and

remove the cab or platform (2) to the right or
left of the vehicle, away from the half shaft to be
removed, Figure 9.

9
4. Support the axle shaft housing (1) on a suitable
trolley jack (2). Remove the securing bolts and
withdraw the axle housing from the tractor,
Figure 10.

10
DISASSEMBLY
1. Remove the large ‘O’ ring located in the inner
end of the axle housing.
2. If the right hand housing has been removed,
withdraw the differential assembly (1) to
prevent damage during the axle overhaul,
Figure 11.

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12 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

3. Remove the two hydraulic brake tubes from

the inner housing and the bolts securing the
inner brake using to the axle housing then
withdraw the inner brake housing from the axle
housing.

4. Remove the brake friction discs and actuating

disc assembly. Lift the intermediate sun gear
shaft out of the axle then withdraw the outer
brake housing.

5. Remove the axle shaft retaining bolt lock tab

and retaining bolt.

NOTE: It may be necessary to heat the locking tab

to melt the sealant used during production.

6. Lift and withdraw the planet gear and carrier

assembly (2) using puller, Tool No. 943 (1),
expanded under the planet gears. Collect the
shim from underneath the carrier assembly.

WARNING: Ensure when lifting the

planetary gear and carrier assembly
from the axle shaft housing that the puller is
correctly positioned. Do not attempt to remove
or replace the assembly without the specified
puller as personal injury may result .

7. Remove the axle shaft from the housing. The

inner bearing of 12×12, 24×24 and 16×16
models is a press fit onto the axle shaft and
must be pressed out. Fabricate a suitable tool
(1), as shown in Figure 14.

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 13

17.0 in
15.5 in

4.0 in

7.75 in
8.5 in
5/ in
8

1.0 in -- 12 UNF

11.0 in

3/ in
4

Axle Shaft Removal Tool 14

Rear Axle Half Shaft Assembly 15

1. Planetary Reduction Gears and 3. Inner Brake Housing 7. Axle Shaft
Carrier 4. Brake Discs and Actuator 8. Axle Shaft Housing
2. Carrier Retaining Bolt and Lock 5. Outer Brake Housing 9. Axle Shaft Bearing
Tab 6. Sun Gear and Shaft 10. Shim

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14 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

INSPECTION AND REPAIR

1. Inspect all components for damage or

excessive wear. Install new components as
necessary.

2. If the axle shaft outer cone and roller assembly

(3) and or the shaft seal requires removal, use
puller, Tool No. 938 (4), legs, Tool No. 930B (1),
pulling attachment, Tool No. 952 (2) and a
suitable shaft protector, Tool No. 625A,
Figure 16.

3. Install the shaft seal followed by the cone

bearing using suitable sleeves and a press.

4. If required, use slide hammer, Tool No. 943S

(4) and puller, Tool No. 943 (1), to remove the
bearing cup (3) from the outer end of the axle
housing (2), Figure 17. To replace the cup use
a suitable stepped plate and a mallet, install
cup until fully seated in housing.

RE--ASSEMBLY AND INSTALLATION

Re--assembly and installation of the rear axle shaft
assembly follows the disassembly procedure in
reverse, observing the following requirements:
S Ensure the brake actuators (1) and hydraulic
hoses are correctly installed. The left hand
actuator pipework faces towards the wheel
hub. The right hand actuator pipework faces
up, towards the installer.

S Apply a suitable wheel bearing grease to the

shaft seal and cone and roller assembly.
18

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 15

S Prior to installation of the axle housing make

the following adjustments as described under
the ‘Adjustments’ Section of this Chapter:
(i) Adjust the axle shaft bearing pre--load.
(ii) Adjust the differential bearing pre--load if
any of the following components have been re-
placed:
S Planetary ring gear
S Outer brake housing
S Inner brake housing
S Rear axle centre housing
S Right hand axle housing

S Tighten all nuts and bolts to the correct

tightening torques detailed in the
specifications.
S Refill the rear axle with the correct grade and
quantity of oil as detailed in the specifications.
S Check and where necessary, adjust the foot
brakes of mechanically operated systems and
the handbrake of all models.

PLANETARY GEAR ASSEMBLY AND AXLE HOUSING -- OVERHAUL

REMOVAL

Remove the axle housing from the centre housing

and withdraw the planetary gear assembly as
described in the previous section.

DISASSEMBLY

1. Remove the ring retaining the planet gear

shafts.
2. Place the carrier assembly on a press with a
suitable step plate adaptor, Tool No. 630T,
under the cone and roller assembly.

NOTE: The cone and roller assembly is only fitted

to the carrier of 8×2 model tractors. The lower
pulling attachment tool is not required on 12×12
and 16×16 model axles.

3. Using a second step plate adaptor, Tool No.

630T (1), three or four suitable sockets (2),
depending on carrier type, pulling attachment,
Tool No. 952 (4), taper base, Tool No. 370 (6)
and slave ring, Tool No. CT.9056 (7), remove
the cone (5) and planet gear shafts (3).
Figure 19.

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16 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

4. Remove the gears from the carrier and

withdraw the thrust washers and spacers,
Figure 20.

NOTE: Retain the needle rollers located between

the planet gear shafts and the gears for use during
reassembly.

5. Use slide hammer, Tool No. 943S and puller,

Tool No. 943, to remove the bearing cup
located within the axle housing.

INSPECTION AND REPAIR

Planet Gear Carrier Assembly 20
1. Clean and inspect all items for damage and 1. Retaining Ring 6. Cone and Roller
excessive wear. Install new components 2. Thrust Washer Assembly
3. Planet Gear (S Model Only)
where necessary. 4. Rollers 7. Carrier
5. Thrust Washers 8. Planet Gear Shaft
2. If the planetary ring gear requires replacement
observe the following procedure:

S Remove the axle shaft from the housing.

S Fabricate a suitable plate, as shown in

Figure 21, to be used in conjunction with the
sliding ends of Tool No. FT4500. Insert the tool
sliding ends behind the ring gear and tighten
the locknuts (4), Figure 22.

10.0 in

3.0 in 3.0 in

0.5 in
0.5 in 60! 60! 45!

4.0 in 2.5 in

4 x 0.5 in B.S.W. R 5.0 in.

Ring Gear Removal Adaptor Plate 21

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 17

S Position the axle housing under an hydraulic

press with the bell end of the housing on the
floor. Insert a suitable bar between the
remover/replacer (2) and the head of the press
ram. Press the planetary ring gear (1) out of the
housing (3).

S To replace the ring gear position the axle

housing with the bell end upper--most.

22
S Place a new ring gear in the housing, position
the tool on the new ring gear then press into
position. Ensure the gear is seated correctly
and there is no gap between the bottom of the
gear and the housing shoulder.

RE--ASSEMBLY

Re--assembly of the planetary gear assembly

follows the disassembly procedure in reverse. On
reassembly observe the following requirements:

S On reassembly of the planet gear carrier, install

an equal number of rollers either side of the
spacer within the gear (2) bores.

NOTE: There is a total of 58 rollers per planet gear.

Use grease to retain the rollers in position whilst

installing the planet gear shafts. Position the shafts
(1) with the flat portion of the shaft heads away from
the centre of the carrier, Figure 23, then install the
shaft retaining ring (3). Bend each end of the ring
to ensure it maintains the correct position.

Planet Gear Carrier Ring Replacement

1. Planet Gear Shaft
2. Planet Gear
3. Retaining Ring
23

INSTALLATION

Installation of the planetary gear assembly follows

the removal procedure in reverse. On installation
ensure all bolts are correctly tightened to the
torques detailed in Specifications.

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18 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

DIFFERENTIAL AND DIFFERENTIAL LOCK ASSEMBLY -- OVERHAUL

REMOVAL
1. Prior to removal, chock the front wheels and
release the handbrake.
2. Drain the oil from the rear axle housing.
3. Raise and support the rear of the tractor to
allow removal of the right hand wheel and right
hand axle shaft housing.
4. With the axle shaft housing removed withdraw
the differential assembly (1) from the centre
housing.

DISASSEMBLY
With reference to Figure 25.
24

Differential Assembly 25
1. Cone and Roller Assembly 9. Retaining Ring
2. Ring Gear and Housing Assembly 10. Washer
3. Side Gear 11. Spring
4. Pinion Gear Assembly 12. Adaptor
5. Side Gear 13. Retaining Bolt
6. Housing 14. Thrust Washer
7. Cone and Roller Assembly 15. Thrust Washer
8. Coupling

1. Remove the differential lock ring from the end

of the side gear. Withdraw the stop washer,
coupling, spring and adaptor.

2. Mark the two halves of the differential case to

facilitate correct installation on reassembly.

3. Remove the differential cone and roller

assembly (3) from the smaller half of the case.
Use puller, Tool No. 1003 (1), pulling adaptor,
Tool No. 952 (2) and step plate adaptor, Tool
No. 630S/T(4), Figure 26.
26

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 19

4. Extract the differential case retaining bolts.

NOTE: If the cone and roller assembly installed on

the smaller half of the case does not require
removal, withdrawal of the case retaining bolts may
be effected by lifting the smaller half of the case
and gradually removing the bolts.

5. Separate the differential case.

6. Withdraw the thrust washer and side gear, the

spider and pinion assembly and the second
side gear and washer from the case.

7. Remove the cone and roller assembly on the

ring gear half of the housing using puller, Tool
No. 1003, pulling attachment, Tool No. 952 and
step plate adaptor, Tool No. 630S.

8. Separate the pinion gears from the spider.

INSPECTION AND REPAIR

1. Clean and inspect all components for damage

or excessive wear. Install new components
where necessary.

2. If a new differential ring gear is required, it will

be necessary to drill out the rivets, installed
during production and replace them with nuts
and bolts, available from the Parts department.
The bolts should be tightened to a torque value
of 85 lbf.ft (115 Nm).

NOTE: If the ring gear is replaced, a new matching

drive pinion must also be installed. Refer to the
following section, ‘Drive Pinion Assembly
Overhaul’ of this Chapter.

RE--ASSEMBLY

Re--assembly of the differential and differential lock

follows the disassembly procedure in reverse. On
re--assembly observe the following requirements:
S Coat all bearings with a suitable wheel bearing
grease prior to installation.
S Tighten the differential case retaining bolts to a
torque value of 68--92 lbf.ft (92--125 Nm).

INSTALLATION

Installation of the differential and differential lock

follows the removal procedure in reverse. On
installation observe the following requirements:
S Check the differential bearing pre--load, refer to
‘Adjustments” Section of this Chapter.

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20 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

DIFFERENTIAL LOCK OPERATING LINKAGE

OVERHAUL --
(Mechanically Actuated)

REMOVAL

1. Loosen the locknut of the pedal assembly and

remove the pedal assembly.

2. Remove the two bolts securing the hanger to

the centre housing and withdraw the hanger
and operating rods as an assembly.

3. Pull the fork operating rod from the centre Differential Lock Linkage 27
housing.
1. Foot Pedal
2. Floor Panel Sleeve
4. Remove the operating rod oil seal from the 3. Locknut
centre housing if previously leaking or 4. Pedal Operating Rod
5. Washer
damaged. 6. Shaft Operating Rod
7. Bush -- 2 off
8. Hanger
5. If the operating fork requires replacement it will 9. Hanger Pivot Pin
be necessary to remove the left hand axle shaft
housing as described in Section 21 120, Rear
Axle Shaft Overhaul, of this Chapter.

6. With the housing removed, remove the two

bolts securing the fork pivot shaft to the centre
housing and withdraw the shaft and fork as an
assembly.

7. Remove the retaining ring and washer then

slide the pivot shaft from the fork.

INSPECTION AND REPAIR

1. Clean and inspect all components for damage

or excessive wear. Install new components
where necessary.

2. If the pedal hanger bushes require renewal,

observe the following procedure:

(i) Knock the pin out of the hanger and pedal

assembly then separate the pedal from the
hanger.

(ii) Use bushing kit, Tool No. 818, to remove

and install the two bushings of the hanger.

(iii) Align the pedal assembly to the hanger and

replace the pin.

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 21

INSTALLATION

Installation of the differential lock operating linkage

follows the removal procedure in reverse. On
installation observe the following requirements:
S Tighten the differential lock fork pivot shaft
retaining bolts to 42--56 lbf.ft (57--76 Nm).
S Tighten the hanger retaining bolts to 42--56
lbf.ft (57--76 Nm).
S If the rear axle housing has been removed
ensure the the housing retaining bolts are
tightened to 130--190 lbf.ft (176--258 Nm)
S Refill the axle with the correct grade and
quantity of oil, see specifications.

DRIVE PINION ASSEMBLY -- OVERHAUL

REMOVAL

1. Separate the tractor between the transmission

and rear axle housing. Refer to the Section,
‘Separating The Tractor’.

2. Remove the P.T.O. clutch housing as

described in the P.T.O. Section.

3. Where fitted, remove the transmission

handbrake assembly, as detailed in Chapter 2
of this Section.

4. Remove the differential assembly as

described in the Differential Lock Overhaul
Section.

5. Remove the drive pinion assembly (1) by

extracting the retaining bolts and washers and
withdrawing the assembly from the housing
(3), Figure 28

NOTE: To facilitate removal of the drive pinion

assembly, two threaded holes are provided in the
pinion bearing retainer (2), for jacking bolts (4).
28

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22 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

DISASSEMBLY

7 8
1

5 4
MTG27021 3
Drive Pinion Assembly 29
1. Pinion Shaft 5. Cone and Roller Assembly
2. Pinion Bearing 6. Pinion Nut
3. Retaining Ring 7. Spacer
4. Cone and Roller Assembly 8. Pinion Assembly Housing

With reference to Figure 29. INSPECTION AND REPAIR

1. Clean then inspect all components for damage
NOTE: There may be either a staked nut or double or excessive wear. Install new parts where
nut with a locking tab washer arrangement securing necessary.
the pinion shaft to the bearing retainer. 2. If necessary, remove the bearing cups from the
retainer using slide hammer, Tool No. 943S and
1. Remove the stake nut or double nut from the puller, Tool No. 943. Use step plate adaptor,
pinion shaft. Tool No. 630S and a press to install new
bearing cups.
2. Slide the spacer, transmission handbrake drive
3. Use puller, Tool No. 1003, pulling attachment,
gear and shims, where fitted, or the washer
Tool No. 951 and a suitable sleeve to install the
from the pinion shaft.
rear cone and roller assembly to the pinion
3. Use a soft headed mallet to knock the front end shaft.
of the pinion shaft assembly from the bearing
RE--ASSEMBLY
retainer. Lift the front cone and roller assembly
from the retainer. NOTE: If a new pinion shaft is to be installed a new
matching differential gear must also be installed.
4. Remove the lock ring from the front of the pinion Refer to Section, ‘Differential and Differential Lock
gear and pull the pinion bearing from the shaft Assembly Overhaul’, of this Chapter.
using puller, Tool No. 1002 and pulling Re--assembly of the drive pinion assembly follows
attachment, Tool No. 951. the disassembly procedure in reverse. On
reassembly observe the following requirements:
5. Remove the cone and roller assembly from the
shaft using puller, Tool No. 1003 and pulling S Check the pinion bearing pre--load, see
attachment, Tool No. 951. ‘Adjustments’, Section of this Chapter.

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SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 23

INSTALLATION
Installation of the drive pinion assembly follows the
removal procedure in reverse. On installation
observe the following requirement:
S Tighten the bearing retainer support bolts to
100--125 lbf.ft (136--170 Nm).

ADJUSTMENTS

AXLE SHAFT BEARING PRE--LOAD

1. Install the axle shaft into the axle shaft housing.

2. Install the inner bearing cone and roller

assembly onto the shaft. Using a suitable sized
tube, tap the bearing onto the shaft. DO NOT
fully seat the bearing into the bearing cone.

3. Install the largest, (2.16 mm), spacer (1) onto

the axle shaft and install the planetary gear
carrier into the housing.

4. Install and tighten the carrier retaining bolt to

the correct torque value of 250--400 lbf.ft 30
(339--542 Nm).

5. Set a dial indicator (3), as shown in Figure 31.

Zero the gauge and measure the end float by
lifting the axle casing (1).

6. Subtract the measured end float from the size

of the spacer installed. Use the resultant figure
to determine, from table 1, the correct size of
spacer to be installed.

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24 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

EXAMPLE: Table 1:

Spacer Installed 2.16 mm 0.085 in RESULTANT SPACER TO BE

Reading Obtained 0.66 mm 0.026 in FIGURE INSTALLED
Resultant Figure 1.50 mm 0.059 in
0.049--0.052 in 0.045 in
(1.24--1.32 mm) (1.14mm)
From the table, the correct size of spacer to be
used is 1.35 mm (0.053 in). 0.053--0.056 in 0.049 in
(1.35--1.42 mm) (1.24 mm)

7. Remove the axle shaft retaining bolt then 0.057--0.060 in 0.053 in

withdraw the planet gear carrier assembly (2), (1.45--1.52 mm) (1.35 mm)
Figure 31, lock washer and large spacer. 0.057 in
0.061--0.064 in
(1.55--1.63 mm) (1.45 mm)
8. Install the new selected spacer then the 0.065--0.068 in 0.061 in
washer and planet gear carrier assembly and (1.65--1.73 mm) (1.55 mm)
tighten the retaining bolt to a torque of 250--400
lbf.ft (339--542 mm). 0.069--0.072 in 0.065 in
(1.75--1.83 mm) (1.65 mm)

0.073--0.076 in 0.069 in
9. After shimming is complete, measure the axle (1.75 mm)
(1.85--1.93 mm)
shaft rolling torque. Fabricate a plate (1) to
slide over the wheel studs (3) as shown in 0.077--0.080 in 0.073 in
Figure 32, with a nut or bolt head welded in the (1.96--2.03 mm) (1.85 mm)
centre. Using a suitable torque wrench (2) the
rolling torque should be between 8.3 -- 20.8 0.081--0.084 in 0.077 in
lbf.ft. (11.6 -- 28.2 Nm.) If necessary, add shims (2.06--2.13 mm) (1.96 mm)
to reduce the rolling torque or subtract shims to
increase the rolling torque. 0.085--0.088 in 0.081 in
(2.16--2.24 mm) (2.06 mm)

0.089--0.092 in 0.085 in
10. Repeat for the second axle shaft. (2.26--2.34 mm) (2.16 mm)

DIFFERENTIAL BEARING PRE--LOAD

The bearing pre--load is adjusted by adding or
subtracting shims between the differential bearing
cup and the inner brake housing. The adjustment
is made to the bearing in the right hand axle shaft
housing.

604.55.041.00 - 01 - 1998
SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1 25

1. Assemble the inner brake disc into the axle

shaft housing less the sun (intermediate) shaft,
brake discs and actuator assembly.
2. Remove the differential bearing cup and shim
from the inner brake housing (3).
3. Place the gauge ring of Tool No. FT.4501 (1)
into the vacant bearing location, Figure 33.

33
4. Bolt the bridge of Tool No. FT.4501 (4) across
the inner brake housing flange, ensure the Table 2:
spacers are located between the flange and
the tool.
GAP SHIM TO BE
MEASURED INSTALLED
5. Use feeler gauges (2) to measure the gap
between the underside of the gauge bridge and 0.024--0.029 in 0.038--0.040 in
the top side of the gauge ring. (0.61--0.74 mm) (0.97--1.02 mm)

0.030--0.035 in 0.044--0.046 in
6. From Table 2 determine the initial size of shim (0.76--0.87 mm) (1.12--1.17 mm)
to be used.
0.036--0.041 in 0.050--0.052 in
(0.91--1.04 mm) (1.27--1.32 mm)
7. Remove the gauge bridge and gauge ring and
install the selected shim and bearing. 0.042--0.047 in 0.056--0.058 in
(1.07--1.19 mm) (1.42--1.47 mm)
8. When shimming is completed check the rolling
0.048--0.053 in 0.062--0.064 in
torque of the differential assembly using the (1.58--1.63 mm)
(1.22--1.35 mm)
following procedure:
0.054--0.059 in 0.068--0.070 in
(1.37--1.50 mm) (1.73--1.78 mm)
NOTE: It is very important to perform the rolling
torque check as the bridge tool will only identify the 0.060--0.065 0.074--0.076 in
intital shim size. (1.50--1.63 mm) (1.88--1.93 mm)

0.066--0.071 0.080--0.082 in
(1.65--1.78 mm) (2.03--2.08 mm)

(i) Remove the left hand axle shaft housing if not

already removed.
(ii) Remove the pinion and bearing retainer
assembly.
(iii) Remove the differential lock spring and slide
the differential lock coupling into the engaged
position (1).
(iv) With the differential assembly installed and the
right hand inner brake housing flange bolted to
the axle centre housing, install one of
intermediate drive shafts (2) into the
differential assembly.
34

604.55.041.00 - 01 - 1998
26 SECTION 27 -- MECHANICAL REAR WHEEL DRIVE -- CHAPTER 1

(v) Wrap a length of string around the intermediate

shaft and attach to a suitable pull scale (3),
Figure 34. Measure the rolling torque whilst
the shaft is rotating, not at the point where
rotation begins. The rolling torque should
equate to a reading of between 15--67 lbf.
(7.0--30.0 Kgf.) on the pull scale.
(vi) If necessary, add shims to increase the rolling
torque or subtract shims to reduce the rolling
torque
9. Assemble the rear axle as previously
described in this Chapter.

PINION SHAFT BEARING PRE--LOAD

Prior to installation of the drive pinion and retainer
assembly, check the pinion bearing pre--load as
follows:
1. Lubricate the pinion bearings and locate the
pinion (3) and retainer assembly (4) in a vice,
Figure 35.

2. Install the adjusting (stake) nut or adjusting

nut, new lock washer and locknut.

3. Using gauge, Tool No. T.4062 (1) and adaptor,

Tool No. T.4062--2A (2), or a suitable spring pull
gauge, Figure 36 check and adjust to obtain
the correct pre--load as shown in Table 3.

4. When the correct pre--load is obtained tighten

the locknut and bend tabs on the lockwasher or
stake the nut as required.

36
5. Recheck the pre--load. Table 3:

Using Gauge, Tool No. FT.4602

10--17 lb.in (1.1--1.9 Nm)

Using a Spring Pull Gauge

13--23 lbf. (5.9--10.5 Kgf.)

604.55.041.00 - 01 - 1998
SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 1

SECTION 31 -- POWER TAKE--OFF

Chapter 1 -- INDEPENDENT POWER TAKE OFF SYSTEMS

CONTENTS

Section Description Page

31 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PTO--fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Take Off (PTO) Systems -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanically Operated PTO Clutch and Control Valve
--Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
31 114 Mechanically Operated PTO Clutch and Control
Valve--overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
31 000 Solenoid Operated PTO Clutch and Control Valve
--Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31 114 Solenoid Operated PTO Clutch and Control Valve
--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
31 114 PTO Shafts and Gears--overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SPECIFICATIONS

Refer to appropriate hydraulic pump pressure

testing procedure for testing of hydraulic pressures
within the PTO circuit.

Mechanically Operated PTO

Pressure Regulating Valve @ 2100 erpm 170--200 lbf/in2 11.7--13.8 bar

@ 800 erpm 130 lbf/in2 9 bar minimum

Lubrication Circuit Relief Valve @ 800 erpm 42--50 lbf/in2 2.9--3.5 bar

Solenoid Operated PTO with Fixed Displacement Hydraulic Pump

Pressure Regulating Valve @ 2100 erpm 260--290 lbf/in2 18--20 bar

@ 800 erpm 190 lbf/in2 13 bar minimum

Lubrication Circuit Relief Valve 73--123 lbf/in2 5.3 -- 8.5 bar

Solenoid Operated PTO with CCLS Variable Displacement Hydraulic Pump

NOTE: The pressure regulating valve for tractors installed with a variable displacement CCLS hydraulic
pump is incorporated within the hydraulic pump regulating valve. The lubrication circuit relief valve is
housed within the 16 ¢ 16 transmission control valve.
Pressure Regulating Valve @ 2100 erpm 260 -- 290 lbf/in2 18--20 bar
Lubrication Circuit Relief Valve 80 -- 100 lbf/in2 5.5 -- 6.9 bar

604.55.041.00 01 - 1998
2 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Drive Gear End Float (2 Speed PTO Systems)

End Float 0.005 in 0.13 mm

Shim Sizes 0.001 in 0.025 mm
0.003 in 0.076 mm
0.005 in 0.127 mm
0.012 in 0.305 mm
0.020 in 0.508 mm

Rear Shaft End Float

End Float 0.018 -- 0.40 in 0.46 -- 1.0 mm

Shim Size 0.010 in 0.25 mm

TORQUES

Rear Shaft Bearing Retainer Bolts 48 -- 63 lbf ft 65 -- 85 Nm

PTO Output Shaft Bearing Retainer 140 -- 170 lbf ft 190 -- 230 Nm

Solenoid Valve 12 -- 16 lbf ft 16 -- 22 Nm

PTO Valve Location Adjuster

Front Pin 20 -- 26 lbf ft 27 -- 35 Nm

Rear Pin (back off 1/4 turn) 9 lbf ft 1 Nm

Rear Pin Locknut 15 -- 20 lbf ft 21 -- 27 Nm

Brake Band Adjuster (back off 2 1/2 turns) 9 -- 11 lbf ft 1 -- 1.2 Nm

Clutch Support Bolts 14 -- 17 lbf ft 19 -- 23 Nm

Sump Cover Bolts 27 -- 37 lbf ft 37 -- 50 Nm

Shift Fork Bolt 20 -- 25 lbf ft 27 -- 34 Nm

SEALER
New Holland, Thread Lock and Seal, Part Number 82995773

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 3

31 000 PTO -- FAULT FINDING AND SPECIFICATIONS

PTO Will Not Operate Correctly

Is low pressure After engine switched off for

warning light ON?
NO approx 2 minutes can PTO YES
YES shaft be turned by hand?
NO

Check adjustment of
Variable Displacement Fixed Displacement PTO control valve
CCLS Hydraulic Pump Hydraulic Pump retainers on side of
transmission
NO
Perform steering pump
pressure and flow test. Check PTO clutch brake
Refer to Section 35 Refer to Section 35, for sticking or clutch
Chapter 2 Page 22 Chapter 5, pages 19 & 20. plates for damage

Concern identified?
NO

Is feed tube from hydraulic NO Install tube

pump correctly installed? correctly
YES

Is correct PTO valve

assembly installed?
NO

Has circlip at end of feathering NO Overhaul PTO clutch

valve become displaced and valve assembly

Does PTO operate but Attach dynamometer to PTO, set engine speed
with insufficient power YES to 1500 rev/min. fully load dynamometer.
to operate equipment? Engine Stalls?
NO YES NO

Is PTO valve solenoid PTO is OK Overhaul PTO

operated? Check power requirement of clutch pack
NO YES PTO equipment being operated

Is PTO linkage from Disconnect wire on side of tractor to PTO valve

selector lever to solenoid. Attach wire from battery to solenoid wire.
control valve Start tractor and check if PTO now operates.
connected? PTO operates?
NO YES
YES
Remove valve and Is alternator connected?
Test solenoid (use
check for sticking handbrake plate on side of YES
spool transmission for access).
Has Fuse 21 blown?
Solenoid Faulty?
NO
NO

Remove valve and Is PTO module faulty?

NO
check for sticking
spool Check wiring for open circuit

604.55.041.00 01 - 1998
4 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

PTO Shaft Turns Continuously

PTO Continually turns slowly YES

Is feed tube from hydraulic pump is
when disengaged? correctly installed?
NO YES

PTO turns Examine PTO brake band and

quickly? piston
YES
Is PTO valve solenoid Is PTO selector knob
YES
operated? damaged?
NO NO

Is PTO linkage from Remove valve and

selector lever to check for sticking
control valve spool?
connected?
YES

Remove valve and

check for sticking
spool?

604.55.041.00 01 - 1998
SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 5

POWER TAKE--OFF (PTO) SYSTEMS--DESCRIPTION AND OPERATION

The power take off (PTO) enables engine power to
be transferred directly to mounted or trailed
equipment via a splined shaft at the rear of the
tractor, Figure 1.

PTO driven equipment is designed to operate

using either a 6 or 21 splined output shaft at a
specified output shaft speed.

The output shaft speed must be restricted to 540

rev/min for equipment designed for use with the 6
splined shaft and 1000 rev/min for equipment
designed for use with the alternative 21 splined
shaft.
PTO Shaft
The types of PTO system available on TS Series 1
tractors fall into the following three categories:-- 1. PTO Guard
2. PTO Shaft
Single speed PTO, using the standard 6
splined output shaft for operation at
540 rev/min.

Two--speed non shiftable PTO with

interchangeable 6 and 21 splined output
shafts.

Two--speed shiftable PTO enabling the 6

splined output shaft to be operated at
540 rev/min at two separate engine speeds
and an alternative 21 splined output shaft for
operation at 1000 rev/min.

Independent PTO Schematic (Single Speed Shown) 2

1. PTO Output Shaft Cap 5. PTO Valve Assembly 9. PTO Clutch Assembly
2. PTO Output Shaft 6. Hydraulic Pump Idler Gear 10. Brake Band
3. Driven Gear 7. PTO Input Shaft 11. PTO Rear Shaft
4. Oil Supply Pipe 8. Hydraulic Pump Drive Gear 12. Drive Gear

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6 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Single Speed PTO The PTO clutch for single speed PTO systems, can
be either mechanically or electric solenoid
operated. When overhauling the clutch, reference
must be made to the appropriate Description,
Figure 2, shows in simple form the drive line from Operation and Overhaul Sections in this Chapter.
the engine to the output shaft.

The PTO input shaft passes through the

transmission upper shafts and is splined at both
ends into the engine flywheel and PTO clutch hubs. Two Speed Shiftable PTO

The PTO rear shaft is splined into the PTO clutch

and transmits drive to the output shaft drive gear.
The principal objective of two speed shiftable PTO
is to enable operation of the 6 splined 540 rev/min
shaft at two separate engine speeds, offering
When the PTO is engaged the friction and steel economy of operation at a slower engine speed.
plates within the clutch assembly are clamped
together, by the hydraulically operated clutch
piston, transmitting drive from the flywheel to the
PTO output shaft.

The PTO clutch for all two speed PTO systems, can
be either mechanically or electric solenoid
The speed of the output shaft is independent of the operated. When overhauling the clutch, reference
transmission or tractor ‘ground speed’ and is must be made to the appropriate Description,
related directly to the speed of the engine. Operation and Overhaul Sections in this Chapter.

Two Speed Shiftable PTO Schematic 3

1. 1000 rev/min Gear 5. Selector Lever 9. PTO Valve Assembly
2. Bearing Cap 6. 540 rev/min Gear 10. PTO Rear Shaft
3. Output Shaft (6 spline) 7. Solenoid Valve 11. Cluster Gear
4. Sliding Coupler 8. Clutch Assembly

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 7

Drive from the PTO rear shaft is directed through

a cluster gear and either the 540 or 1000 rev/min
gear before being transmitted to the output shaft,
Figure 3.
The required output shaft speed is selected using
the range selector lever mounted on the right hand
side of the drivers seat, Figure 4.

When the selector lever is moved towards the 1900

rev/min engine speed position, the sliding coupler
(2) on the output shaft sleeve (3) moves rearwards,
transmitting drive from the cluster gear (1), through
the 540 rev/min gear (4) to the output shaft, Figure
5.

5
In this position when the engine speed is set to
1900 rev/min and the PTO clutch engaged, the
output shaft will revolve at 540 rev/min. Decreasing
the engine speed similarly reduces PTO output
speed.

Moving the selector lever in the opposite direction

disconnects drive through the 540 rev/min gear (3)
and connects the 1000 rev/min gear (2) to the
output shaft sleeve (1), Figure 6.

When the engine speed is set at 1135 rev/min the

PTO shaft once again revolves at 540 rev/min but
with less engine power offering ‘Economy of
Operation’.
6
Where it is necessary to operate equipment at
1000 rev/min the 6 splined shaft must be removed
and replaced with the 21 splined version. When the
engine speed is increased to 2100 rev/min the
shaft will rotate at 1000 rev/min.

NOTE: The 6 splined PTO shaft must not be

operated at speeds above 540 rev/min.

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8 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Non Shiftable Two Speed PTO Shaft Installation 7

1. Drive Gear Assembly 6. Output Shaft Snap Ring 11. Needle Thrust Bearing
2. Drive Gear Bearing Shims 7. Output Shaft 12. Output Shaft Front Bearing
3. Bearing Retainer 8. Sleeve 13. Upper Shaft
4. 540 rev/min Driven Gear 9. Thrust Washers 14. Snap Ring
5. 1000 rev/min Driven Gear 10. Sump Cover Plate

Non Shiftable Two Speed PTO

On tractors installed with the non shiftable two

speed PTO, drive from the PTO rear shaft is also
transferred via a cluster gear and either the 540 or
1000 rev/min gear to the output shaft.

When the 6 splined PTO shaft is installed, splines

on the shaft engage with the 540 rev/min gear,
Figure 7. This output shaft will now rotate at 540
rev/min when the engine speed is set to
2890 rev/min.

When the 21 splined shaft is installed the splines on

this shaft engage with the 1000 rev/min gear
enabling the output shaft to rotate at 1000 rev/min
when the engine speed is set to 2050 rev/min.

NOTE: The PTO shafts used on shiftable PTO

Systems can not be installed onto tractors with the
non shiftable system.

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 9

MECHANICALLY OPERATED PTO CLUTCH and CONTROL VALVE--

DESCRIPTION and OPERATION

The PTO on mechanically operated PTO clutch

and control valves is engaged using a selector
lever on the left hand side of the drivers seat,
Figure 1. When the lever is operated, linkage
between the lever and the PTO control valve spool
moves the spool to the engaged or disengaged
position.

PTO Selector Lever 1

PTO Clutch Disengaged When the PTO selector lever is in the disengaged
position the control valve spool is positioned to the
left, Figure 2.
With reference to Figure 2.
Low pressure circuit oil entering the valve flows past
the control valve spool to operate the brake piston.
When the engine is running oil flows from the rear As the piston is applied the brake band tightens
pump (steering pump), within the hydraulic pump to preventing the output shaft from turning.
the inlet port of the PTO control valve. The pressure
of oil in this, the low pressure circuit, is maintained
by the pressure regulating valve housed within the When the engine stops running the pressure
PTO assembly. regulating valve closes and a groove in the valve
land allows oil applied to the brake piston to return
to sump, releasing the brake.
The low pressure hydraulic circuit operates the
PTO clutch and dual power circuits (where fitted).
This circuit is maintained at 130--160 lbf/in2 Engaging PTO Clutch
(9.0--11.0 bar) when the engine is at 800 rev/min
idle and the hydraulic pump is delivering 9.0--9.5
ltrs/min. When the engine speed is increased to With reference to Figure 3 and Figure 4.
2100 rev/min and pump output increases, the oil
pressure will increase to 170--200 lbf/in2
(11.7--13.8 bar). Refer to Section 35, Chapter 1, for The control valve spool comprises of two parts
the description and operation of the low pressure connected by a link and spring which enable a
hydraulic circuits. feathering engagement of the clutch.

Oil flowing through the pressure regulating valve When the PTO selector lever initially starts moving
provides lubrication to the PTO clutch and dual to the engaged position the control valve moves to
power circuits. The pressure of oil in these circuits the right blocking the supply of oil from the pump,
is limited to a maximum of 50 lbf/in2 (3.5 bar) by the while at the same time allowing clutch brake
cooler/lubrication circuit relief valve. Under normal pressure oil to return to reservoir (rear axle). This
operation and with the oil warm, this valve assumes results in a ‘Brake Off’ and ‘Clutch Off’ situation,
a normally closed position. Figure 3B.

604.55.041.00 01 - 1998
10 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

R6--49

PTO Oil Flow -- Clutch Disengaged 2

(Mechanically Operated PTO Control Valve)

Low Pressure Circuit Oil Lubrication Oil Return to Reservoir Oil

1. Clutch Housing 10. Detent Ball and Spring

2. Sealing Rings 11. Brake Piston
3. Clutch Support 12. Brake Piston Return Spring
4. Orifice 13. Clutch Piston Return Spring
5. Cooler/Lubrication circuit Relief Valve 14. Clutch Hub
6. Pressure Regulating Valve 15. Clutch Plates
7. Transfer Port to Oil Cooler 16. Brake Band
8. Orifice 17. Clutch Piston
9. Control Valve Spool

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 11

R6--50

PTO Clutch Engagement 3

‘A’Brake Applied--Clutch Off ‘C’Brake Off--Clutch Feathering
‘B’Brake Off--Clutch Off ‘D’Brake Off--Clutch Engaged

Low Pressure Circuit Oil Lubrication Oil Return to Reservoir Oil

1. Pressure Sensing Drilling 4. Valve Spool Connecting link and Spring

2. Pressure Regulating Valve 5. Detent Ball and Spring
3. Orifice

As the selector lever continues to move toward the This restriction of oil flow ensures a feathering of the
engaged position the spool is moved further to the clutch engagement in relation to the movement of
right uncovering the supply orifice to the clutch. A the selector lever.
controlled oil flow now flows to the clutch and at the
When the selector lever has moved to the fully
same time through a drilling to the right hand end of
engaged position the spring in the middle of the
the spool.
spool is fully compressed and the spool is held to
the right. Further feathering against the
compressed spring is now no longer possible and
maximum pressure is applied to fully engage the
As the pressure applied to the clutch increases the clutch, Figure 4.
pressure rise is sensed at the right hand end of the
spool. The spool will now move towards the left If the selector lever is moved quickly to the engaged
compressing the spring located between the two position the orifice (item 8, Figure 4) will restrict oil
halves of the spool and also restricting flow of oil to flow to the clutch and subsequent shock loading
the clutch. engagement.

604.55.041.00 01 - 1998
12 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

R6--51

PTO Oil Flow -- Clutch Engaged 4

(Mechanically Operated PTO Control Valve)

Low Pressure Circuit Oil Lubrication Oil Return to Reservoir Oil

1. Clutch Housing 10. Detent Ball and Spring

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 13

31 114 MECHANICALLY OPERATED PTO CLUTCH and CONTROL VALVE--OVERHAUL

Removal
1. Remove hydraulic top cover to expose PTO
clutch (1) and valve assembly (5), Figure 1.

2. Remove PTO rear shaft bearing retainer (1)

and withdraw shaft, bearing and drive gear (2),
Figure 2.

3. Remove cooler tube banjo bolt (1) and both

locating pins 2 & 3, Figure 3.

4. Remove plastic transfer tube from oil cooler

feed port.

5. Release intake tube retaining clip (2), Figure

6. Slide PTO clutch assembly rearwards and

disengage linkage to control valve spool.

604.55.041.00 01 - 1998
14 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

7. Remove clutch and control valve assembly,

Figure 4.

PTO Clutch and Valve Assembly

1. Brake Band
2. PTO Clutch Housing
3. Clutch Support
4. Valve Assembly
5. Pressure Regulating Valve
6. Control Valve Spool Detent
7. Cooler/Lubrication Circuit Relief Valve

Disassembly

1. Remove hub and thrust washer, Figure 5.

PTO Hub and Clutch Assembly

1. Clutch
2. Hub
3. Thrust Washer

2. Slide clutch from clutch support. Remove snap

ring and disassemble clutch pack, Figure 6.

Clutch Housing and Drive Plates

1. Clutch Housing
2. Feathering Spring
3. Internally Splined Friction Plates (5 off)
4. Snap Ring
5. Pressure Plate
6. Externally Splined Steel Plates (5 off)

604.55.041.00 01 - 1998
SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 15

3. Using spring compressor FT 4101 or

FNH 01312 and suitable press, remove piston
and return spring, Figure 7.

Clutch and Valve Assembly

1. Clutch Housing
2. Piston
3. Spring Keeper
4. Snap Ring
5. Return Spring
6. Piston Seals

4. Examine the cast iron sealing rings on the

clutch housing (1), Figure 8. Replace if worn or
damaged.

5. Disassemble clutch brake band assembly,

Figure 9.

6. Separate clutch support from valve body.

PTO Control Valve and Brake Band

1. Pressure Regulating Valve
2. Brake Cylinder
3. Valve Body
4. Brake Band Securing Pin
5. Clutch Support
6. Brake Band
7. Cooler/Lubrication Circuit Relief Valve

7. With reference to Figure 10, disassemble

clutch control valve components.
9

604.55.041.00 01 - 1998
16 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

PTO Clutch Control Valve and Brake Components 10

1. Split Pin 8. Guide
2. Spring 9. Plug (chamfer facing spring)
3. Control Valve Spool 10. Snap Ring
4. Control Valve Body 11. Cooler/Lubrication Circuit Relief Valve
5. Brake/Piston 12. Pressure Regulating Valve
6. Return Spring 13. Detent Ball and Spring
7. Snap Ring

INSPECTION AND REPAIR

1. Inspect all components for wear or damage

and replace as necessary.

2. Replace all ‘O’ ring seals.

RE--ASSEMBLY

Re--assembly follows the disassembly procedure

in reverse.

1. Install pressure regulating valve with the ‘V’

groove land positioned ‘away’ from the valve
spring.

2. If PTO brake band requires replacement soak

the band in rear axle oil for at least 3 minutes
before installation.

604.55.041.00 01 - 1998
SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 17

3. Adjust brake band as follows:--

Slacken locknut (1), Figure 11.
Screw in adjuster (2), Figure 11, to tighten
brake band, until screw torque is 9--11 lbf in
(1--1.2 Nm).
Loosen adjuster screw by 21/2 turns and
tighten locknut.
To check brake band concentricity after
adjustment, hold PTO clutch and brake
assembly as shown in Figure 11.
Position control valve housing at 3 o’clock. The
control valve housing should fall to 6 o’clock 11
position under its own weight.
Lightly bend band to shape if required and
repeat adjustment procedure.

INSTALLATION
Installation follows removal procedure in reverse.
During installation tighten locating pins as follows:--
Install front pin (3) and tighten to 20--26 lbf ft
(27--35 Nm).
Install rear pin (2) and tighten to 9 lbf in (1 Nm).
Loosen rear pin by 1/4 turn and tighten locknut
to 15--20 lbf ft (21--27 Nm).
Check clutch is free to rotate.

PTO Control Valve Retainers

1. Oil Cooler Tube Banjo Bolt 12
2. Rear Locating Pin and Locknut
3. Front Locating Pin

SOLENOID OPERATED PTO CLUTCH AND CONTROL VALVE

DESCRIPTION AND OPERATION

Tractors installed with a solenoid operated PTO

clutch can be identified by the unique PTO selector
knob, Figure 1. The PTO clutch is engaged by
depressing the central button (2) and pulling out
the outer know (3).

The knob will remain out while the PTO is engaged

and the adjacent warning lamp (1) will be
illuminated.

Tap the PTO selector knob sharply in to disengage.

604.55.041.00 01 - 1998
18 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

To allow the PTO to function, the control module

located in the fuse box, Figure 2, must receive a
signal from the alternator. The module also 1
includes an inbuilt safety feature preventing the
PTO from being engaged inadvertently.

When the engine is stopped the signal from the

alternator is no longer generated and the PTO is
disengaged.
When the engine is re--started, to engage the PTO
the selector knob must be re--set and then pulled
out to energise the module.

Hydraulic Operation of Solenoid Operated

PTO Control Valves

The type of PTO hydraulic control valve installed on

tractors is dependent on the hydraulic pump used
on the tractor.

Tractors installed with a fixed displacement gear

type pump, use low pressure (B) and lubrication
circuit (A) regulating valves within the PTO control
valve housing (2) to limit oil pressure within these
circuits, Figure 3.

Tractors fitted with the variable displacement

CCLS hydraulic pump do not require these valves
because circuit pressures are regulated by the
pressure regulating valve within the CCLS pump
and lubrication circuit relief valve within the 16 x 16
transmission control valve cover. Refer to Section
35, Chapter 1 for further details.
The lubrication circuit relief valve is not required on
tractors installed with the variable displacement
CCLS hydraulic pump and 12 x 12 transmission.
Never install the incorrect type of PTO valve into a
tractor. The PTO valve assembly installed on
tractors with fixed displacement gear type pump
can be easily recognised by the presence of ‘split
pins’ at ‘A’ and ‘B’, Figure 3.

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 19

Tractors with Fixed Displacement Gear Type Oil flowing through the centre of the spool is now
Pump directed to the feathering valve and PTO clutch
plates.

With reference to Figure 4 and Figure 5.

The pressure applied to the feathering valve

gradually moves the feathering valve to the left,
controlling the increase and gradual application of
When the engine is running oil flows from the pressure to the clutch, Figure 5.
hydraulic pump assembly to the inlet port of the
PTO valve body.

After approximately one second the feathering

Oil entering the PTO valve is regulated to a valve has moved to the full extent of travel, blocking
pressure of 260--290 lbf/in2 (18--20 bar) by the low any oil from returning to reservoir through the bleed
pressure regulating valve. Oil flowing through this port. The pressure of oil applied to the clutch will
valve is then further reduced in pressure by the now have increased to 260--290 lbf/in2 (18--20 bar)
lubrication circuit relief valve which limits the and the PTO clutch will be fully engaged.
maximum pressure of oil in the lubrication circuit to
73--123 lbf/in2 (5.3--8.5 bar) depending on engine
speed. Oil in this circuit provides lubrication to the
PTO clutch, transmission synchroniser, bearing
and output shaft. Switching the PTO off, opens the solenoid allowing
pressure to be applied to the right hand side of the
control valve spool. The spool now moves to the
left, allowing pressure applied to the clutch to return
to reservoir while oil pressure applied to the brake
When the PTO is not in operation low pressure piston stops the output shaft from revolving. Refer
circuit oil is directed to the right hand end of the to Figure 4.
control valve, moving the spool to the left, opening
the clutch pressure gallery to reservoir.

Hydraulic Operation of PTO Control Valve for

Because the spool has moved to the left, oil flows Tractors with Variable Displacement CCLS
through a drilling down the centre of the spool and Hydraulic Pump
onto the brake piston. As the piston protrudes the
brake band tightens, preventing rotation of the
output shaft while the PTO is disengaged and the
engine is running.
On tractors installed with the variable displacement
CCLS hydraulic pump their are no low pressure
regulating and lubrication circuit relief valves in the
PTO valve housing, Figure 6.
When the PTO is switched to the engaged condition
the solenoid on the end of the valve is energised
causing a plunger to move forward blocking the flow
of oil to the right hand end of the valve spool,
Figure 5.
Low pressure circuit oil for operation of the PTO
clutch is regulated by the low pressure regulating
valve located on top of the pump. Oil for lubricating
the PTO clutch plates, unlike the oil supply for
Because the bleed gallery at the right hand end of tractors installed with the tandem gear pump, flows
the valve is continually open to reservoir, oil from the 16 x 16 transmission and is regulated by
pressure applied to the left hand end of the valve the lubrication circuit relief valve located in the
causes the spool to move to the right, releasing the transmission. Refer to Section 35, Chapters 1 and
pressure applied to the brake piston. 2.

604.55.041.00 01 - 1998
20 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

R6--34
PTO Oil Flow -- Clutch Disengaged 4
Tractors with Fixed Displacement Gear Type Hydraulic Pump and Solenoid Operated PTO Control Valve
Low Pressure Circuit Oil Lubrication Circuit Oil Return to Reservoir Oil
1. Clutch Housing 7. Solenoid 13. Bleed Port
2. Sealing Rings 8. Solenoid Plunger 14. Brake Piston
3. Rear Shaft 9. Control Valve Spool 15. Clutch Piston Return Spring
4. Orifice 10. Screen 16. Clutch Hub
5. Feathering Valve 11. Pressure Regulating Valve 17. Brake Band
6. To Lubrication Circuit and Oil 12. Lubrication Circuit Relief Valve 18. Clutch Piston
Cooler

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 21

R6--35
PTO Oil Flow -- Clutch Engaging 5
Tractors with Fixed Displacement Gear Type Hydraulic Pump and Solenoid Operated PTO Control Valve
Low Pressure Circuit Oil Lubrication Circuit Oil Return to Reservoir Oil

1. Clutch Housing 7. Solenoid 13. Bleed Port

2. Sealing Rings 8. Solenoid Plunger 14. Brake Piston
3. Rear Shaft 9. Control Valve Spool 15. Clutch Piston Return Spring
4. Orifice 10. Screen 16. Clutch Hub
5. Feathering Valve 11. Pressure Regulating Valve 17. Brake Band
6. To Lubrication Circuit and Oil 12. Lubrication Circuit Relief Valve 18. Clutch Piston
Cooler

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22 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

R6--36

PTO Oil Flow -- Clutch Engaging 6

Tractors with Variable Displacement CCLS Hydraulic Pump

Low Pressure Circuit Oil Lubrication Circuit Oil Return to Reservoir Oil

1. Clutch Housing 7. Solenoid 12. Brake Piston

2. Sealing Rings 8. Solenoid Plunger 13. Clutch Piston Return Spring
3. Rear Shaft 9. Control Valve Spool 14. Clutch Hub
4. Orifice 10. Screen 15. Brake Band
5. Feathering Valve 11. Bleed Port 16. Clutch Piston
6. Lubrication Circuit Oil

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 23

31 114 SOLENOID OPERATED PTO CLUTCH AND CONTROL VALVE--OVERHAUL

1. Remove hydraulic top cover to expose PTO
clutch and valve assembly, Figure 1.

PTO Clutch and Valve Installation

1. PTO Clutch Assembly
2. Rear Shaft
3. Valve Body
4. Clutch Support

2. Remove rear shaft bearing retainer, Figure 2.

PTO Rear Shaft Bearing Retainer

1. Cluster Gear
2. Rear Axle Casing
3. Bearing Cup
4. Retainer
5. Seal

3. Withdraw cluster gear, Figure 3.

Cluster Gear Removal

1. Taper Roller Bearing
2. Cluster Gear
3. Taper Roller Bearing

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24 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

4. Remove shims from rear shaft and pull shaft

from tractor, Figure 4.

PTO Rear Shaft Removal

1. PTO Clutch Housing
2. Snap Ring
3. Rear Shaft
4. Shims
5. Snap Ring

4
5. Pull hydraulic supply pipe retaining clip,
located on bottom of PTO valve and
disconnect pipe, Figure 5.

PTO Clutch Oil Supply Pipe

1. ‘O’ Ring Seal
2. Supply Pipe
3. Retaining Clip

5
6. Where fitted, remove engine mounted gear
pump filter assembly on left hand side of rear
axle centre housing, Figure 6.

Auxiliary Engine Mounted Pump Filter

Clutch and Valve Assembly

1. Clutch Housing
2. Piston
3. Spring Keeper
4. Snap Ring
5. Return Spring
6. Piston Inner Seal

13. Using spring compressor FT 4101 or

FNH 01312 and suitable press, remove piston
and return spring, Figure 13. 13

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 27

14. Examine the cast iron sealing rings on the

clutch housing, Figure 14. Replace if worn or
damaged.

Clutch Assembly Sealing Rings

1. Cast Iron Sealing Rings (3 off)

14
15. Separate clutch support from valve body,
Figure 15.

Clutch Support and Valve Housing

1. Clutch Support
2. Oil Supply Galleries
3. Gauze Filter Location
4. Valve Body

15
16. Remove and wash control valve pilot line fliter,
Figure 16.

Control Valve Pilot Line Filter

1. Screen Filter
2. Filter Seat
3. Valve Body

16
17. Remove the clutch brake band, Figure 17.

Clutch Brake Band

1. Valve Body
2. Brake Lever
3. Locating Pin
4. Adjuster
5. Clutch Support
6. Brake Band

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28 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

18. Remove brake piston components, Figure 18.

Clutch Brake Piston Components

1. Return Spring
2. Snap Ring
3. Spacer
4. Brake Piston
5. ‘O’ Ring Seal

19. Disassemble PTO control valve assembly.

See Figure 19 to Figure 23.

PTO Control Valve Assembly Tractors (with Fixed Displacement Gear Type Pump) 19
1. Sleeve 7. Solenoid Operated Pilot Valve
2. Lubrication Relief Valve and Spring 8. Solenoid Coil
3. Shims 9. Control Valve Spool
4. Regulating Valve and Spring 10. Brake Piston Assembly
5. Plug 11. Feathering Valve and Spring
6. Valve Body

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 29

PTO Control Valve Assembly (Tractors with Variable Displacement CCLS Hydraulic Pump) 20
1. Feathering Valve and Spring 6. Solenoid Operated Pilot Valve
2. Sleeve 7. Solenoid Coil
3. Plug 8. Valve Body
4. Oil Supply Pipe Retainer 9. Brake Piston Assembly
5. Control Valve Spool

NOTE: For location of feathering valve orifice refer to Figure 24.

Feathering Valve
1. Sleeve
2. Circlip
3. Spacer
4. Feathering Spring
5. Feathering Piston

21
Control Valve and Solenoid Components
1. Valve Body
2. Control Valve
3. Pilot Valve
4. Solenoid Coil

NOTE: The pressure regulating and lubrication

circuit relief valves are only fitted on solenoid
operated PTO valves installed on tractors with
fixed displacement gear type hydraulic pump.

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30 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Pressure Regulating and Lubrication Circuit Relief

Valves
1. Shim
2. Shims
3. Regulating Valve Spring
4. Regulating Valve
5. Lubrication Circuit Relief Valve
6. Lubrication Valve Spring

23
INSPECTION AND REPAIR

1. Inspect all components for wear and damage.

2. Replace all ‘O’ ring seals.

Feathering Valve Orifice

1. Orifice
2. Plug
3. Valve Body

3. Ensure the feathering valve orifice is free from

obstruction, Figure 24.

24
RE--ASSEMBLY
Re--assembly follows the disassembly procedure
in reverse.
1. If PTO brake band requires replacement soak
the band in rear axle oil for at least 3 minutes
before installation.

2. Adjust brake band as follows:--

Slacken locknut (1).

Screw in adjuster (2), refer to Figure 25, to

tighten brake band until screw torque is
9--11 lbf in (1--1.2 Nm).
Loosen adjuster screw by 21/2 turns and
tighten locknut.
To check brake band concentricity after
adjustment, hold PTO clutch and brake
assembly as shown in Figure 25.
Position control valve housing at 3 o’clock. The
control valve housing should fall to 6 o’clock
position under its own weight.
Lightly hammer brake band to shape if
required. Repeat adjustment and check
procedure. 25

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 31

INSTALLATION
Installation follows removal procedure in reverse.
During installation tighten locating pins as follows:--
1. Install front pin (4) and tighten to 20--26 lbf ft
(27--35 Nm).
Install rear pin (3) and tighten to 9 lbf in (1 Nm).
Check that clutch is stiff to rotate.
Loosen rear pin by 1/4 turn and tighten locknut
to 15--20 lbf ft (21--27 Nm).
Check clutch is free to rotate.

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32 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

31 114 PTO SHAFTS AND GEARS--OVERHAUL

SINGLE SPEED PTO SHAFTS AND GEARS

PTO Rear Shaft and Bearing Retainer

1. Bearing Retainer
2. Rear Shaft, Gear and Bearing

1
REMOVAL

With reference to Figure 2.

1. Drain oil from rear axle/transmission.

2. Remove rear shaft assembly from rear of

tractor, Figure 1.

3. Where fitted remove drawbar/auto pick up

hitch, then remove sump cover.

4. Remove PTO bearing retainer.

5. Support the driven gear, withdraw PTO output

shaft and remove gear, thrust washers and
bearing.

6. Remove the front bearing, item 11 from the

transmission housing.

INSPECTION

1. Inspect all components for damage and Single Speed PTO Shaft Installation 2
replace where necessary. 1. Bearing Retainer
2. Thrust Bearing
2. Replace all seals and gaskets. 3. Thrust Washer (thin)
4. Thrust Washer (thick)
5. PTO Bearing Retainer
6. PTO Output Shaft
7. Oil Seal
8. Bearing
9. Sump Cover
10. Driven Gear
11. PTO Shaft Front Bearing
12. Rear Shaft
13. Drive Gear
14. Bearing

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 33

RE--ASSEMBLY
Re--assembly follows the disassembly procedure
in reverse.
1. Apply sealant, New Holland Tread Lock and
Seal, Part Number 82995773, to the rear shaft
bearing retainer bolts and tighten to a torque of
50--60 lbf ft (65--85 Nm).

2. Tighten sump cover retaining bolts to a torque

of 27--37 lbf ft (37--50 Nm)

3. Tighten the PTO shaft bearing retainer bolts to

a torque of 140--170 lbf ft (190--230 Nm).

NON--SHIFTABLE TWO SPEED PTO SHAFTS

AND GEARS
REMOVAL
1. Drain oil from rear axle/transmission.

2. Remove rear shaft bearing retainer (4),

Figure 3.

3
3. Withdraw cluster gear (2), Figure 4.

4. Remove shims (4) from rear shaft (3) and pull

shaft from tractor, Figure 5.

5. Where fitted remove drawbar/auto pick--up

hitch.

6. Remove sump cover.

4
7. Remove PTO output shaft.

8. Support the driven gears and remove output

shaft sleeve and bearing assembly. Refer to
Figure 8. Remove driven gears and thrust
washers.

9. Remove output shaft front bearing.

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34 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Two Speed PTO Upper Shaft Components 6

1. Bearing Retainer 6. Snap Ring
2. Shims (drive gear end float) 7. Snap Ring
3. Drive Gear Assembly 8. Bearing
4. Shims (rear shaft end float) 9. Bearing
5. Upper Shaft

Two Speed Non Shiftable PTO Output Shaft and Driven Gears 7
1. Output Shaft Retaining Ring 9. Thrust Washer (thin)
2. Output Shaft Cap 10. Thrust Washer (thick)
3. Output Shaft Bearing Retainer 11. Output Shaft Front Bearing
4. Gasket 12. Needle Thrust Bearing
5. Output Shaft Sleeve Oil Seal 13. 1000 rev/min Driven Gear
6. Output Shaft Sleeve 14. Output Shaft Rear Bearing
7. Thrust Washers 15. Snap Ring
8. 540 rev/min Drive Gear 16. PTO Output Shaft

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 35

INSPECTION
With reference to Figure 6 and Figure 7.
Inspect components for wear or damage and
replace as necessary.
Replace all ‘O’ rings, oil seals and gasket.

RE--ASSEMBLY

Two Speed Non Shiftable PTO Shaft Installation

1. Drive Gear Assembly
2. Shims (drive gear end float)
3. Bearing Retainer
4. 540 rev/min Driven Gear
5. 1000 rev/min Driven Gear
6. Output Shaft Retaining Ring
7. PTO Output Shaft
8. Sleeve
9. Bronze Thrust Washers
10. Sump Cover Plate
11. Thrust Washers and Bearing (see Figure 7)
12. Needle Bearing
13. Rear Shaft
14. Snap Ring and Shims

Re--assembly follows the disassembly procedure

in reverse.
Re--assemble with reference to Figure 8.
If the upper shaft, drive gear assembly bearings,
rear bearing retainer or rear axle centre housing
has been replaced the following adjustments must
be carried out.

8
Drive Gear End Float Adjustment
1. Locate drive gear and bearing assembly into
centre housing.

2. Install approximately 0.080 in (2.0 mm) of

shims behind the rear bearing cup. DO NOT fit
‘O’ ring seal.

3. Locate bearing retainer (1) (with word ‘TOP’

upwards) and tighten bolts sufficiently to
ensure bearings are seated.

4. Measure the gap at several locations to

determine average gap, Figure 9.
9

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36 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

5. Calculate shim thickness required:--

Shims thickness
Installed 0.080 in 2.03 mm
Average Gap 0.014 in 0.36 mm
(subtract) 0.066 in 1.67 mm
End Float 0.004 in 0.10 mm
(subtract) 0.062 in 1.57 mm
Shims Thickness
Required 0.062 in 1.57 mm
6. Install shim thickness behind bearing cup.

7. Install rear shaft shim(s) removed during

disassembly.

8. Install bearing retainer using new ‘O’ ring seal.

Rear Shaft End Float Adjustment

1. Using feeler gauge (1) check upper shaft (2)
end float, Figure 10.

2. Remove/add shims Item 14, Figure 8 between

rear snap ring and front bearing to achieve end
float of 0.018--0.040 in (0.46--1.0 mm).

TWO SPEED SHIFTABLE PTO SHAFTS

AND GEARS

REMOVAL

1. Drain rear axle and transmission.

2. Move the shift lever to 540 rev/min position

and disconnect cable, Figure 11.

Cable Assembly 11
1. Locknuts
2. Snap Ring
3. Lower Shift Lever
4. Thread
5. Pivot

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 37

3. Remove rear PTO shaft using same procedure

described for non--shiftable PTO shafts and
gears.
4. Where fitted remove drawbar/auto pick--up
hitch.
5. Remove sump cover.
6. From within the axle centre housing remove
shift fork locking bolt. Refer to Figure 13.
7. Support the shift fork and withdraw the lower
shift lever from centre housing. Remove fork.

12
8. Remove output shaft retainer bolts and install
two 7 in (178 mm) long locating studs (3),
Figure 12.

9. Supporting the gears through the bottom of the

centre housing, pull the output shaft (2),
Figure 12 rearwards until the larger
(540 rev/min) gear, thrust washers and needle
roller bearings can be removed. Refer to
Figure 13.

10. Continue pulling output shaft to remove

smaller (1000 rev/min) gear.

NOTE: The 540 rev/min counter shaft may remain

in the centre housing. Should this occur lever back
the countershaft while supporting the gears.

11. Disassemble the output shaft and coupler

assembly with reference to Figure 14.

NOTE: When separating the coupler, wrap a clean

rag around the coupler assembly to catch the
detent balls and springs.

INSPECTION

Inspect components for wear or damage and

replace as necessary. Refer to Figure 6 and
Figure 14.
Two Speed Shiftable PTO Output Shaft 13
and Driven Gears
Replace all ‘O’ rings and oil seals. 1. Bearing Retainer 11. Sump Cover
2. Thrust Washer 12. 1000 rev/min
(thick) Driven Gear
3. Thrust Washers 13. 540 rev/min
(thin) Driven Gear
4. Thrust Bearings 14. Needle Roller
5. Detent Spring and Bearings
Ball 15. Rear Shaft Snap
6. PTO Output Shaft Ring and Shim(s)
7. Oil Seal 16. Drive Gear
8. Retainer and Assembly
Bearing Assembly 17. Shim(s) Drive
9. Coupler Gear End Float
10. Shift Fork

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38 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

Two Speed Shiftable PTO Output Shaft and Driven Gears 14

1. Shift Fork 15. Snap Ring
2. Bearing 16. Oil Seal
3. Sleeve 17. Shaft
4. Bearing 18. Detent Spring and Ball
5. Coupler 19. Needle Roller Bearing
6. Lower Shift Lever 20. Thrust Washer (thick)
7. Cap 21. Thrust Bearing
8. Output Shaft Retainer 22. Thrust Washer (thin)
9. Oil Seal 23. 540 rev/min Driven Gear
10. Gasket 24. Thrust Washer (thin)
11. Retaining Ring 25. Thrust Bearing
12. PTO Output Shaft 26. 1000 rev/min Driven Gear
13. Snap Ring 27. Needle Roller Bearing
14. Bearing 28. Pin and ‘O’ Ring (2 off)

RE--ASSEMBLY

Re--assembly follows the disassembly procedure in has been replaced, the Drive Gear End Float
reverse. and Upper Shaft End Float Adjustment as
described for non shiftable two speed shafts and
gears on Page 35 must be performed.
During re--assembly observe the following:--
2. Install bearing Item 19, Figure 14 so that
1. If the upper shaft, drive gear assembly bearings, trademark on end of bearing is visible after
rear bearing retainer or rear axle centre housing installation into bore of rear axle centre housing.

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SECTION 31 -- POWER TAKE OFF -- CHAPTER 1 39

3. A suitable clamp (1) may be used to assist in

holding detent balls and springs during
re--assembly of coupler to output shaft sleeve,
Figure 15.

15
Cable Installation

1. Move lower shift lever (3) upwards to ensure

coupler detent has engaged, Figure 16.

2. Move selector lever in cab to 540 rev/min

position.

3. Install cable to lower shift lever and position

pivot (4) to mid point of threaded portion of
cable (3).

4. Adjust cable to ensure selector lever in cab is

freely located in 540 rev/min position.

5. Move selector lever to 1000 rev/min position 16

and check that coupler detents have engaged
correctly.

604.55.041.00 01 - 1998
40 SECTION 31 -- POWER TAKE OFF -- CHAPTER 1

NOTES

604.55.041.00 01 - 1998
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 1

SECTION 33 -- BRAKING SYSTEM

Chapter 1 -- Brakes
Section Page
33 000 Specifications, Torques and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
33 202 Brake System Component Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handbrake Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Pedals and Linkage Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SPECIFICATIONS, TIGHTENING TORQUES AND SPECIAL TOOLS

SPECIFICATIONS
Service Brake

Tractor Model 8×2 Models 12×12 and 16×16 models

Component

Brake Type Wet Brakes Wet Brakes

Brake Operation Mechanical Hydraulic
+ Ball ramp + Ball ramp
Brake Discs (Per Side) 3 3/4*

Brake Disc Total Friction Area 2452.8 cm2 2452.8 cm2/

3270.4 cm2

* 3 per side on 30 kph models with single speed or 2 speed changeable PTO shaft.

Standard Secondary Brake -- 12×12 and 16×16 Models

NOTE: 8×2 Models do not have a secondary brake system.
Brake Type Twin cable mechanically operated
using actuator assemblies of
service brake.
Optional Secondary Brake -- 12×12 and 16×16
Models
Brake Type Single cable, mechanically
operated, dry disc,
transmission handbrake
Friction Area 195.1 cm2 (30.24 in2)
Brake Shaft Bearing Pre--Load:
Using gauge , Tool No. T4062 12--16 lb.in (1.4--1.7 Nm)
Using a spring balance 20--26 lb (9.1--11.8 Kg)
Bearing Retainer To Rear Axle 0.005 in (0.127 mm) &
Centre Housing Available Shims: 0.020 in (0.508 mm)
Brake Hydraulics
Master Cylinder 0.6 mm (0.024 in) Minimum
Push Rod to Plunger Clearance
Brake Fluid Ambra brake LHM (NH610A)

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2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

TIGHTENING TORQUES

Components lbf. ft Nm

Master Cylinder Retaining Bolts 17 23

Handbrake Adjuster Locknut 20 27

Handbrake Retaining Bolts 33 45

Transmission Handbrake Housing Retaining Bolts 49 66

Transmission Handbrake Cover Bolts 32 44

Transmission Handbrake Pinion Locknut 75 102

Brake Pedal and operating Lever Pinch Bolts 49 66

SPECIAL TOOLS

DESCRIPTION V.L. CHURCHILL NUDAY

LTD TOOLS TOOLS

Step Plates 630S 9210

Drive Pinion Pre--Load Gauge T.4062 (Pull Scale)

Internal/External Puller 943 9507

Slide Hammer 943S 9567

Pulling Attachments:
Small 951 9190

Pullers:
Medium 1002 9198
Large 1003 9516

Handbrake Pinion Locknut Wrenches FT.2010 --

Bushing Kit 818 --

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 3

DESCRIPTION AND OPERATION

REAR BRAKE ASSEMBLIES

Wet disc type rear brake assemblies are located

within each axle housing.

The brake actuation of tractors with 8×2/16×4

transmission is by mechanical means using a rod
and linkage arrangement. 3 Brake friction discs, per
side, are installed as standard.

12×12 and 16×16 tractors employ a hydraulically

actuated braking system, which has 4 brake friction
discs installed per side as standard with 3 per side
on 30 kph models with single speed or 2 speed
changeable PTO shaft.

The brake assembly consists of internally splined

brake discs in each half axle housing which
sandwich an actuator assembly and an
intermediate disc.

The actuator assembly consists of two plates with

ramped pockets into which are located steel balls.
The discs are held together by springs and are
connected to the actuating lever by two links.

The actuating lever is operated by linkage

connected to the brake pedals on the 8×2 and
16×4 Model range and operated by a hydraulic
cylinder mounted on the actuator assembly on
12×12 and 16×16 Models.

Upon operation of the brake pedals the actuating

plates rotate relative to one another, which causes
the steel balls to ride up the ramped pockets forcing
the actuating discs apart. As the actuating discs
move apart the brake discs are forced against the
brake housing to effect a braking action on the
intermediate shaft.

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4 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

A common, compartmental, reservoir is used for

both the hydraulic clutch and brake systems, this
provides the hydraulic oil for the brake master
cylinders.

The Master cylinders, one on each brake pedal, are

push rod operated via suspended brake pedals. A
bridging pipe between the two cylinders and a
compensating ball and valve assembly in each
master cylinder provides an automatic brake
balance system which allows for some unequal
brake disc wear or poorly adjusted brakes.
Handbrake Operation
(12×12 and 16×16 Models)
A handbrake lever located to the left of the drivers
seat on either with or less cab models is connected,
via two operating cables, to the brake control rods
(footbrake adjustment assemblies) of each rear
brake assembly. When the lever is operated the
brake actuators, described previously, function in
the same way as if the footbrakes were operated.

Park Brake Latch

(8×2 and 16×4 Models Only)

A park brake latch is provided on 8×2 and 16×4

model tractors. This consists of a ratchet assembly
on the left hand brake pedal and a pull rod located
to the right hand side of the transmission. To
operate the latch, lock the footbrakes together, pull
up the latch (1) and rotate a quarter of a turn. When
the footbrakes are applied they will lock in the
applied position. To disengage rotate the latch a
quarter of a turn and release and momentarily
depress the footbrakes to disengage the ratchet

1
Transmission Handbrake
(Optional 12×12 and 16×16 Models)

A transmission handbrake is available in certain

markets where legislation demands an entirely
separate handbrake. A brake housing consisting of
two dry friction discs and an actuator assembly is
located on the left hand side of the rear axle centre
housing. An actuating cable connects the
operating lever to the housing.

A bevel gear is splined onto the main rear axle drive

pinion shaft to mesh with a driven gear mounted on
the inner end of the handbrake pinion shaft. When
the operating lever is lifted to the ‘ON’ position, the
actuator forces the friction discs against the brake
housing, effecting a braking action on the brake
shaft, locking the main rear axle drive pinion.

604.55.041.00 - 01 - 1998
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 5

FOUR WHEEL BRAKING

Four wheel braking is available on 12×12 and
16×16 models with front wheel drive.

There are two systems. On 12×12 models (less

dual command and Electronic Draft Control) i.e. no
‘Processor’ unit, the four wheel braking is activated
directly from the brake switches, i.e. , both pedals
depressed cuts the power to the FWD Solenoid
which allows the FWD to engage and provide four
wheel braking.

The second system, on 12×12 and 16×16

models utilising a processor unit, uses the
processor to engage/disengage the four wheel
braking. The brake switches send a signal to the
processor which then controls the signal to the
FWD solenoid, taking into account wheel speed.
The four wheel braking will operate at speeds
above 8.5 km/h (4 mph) but will not function below
this speed.

NOTE: To avoid possible serious mechanical

damage to the dog teeth of the four wheel drive
unit, it is important that the brake switches are
correctly adjusted to ensure that the front wheel
drive becomes engaged before the rear brake
assemblies start operating.

TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSES REMEDY

Excessive Pedal Travel Brakes Require Adjustment Adjust Brakes

Pedal Feels ’Spongy’ Air in System Bleed Brakes

Reservoir Oil Requires Leak In System Check Tube Connections and Tube
Regular Topping Up Condition.
Check Master Cylinder Push Rod End
For fluid Weepage.
Check Slave Cylinders.

Unequal Braking Brakes Badly Out of Adjust Brakes

Adjustment

Air in one side of System Bleed System

Only One Brake Operating Jack up Tractor , Check brake
Operation, Inspect adjusted Linkage.

Slave Cylinder Seized. Inspect Tubes and Connections.

Sudden Loss of Fluid From Inspect Brake Actuators and Brake

One Side. Plates.

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6 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

33 202 BRAKE SYSTEM COMPONENT OVERHAUL

MASTER CYLINDER -- Removal

1. Remove the instrument console right hand side

cover.

2. Disconnect hose from reservoir (1). Plug to

prevent excessive fluid loss.

3. Disconnect outlet tubes (2) and plug.

4. Disconnect the push rods from the brake

pedals (4).

5. Remove the four bolts (3) securing the cylinder

assemblies to the tractor bulkhead and 2
withdraw cylinders.

6. Installation is the reversal of the removal

procedure.

Master Cylinder -- Exploded View 3

1. Master Cylinder Body 4. Spring and retainer 7. Seal
2. Push Rod and Boot Assembly 5. Rod and seal 8. Compensating ball and valve
3. Spool 6. Oil inlet adaptor assembly

604.55.041.00 - 01 - 1998
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 7

MASTER CYLINDER -- OVERHAUL Reassembly

Disassembly
1. Reassembly is the reversal of the disassembly
procedure.

1. Roll back push rod rubber sleeve, remove

circlip, retaining push rod and spool assembly.
BRAKE ACTUATOR AND SLAVE CYLINDER --
OVERHAUL

2. Remove the balance tube and the system

compensating balls and valves from each Removal
cylinder.

For removal procedures of the brake assembly

3. Gently tap the cylinder, spool end downwards, refer to ‘Rear Axle Shaft Assembly Overhaul’
onto a firm surface to remove the spool Section 27.
assembly.

Disassembly
4. Withdraw the fluid inlet adaptors and hook out
end seals.

With reference to Figure 4.

5. From the spool and spring assembly, bend back

the locking tab and withdraw spring assembly.
Unhook the rod and disassemble.
1. Remove the split pin and clevis pin and
disconnect the brake handbrake and footbrake
adjusting rod from the actuating links.
Inspection and Repair

2. Unscrew and remove the nuts and bolts

1. Inspect the cylinder bore for wear, score marks retaining the links to the actuating discs.
or burrs. If the bore is not in perfect condition
replace the cylinder assembly. Do not attempt
to repair.
3. Unclip the springs retaining the brake master
cylinder to the actuating discs and remove the
cylinder.
2. A seal kit is available in Service. When
overhauling the master cylinder obtain a kit and
replace ALL seals.
4. Unclip and remove the four actuating disc
retaining springs and separate the discs.
3. Coat all seals in clean brake fluid prior to
fitment.

NOTE: Retain the steel balls located between the

actuating discs for use during re--assembly.
IMPORTANT: Use only the specified type of brake
fluid (see specifications). The fluid used in this
system is a ’Mineral’ based fluid. Use of a non 5. To replace the seal of the slave cylinder or to
specified fluid may cause seal damage and a inspect the cylinder bore, pull the piston from the
resultant brake failure. cylinder assembly as shown in Figure 5.

604.55.041.00 - 01 - 1998
8 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

Brake Assembly Components 4

Standard Rear Axle Half Shaft Assembly
1. Planetary Reduction Gears 3. Inner Brake Housing 7. Axle Shaft and Outer Bearing
and Carrier 4. Brake Discs and Actuator 8. Axle Shaft Housing
2. Carrier Retaining Bolt and 5. Outer Brake Housing 9. Axle Shaft Inner Bearing
Lock Tab 6. Sun Gear and Shaft 10. Shim

Inspection and Repair

1. Clean and inspect all items for damage or
excessive wear. Install new components
where necessary.
2. Inspect the slave cylinder bore for wear, score
marks or burrs. If the bore is not in perfect
condition replace the cylinder assembly. Do not
attempt to repair.
3. A replacement seal (2) is available in Service.
When overhauling the slave cylinder the seal
edge should have a pointed, sharp appearance
and not rounded.
4. Prior to assembly of the piston (1) to the 5
cylinder coat the seal and cylinder (3) bore in
clean brake fluid.
IMPORTANT: Use only the specified type of brake
fluid (see specifications). The fluid used in this
system is a ’Mineral’ based fluid. Use of a non
specified fluid may cause seal damage and a
resultant brake failure.

604.55.041.00 - 01 - 1998
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 9

Reassembly 3. Bleed the system using the following sequence,

1. Reassembly is the reversal of the disassembly referring to Figure 6: A, B, and if trailer brakes
procedure. are fitted, C, D and E.
Installation
Installation of the brake disc follows the removal NOTE: Regularly inspect the fluid level in the
procedure in reverse, refer to ‘Rear Axle Shaft reservoir during bleeding. Do not allow it to empty.
Assembly Overhaul’ Section 27.
SYSTEM BLEEDING 4. Install a suitable rubber tube over the bleed
screw. Immerse the tube into a jar of clean and
1. Ensure the reservoir is filled up to the maximum of correct specification brake fluid. Position the
line with the specified brake fluid. jar above the bleed screw, this prevents
2. When bleeding a system which has been possible air ingress at the bleed screw.
completely drained of fluid, it will be necessary
to prime the system. Open all the bleed screws 5. Open the bleed screw and fully stroke the
and pump the coupled pedals several times, coupled brake pedals several times until ‘air
close the bleed screws. free’ fluid is entering the jar.

Braking System Component Layout 6

1. Reservoir 4. Brake Assemblies
2. Right Hand Brake Master Cylinder 5. Handbrake
3. Trailer Brake Valve (where Fitted) 6. Left Hand Brake Master Cylinder
A,B,C,D,E Brake Bleed Screws

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10 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

6. With the pedals held down lock the bleed

screw. Repeat procedure in the correct
sequence on the remaining bleed screws,
until all the air is removed from the system.
7. Check the fluid level in the reservoir.

BRAKE ADJUSTMENT
Footbrake -- 12×12 and 16×16 Models
1. Raise the vehicle and support on stands,
remove the 4WD shaft if fitted.
2. Ensure that the handbrake cable adjustment is
not affecting the footbrake adjustment.
Slacken handbrake cables if necessary. 7
3. On one side of the tractor tighten the adjuster
nut (1) until the wheel just locks, Figure 7. Back
off the adjuster by one revolution and a third (8
flats) and ensure that the wheel is free to rotate.
Repeat the operation for the other wheel.

Footbrake -- 8×2 and 16×4 models

Free play at the brake pedals should be 1.5 in. (38
mm). With the brake pedals locked together, the
tractor should stop in a straight line when the
brakes are applied.
1. Adjustment is made to the brake pull rods
beneath the tractor. Block the wheels, front and
rear, unlock the brake pedals and release the
parking brake latch.
2. Loosen the locknut on the left hand brake pull
rod, Figure 8, and turn the adjuster nut until
free play at the left hand brake pedal is 1.5 in
(38 mm). Tighten the locknut.
3. Repeat on the right hand brake pull rod. 8
Handbrake

1. Pull the handbrake lever on 3 to 4 notches, then

tighten the upper adjusting nuts (1) while
turning the corresponding wheel, until it just
locks. Tighten the lower locknuts (2) to the the
handbrake lever. DO NOT move the upper
nuts. Repeat this for the other wheel. Apply
the handbrake a further 1 to 2 notches and the
wheels should be fully locked.
Release the handbrake completely. Check the
cable has fully released, i.e. the clevis pins
rotate freely.
9
Road Test

1. With the brake pedals coupled, drive the tractor

and apply the footbrakes. The tractor should
stop in a straight line.
2. Repeat the procedure using the handbrake.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 11

HANDBRAKE ASSEMBLY OVERHAUL

Handbrake Assembly 10
1. Protective Rubber Boot 6. Footbrake Adjuster Nut
2. Retaining Bolt -- 2 off 7. Clevis
3. Cable Retaining Screw 8. Cable End Ferrule
4. Left Hand Cable 9. ‘C’ Clip
5. Right Hand Cable 10. Cable Adjuster and Locknuts

CABLE REMOVAL 3. From under the cab/platform, remove the cable

(12×12 and 16×16 Models) end ferrule from the clevis and remove the ‘C’
clip securing the outer cable to the axle bracket.

With reference to Figure 10.

4. Remove the upper cable retaining screw.

1. Chock a wheel and release the handbrake.

2. Lift the protective rubber boot up from the floor

and remove the nuts from the top of the cables. 5. Note the cable routing and remove the cables.

604.55.041.00 - 01 - 1998
12 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

HANDBRAKE LEVER REMOVAL

(12×12 and 16×16 Models)
With reference to Figure 11.
1. Chock a wheel and release the handbrake.

2. Lift the protective rubber boot up from the floor

and remove the nuts from the top of the cables.

3. Disconnect the handbrake warning

light/buzzer switch connector.

4. Remove the two bolts securing the lever to the

floor and remove the lever from the vehicle.
11
PARKING BRAKE ASSEMBLY
(8×2 and 16×4 models only)

1. Chock a wheel and release the parking brake.

2. Remove the split pin from the lower end of the

lever rod and withdraw the lever and rod
assembly from the tractor.

INSPECTION (All Models)

1. Inspect the cables for kinking, inner to outer

cable tightness, frayed wire and outer covering
damage, replace if damaged.

2. Inspect the lever and rod assembly of 8×2 and

16×4 models, ensure the rod is not bent.

3. Inspect the ratchet mechanism of the

handbrake lever, 12×12 and 16×16 models
and the ratchet teeth of the footbrake pedal of
the 8×2 and 16×4 models. Replace if the
teeth are worn.

INSTALLATION (All Models)

Installation of all the handbrake components is the

reverse of the removal procedure observing the
following points:
S Tighten the handbrake lever to floor securing
bolts to a torque of 33 lbf.ft (45 Nm)

S Ensure the cable is routed correctly, avoiding

moving components and without any sharp
bends. Secure as required using nylon straps.

S If split pins have been removed always replace

with new items.

S Ensure the footbrakes are correctly adjusted

and then adjust the handbrake. Adjustment
procedures are detailed in the Brake System
Component Overhaul Section of this Chapter.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 13

TRANSMISSION HANDBRAKE ASSEMBLY

Removal

1. Chock the rear wheels and release the 5. Remove the four bolts retaining the housing to
handbrake. the axle and withdraw the housing. NOTE:
Place a suitable container under the brake
housing assembly to catch any oil that may leak
2. Slacken the cable adjuster and disconnect the out.
cable.

3. Remove the retaining bolts and withdraw the

brake housing cover plate. 6. Pull the bearing retainer and brake shaft
assembly from the housing if not previously
withdrawn with the outer housing. Note the
4. Withdraw the outer friction disc from the number of shims between the retainer and
housing. Centre housing to ensure correct reassembly.

Transmission Handbrake Assembly 12

1. Handbrake Lever 11. Bearing Cup 20. Housing Retaining Bolt
2. Single Operating Cable 12. Retainer Assembly 21. Inner Brake Disc
3. Control Rod Seal 13. Spring 22. Actuator Spring
4. Control Rod 14. Cone and Roller Assembly 23. Actuating Disc Steel Ball
5. Rod Retaining pin 15. Adjusting Nut 24. Outer Brake Disc
6. Brake Housing 16. Lock Washer 25. Actuator Assembly
7. Oil Seal 17. Locknut 26. Actuator Links
8. Driven Shaft 18. Outer Cover Gasket 27. Cable Clevis
9. Shims 19. Outer Cover 28. Retaining Bolt
10. Cone and Roller Assembly

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14 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

DISASSEMBLY INSPECTION AND REPAIR

With reference to Figure 12. 1. Clean and inspect all components for damage
or excessive wear. Replace parts as required.
1. Remove the bolt securing the cable bracket to
the housing and remove the bracket.
2. If replacement of the retainer bearing cups is
required use slide hammer, Tool No. 943S and
puller Tool No. 943 to remove. Use step plate
2. Remove the brake rod seal from the top of the adaptor, Tool No. 630S to effect replacement.
housing.

3. If required, remove the oil seal using a suitable

drift and replace using step plate adaptor, Tool
3. Withdraw the actuator assembly and the inner No. 630S.
brake disc from the housing.

4. Withdraw the retaining pin and remove the RE--ASSEMBLY

control rod from the actuator. Remove the nuts
and bolts securing the actuator links and
remove from the actuator plates. Re--assembly of the transmission handbrake
follows the disassembly in reverse. Observe the
following points during re--assembly:

S Use puller, Tool No. 1002, pulling attachment,

5. Carefully remove both springs and separate the
Tool No. 951 and a suitable sleeve to install the
actuator discs. Retain the steel balls located
inner cone and roller assembly on the brake
between the discs for use on re--assembly.
shaft.

6. Bend down the locking tabs then unscrew and S Using gauge, Tool No. T4062, check the re-
remove the nuts from the outer end of the brake tainer assembly bearing pre--load. If necessary
shaft. Use wrenches, Tool No. FT.2010 to loosen or tighten the inner locknut until the cor-
facilitate nut removal. rect pre--load of 12--16 lb.in. is achieved. When
achieved tighten the outer locknut to a torque
value of 50--100 lbf.ft (68--136 Nm) and ensure
the locktab is correctly bent over, one tab over
7. Pull the brake shaft out of the bearing retainer. the inner nut and one tab over the outer nut.

NOTE: The inner cone and roller assembly will NOTE: If gauge, Tool No. T4062 is not available a
remain on the brake shaft. spring balance may be used. A reading of between
20--26 lb should be achieved.

8. Extract the brake shaft outer cone and roller S Check and adjust as necessary the brake shaft
assembly from the bearing retainer. pinion gear to rear axle pinion gear backlash.
This procedure is described below.

9. Using puller, Tool No. 1003 and attachment,

Tool No. 951, remove the inner cone and roller S Ensure the oil seal is protected during re--as-
assembly from the brake shaft. sembly.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 15

Pinion Assembly 13
1. Retaining nut 4. Shims as required
2. Spacer 5. Pinion gear (crown wheel)
3. Bevel gear (Hand brake) 6. Spacer

TRANSMISSION HANDBRAKE PINION GEAR 3. Use a combination of shims to equal the

BACKLASH measured gap then add 0.013 in (0.33 mm)
extra shims to obtain the required backlash.

1. Install the bearing retainer assembly into the NOTE: Shims are available in .005 in (0.13mm) or
centre housing. Ensure the pinion and gear are 0.020 in (0.51 mm) sizes.
in full mesh.

2. Use feeler gauges to check the gap between 4. On installation of the bearing retainer, install the
the inner edge of the retainer and the centre shim pack between the retainer and centre
housing. housing.

604.55.041.00 - 01 - 1998
16 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

BRAKE PEDALS AND LINKAGE OVERHAUL

BRAKE PEDAL REMOVAL

(12×12 and 16×16 Models)

1. Remove the right hand side panel from the

instrument console assembly.

2. Disconnect the two return springs (6) from the

pedal assemblies.

3. Remove the split pins and clevis pins (4)

securing the master cylinder push rods to the
brake pedals.

Brake Pedal Components 14

4. Remove the circlip retaining the brake pedal
pivot shaft (7) and withdraw the shaft. 1. Pedal Spacer
2. Pivot Shaft Bush -- 4 off
3. Pedal Pivot Shaft
5. Collect the brake pedal spacer (1) and remove 4. Master Cylinder to Brake Pedal Clevis Pin
the two brake pedals from the tractor. 5. Brake Pedals
6. Return Spring
7. Pedal Pivot Shaft Retaining Ring

BRAKE PEDAL AND LINKAGE REMOVAL

(8×2 and 16×4 Models)

1. Chock the rear wheels and release the parking

brake.

2. Disconnect the two return springs (2) from the

pedal assemblies (1), located under the floor
pan.

3. Remove the split pin and clevis pin securing the

right hand brake pedal to the brake pull rod
clevis.
Brake Pedal Components 8×2 Models 15
1. Brake Pedal Assemblies
4. Remove the circlip and washer retaining the 2. Return Spring
right hand pedal to the brake cross shaft (8) 3. Right Hand Pedal Retaining Ring
and withdraw the right hand pedal assembly. 4. Bush
5. Left Hand Pedal Locking Bolt
6. Woodruff Key
7. Washers
8. Brake Pedal Cross Shaft
9. Left Hand Lever
10. Bush
11. Park Brake Pivot Arm and Pivot Post
12. Park Brake Lever Guide
13. Park Brake Lever

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 17

5. Remove the pinch bolt locking the left hand

brake pedal to the cross shaft. Slide the pedal
from the cross shaft, collecting the woodruff
key if loose in the recess and washer.
6. If required the brake cross shaft may be
removed using the following procedure:
S Remove the split pin and clevis pin securing the
left hand operating lever to the brake pull rod
clevis.
S Drain the rear axle oil.
S Pull the shaft from the centre housing using the
left hand, brake operating lever.

INSPECTION AND REPAIR

1. Clean and inspect all components for damage
or excessive wear. Install new components
where necessary.
2. Replace the brake cross shaft oil seals if the
shaft has been removed.
3. If the brake cross shaft bushes are worn,
i) Remove the oil seals, then using puller, Tool
No. 954--C remove the bushes.
ii) Use bushing kit, Tool No. 818, to install the new
bushes
iii) Press new shaft oil seals into the housing with
the steel face of the seals facing outwards.
iv) Ensure there are no burrs on the brake shaft
then install into the centre housing.
v) Refill the rear axle with the correct grade and
quantity of oil, specification Ambra Multi--G,
14.5 imp.gallons (17.4 U.S. gallons, 66 litres).

RE--ASSEMBLY AND INSTALLATION

Re--assembly and installation of the brake pedals
and linkage follows the removal and disassembly
procedures in reverse.
On reassembly and installation observe the
following requirements:
S Grease the ends of the operating rods and
clevis pins with a suitable grease.
S Tighten the brake pedal and operating lever
pinch bolts to a torque of 42--56 lbf.ft
(57--76Nm).
S Adjust the foot brakes and handbrake as
described previously in the Brake System
Component Overhaul Section of this Chapter.

604.55.041.00 - 01 - 1998
18 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

NOTES

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 1 -- INTRODUCTION

Section Page

35 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure, Steering and Lubrication Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 8

35 000 INTRODUCTION

The function of the hydraulic system on TS Series S Tractors installed with a 12×12 transmission,
tractors is to provide hydraulic oil flow at regulated hydraulic lift assembly with Electrolink" and a
pressure for the various hydraulic circuits within the fixed displacement tandem gear type pump in-
tractor. corporating a hydraulic lift pump and steering
system/low pressure circuit pump.

The major hydraulically operated or lubricated S Tractors installed with a 12 x 12 transmission,

components fall into the following categories of top link sensing hydraulic system and hydraulic
tractor build:-- pump assembly incorporating a fixed displace-
ment tandem gear type pump incorporating a
hydraulic lift pump and steering system/low
pressure circuit pump.

S Tractors installed with a 16 x 16 transmission,

hydraulic lift assembly with Electrolink! (elec-
tronic draft control) and hydraulic pump assem- S Tractors installed with a 12 x 12, 8 x 2 or 16 x 4
bly incorporating a variable displacement transmission, with top link sensing hydraulic lift
closed centre load sensing (CCLS) piston assembly and a fixed displacement tandem
pump and integral fixed displacement charge gear type pump incorporating a hydraulic lift
and steering pumps. pump and steering system/low pressure circuit
pump.

S Tractors installed with a 16 x 16 transmission, Additional options such as trailer brakes, where
top link sensing hydraulic lift assembly and hy- fitted and remote control valves are available on all
draulic pump assembly incorporating a variable model builds. An optional engine mounted
displacement closed centre load sensing piston hydraulic pump is available on all tractors installed
pump and integral fixed displacement charge with the fixed displacement tandem gear type
and steering pumps. pump.

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

To assist in identifying the hydraulic system

installed on the tractor refer to the following
illustrations.

The hydraulic pump with closed centre load

sensing (CCLS) variable displacement piston
pump can be identified by the two vertical intake
filters and horizontal charge pressure filter,
Figure 1.

1
Tractors installed with electronic draft control
(EDC) utilise a unique solenoid operated control
valve situated on top of the hydraulic lift cover,
Figure 2.

2
The EDC system can also be identified by the
unique operators control panel, Figure 3.

3
Tractors installed with the variable displacement
hydraulic pump and top link sensing hydraulic
system use an unload valve, installed on top of the
hydraulic lift cover, Figure 4.

The unload valve used with top link sensing

replaces the solenoid operated hydraulic control
valve installed on tractors with electronic draft
control.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 3

The Fixed displacement tandem gear type pump is

located on the right hand side of the rear axle
centre housing and incorporates a single inlet filter,
Figure 5.

5
The auxiliary engine mounted hydraulic pump,
where fitted, is installed on the front left hand side
of the tractor and is driven by the camshaft drive
gear, Figure 6.

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
HYDRAULIC CIRCUIT DESCRIPTION

The circuits provided with oil by the transmission S Hydrostatic steering system oil up to a
mounted hydraulic pumps can be separated into maximum pressure of 2500 lbf/in2 (172 bar)
the following categories:-- which is then regulated to provide low pressure
oil for operation of the PTO, four wheel drive
disengagement system, differential lock and
lubrication of 12 x 12 transmission
Tractors With Closed Centre Load Sensing synchronisers, bearings, output shaft and PTO.
Variable Displacement Hydraulic Pump:
The basic hydraulic circuits for each type of
S High pressure circuit oil up to a maximum installation are shown in schematic format in
pressure of 2800 lbf/in2 (193 bar) for operation Figure 7, Figure 8 and Figure 9 of this Chapter.
of the hydraulic lift assembly, remote control
valves and auxiliary hydraulic equipment,
where fitted. For a detailed description and operation of the high
pressure hydraulic lift circuits refer to the following
Chapters in this Part of the Repair Manual.
S Low pressure circuit oil for operation of the
16 x 16 transmission control circuits, PTO,
differential lock, electronic draft control valve For tractors installed with the variable
pilot pressure and four wheel drive circuits, displacement hydraulic pump and electronic
where fitted. draft control, refer to Chapters 2 and 3.

S Hydrostatic steering system oil up to a

maximum pressure of 2500 lbf/in2 (172 bar) For tractors installed with the variable
which is then regulated to provide low pressure displacement hydraulic pump and top link
oil for lubrication of the PTO and 16 x 16 sensing, refer to Chapters 2 and 4.
transmission.

For tractors installed with fixed displacement

gear type hydraulic pumps, refer to Chapter 5.
Tractors With Fixed Displacement Tandem
Gear Type Pump:
For the hydraulic operation of the transmission,
S High pressure oil up to a maximum pressure of PTO, differential lock, steering and four wheel drive
2650 lbf/in2 (183 bar) for operation of the disengagement systems, refer to the appropriate
hydraulic lift assembly, remote control valves Part and Chapters of this Repair Manual which
and auxiliary hydraulic equipment, where fitted. describe the operation of the component.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 5

NOTES

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Figure 7
Hydraulic Circuit for Tractor with CCLS Variable Displacement Piston Pump and Electronic Draft Control
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure Bypass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and PTO Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40#C, 104#F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 7

R8--146

Hydraulic Circuit for Tractor with CCLS Variable Displacement Piston Pump and Electronic Draft Control 7
Charge Pressure Oil @
Steering System Oil 23--50 lbf/in2 (1.6--3.4 bar)

Low Pressure Circuit Oil Suction/Return to Reservoir Oil

@ 250--280 lbf/in2 (17--19 bar)

System Pressure Oil

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Figure 8
Hydraulic Circuit for Tractor with CCLS Variable Displacement Piston Pump
and Top Link Sensing Hydraulic Lift Assembly
1. Top Link Sensing Hydraulic Lift Unload Valve
2. Load Sensing Line from Hydraulic Lift Unload Valve
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure Bypass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and PTO Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40#C, 104#F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 9

R8--149
Hydraulic Circuit for Tractor with CCLS Variable Displacement Piston Pump and Top Link Sensing 8
Hydraulic Lift Assembly
Charge Pressure Oil @
Steering System Oil 23--50 lbf/in2 (1.6--3.4 bar)

Low Pressure Circuit Oil Suction/Return to Reservoir Oil

@ 250--280 lbf/in2 (17--19 bar)

System Pressure Oil

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

R8--234
Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump 9
and Top Link Sensing Hydraulic Lift Assembly
1. Position Control Link 13. Exhaust Valve
2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly 17. Check Valve
6. Actuating Link 18. Combining (Sequencing) Valve
7. Pressure Relief Valve 19. Flow Control Valve
8. Steering Pump 20. Priority Valve Pack
9. Transmission Mounted Hydraulic Pump 21. Unload Valve
10. Pump Intake Filter 22. Check Valve
11. Lift Piston 23. Lift Arms
12. Control Valve

Pump Pressure Oil Trapped Oil

Suction/Return to Reservoir Oil

LOW PRESSURE, STEERING AND LUBRICATION HYDRAULIC CIRCUITS

Tractors Installed with Variable Displacement Figure 10, illustrates the flow of oil from the
CCLS Hydraulic Pump hydraulic pumps to the low pressure, steering and
The low pressure, steering and lubrication circuits lubrication hydraulic circuits on a tractor installed
have two functions respectively:-- with a variable displacement CCLS hydraulic
pump.
Low Pressure Circuit:
To operate the 16 x 16 transmission (where fitted), It can also be seen from Figure 7, that the oil
PTO, differential lock and four wheel drive supplied to the low pressure circuit is regulated at
disengagement system with regulated low a pressure of 250--280 lbf/in2 (17--19 bar) by the
pressure oil supplied by the variable displacement low pressure regulating valve housed on top of the
CCLS piston pump. pump. When this low pressure oil is directed to the
transmission clutch control circuits, the pressure is
Steering and Lubrication Circuit: further regulated within the transmission control
To operate the hydrostatic steering system and valve. Refer to Section 21, Chapter 1, for the
lubricate the PTO clutch assembly, transmission description and operation of the hydraulic circuits
clutches, bearings and shafts with oil supplied by within the 16 x 16 transmission.
the integral fixed displacement steering pump.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 11

R8--228
10
Low Pressure Steering and Lubrication Hydraulic System Layout
(Tractors Installed with Variable Displacement CCLS Hydraulic Pump and 16 x 16 Transmission)
1. Transmission Oil Cooler 10. EDC Hydraulic Control Valve
2. Cooler Bypass Valve 11. Steering Motor
3. 16 x 16 Transmission Control Valve 12. Steering Motor Relief Valve
4. Transmission Accumulator A. Differential Lock Supply (17--19 bar)
5. Steering Pump Filter B. 16 x 16 Transmission Supply (17--19 bar) and
6. Low Pressure Regulating Valve FWD Drive Clutch Supply
7. Differential Lock Solenoid Valve C. Internal Supply to PTO Clutch
8. PTO Valve Supply Tube D. EDC Pilot Supply (17--19 bar)
9. PTO Clutch S. Output to Steering and Lubrication Circuits

Steering Pump Pressure Oil Lubrication Circuit Oil

Low Pressure Circuit Oil Return to Reservoir

When the hydrostatic steering system is in Should the oil cooler become restricted, which
operation, the pressure of oil supplied by the would cause oil starvation to the lubrication
steering pump to the steering motor, can rise circuits, the cooler bypass valve will operate,
towards the maximum setting of the steering motor diverting oil directly to the lubrication circuit and
relief valve, which is 2100--2500 lbf/in2 bypassing the cooler.
(145--172 bar) depending on tractor model. The operating pressure of the bypass valve should
the cooler become restricted is 100 lbf/in2 (7 bar).
The pressure of oil, however, on leaving the The cooler bypass valve is also thermostatically
steering motor and returning via the oil cooler to the controlled enabling a proportion of the cold oil
16 x 16 transmission and PTO clutch lubrication during initial start up to bypass the cooler until the
circuits, is limited to a maximum pressure of nominal operating temperature of 68#C (155#F)
100 lbf/in2 (7 bar) by the lubrication circuit relief has been reached. This feature enables a faster
valve, located within the transmission control warm up cycle of the hydraulic oil.
valve.

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

R8--229

Steering, Low Pressure and Lubrication Hydraulic System Layout 11

(Tractors Installed with Fixed Displacement Tandem Gear Type Pump and 12 x 12 Transmission)
1. Transmission Oil Cooler 9. Low Pressure Regulating Valve
2. Cooler Bypass Valve 10. Lubrication Relief Valve
3. FWD Solenoid Valve 11. Steering Motor
4. Tandem Pump Filter 12. Steering Motor Relief Valve
5. Tandem Pump Body A. Outlet to Steering Motor
6. Differential Lock Solenoid Valve B. Return from Steering Motor
7. PTO Supply Tube (Internal) C. Supply to Four Wheel Drive Valve
8. PTO Clutch D. Supply to Differential Lock Valve

Steering Pump Pressure Oil Lubrication Circuit Oil

Low Pressure Circuit Oil Return to Reservoir

Tractors Installed with Fixed Displacement Figure 12, illustrates the flow of oil from the steering
Tandem Gear Type Pumps pump to the steering motor, low pressure and
lubrication circuits on tractors installed with the
16 x 4 transmission.
On tractors installed with the fixed displacement
tandem gear type pump the oil supply for the
steering, low pressure and lubrication circuits is As with tractors installed with the variable
only supplied by the steering pump within the displacement CCLS hydraulic pump, the maximum
tandem pump assembly. pressure of oil supplied by the pump to the
hydrostatic steering circuit, during steering
Figure 11, illustrates the flow of oil from the steering operations, is regulated by the steering motor relief
pump to the steering motor, low pressure and valve. This valve operates at 2100 lbf/in2 (145 bar)
lubrication circuits on tractors installed with the on two wheel drive tractors and 2500 lbf/in2
12 x 12 transmission. (172 bar) on all other models.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 13

R8--230

Steering, Low Pressure and Lubrication Hydraulic System Layout 12

(Tractors Installed with Fixed Displacement Tandem Gear Type Pump and 16 x 4 Transmission)
1. Transmission Oil Cooler 9. Dual Power Housing
2. Dual Power Control Valve 10. Steering Motor
3. FWD Solenoid Valve 11. Steering Motor Relief Valve
4. Tandem Pump Body A. Outlet to Steering Motor
5. PTO Supply Tube (Internal) B. Return from Steering Motor
6. PTO Clutch C. Supply to Four Wheel Drive Valve
7. Low Pressure Regulating Valve D. Supply to Dual Power Control Valve
8. Lubrication Relief Valve

Steering Pump Pressure Oil Lubrication Circuit Oil

Low Pressure Circuit Oil

The flow of oil on leaving the steering motor returns The lubrication circuit on 12x12 transmission
to the pump body for distribution to the low pressure tractors provides oil to the PTO clutch, transmission
and lubrication circuits. The pressure of oil returning synchronisers, bearing and output shaft.
from the steering motor is regulated at a pressure On 16 x 4 transmission tractors lubrication is
of 220--240 lbf/in2 (15.2-- 16.6 bar) by the low provided to the dual power, transmission output
pressure regulating valve in the PTO clutch shaft and PTO clutch. This is also similar to that for
assembly. As the pressure is regulated, excess oil tractors with the 8 x 2 transmission, except that the
in the low pressure circuit flows through the dual power assembly is not fitted.
regulating valve, into an adjacent lubrication circuit
relief valve which limits the pressure of oil in the It will be noted in Figure 12 that the cooler bypass
lubrication circuit to 77 lbf/in2 (5.3 bar). valve is not fitted on tractors with the 16 x 4 or 8 x 2
transmission. This valve, however, is installed on
The low pressure circuit provides oil for operation of tractors with the 12 x 12 transmission and
the PTO clutch, electro hydraulic differential lock improves the oil temperature warm up in exactly the
and transmission clutches and four wheel drive same way as described for tractors with the 16 x 16
disengagement (where fitted). transmission.

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

NOTES

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 15

TS SERIES 8x2 ECONOSHIFT

LOW PRESSURE HYDRAULIC OIL FLOW

604.55.041.00 - 01 - 1998
16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TS SERIES 8x2 ECONOSHIFT

LOW PRESSURE HYDRAULIC OIL FLOW
A = High Pressure Oil 180 Bar (2600 lbf.in2)
B = Steering Pressure up to 145 Bar (2100 lbf.in2) 2WD
172 Bar (2500 lbf.in2) 4WD
C = Steering Return Oil,
Low Pressure Oil 12--14 Bar (170--200 ibf.in2)
D = Lubrication Oil 5.3 -- 8.5 Bar (77--123 ibf.in2)
E = Suction / Return to Sump

1. Transmission Mounted Tandem Gear Pump

2. Transmission 8x2
3. 4WD Clutch
4. Pressure Regulating Valve
5. Lubrication Relief Valve
6. PTO Control Valve -- Engaged
7. PTO Clutch Assembly -- Engaged

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 17

TS SERIES 12x12 SYNCHRO COMMAND

LOW PRESSURE HYDRAULIC OIL FLOW

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18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TS SERIES 12x12 SYNCHRO COMMAND

LOW PRESSURE HYDRAULIC OIL FLOW
A = High Pressure Oil 180 Bar (2600 lbf.in2)
B = Steering Pressure up to 145 Bar (2100 lbf.in2) 2WD
172 Bar (2500 lbf.in2) 4WD
C = Steering Return Oil,
Low Pressure Oil 15--18 Bar (220--260 ibf.in2)
D = Lubrication Oil 5.0 Bar (70 ibf.in2)
E = Suction / Return to Sump

1. Transmission Mounted Gear Pump

2. Oil Cooler By--pass Valve
3. Synchro Command Transmission
4. 4WD Solenoid
5. Differential Lock Solenoid Valve
6. PTO Control Valve -- Engaged
7. Pressure Regulating Valve
8. Lubrication Circuit Relief Valve
9. PTO Clutch Assembly -- Disengaged

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 19

TS SERIES 24X24 DUAL COMMAND

LOW PRESSURE HYDRAULIC OIL FLOW

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TS SERIES 24x24 DUAL COMMAND

LOW PRESSURE HYDRAULIC OIL FLOW
A = High Pressure Oil 180 Bar (2600 lbf.in2)
B = Steering Pressure up to 145 Bar (2100 lbf.in2) 2WD
172 Bar (2500 lbf.in2) 4WD
C = Steering Return Oil,
Low Pressure Oil 15--18 Bar (220--260 ibf.in2)
D = Lubrication Oil 5.0 Bar (70 ibf.in2)
E = Restricted Pressure Lubrication Oil
F = Suction / Return to Sump

1. Transmission Mounted Gear Pump

2. Oil Cooler By--pass Valve
3. 24x24 Dual Command Transmission
4. Lubrication Control Valve
5. Transmission Control Valve Assembly
6. Differential Lock
7. PTO Control Valve
8. Pressure Regulating Valve
9. Lubrication Circuit Relief Valve
10. PTO Clutch Assembly -- Disengaged

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 21

TS SERIES 16X16 ELECTROSHIFT

LOW PRESSURE HYDRAULIC OIL FLOW

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22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TS SERIES 16x16 ELECTROSHIFT

LOW PRESSURE HYDRAULIC OIL FLOW
A = Steering Pressure up to 145 Bar (2100 lbf.in2) 2WD
172 Bar (2500 lbf.in2) 4WD
B = Standby Pressure Oil 24 Bar (350 lbf.in2)
C = Control Pressure Oil
D = Low Pressure Oil
E = Lubrication Oil Combined with Low Pressure Oil
F = Lubrication Oil 7 Bar (100 lbf.in2)
G = Restricted Lubrication Oil
H= Charge Pressure 1.6--3.4 Bar (23--50 lbf.in2)
I = Suction/Return to Sump
J = Trapped Oil

1. PTO Hub Assembly

2. Lubrication Control Valve Assembly
3. Cooler Bypass Valve
4. 16x16 Electroshift Transmission
5. Transmission Control Valve Block (engaging C3)
6. Electronic Draft Control Valve
7. Flow Compensating Valve
8. Pressure Compensating Valve
9. Steering Pump
10. Charge Pump
11. Differential Lock Solenoid Valve
12. Piston Pump
13. Pressure Regulating Valve
14. Low Pressure Safety Valve
15. PTO Control Valve

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 2 -- HYDRAULIC PUMP ASSEMBLY WITH VARIABLE

DISPLACEMENT CLOSED CENTRE LOAD SENSING (CCLS)
Section Page
35 000 Specifications and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35 106 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

35 000 SPECIFICATIONS AND SPECIAL TOOLS

Variable Displacement Closed Centre Load Sensing Swash Plate Pump
with Integral Charge and Steering Pumps
Charge Pump
Type Gear Type Pump
Minimum Output @ 2100 eng rev/min (New Pump) 24 US Galls/min,
(20 Imp Galls/min, 90 ltrs/min)
@ 90 lbf/in2 (6.2 bar)
Charge Pressure Filter Dump Valve Crack open @ 100 lbf/in2 (6.9 bar)
Fully open @ 180 lbf/in2 (12.4 bar)
Minimum 23 lbf/in2 (1.6 bar)
Charge Pressure @ 2100 rev/min and variable displacement
pump ‘On’ load
Maximum 50 lbf/in2 (3.4 bar)
@ 2100 rev/min and variable
displacement pump ‘Off’ load
Charge Pressure Switch Close @ 8--12 lbf/in2 (0.55--0.82 bar)
Making charge pressure warning light flash
Variable Displacement Closed Centre Load Sensing Pump
Type Variable Piston Pump
(Swash Plate Controlled)
Minimum Output @ 2100 eng rev/min (New Pump) 20 US Galls/min,
(16.6 Imp Galls/min, 76 Ltrs/min)
@ 2550 lbf/in2 (176 bar)
Standby Pressure (Low Pressure Standby) 310--350 lbf/in2 (21--24 bar)
Maximum System Pressure (High Pressure Standby) 2700--2800 lbf/in2 (186--193 bar)
Low Pressure Hydraulic Circuit 250--280 lbf/in2 (17--19 bar)
Pressure Regulating Valve
Low Pressure Circuit Safety Valve Crack open @ 290 lbf/in2 (20 bar)
Fully open @ 415 lbf/in2 (29 bar)
Low Transmission Oil Pressure Switch Close @ 210--220 lbf/in2
(Tractors with 16 x 16 transmission only) (14.5--15.2 bar) making low
transmission oil pressure warning light
come ‘On’
Open @ 240--250 lbf/in2 (16.5--17.2 bar)
Making low transmission oil pressure
warning light go ‘Off’
Low Transmission Oil Pressure Switch Close @ 80 lbf/in2 (5.5 bar)
(Tractors with 12 x 12 transmission only) Making low transmission oil pressure warning
light come ‘On’
Open @ 120 lbf/in2 (8.3 bar)
Making low transmission oil pressure warning
light go ‘Off’
High Oil Temperature Switch Close @ 104--110!C (219--230!F)

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Steering Pump
Type Gear Type Pump
Minimum Output @ 2100 eng rev/min (New Pump) 9.2 US Galls/min
(7.7 Imp Galls/min 34.8 Ltrs/min)
@ 2600 lbf/in2 (169 bar)
Maximum Operating Pressure 2600 lbf/in2 (179 bar)
Blocked Steering Filter Vacuum Switch Close @ 18 in Hg.
making blocked steering filter warning light
come ‘On’ providing oil temperature
42--48!C (107--118!F)
Low Steering Oil Temperature Switch Close @ 42--48!C (107--118!F)

THREAD SEALANT
New Holland Thread Lock & Seal, Part Number 82995773
Applied to pump driveshaft gear retaining nut.

SPECIAL TOOLS
DESCRIPTION TOOL NUMBER
V.L. Churchill FNH Part No
(America only)
Pressure Gauge 0--100 lbf/in2 (0--6.6 bar) FT. 4096 FNH 02026
Pressure Gauge 0--600 lbf/in2 (0--42 bar) FT. 4100 FNH 02027
Pressure Gauge 0--6000 lbf/in2 (0--414 bar) FT. 8503A FNH 02028
Pressure Gauge 0--400 lbf/in2 (0--30 bar) FT. 8616 FNH 06653
Elbow--Standby Pressure Test 86246--S36
Adaptor--Pressure Test FT. 8503--8 FNH 0705
Adaptor--By--pass Valve Pressure Test 4FT.850
(1/4’’--18NPSF male-- 7/16’’ JIC male)
Adaptor--Standby Pressure Test 4FT.851
(M14 x 1.5 male-- 7/16’’ JIC male)
Adaptor--Steering Flow Test 4FT.852
(3/4 ’’--18UNS female-- 3/4’’ JIC male)
Adaptor--Steering Pressure Test 4FT.853
(11/16 ’’--16UN to 7/16 ’’ JIC male)
Adaptor* --Trailer Brake Pressure Test 4FT.854
(M18--1.5 male to 7/16’’ JIC male)
Charge Pump Drive Gear Extractor 4FT.856
By--pass and Dump Valve Extractor 4FT.857
Flowmeter MS. 820A or suitable equivalent FNH 02755
Flowmeter Hoses Procure locally to suit flowmeter used
Adaptor--Hose to Flowmeter Procure locally to suit flowmeter used
Test Hose--Pressure Testing Part No 83936707
Test Hose--Pressure Testing Part No 83926717
Hose Clamp Procure or manufacture locally
Remote Control Valve Connectors Procure through New Holland to suit
hoses
*Or suitable M18x1.5 male adaptor to suit test hose on pressure gauge if 83936707 not used

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 3

= Nm TORQUES
= lbf ft

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Hydraulic Connections

Plan View of Variable Displacement Hydraulic Pump Tube Connections

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 5

FAULT FINDING

This fault finding section is designed to assist in Trailer Brakes not Working
identifying the cause of incorrect operation of those Remote Control Valves not Working
hydraulic systems which are supplied with oil by the
variable displacement hydraulic pump assembly Differential lock, PTO, 16 x 16 Transmission and
with closed centre load sensing (CCLS) and Four Wheel Drive Clutch Not Working (where
integral charge and steering pumps. fitted)
The following fault finding diagnostic charts Before proceeding to the individual fault finding
detailed in this section and should be referred to diagnostic charts it is important that reference is
when analysing concerns with the hydraulic made to the initial check fault finding chart which
system on the tractor. may identify an obvious cause for the concern and
prevent unnecessary component disassembly.
Initial Fault Finding Check
Where the fault finding specifies pressure or flow
Charge Pressure Light Flashing testing the pump or hydraulic circuit refer to Section
Transmission Pressure Warning Light ‘On’ D for the test procedure.
Hydraulic Lift not Working Correctly IMPORTANT: If the steering is inoperative, their
Power Steering not Working Correctly will be no lubrication to the transmission or PTO
clutch and the tractor must not be run for more than
5 minutes at a maximum engine speed of
1000 rev/min.
Initial Fault Finding Checks to be Performed Before Proceeding to General Diagnostic
Procedure

Is ASC valve in disengaged NO Turn ASC to

position? disengaged position
YES

Is rear axle oil at correct NO Add oil to rear axle

level on dipstick?
YES

Is oil contaminated with dirt, YES Investigate cause of contamination.

water or anti--freeze? Drain and replace oil
NO

Have oil filters been replaced NO Replace all three filters on pump
at correct service interval?
YES

Is hydraulic oil operating at a Operate tractor until correct oil

temperature of 40--70!C NO
temperature is reached Where necessary
(104--158!F)? use a piece of card positioned over the oil
cooler to raise temperature
YES

Has all air been bled from tractor NO Bleed trailer

trailer brakes (where fitted) brakes
YES

Is a warning light displayed YES Proceed to appropriate fault finding

on the instrument panel? diagnostic chart
NO

Perform load sensing circuit and

steering tests as described on
Pages 48 and 55 of the Pressure
Testing section of this Chapter to
identify circuits which are not
operating correctly.

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Charge Pressure Light Flashing

1
5
2

3
4

CCLS Hydraulic Pump Switch Identification 1

1. Low Transmission Oil Pressure Switch
2. Low Charge Pressure Switch
3. High Oil Temperature Switch
4. Steering Filter Low Temperature Switch
5. Blocked Steering Filter Vacuum Switch

Check for large oil leaks on

external hydraulic pipework. YES Repair leak and retest
Oil leak? tractor
NO
Test tractor steering
Is power steering NO Disassemble pump and check
working? for broken drive to pump
YES

Replace charge pump

and inlet filters
Fault cleared?
NO

Check hydraulic lift is working Disconnect wiring to low charge

satisfactorily and P.T.O. stops and starts YES pressure switch
when engagement switch is actuated Light is extinguished?
Correct operation? NO YES
NO
Locate and repair short Replace low
Check charge pressure. circuit to chassis in charge
See Section D. R/N/B colour wire from pressure
Is charge pressure 23--50 lbf/in2 instrument console switch
(1.6--3.4 bar)? connector J2 and
YES NO charge pressure switch
Replace low Examine charge pressure filter dump valve and
charge charge pressure by--pass valve
pressure (DO Not re--adjust these valves)
switch Fault cleared?
NO

Remove pump and check

that intake pipe is not
blocked or seal on intake NO Overhaul
tube is damaged charge pump
Fault found?

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 7

Transmission Pressure Warning Light ‘ON’

1
5
2

3
4

Pressure Regulating Valve 2 CCLS Hydraulic Pump Switch Identification 3

1. Pressure Regulating Valve 1. Low Transmission Oil Pressure Switch
2. Low Pressure Circuit Safety Valve 2. Low Charge Pressure Switch
3. High Oil Temperature Switch
4. Steering Filter Low Temperature Switch
5. Blocked Steering Filter Vacuum Switch

Is steering working NO Refer to fault finding chart for

correctly? steering not working check for short to
YES chassis in Y/O
Disconnect wiring to low colour wires from
Disconnect wiring to low instrument
transmission oil flow steering/lubrication YES
YES circuit pressure switch (1) console connector
pressure switch C080 to pressure
Is warning light ‘On’? Is warning light ‘On’?
NO switches
NO
Flow test oil cooler and check for
Perform low pressure circuit Replace low leaks/restriction in cooler circuit
check See Section D YES
transmission Fault found?
Is pressure 250--280 lbf/in2 oil pressure NO
(17--20 bar)? switch
NO
Replace low flow
steering/lubrication circuit
Remove and examine pressure switch
pressure regulating valve
for sticking
Fault cleared?
NO

Remove and examine low

pressure circuit relief valve
for sticking
Fault cleared?
NO

Check for large leak in PTO

differential lock, 4 wheel drive
and transmission pressure
circuits.

Low Flow Steering/Lubrication Circuit Pressure

Switch

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8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Hydraulic Lift Not Working Correctly

Flow and Pressure Compensating Valves 4 Shuttle Valve Location 5

1. Flow Compensating Valve 1. Shuttle Valve to EDC/Unload Valve and Remote
2. Pressure Compensating Valve Control Valves

Is steering system Stop tractor engine immediately,

working?
NO Remove and disassemble pump to
YES
check for broken or no drive to pump

Is charge Is transmission Refer to transmission

pressure light NO pressure warning YES pressure warning light
flashing? light on? fault finding chart
YES NO

Refer to charge If tractor fitted with electronic draft control refer to

pressure light flashing Chapter 3, EDC fault finding, before proceeding?
fault finding chart Fault cleared?
NO

Perform standby pressure Examine flow

Is pressure compensating valve for
test NO 2700--2800 lbf/in2 YES
Is pressure 300--350 lbf/in2 sticking
(186--193 bar)? Fault cleared?
(21--24 bar)? NO NO
YES
Adjust flow/pressure Disassemble variable
Perform maximum system compensating valve
pressure test displacement pump
Fault cleared? and check swash plate
Is pressure 2700--2800 lbf/in2 piston for sticking
NO
(186--193 bar)?
YES NO
Examine flow/pressure
Adjust pressure compensating valve for
Test maximum system sticking
pressure at remote compensating valve NO
Fault cleared? Fault cleared?
valve coupler.
Pressure
2700--2800 lbf/in2 If pressure is greater than
(186--193 bar)? NO standby pressure check for leak
YES in low pressure circuit

Examine shuttle valve in load

sensing line between hydraulic lift Overhaul lift
NO
EDC or unload valve and Cylinder
pressure/flow compensating valve
Fault cleared?

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 9

Power Steering Not Working or Working Incorrectly

1
5
2

3
4

CCLS Hydraulic Pump Switch Identification 6 Hydraulic Pump Intake Tubes 7

1. Low Transmission Oil Pressure Switch 1. PTO Supply Tube
2. Low Charge Pressure Switch 2. Steering Pump Intake Tube
3. High Oil Temperature Switch 3. Charge Pump Intake Tube
4. Steering Filter Low Temperature Switch
5. Blocked Steering Filter Vacuum Switch

Is blocked steering YES Stop tractor immediately and replace steering filter
filter light on? Light extinguished?
NO NO
Stop tractor engine immediately,
Is hydraulic lift Remove and disassemble pump Remove black (ground)
NO to check for broken or no drive
working? wire from blocked steering
YES to pump filter vacuum switch
Light extinguished?
Flow check steering pump as detailed in YES NO
”Pressure Testing”
Is pump output to specification? NO Replace switch Trace short to
YES NO Fault cleared? battery supply
in wiring circuit
Examine steering circuit for Remove pump and check to switch
leaks that intake pipe is not
Leaks found? blocked or seal on intake
NO tube is damaged
Fault found?
Refer to Section 41 NO
Steering System Fault
Finding Overhaul
steering pump

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Trailer Brakes and Remote Control Valves Not Working

Trailer Brake Shuttle Valve Location 8 Shuttle Valve Location 9

1. Trailer Brake Shuttle Valve 1. Shuttle Valve to EDC/Unload Valve and Remote
Control Valves

Trailer Brakes not Working

Is hydraulic lift working

Pressure test trailer satisfactorily? Test maximum Refer to hydraulic
brakes. YES
system pressure at remote NO
lift not working
valve coupler. correctly fault
Fault confirmed?
Pressure 2700--2800 lbf/in2 finding chart
(186--193 bar)?
YES

Examine shuttle valve in load

Clean/replace sensing line between trailer
shuttle valve to YES brake and pressure/flow NO Overhaul trailer
trailer brake valve compensating valve brake valve
Valve sticking?

Remote Control Valves not Working

Is hydraulic lift NO Refer to hydraulic lift not

working? working fault finding chart
YES

Test maximum system pressure at

each remote valve coupler.
Are pressures at each valve NO Overhaul remote control
coupler below 2700--2800 lbf/in2 valve(s) which fail pressure
(186--193 bar)? test
YES

Examine shuttle valves in load

sensing line between remote
control valves and hydraulic
pump

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 11

Differential Lock, PTO, 16 x 16 Transmission and Four Wheel Drive Clutch

Not Working (where fitted)

Pressure Regulating Valve 10

1. Pressure Regulating Valve
2. Low Pressure Circuit Safety Valve

NOTE: A fault in only one of the components listed above indicates that the Hydraulic pump with
closed centre load sensing is not the cause of the concern but is due to a malfunction in the circuit
or valves which operate the defective system. Use the following fault finding chart when all of the
above functions fail to operate correctly

Is hydraulic lift NO Refer to hydraulic fault

operating correctly? finding chart
YES

Remove and examine

pressure regulating valve
for sticking
Fault cleared?
NO

Remove and examine low

pressure circuit relief valve
for sticking

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

DESCRIPTION AND OPERATION

Hydraulic Pump Assembly With Variable Displacement Closed Centre Load Sensing 1
1. Variable Displacement Piston Type Pump
2. Fixed Displacement Gear Type Pump--Steering
3. Gear Type Charge Pump

The hydraulic pump assembly, Figure 1, is steering system and transmission and PTO
mounted on the right hand side of the rear axle lubrication circuits.
centre housing and contains within its body three
hydraulic pumps.

S A variable displacement piston type pump

S A charge pump of the gear type, supplies oil at
installed in a closed centre load sensing
a charge pressure of 23--50 lb/in2 (1.6--3.4 bar)
system, supplying oil for the requirements of
to a variable displacement piston pump.
the trailer brake system and the regulated
pressure circuit for the power take off (PTO),
differential lock, four wheel drive
S A fixed displacement pump of the gear type, disengagement system, transmission control
supplying oil for operation of the hydrostatic valves and remote and hydraulic lift valves.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 13

Hydraulic Pump Assembly Drive Train 2

1. Steering Pump (Gear Type) 6. Pump Idler Gear
2. Drive Link--Charge to Steering Pump 7. Variable Displacement Pump Drive Gear
3. Charge Pump (Gear Type) 8. Variable Displacement Pump Drive Shaft
4. Drive Link--Drive Gear to Charge Pump 9. Variable Displacement Pump (Piston Type)
5. Charge and Steering Pump Drive Gear

Illustrated in Figure 2, is the drive train for the

charge and steering gear pumps and variable
displacement piston pump. Note the mechanism
which adjusts the swash of the pistons in the piston
pump has been omitted for clarity.
All three pumping elements are driven through the
charge and steering pump drive gear. This is in turn
is driven by a gear on the independent power take
off (P.T.O.) drive clutch hub and an idler gear
mounted on the rear of the transmission.
Charge and Steering Pumps
The steering pump is mounted behind the charge
pump and driven by a drive link directly connecting
the two pumps.
The charge pump supplies oil to the variable
displacement piston pump while the steering pump
supplies oil to the hydrostatic steering system and
transmission and P.T.O. lubrication circuit.
Oil for both the charge and steering pump circuits
is drawn from the rear axle centre housing using
two separate intake ports, the steering pump intake
(1) and charge pump intake (2), Figure 3.
External pipework links the steering pump to the
steering system. 3
NOTE: The relief valve for the steering system is
located within the steering motor.

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14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Variable Displacement Piston Pump--Sectional Drawing 4

1. Swash Plate Servo Piston 7. Pump Head
2. Outlet Pressure Port 8. Slipper (9 off)
3. Pump Head and Slipper Pre--load Spring 9. Driveshaft
4. Inlet Port 10. Swash Plate Return Springs
5. Port Plate 11. Swash Plate
6. Piston (9 off)

Variable Displacement Piston Pump As the pumping head rotates, the pistons move in
and out of their barrels, following the contour of the
The variable displacement piston pump with closed swash plate. For every revolution of the drive shaft
centre load sensing consists of:-- each piston completes one pumping cycle.

The swash plate, which does not rotate but pivots

1. A nine element pumping head. about the front of the pumping head, is the control
mechanism that limits the stroke of each piston.
2. A plate mechanism to adjust piston stroke and
corresponding pump output. This plate will be Situated between the rotating pumping head and
referred to as a swash plate. the pump housing is a double kidney ported valve
plate which allows each piston barrel to be filled with
3. A load sensing valve which monitors the oil during the inlet stroke and to expel the oil on the
requirements of the hydraulic circuits and exhaust or power stroke. The inlet port is forcibly
signals the pump to increase or decrease fed with oil supplied by the charge pump and the
hydraulic oil flow accordingly. exhaust port discharges oil to the hydraulic circuits.

A sectional drawing of the piston pump assembly is As the pumping head rotates the barrel, each piston
shown in Figure 4. passes over the inlet and then the outlet ports of the
pump. During the inlet cycle for each piston and
barrel, oil is pumped into the barrel pushing the
The nine element pumping head is cylindrical in
piston forward so that it always remains in contact
shape and has nine barrels, into each of which, is
with the swash plate. The stroke of each piston and
installed a piston. On the end of each piston is
volume of oil charged into its barrel is dependent on
pressed a slipper which always remains in contact
the angle of the swash plate.
with the face of the swash plate located at the front
of the pumping head.
After a piston and barrel has completed the inlet
stroke, further rotation of the head aligns the barrel
The drive shaft, which is driven by the pump drive with the outlet port. Oil within the barrel is then
gear, rotates the pumping head in a clockwise forcibly ejected by the piston through the exhaust
direction, viewed from the drive end of the pump. port to the hydraulic circuits.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 15

Hydraulic Pump Assembly--Filter and Valve Identification 5

1. Charge Pressure Filter 6. Steering Pump Inlet Filter
2. Charge Pump Inlet Filter 7. Blocked charge Pressure Filter Dump Valve
3. Flow Compensating Valve 8. Low Pressure Circuit Safety Valve
4. Pressure Compensating Valve 9. Pressure Regulating Valve
5. Charge Pressure By--Pass Valve

A comprehensive description and operation of the Pressure Compensating Valve

closed centre load sensing system, used to control
the angle of the swash plate, is described later on
The pressure compensating valve works in
in this Section using a series of hydraulic circuit
conjunction with the flow compensating valve to
diagrams.
restrict the maximum pressure in the variable
displacement piston pump to 2700--2800 lbf/in2
These circuits are drawn depicting all the filters, (186--193 bar).
valves and pumping elements used in the hydraulic
system. To understand the circuits it is necessary
to be aware of the location and principal function of Charge Pressure By--Pass Valve
each valve and filter within the pump assembly.
Figure 5 illustrates the location of these items and Any excess oil supplied by the charge pump and not
is followed by a brief description of their principal required by the variable displacement piston pump
function. is returned to sump by the function of the charge
pressure by--pass valve. This valve starts to
operate when the pressure of oil delivered to the
Flow Compensating Valve
piston pump reaches 23 lbf/in2 (1.6 bar). It should
be noted that this is not the charge pressure but the
The flow compensating valve controls operation of pressure at which the by pass valve starts to ’bleed’
the swash plate in the variable displacement piston the excess oil delivery to sump. The valve when
pump. This valve is the principal component of the fully open limits the charge pressure to a maximum
load sensing system. of 50 lbf/in2 (3.4 bar).

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16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Charge Pressure Filter Dump Valve charge pressure filter. The oil then enters the
variable displacement piston pump.
The charge pressure filter dump valve is a safety
relief valve for relieving excess pressure on the
charge pump should the filter be restricted. This It should be noted that the inlet filter incorporates a
valve will begin to operate if the charge pressure by--pass valve, which is an integral part of the
exceeds 100 lbf/in2 (7 bar). replaceable filter. It is, therefore, essential that the
correct filter is installed at every filter change.
Pressure Regulating Valve
When the hydraulic lift and remote valves are not
The pressure regulating valve controls the operating, demand by the hydraulic circuits is
maximum pressure of oil in the P.T.O., differential minimal and the only requirement of the pump is to
lock, four wheel drive disengagement system and supply oil at standby pressure, sufficient to operate
transmission control circuits to 250--280 lbf/in2 the low pressure hydraulic system.
(17--19 bar) while at the same time directing high
pressure system oil to the hydraulic power lift and
remote valves. For detailed description and Because output of the variable displacement piston
operation of this valve refer to the sub heading pump is always less than that of the charge pump
’Operation of Pressure Regulating Valve’ at the end delivery, excess oil flow supplied by the charge
of this Section. pump is returned to sump through the charge
pressure by--pass valve.
Low Pressure Circuit Safety Valve
If the charge pressure filter becomes restricted and
The low pressure circuit safety valve is a relief valve the pressure on the inlet side of the filter reaches
preventing pressure in the low pressure hydraulic 100 lbf/in2 (7 bar), the blocked filter dump valve will
circuit exceeding a maximum of 415 lbf/in2 start to operate allowing oil to be returned directly
(28.6 bar). to sump. If the charge pressure filter is fully
restricted and ‘full charge pump flow’ has to pass
This valve will only operate in the unlikely event that over the dump valve, the pressure at the filter will
the pressure regulating valve fails to function be limited to a maximum of 180 lbf/in2 (12.5 bar).
correctly. provided the oil is at an operating temperature of
170!F (77!C).
HYDRAULIC CIRCUIT OPERATION
Should the charge pressure at the inlet of the piston
The following hydraulic circuit diagrams in this pump fall to 8--12 lbf//in2 (0.55--0.82 bar), a warning
Section are illustrated with the hydraulic lift light on the instrument panel will ‘flash’ indicating a
assembly and lower link sensing electronic draft low charge pressure.
control system. The principal of operation of the
variable displacement piston pump is, however, the
same if a mechanical top link sensing hydraulic The original equipment charge pressure filter
system is fitted as shown in Figure 11. contains a high performance synthetic media which
results in high efficiency with low pressure drop to
With reference to Figure 6. give maximum protection to the piston pump and
hydraulic valves and to allow the required service
life. It is, therefore, essential that the correct
The charge pressure pump draws oil through the element is installed at every filter change and that
charge pump inlet filter and passes it through the the only the specific filter is used.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 17

The steering pump similarly draws oil through an Control of Variable Displacement Piston
inlet filter which contains a by--pass valve which is Pump when Generating Standby Pressure
an integral part of the replaceable filter. It is, With reference to Figure 6 and Figure 7.
therefore, essential that the correct filter is installed
at every filter change. A dump valve, as used in the Control of the swash plate, which regulates the
charge pump circuit is not, however, required as output of the variable displacement piston pump, is
total output from the steering pump is directed to the achieved by the flow and pressure compensating
steering system and transmission lubrication valves located at the base of the pump.
circuits. Should the steering filter become restricted When the engine is first started, the swash plate
and providing the oil temperature is above 40!C return spring positions the swash plate for
(104!F), a warning light on the instrument panel will maximum output of the pump, Figure 6. During
be illuminated and a continuous audible alarm will engine start up, standby pressure has not yet been
sound. generated by the pump and the flow compensating
valve spool is held to the left by spring pressure.
For details of the steering and transmission The position of the spool prevents oil pressure
lubrication circuits refer to the appropriate Steering generated by the pump, being applied through
and Transmission Sections of this Repair Manual. gallery D to the swash plate servo piston through
gallery C. The swash plate consequently remains in
the maximum flow position until the piston pump
has developed standby pressure.

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Figure 6
Control of Variable Displacement Piston Pump with CCLS when Generating Standby Pressure
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
(or Unload Valve if Tractor Fitted with Top Link Sensing)
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 19

R8--144
Control of Variable Displacement Piston Pump with CCLS when Generating Standby Pressure 6

Steering System Oil Charge Pressure Oil @

23--50 lbf/in2 (1.6--3.4 bar)
Standby Pressure Oil @ Less Than Suction, Return to Reservoir and Zero
250 lbf/in2 (17 bar) Pressure Oil

Trapped Oil

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20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

As pump output pressure increases to the spring in the flow compensating valve gradually
310--350 lbf/in2 (21--24 bar), known as standby moves the spool to the left opening gallery C to
pressure (low pressure standby), the increase in sump through gallery B, via the spring cavity of the
pressure is sensed in gallery D and applied to the pressure compensating valve. This reduces the
end of the flow compensator spool. The spool pressure applied to the servo piston, allowing the
gradually moves against the spring allowing oil flow servo piston to retract at a controlled rate under
from gallery D to gallery C, Figure 7. pressure from the swash plate return spring, which
re--adjusts the angle of the swash plate to increase
pump output.
The controlled pressure rise in gallery C operates
the swash plate servo piston, changing the angle of
the swash plate in relation to the pumping head.
The change in angle reduces the operating stroke This process where the flow compensating valve
of the pistons and output of the pump. spool moves back and forth to control the pressure
applied to the servo piston, continues until there is
a demand by the hydraulic system to increase
As pump output decreases and the pressure in output to operate the hydraulic lift, remote control
gallery D reduces to less than 350 lbf/in2 (24 bar), valves or trailer brakes (where fitted).

Figure 7
Control of Variable Displacement Piston Pump with CCLS when Regulating Standby Pressure
(Low Pressure Standby)
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
(or Unload Valve if Tractor Fitted with Top Link Sensing)
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 21

R8--145
Control of Variable Displacement Piston Pump with CCLS when Regulating Standby Pressure 7
(Low Pressure Standby)

Steering System Oil Charge Pressure Oil @

23--50 lbf/in2 (1.6--3.4 bar)
Standby Pressure Oil Suction/Return to
@ 310--350 lbf/in2 (21--24 bar) Reservoir Oil
Low Pressure Circuit Oil
@ 250--280 lbf/in2 (17--19 bar) Trapped Oil Control Pressure Oil

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22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Control of Variable Displacement Piston The combined pressure from the pilot line and flow
Pump when High Pressure Hydraulic Circuits compensating valve return spring causes the flow
are Operated compensating spool to move against the standby
pressure in gallery D, preventing the flow of oil to the
With reference to Figure 8 and Figure 9. swash plate servo piston through gallery C.

After the pump has reached standby pressure and

the hydraulic power lift, remote valves or trailer
brakes (where fitted) are operated, the pressure The movement of the spool opens gallery C to the
rise in the hydraulic circuit being operated is sensed return to sump gallery B, allowing the servo piston
by the load sensing line A. The pressure in the to retract under pressure from the swash plate
sensing line is now applied to the spring loaded end return spring, which re--adjusts the angle of the
of the flow compensator valve. swash plate to increase pump output, Figure 8.

Figure 8
Control of Variable Displacement Piston Pump with CCLS when High Pressure Hydraulic Circuits are Operated
(Fast Lift)
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
(or Unload Valve if Tractor Fitted with Top Link Sensing)
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 23

R8--146
Control of Variable Displacement Piston Pump with CCLS when High Pressure 8
Hydraulic Circuits are Operated (Fast Lift)
Charge Pressure Oil @
Steering System Oil 23--50 lbf/in2 (1.6--3.4 bar)

Low Pressure Circuit Oil Suction/Return to Reservoir Oil

@ 250--280 lbf/in2 (17--19 bar)

System Pressure Oil

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

As pump output increases so does the system plate servo piston and changes the swash plate
pressure generated and applied to the end of the angle to reduce pump output and the speed of lift,
flow compensating spool through gallery D. Figure 9.

When the hydraulic operating cycle nears

completion, eg. the hydraulic lift is raised out of the It can now be seen that the basic principle of pump
ground and the main spool in the electronic draft control, when operating the hydraulic high pressure
control valve gradually returns to the neutral circuits, is similar to that for operation of the pump
position, the pressure in the load sensing line at standby pressure when there is no high pressure
similarly begins to decrease. When the pressure hydraulic demand. The only difference is that
generated in gallery D is 300 lbf/in2 (21 bar) because the pressure in the hydraulic system
greater than that in the load sensing gallery A the circuit being operated is sensed through the load
flow compensator spool moves back against the sensing line A, the pressure required to operate the
spring to open gallery D to gallery C. The controlled flow compensating valve is higher than that for
pressure rise in gallery C now operates the swash standby pressure operation.

Figure 9
Control of Variable Displacement Piston Pump with CCLS when High Pressure Hydraulic Circuits are Operated
(Slow Lift)
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
(or Unload Valve if Tractor Fitted with Top Link Sensing)
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 25

R8--147
Control of Variable Displacement Piston Pump with CCLS when High Pressure Hydraulic 9
Circuits are Operated (Slow Lift)

Steering System Oil Charge Pressure Oil @

23--50 lbf/in2 (1.6--3.4 bar)

System Pressure Oil Suction/Return to Reservoir Oil

Control Pressure Oil Low Pressure Circuit Oil

@ 250--280 lbf/in2 (17--19 bar)

604.55.041.00 - 01 - 1998
26 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Limiting Maximum System Pressure of to 2700--2800 lbf/in2 (186--193 bar) and operates
Variable Displacement Piston Pump as follows:--

With reference to Figure 10.

As the pressure in gallery D increases to
2800 lbf/in2 (193 bar) the pressure compensator
To limit the maximum output pressure of the piston valve spool moves against the valve return spring
pump and prevent consequential damage that may and opens gallery D to gallery C. The pressure in
occur due to excessive pressures, a pressure gallery D is now applied to the servo piston which
compensating valve, located adjacent to the flow changes the swash plate angle to reduce pump
compensator valve, is incorporated in the swash output to minimum flow. This operating mode is
plate control circuit. This valve limits the pressure referred to as high pressure standby.

Figure 10
Variable Displacement Piston Pump Assembly Operation when Limiting Maximum System Pressure
(High Pressure Standby)
1. Electronic Draft Control Valve
2. Load Sensing Line from Electronic Draft Control Valve
(or Unload Valve if Tractor Fitted with Top Link Sensing)
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to Flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 27

R8--148
Variable Displacement Piston Pump Assembly Operation when Limiting Maximum System Pressure 10
(High Pressure Standby)
Steering System Oil Charge Pressure Oil @
23--50 lbf/in2 (1.6--3.4 bar)
System Pressure Oil
@ 2800 lbf/in2 (193 bar) Suction/Return to Reservoir Oil

Control Pressure Oil Low Pressure Circuit Oil

@ 250--280 lbf/in2 (17--19 bar)

604.55.041.00 - 01 - 1998
28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Control of Variable Displacement Pump With Figure 6 to Figure 10 illustrate the operation of the
Top Link Sensing Hydraulic Lift CCLS hydraulic pump when installed on a tractor
with electronic draft control. The principle of
With reference to Figure 11. operation of the pump when the tractor is installed
with a top link sensing hydraulic lift assembly is
exactly the same as that for the electronic draft
When a tractor installed with a variable control system. To illustrate the similarity Figure 11
displacement closed centre load sensing hydraulic shows the installation of the top link sensing unload
pump is also fitted with a top link sensing hydraulic valve instead of the EDC hydraulic valve shown
lift assembly, a special unload valve with a load previously.
sensing capability is installed on the hydraulic lift
assembly.
For the operation and overhaul of the top link
This primary function of this valve is to signal the sensing unload valve refer to the ‘Hydraulic Lift
CCLS pump whenever the hydraulic demand of Assembly With Top Link Sensing’ Chapter in this
the hydraulic lift assembly changes. Part of the Repair Manual.

Figure 11
Control of Variable Displacement Piston Pump with Top Link Sensing Hydraulic Lift Assembly Unload Valve
(Fast Lift)
1. Top Link Sensing Hydraulic Lift Unload Valve
2. Load Sensing Line from Hydraulic Lift Unload Valve
3. Load Sensing Line from Remote Valves
4. Shuttle Valves
5. Flow Compensating Valve
6. Pressure Compensating Valve
7. Charge Pressure By--Pass Valve
8. Charge Pressure Filter
9. Charge Pressure Filter Dump Valve
10. Low Charge Pressure Switch
11. Oil Supply to Power Steering Motor, Oil Cooler, Transmission and P.T.O. Lubrication Circuits
12. Steering Pump
13. High Oil Temperature Switch
14. Steering Pump Inlet Filter
15. Steering Filter Low Temperature Switch
(Prevents Blocked Steering Filter Light Working when Oil Temperature Below 40!C, 104!F)
16. Blocked Steering Filter Vacuum Switch
17. Charge Pump Inlet Filter
18. Charge Pump
19. Pump Gear Drive Train
20. Variable Displacement Piston Pump
21. Trailer Brake Valve (where fitted)
22. Pressure Regulating Valve
23. Low Pressure Circuit Safety Valve
24. Low Transmission Oil Pressure Switch
25. Low Pressure Circuit Oil Supply to PTO, Differential Lock, Transmission Control Circuits
and Four Wheel Drive
26. To Hydraulic Lift Cylinder
27. To Remote Valves
28. Load Sensing Line from Trailer Brake Valve
A Load Sensing Line from Hydraulic Lift, Trailer Brake and Remote Control Valve Circuits
B Return to Sump Gallery from Flow and Pressure Compensating Valves
C Gallery to Swash Plate Servo Piston from Flow and Pressure Compensating Valves
D System Pressure Sensing Gallery to flow and Pressure Compensating Valves

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 29

R8--149
Control of Variable Displacement Piston Pump with Top Link Sensing 11
Hydraulic Lift Assembly Unload Valve (Fast Lift)
Charge Pressure Oil @
Steering System Oil 23--50 lbf/in2 (1.6--3.4 bar)

System Pressure Oil Suction/Return to Reservoir Oil

Low Pressure Circuit Oil

@ 250--280 lbf/in2 (17--19 bar)

604.55.041.00 - 01 - 1998
30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Operation Of Pressure Regulating Valve The resulting pressure in gallery F is sensed in the
pressure sensing gallery H drilled through the
centre of the spool. As the pressure in gallery F
increases, the spool moves against the spring
The regulated flow of oil discharged from the restricting the flow of oil into gallery F to maintain
variable displacement piston pump is directed to the pressure of oil in the low pressure hydraulic
the low and high pressure hydraulic circuits via the circuit at 250--280 lbf/in2 (17--19 bar), while at the
trailer brake valve (where fitted) and the pressure same time allowing system pressure oil to flow into
regulating valve. gallery G.

Because pump output is initially directed through When the high pressure hydraulic circuits are not in
the trailer brake valve, where fitted, the system operation the variable displacement piston pump is
ensures that the trailer brakes have priority over on minimal delivery and the pressure regulating
other hydraulic circuits. valve spool directs most of the flow from gallery E
to gallery F, in order to maintain the low pressure
hydraulic circuit pressure of 250--280 lbf/in2
The pressure regulating valve, located on the top of (17--19 bar), Figure 12.
the pump, controls the maximum pressure of oil in
the low pressure hydraulic circuit while at the same
time directing high pressure system oil to the
When the high pressure hydraulic circuits are in
hydraulic power lift and remote control valves.
operation and the variable displacement piston
pump has increased delivery to satisfy demand, the
spool moves almost totally against the spring in
The low pressure hydraulic circuit, which is at a order to regulate the pressure of oil in the low
pressure of 250--280 lbf/in2 (17--19 bar) operates pressure hydraulic circuit, .
the electronic draft control valve (where fitted),
P.T.O., differential lock, four wheel drive
engagement system and transmission control
circuits. It can now be seen that the spool moves back and
forth to maintain the low pressure circuit oil at
250--280 lbf/in2 (17--19 bar) while at the same time
allowing system pressure oil to be directed to the
With reference to Figure 12 and Figure 13, high pressure hydraulic circuit for operation of the
operation of the pressure regulating valve is as hydraulic lift and remote control valves.
follows:--

To prevent any damage occurring due to excessive

Spring pressure applied to the end of the pressure pressures in the low pressure hydraulic circuit, the
regulating valve spool moves the spool to the right low pressure circuit safety valve will operate
allowing system pressure oil from the variable whenever the pressure increases to
displacement piston pump to flow from gallery E to 400--415 lbf/in2 (28.6 bar). Should this occur the
the low pressure hydraulic circuits through gallery safety valve poppet will lift off its seat and vent the
F. circuit to reservoir.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 31

R8--35
Pressure Regulating Valve and Low Pressure Circuit Safety Valve 12
(Low Pressure Circuit Operation)
1. Pressure Regulating Valve 2. Low Pressure Circuit Safety Valve

E System Pressure Oil from Variable Displace- G To High Pressure Hydraulic Circuit
ment Piston Pump H Low Pressure Circuit Sensing Gallery
F To Low Pressure Hydraulic Circuit

System Pressure Oil Low Pressure Circuit Oil Return to Reservoir

R8--36
Pressure Regulating Valve and Low Pressure Circuit Safety Valve 13
(Low and High Pressure Circuit Operation)
1. Pressure Regulating Valve 2. Low Pressure Circuit Safety Valve

E System Pressure Oil from Variable Displace- G To High Pressure Hydraulic Circuit
ment Pump H Low Pressure Circuit Sensing Gallery
F To Low Pressure Hydraulic Circuit

System Pressure Oil Low Pressure Circuit Oil Return to Reservoir

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32 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

35 106 OVERHAUL

Installation of Variable Displacement Hydraulic Pump Assembly with Closed Centre Load Sensing 1
1. Tractor Brake Lines 9. Differential Lock Feed
2. Remote Valve Return 10. Differential Lock Return
3. Load Sense Line to Flow Compensating Valve 11. Power Steering and Transmission Lubrication Feed
4. Pilot Pressure to EDC Valve 12. To Rear Rear Tractor Brakes
5. Trailer Brake Pilot Head Sense Line 13. Remote Valve Feed
(Right Hand Brake) 14. Trailer Brake Feed
6. Transmission Pressure Feed (Connects Into Rear of Trailer Brake Valve)
7. Load Sense Line to EDC Valve and Remote Valves 15. Trailer Brake Load Sense Line
8. Trailer Brake Pilot Head Sense Line
(Left Hand Brake)

This procedure describes the overhaul of the

complete pump assembly when removed from the
tractor, however, the valves shown in Figure 2 can
be serviced with the pump installed on the vehicle.

PUMP REMOVAL

1. Securely support the tractor on suitable axle

stands and remove the right hand rear wheel.

2. Drain oil through rear axle.

3. Disconnect all electrical and hydraulic

connections to pump. Refer to Figure 1. Valves Serviced with Pump Installed on Tractor 2
1. Pressure Regulating Valve
4. Where fitted, remove trailer brake valve 2. Flow Compensating Valve
3. Pressure Compensating Valve
retaining bolts and separate valve from pump 4. Charge Pressure By--pass Valve
body. This will avoid the necessity to 5. Charge Pressure Filter Dump Valve
disconnect the tractor brake lines. 6. Low Pressure Circuit Safety Valve

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 33

5. Remove hydraulic filters, support pump on

suitable lift or trolley jack and remove from
tractor, Figure 3.

WARNING: The hydraulic pump is a

heavy component and weighs 88 lbf
(4o kgf). It is important that it is securely supported
when being removed from the tractor.

REMOVAL AND DISASSEMBLY OF VALVES

1. Where fitted, remove trailer brake valve. For
overhaul of valve refer to trailer brake valve
Section of the Repair Manual.
3

Charge Pressure By--pass Valve

1. Remove plug to expose charge pressure

by--pass valve (1), Figure 4.

4
2. Use Tool No 4FT.857 which engages in the peg
locating holes of the valve, unscrew the charge
pressure bypass valve from the pump body,
Figure 5.

NOTE: If during pressure testing the charge

pressure reading was away from the specified
value of 23--50 lbf/in 2 (1.6--3.4 bar) the bypass
valve must be examined together with the charge
pressure filter dump valve for faulty operation. Do
not attempt to adjust the valve which is supplied as
a pre--set assembly and should not be adjusted.

5
Pressure Regulating and Low Pressure
Circuit Safety Valves

NOTE: The pressure regulating and low pressure

circuit safety valves are supplied as a pre--set
assembly and should not be adjusted.

1. Remove pressure regulating (1) and low

pressure circuit safety valve (2), Figure 6.

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34 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Pressure Regulating Valve and Low Pressure Circuit Safety Valve 7

1. Shims 8. Housing
2. Pressure Regulating Valve Cap 9. Plug
3. Low Pressure Circuit Safety Valve Cap 10. Pressure Regulating Valve Spool
4. Shims 11. Stop (washer)
5. Dowty Seal 12. Spring Guide
6. Spring 13. Spring
7. Poppet 14. Spring

2. Carefully remove pressure reducing and low

pressure circuit safety valve caps which are
under pressure from the springs within the
valve. Remove the valve components,
Figure 7.

3. Remove transfer tubes (1) and ‘O’ rings (2)

from oil galleries connecting pump and valve
housings, Figure 8.

8
Charge Pressure Filter Dump Valve

NOTE: The valve is supplied as a pre--set

assembly and should not be adjusted. Install a new
valve assembly whenever the valve does not
operate correctly.

1. Remove charge pressure filter manifold to

expose dump valve (1), Figure 9.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 35

2. Using Tool No 4FT.857 which engages in the

two slots in the valve body unscrew and
remove valve. Refer to Figure 10.

10
Pressure and Flow Compensator Valve
1. Remove housing containing pressure (2) and
flow (1) compensating valves, Figure 11.

2. Remove the tamper proof caps, carefully

unscrew each adjuster and remove the
component parts, Figure 12.

3. To ensure correct re--assembly keep the

component parts for each valve separate.
NOTE: The stem on the flow compensating spool
is longer than that on the pressure compensating
spool
11
IMPORTANT: Due to extreme spring pressure
within valves DO NOT remove rear plugs until the
adjusters have been removed.

Flow and Pressure Compensating Valves 12

1. Locknut 7. Seat 12. Plug and ‘O’ Ring
2. Tamperproof Cap 8. Pressure Compensator Spool 13. Flow Compensating Spool
3. Tamperproof Cap 9. Housing 14. Seat
4. Locknut 10. ‘O’ Ring Seals 15. Spring
5. Adjuster and ‘O’ Ring Seal 11. Plug and ‘O’ Ring 16. Adjuster and ‘O’ Ring Seal
6. Spring

604.55.041.00 - 01 - 1998
36 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

INSPECTION AND RE--ASSEMBLY OF

VALVES
Re--assembly of the valves follows the removal
procedure in reverse. On re--assembly observe the
following:--

1. To aid re--assembly of pressure and flow

compensating valves, the spools should be
inserted into the rear of the housing, Figure 13.

S Wash all components in a suitable solvent.

S Examine all components for wear or damage.
If the spools are damaged it is necessary to
replace the complete valve assembly.
13
S Lubricate all parts with clean hydraulic oil.
S Replace all ‘O’ ring seals and lubricate with
petroleum jelly.
S Refer to Figure 14 for installation of transfer
tubes (2) in charge pressure filter manifold (1).
S Pressure test the pump and adjust the
pressure and flow compensating valves to the
correct specification as detailed in this
Chapter.
S Tighten all plugs and locknuts to the correct
torque as detailed in Specifications.
14
DISASSEMBLY OF CHARGE AND STEERING
PUMPS

1. Push in driveshaft (2) to allow removal of snap

ring (3). Withdraw driveshaft and small spring
(1), Figure 15.

15
2. Using special Tool 4FT.856 (1), engaged in slot
in gear retainer and an impact wrench to break
loctite seal on the retainer thread, unscrew the
retainer which will at the same time ‘jack’ the
gear (2) from the cover support plate,
Figure 16.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 37

3. Remove idler gear shaft roll pin and using an

M8 x 1.25 bolt (4), withdraw shaft (3).
Figure 17.

17
4. Remove the cover support plate (1), Figure 18
then withdraw idler gear (1) and thrust washers
(2), Figure 17.

18
5. Place 15mm spacers (2) under the bolt heads
of two of the cover support plate bolts (1)
previously removed and use these bolts to
re--clamp the steering pump to the charge
pump body, Figure 19.

19
6. Remove charge pump gears and bearings,
Figure 20.

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38 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

7. Remove clamping bolts and pull steering pump

assembly from main pump housing, Figure 21

8. Prior to disassembly and to ensure correct

re--assembly mark all charge and steering
pump components on a non critical area with a
felt pen. Separate pumps with reference to
Figure 22.

The drive link is fixed in the charge pump driven

gear with an internal snap ring. It is not
recommended to separate these items. 21

Charge and Steering Pump Assembly--Exploded View 22

1. Charge Pump Housing 8. Seal 15. Cover Support Plate
2. Steering Pump Housing 9. Oil Seal 16. Seal
3. Bearing Block and Seals 10. Snap Ring 17. Oil Seal
4. Steering Pump Gears 11. Drive Link 18. Bearing Block and Seals
5. Bearing Block and Seals 12. Spring 19. Charge Pump Gears
6. Seal 13. Drive Gear and Bearing 20. Drive Link
7. Sandwich Plate 14. Washer 21. Bearing Block and Seals

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 39

INSPECTION AND REPAIR OF CHARGE AND

STEERING PUMPS
1. Pull transfer tubes from steering pump
housing, Figure 23.

2. Wash all components in a suitable solvent and

dry thoroughly.

3. Examine each bearing block for wear. Light

score marking should be removed by placing a
sheet of ‘0’ grade emery paper, lubricated with
paraffin, on a truly flat surface, then polish the
bearing face using a light rotary motion.
Bushes within the bearing blocks may show a
bronze colour but are worn beyond acceptable 23
limits if the bronze colour can be seen over the
full length of the bush.
4. Inspect pump bodies for wear and damage. It
is normal for gears to cut a light track on the
inlet side of the body bore and providing the
depth of the track does not exceed 0.004 in
(0.10 mm), the body is re--usable. Using an
internal micrometer measure the body at the
bearing location and then at the track position
to assess the track depth.

5. Examine pump gears for scored or worn side

faces, journals and damaged teeth. Lightly
scored side faces may be renovated by
sandwiching emery paper between the gear
face and a scrap bearing and rotating the gear.
NOTE: If pump gears or bearing blocks are worn
and require replacement the worn pumping
element must be replaced as an assembly.
IMPORTANT: Whilst servicing the pump gears,
particular attention must be paid to the following
points:

S The width of each gear set must be within

0.0002 in. (0.005 mm) of each other to ensure
satisfactory pump efficiency.

S Journals must be within 0.0005 in. (0.013 mm)

of each other.

S Gear faces must be flat. This feature may be

checked by blueing a bearing face and rotating
against the gear. This check will also reveal
any sharp edges on the teeth.

6. Install new seals and ‘O’ rings. 24

7. Examine bearing (1) in pump drive gear (2) and

replace if worn or damaged by removing
retaining ring (3), Figure 24.

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40 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

RE--ASSEMBLY OF CHARGE AND STEERING

PUMPS
IMPORTANT: The charge and steering pumps
must be re--assembled using the following
procedure. Attempts to deviate from this procedure
may lead to incorrect assembly and damage of the
pumps.
When assembling the pump observe the
following:--
S Lubricate all parts with hydraulic oil.
S Install new seals and ‘O’ rings and coat with
petroleum jelly.

1. Apply petroleum jelly to the charge pump

bearing block bore (2) and steering pump ports
(1) & (3). Refer to Figure 25.

2. Position new seals in the charge pump bearing

block and install the block in the charge pump
housing, Figure 25. When installing the seals
ensure that the plastic back--up seal is
correctly positioned in the rubber seal.

25
3. Fit the transfer tubes into the steering pump
housing.

4. Install new seals into the steering pump

bearing blocks and re--assemble the steering
pump. Ensure that the bearing block with a
‘radiused edge’ (1) is installed at the bottom
of the steering pump body bore (2) Figure 26.

26
NOTE: Only one of the two bearing blocks used in
the steering pump is radiused on the corner edge.
Installation of the sharp edged radius block at the
bottom of the bore will prevent correct re--assembly
and cause damage to the pump.

5. Position the sandwich plate (2) onto the

steering pump (1), Figure 27.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 41

6. Position a tough flexible plastic sheet (2) over

the face of the charge pump. (This sheet will
prevent the seals in the pump assembly being
displaced when installing the steering pump).

7. Place the steering pump (1) onto the charge

pump housing and push the steering pump
forward until the transfer tubes fully engage in
the charge pump housing, Figure 28.

28
8. Slide the plastic sheet away from the pump.

9. Using two cover support plate bolts with 15mm

spacers (1), Figure 29, placed under their
heads, align and clamp the sandwich plate (3),
Figure 28 and steering pump to the charge
pump housing. When the pump is aligned the
bolts (2) should be tightened sufficiently to
clamp the pump bodies together, Figure 29.

29
NOTE: The spacers ensure the pump face is not
damaged when the bolts are tightened. If difficulty
is experienced in aligning the bolts to the threaded
holes in the steering pump body, alignment bolts
can be manufactured by turning a point onto the
end of two M15 x 100mm long bolts and using
these to align and clamp the pump body.

10. Install the charge pump drive and driven gears,

Figure 30 and lubricate using oil to
Specification NH410B (Ambra Multi--G).

11. Install the charge pump bearing block (1),

Figure 31.

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42 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

12. Remove cover support plate clamping bolts

and install idler gear (1) and thrust plates (2),
Figure 32. Do not install the idler gear shaft.

32
13. Install the cover support plate and tighten the
retaining bolts to a torque of 30--37 lbf ft
(40--50 Nm), Figure 33.

33
14. Install the idler shaft and roll pin (1). Refer to
Figure 34.

34
15. Apply one drop of New Holland Thread Lock,
Part No. 82995773, to the threads in the drive
gear and bearing assembly. Using drive gear
tightening tool 4FT.856 (1), Figure 35, tighten
the gear (2) to the cover support plate until a
torque of 26--33 lbf ft (35--45 Nm) is achieved.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 43

DISASSEMBLY OF VARIABLE
DISPLACEMENT PISTON PUMP
If it is desirable to disassemble the variable
displacement piston pump without removing the
charge and steering pump, disconnect the steering
pump oil gallery transfer tubes from the piston
pump housing (2) as detailed in Step 1 below.
1. Remove the ‘C’ clip from the larger of the two
sleeves connecting steering pump oil galleries
to piston pump housing (3). Disengage
sleeves from piston pump housing by using a
screwdriver to ease each of the sleeves (1)
toward the steering pump (4). Refer to
Figure 36.
36

2. Remove pressure regulating valve housing

(1), Figure 37.

37
3. Remove four bolts and separate the two
sections of variable displacement piston pump
housing, Figure 38.

38
4. Remove pumping head assembly, Figure 39.

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44 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

5. Using a suitable marker identify each piston

and slipper to their corresponding barrel in the
pumping head, Figure 40.

40
6. Separate pistons and slippers, Figure 41.

Pumping Head Slipper Assembly

1. Pistons and Slippers
2. Cone
3. Washer
4. Pumping Head
5. Pins (3 off)

41
7. If necessary disassemble the spring assembly
within the pumping head (5) by compressing
the collar (2) against the spring (1) and
removing the retaining ring (3) Figure 42. Note
the washer behind the spring.

IMPORTANT: Due to high spring pressure of

pumping head spring assembly take care when
removing retaining ring.

42
8. Remove swash plate (2), thrust plate (3) and
return spring (1). Refer to Figure 43.

NOTE: The bearings on the swash plate can be a

tight fit in their locating bores of the pump housing.
Under these circumstances it may be necessary to
tap the face of the pump housing casting against a
clean flat wooden bench in order to release the
swash plate from the housing.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 45

9. Remove snap ring and withdraw pump

driveshaft assembly, Figure 44.

44
10. Separate the pump driveshaft and gear
assembly, Figure 45.

Pump Driveshaft and Gear Assembly

1. Bearing
2. Shaft
3. Plate
4. Woodruff Key
5. Nut
6. Washer
7. Gear
8. Snap Ring
9. Snap Ring

45
11. Remove swash plate servo piston (2),
Figure 46.

12. Inspect the port plate (1) for damage but do not
remove plate unless replacement is required.

INSPECTION

1. Wash all components in a suitable solvent and

dry thoroughly.
46
2. Check that the lubrication orifice in the idler
gear shaft is unrestricted

3. Examine driveshaft locating bush (1) in pump

cover, Figure 47. If the bush is worn or
damaged the pump cover and bush must be
replaced as an assembly.

4. Examine all components for wear or damage.

If the pistons or slippers are worn the complete
assembly should be replaced.

604.55.041.00 - 01 - 1998
46 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

RE--ASSEMBLY S Refer to Figure 48 to assist in installing the

driveshaft and swash plate assembly.

Re--assembly follows the disassembly procedure in

reverse. On re--assembly observe the following:-- S To assist in re--assembly of pumping head
apply petroleum jelly to the cone and washer.

S Apply New Holland Thread Lock, Part No. S When installing pumping head onto driveshaft,
82995773, to threads of pump driveshaft gear ensure that splines on both the driveshaft and
and tighten the gear retaining nut to a torque of pumping head are aligned. Apply pressure to
86--90 lbf ft (117--123 Nm). the base of the pumping head to ensure that the
spring within the head reacts against the piston
and slippers. If when applying pressure the re-
sistance of the spring can not be felt it is an in-
S Install new seals and ‘O’ rings. dication that the cone and washer have been
displaced during assembly.

S Lubricate all parts with hydraulic oil and coat all S Tighten all bolts to the correct torque. See
seals and ‘O’ rings with petroleum jelly. Specifications.

Piston Pumping Head and Swash Plate Installation 48

1. Spring 5. Bearing 8. Swash Plate
2. Spring 6. Thrust plate 9. Bearing
3. Driveshaft Assembly 7. Pumping Head Assembly 10. Spring Seat
4. Snap Ring

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 47

S When installing pressure regulating and low

pressure circuit safety valve housing (1),
accurately position the housing at 90! to pump
mounting face (2), Figure 49. This is necessary
to ensure that during installation the transfer
tube (3) engages with the locating oil gallery in
the transmission housing.

INSTALLATION
Installation follows the removal procedure in
reverse. During installation observe the following:--
49
S Fit new seals (2) & (4) and washers (1) & (5) to
the transfer tube Figure 50.

NOTE: There are two designs of transfer tube. The

tube shown in Figure 50 is that for tractors installed
with a hydraulic lift assembly. On those special
builds where a hydraulic lift assembly is not fitted
the transfer tube is blanked off at one end.
1. Washer
2. ‘O’ Ring
3. Tube
4. ‘O’ Ring
5. Washer

50
S Ensure seals and washers on the steering,
charge pump and PTO tubes in rear axle centre
housing are correctly fitted. Refer to Figure 51.

NOTE: The charge pump intake tube is locked in

position in the rear axle centre housing by a wire
locking ring attached to the end of the tube.

S Ensure steering pump intake tube is correctly

located.

S Push the transfer tube into the rear axle centre

1. Gasket 51
housing, fit a new gasket and install the pump. 2. Idler Gear
3. Dowel
4. Seal (PTO Feed Tube)
S Tighten all bolts to the correct torque. See 5. Seal (Steering Pump Intake Tube)
6. ‘O’ Ring
Specifications Section 35 000. 7. Washer
8. Transfer Tube
9. Charge Pump Intake Tube
(Retained with a Wire Ring)
S Refill the rear axle/transmission with 13.3 Imp
Galls (16.0 US Galls, 60.6 Litres) of oil to New
Holland specificatio NH410B (Ambra Multi--G).

Pressure test the pump after installation as

described in Section D and test drive tractor for
correct operation.

604.55.041.00 - 01 - 1998
48 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

PRESSURE TESTING
This Section describes the procedure for pressure
testing tractors installed with the variable
displacement hydraulic pump with closed centre
load sensing and integral charge and steering
pumps. The procedure also includes the test
procedure for checking steering relief valve,
remote control valves and trailer brakes where
fitted.

The pressure test values quoted in this procedure

make allowances for time in service, however the
values quoted in the Specifications are for new
components.

Improved access to the test ports on the hydraulic

pump can be achieved by supporting the tractor on
suitable axle stands and removing the right hand
rear wheel.

WARNING: To prevent inadvertent

movement of the tractor during pressure
testing the following precautions must be taken.

Remove fuse No 15 from the fuse panel.

If the tractor is fitted with four wheel drive dis-

connect the driveshaft coupling at the front
axle pinion.

This precaution will prevent inadvertent move-

ment of the tractor if the transmission gear
shift levers are moved into the engaged posi-
tion while performing the pressure tests.

IMPORTANT: Before performing any flow or

pressure checks it is important that the oil in the
transmission or rear axle is at an operating
temperature of 75!C (170!F). The method of
achieving this temperature is detailed in steps
3--10 of the procedure for testing charge pressure.

WARNING: To avoid burning

yourself with high temperature oil
always warm the oil to temperature after installing
all the test equipment.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 49

Load Sensing Circuit Test

This test should be performed before proceeding to
other pressure tests, as it will help to identify any
concerns related to hydraulic circuits which are not
caused by a fault within the hydraulic pump
assembly.
The test will check operation of the hydraulic
circuits and load sensing lines to the trailer brake,
hydraulic lift, remote control valves and trailer
brake, where fitted.
1. Remove system and standby pressure test
plug (1), Figure 1 or (1), Figure 2.
1

NOTE: The thread size of the standby pressure

test port is M14 x 1,5.

2
2. Install the 0--6000 lbf/in2 (0--414 bar) pressure
gauge FT. 8503A, Figure 3.

NOTE: This test can be performed with a

0--3000 lbf/in 2 (0--207 bar) pressure gauge if
available.

3. Set the engine speed to 1500 rev/min.

4. Operate in turn the hydraulic lift, each remote

control valve and the trailer brakes (where
fitted). As each circuit is put under load the
Load Sensing Circuit Test Gauge Installation 3
pressure reading should increase from
300--360 lbf/in2 (21--25 bar) up to a maximum 1. Elbow 86246--S36
of 2825 lbf/in2 (195 bar). When operating the 2. Adaptor 4FT.851 (M14x1,5-- 7/16 JIC)
trailer brake the pressure will rise to a 3. Adaptor FT. 8503--8 or FNH 0705
maximum of 2140 lbf/in2 (148 bar). 4. Test Hose 83936707
5. Pressure Gauge FT. 8503A

If the tractor is known to have a hydraulic

malfunction and this test registers a pressure
increases for at least one, but not all, of the
hydraulic circuits being tested it is an indication that
the concern is probably not related to the hydraulic
pump.

604.55.041.00 - 01 - 1998
50 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Should this occur the shuttle valves in the load

sensing line of the circuit not producing a pressure
increase should be examined for sticking in an
open position prior to continuing with the pump
pressure test.

For the location of the shuttle valves refer to

Figure 4 and Figure 5.

If the trailer brake valve pressure reading is

incorrect examine the shuttle valve adjacent to the
trailer brake valve (1), Figure 4.

4
If the hydraulic lift pressure reading is incorrect,
examine the shuttle valve leading to the hydraulic
lift control valve (1), Figure 5 (EDC valve or unload
valve as fitted) and the shuttle valve adjacent to the
trailer brake valve, where fitted.

If the remote control valve pressure readings are

incorrect examine all shuttle valves.

NOTE: Shuttle valves are also located within each

of the remote valves installed on the tractor.

5
If the shuttle valves are not sticking, attention
should also be given to the hydraulic valves and
components within the circuit that does not operate
correctly.

Charge and Variable Displacement Piston

Pump Pressure Testing
Charge Pressure Test

1. Remove charge pressure switch (1), Figure 6.

6
2. Install 0--100 lbf/in2 (0--6.6 bar) pressure
gauge FT. 4096, Figure 7.
NOTE: The thread size of the charge pressure
switch port is M10 x 1.

Checking Charge Pressure

1. Pressure Gauge FT. 4096
2. Adaptor FT. 8503--8
3. Test Hose 83936707
4. Test Hose 83926717

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 51

3. Using remote control valve couplers, install

inlet hose (4) of flow meter into lift coupler of left
hand side inner remote control valve. Install
return hose (2) from flow meter into the rear
axle oil filler tube, Figure 8.

4. Set flow control knob (1) on remote control

valves to minimum flow.

5. Ensure load valve (3) on flow meter is fully

open.

8
6. Blank oil cooler with a piece of card. Start
engine and set engine speed to 2100 rev/min.

7. Move appropriate remote control valve

operating lever (1) or (2) to cylinder extend
position and direct the oil flow from the remote
valve to the flow meter.

9
8. After ensuring that flow meter is measuring oil
flow correctly, set remote control valve flow
knobs to maximum flow.

9. Adjust load valve on flow meter until hydraulic

oil is at pressure of 2000 lbf/in2 and allow
engine to run until hydraulic oil is at an
operating temperature of 75!C (170!F).

10. Open load valve on flowmeter and set engine

speed to 1500 rev/min.

11. Move remote control valve lever between

cylinder extend and neutral positions while
observing the pressure gauge readings. The
pressure reading should not vary outside
23--50 lbf/in2 (1.6--3.4 bar).

Pressure readings conforming to the specified

values, confirm that the charge pump inlet filter (1),
charge pump, charge pressure bypass valve (2)
and charge pressure filter dump valve (3), are
working correctly, Figure 10.

604.55.041.00 - 01 - 1998
52 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Maximum System Pressure Test

(High Pressure Standby)

1. With flow meter installed as for the charge

pressure test, set engine speed to
1500 rev/min. Using an assisstant to hold blue
remote control valve lever in extend position,
slowly close load valve on flow meter. Observe
on the flow meter or pressure gauge installed
for the load sensing circuit test, the maximum
pressure recorded. The pressure reading
should be between 2675--2825 lbf/in2
(184--195 bar).

Pressure readings conforming to the specified

values, confirm that the pressure compensating
valve (2) is working correctly.

If the pressure reading is marginally away from

specification, remove the tamperproof cap, loosen
the locknut on the pressure compensating valve
adjuster and adjust the pressure.

11
If a maximum system pressure of only
310--350 lbf/in2 (21--24 bar) is recorded and the
load sensing valves are not sticking, examine the
flow (1) and pressure (2) compensating valves for
sticking in an open position.

Fit new tamperproof cap(s) after adjustment has

been completed.

Swash Plate Servo Piston Test

1. Perform maximum system pressure test then

fully open the load valve on the flow meter.

2. Observe the pressure on the flowmeter or load

sensing circuit test pressure gauge.

If the pressure drops from maximum system

pressure to approximately 400 lbf/in2 (27 bar) the
servo piston is operating correctly. The reduction in
pressure is also an indication that standby
pressure is correct. Where it is necessary to
accurately confirm the standby pressure value
perform the Standby Pressure test using the
0--600 lbf/in2 (0--42 bar) pressure gauge FT. 4100
as described on page 53.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 53

Standby Pressure Test

(Low Pressure Standby)

This test procedure will enable an accurate reading

of the standby pressure to be recorded.

1. Remove the pressure gauge installed for the

load sensing circuit pressure test and install a
0--600 lbf/in2 (0--42 bar) pressure gauge
FT. 4100 in its place, Figure 12.

Checking Standby Pressures 12

2. Ensure remote control valve levers are in 1. Elbow 82512933
‘Neutral’ position and tractor footbrake is not 2. Adaptor 4FT.851 (M14x1,5-- 7/16 JIC)
being applied. 3. Adaptor FT. 8503--8 or FNH 0705
4. Test Hose 83936707
5. Pressure Gauge FT. 4100

IMPORTANT: Do Not operate the hydraulic lift,

remote valves or tractor brakes. If these circuits are
operated the standby pressure can increase
towards the maximum system pressure of
2800 lbf/in 2, resulting in damage to the pressure
gauge.

3. Vary engine speed between

1000--2100 rev/min and observe pressure
reading. The pressure recorded should be
between 300--360 lbf/in2 (21--25 bar).

If the pressure reading is marginally away from

specification, remove the tamperproof cap, loosen
the locknut on the flow compensating valve
adjuster (1) and adjust the pressure.

If the reading is high examine the flow

compensating valve spool for sticking, Figure 13.

Fit new tamper proof cap(s) after adjustment has

been completed.
13

If the reading is low and the charge pressure is to

Specification, the concern may be due to a large
leak in the low pressure circuit, refer to low
pressure circuit test.

604.55.041.00 - 01 - 1998
54 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Variable Displacement Piston Pump Flow

(Output)

1. With flow meter installed as for the charge

pressure test, increase engine speed to
2100 rev/min.

2. Engage P.T.O., disengage four wheel drive

and ensure transmission is in neutral and that
the tractor clutch pedal is not being depressed.

3. Slowly close load valve on flow meter until a

pressure of 2500 lbf/in2 (172 bar) is observed
on the flow meter pressure gauge.

4. Record pump flow (output).

If pump flow is less than 16 U.S Gals/min

(13 Imp Gals/min 60 Ltrs/min) and the following
low pressure circuit test is to specification the pump
must be overhauled.

Low Pressure Circuit Test

This pressure test will check that oil at a minimum

pressure of 250 lbf/in2 (17 bar) is being directed by
the pressure regulating valve to the low pressure
circuits which operate the P.T.O., differential lock,
four wheel drive disengagement system, electronic
draft control valve and 16 x 6 transmission
clutches, where fitted.

1. Remove transmission pressure switch,

Figure 14.

14
2. Install 0--600 lbf/in2 (0--42 bar) pressure
gauge FT. 4100, Figure 15.

3. Set engine speed to 1500 rev/min.

4. Observe pressure reading. Pressure recorded

should be between 250--280lbf/in2 (17--19
bar).

Low Pressure Circuit Test 15

1. Pressure Gauge FT. 4100
2. Adaptor FT. 8503--8 or FNH 00705
3. Test Hose 83936707
4. Test Hose 83926717

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 55

If the pressure reading is marginally away from

specification re--shim the pressure regulating
valve. One shim represents a change in pressure
of 5 lbf/in2 (0.35 bar).

If the pressure reading is considerably away from

specification examine the pressure regulating
valve for sticking, Figure 16.

If the pressure regulating valve (1) is functioning

correctly, examine the low pressure circuit safety
valve for sticking in ‘Open’ position.

16
5. If no fault can be found, loosen the pump body
and place a piece of 0.010 in (0.25mm) shim
steel over the pump outlet port to the PTO
clutch feed tube (1) Refer to Figure 17 and
Figure 18.

17
6. Ensure the shim steel is positioned between
the pump flange and mounting face gasket (1),
then tighten the pump retaining bolts
sufficiently to hold the shim steel in position
without a leakage of oil Figure 18. (Do Not
over--tighten the bolts or damage may occur to
the pump mounting flange). Re--check the
pressure in the low pressure circuit.

If the reading is now correct, check for a large leak

on the P.T.O. circuit which may be due to the feed
pipe and sealing washer being incorrectly fitted, the
wrong P.T.O. valve fitted or a large leak in the
P.T.O. clutch.
18
7. If the low pressure readings are still below
specified value disconnect the feed tube to the
transmission (2), Figure 19 and install a
11/ in (18 mm) blanking shim in the tube (1).
16
Reconnect the tube and re--test the low
pressure circuit.

If the reading is now to specification a leakage is

occurring within the transmission clutch circuits.

If no fault can be found and standby pressure test

was to specification re--shim the pressure
regulating valve to the correct pressure.

604.55.041.00 - 01 - 1998
56 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Trailer Brake Valve Pressure Test

1. Connect 0--6000 lbf/in2 (0--414 bar) pressure

gauge FT.8503A to trailer brake coupler,
Figure 20.

2. Set engine speed to 1500 rev/min.

3. Depress right hand brake pedal. There should

be no reading on the pressure gauge.
Trailer Brake Pressure Test 20
1. Adaptor 4FT.854
4. Depress left hand brake pedal. There should 2. Test Hose 83936707
be no reading on the pressure gauge. 3. Adaptor FT. 8503--8 or FNH 00705
4. Pressure Gauge FT.8503A
5. Trailer Brake Coupler

5. Couple together and depress both brake

pedals. The reading on the pressure gauge
should increase as the brake pedals are
depressed harder. The pressure recorded,
depending on pedal effort, should increase up,
to a maximum pressure of 2140 lbf/in2
(147 bar).

6. Release brake pedals. Pressure should

reduce to zero.

Steering Pump

There is no relief valve in the steering pump. The

following practical test will determine if steering
pump output is sufficient to allow satisfactory
operation of the steering system.

Steering Test

1. Set engine speed to 1000 rev/min.

2. Turn steering quickly from lock to lock. If

steering is operating correctly the reaction of
the steering should be immediate with no time
delay between turning the steering wheel and
movement of the wheels. At full lock the relief
valve in the steering motor should be heard to
blow and the engine speed should drop to
approximately 970 rev/min.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 57

Steering Pump Flow Test

1. Disconnect and remove oil cooler bypass

valve (1), Figure 21.

2. Plug feed (2) and return (3) tubes to oil cooler

to prevent contamination and loss of oil.

3. Using Adaptors 4FT.852 (1) install flowmeter

between tube from steering motor (5),
Figure 21 and tube to transmission/rear axle
lubrication circuits (4), Figure 21.

21
NOTE: Adaptors 4FT.852 are suitable for installing
3/4 in JIC hoses to flowmeter. If hoses of a
different size are used with the flowmeter, suitable
adaptors with a female thread size of 3/4 --18 UNS
on one end will be required.

4. ‘Ensure’ flowmeter load valve is fully open,

Figure 22.

IMPORTANT: If the flowmeter load valve remains

closed damage will occur to the steering pump.

5. Set engine speed to 2100 rev/min and turn

steering onto full left hand lock. Hold steering
on full lock so that steering motor relief valve
Flow Testing Steering Pump 22
can be heard to ‘blow’.
1. Adaptor 4FT. 852
6. Record pump flow. 2. Supply Hose to Flowmeter
3. Flowmeter Return Hose
4. Adaptor 4FT. 852
If pump flow is less than 8.2 U.S Galls/min
(6.8 Imp Galls/min 31 Ltrs/min) the steering pump
requires overhaul.

Steering Relief Valve Pressure Test

IMPORTANT: There is no relief valve in the

steering pump and the following pressure tests
must only be performed as specified below. Failure
to observe this precaution may result in severe
damage to the steering and lubrication circuit
hydraulic pump.

1. Turn steering onto full left hand lock.

2. Disconnect left hand turn feed hose at steering

cylinder.

604.55.041.00 - 01 - 1998
58 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3. Install a 0--6000 lbf/in2 pressure gauge

FT.8503A, (1) Figure 23, using adaptor
FT5803--8, (2) Figure 23, and a locally
procured 7/16 JIC male × 9/16 JIC male
adaptor, (3), Figure 23.

Using kit 292870 install adaptor 293874 and

291318 into the place of the banjo fitting of the
steering hydraulic cylinder.

4. Start tractor and set engine speed to

1000 rev/min. Turn steering wheel to the left Power Steering Circuit Pressure Test 23
with a pull of approximately 5 lbf and observe 1. Pressure Gauge FT. 8503A
the pressure reading. 2. Adaptor FT. 8503--8 or FNH 00705
3. Test Hose E1NN F493 AA Finis Code 3936707
4. Adaptor 4FT.853 (11/16 x 16UN to 7/16 JIC)
5. Left Hand Turn Steering Hose

The pressure reading should be 186 bar (2700

ibf.in2) for all models.

If the steering test was satisfactory but the

pressure readings are away from specification the
relief valve in the steering motor must be replaced
or adjusted. Refer to Section 41.

Oil Cooler and Lubrication Circuit Pressure

Test

IMPORTANT: To obtain correct pressure readings

in this test it is important that the temperature of the
oil in the transmission/rear axle must be 75 0C
(170 0F).

1. Remove low flow steering/lubrication circuit

24
pressure switch (1), Figure 24.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 59

2. Install 0--400 lbf/in2 pressure gauge FT. 8616,

Figure 25.

3. Set engine speed to 2100 rev/min and observe

pressure reading. A pressure of 5.5--7 bar
(80--100 lbf/in2) should be recorded.

IMPORTANT: If a pressure reading was not

observed stop the tractor immediately because
Oil Cooler and Bypass Valve Pressure Test 25
lubrication oil is not being supplied to the
transmission. 1. Pressure Gauge FT. 8616 or FNH 06653
2. Adaptor FT. 8503--8
3. Test Hose 83936707
4. Elbow 86512933
4. Return engine speed to idle. 5. Adaptor 4FT. 850 (1/4 --18NPSF to 7/16 --20 JIC)

5. Using a hose clamp (1) restrict the flow of oil

through the cooler inlet hose (2), Figure 26.

6. Set engine speed to 2100 rev/min and observe

pressure reading. The pressure reading
should be approximately 7 bar (100 lbf/in2).

7. Remove hose clamp restriction from oil cooler

hose and observe pressure reading. The
pressure reading should decrease to
26
approximately 5.5 bar (80 lbf/in2).

The pressure reading of 100 lbf/in2 followed by a

reduction to approximately 80 lbf/in2 indicates that
when the oil cooler inlet hose was restricted the
cooler bypass valve was operating correctly.

If the cooler bypass valve is not to specification

refer to the Oil Cooler and Cooler By--pass Valve
Chapter in this Part of Repair Manual.

The reduction in pressure when the cooler inlet

hose restriction was removed indicates that the oil
cooler is not blocked.

604.55.041.00 - 01 - 1998
60 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

NOTES

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 3 -- HYDRAULIC LIFT ASSEMBLY WITH ELECTROLINK!

FOR TRACTORS WITH VARIABLE DISPLACEMENT CLOSED CENTRE
LOAD SENSING HYDRAULIC PUMP

Section Page

35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic Lift Assembly with Electrolink
Electronic Draft Control) -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35 000 Hydraulic Lift Cover Assembly--overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hydraulic Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

CAUTION: Observe the following precautions when arc welding on tractors installed
with electronic draft control

S Where possible, disconnect the part or implement to be arc welded from the tractor.

S Disconnect both battery cables from the battery. Isolate the cable ends to avoid contact with each other and
the tractor.

S Position the welder earth (ground) clamp as close to the welding area as possible.

S If welding is to be carried out in close proximity to the electronic draft control Processor then the Processor
should be removed from the tractor.

S Never allow welding cables to lay on, near or across any electrical wiring or electronic component while
welding is in progress.

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

SPECIFICATIONS

MAXIMUM LIFT CAPACITY

New Holland test results to OECD criteria--links horizontal, maximum hydraulic pressure:

TS90 TS100 TS110

Without Assist Rams
at link ends lb 6712 6712 n/a
kg 3045 3045 n/a
24 in. to rear of link ends lb 5190 5190 n/a
kg 2354 2354 n/a
With One Assist Ram
at link ends lb 9904 9904 9904
kg 4492 4492 4492
24 in. to rear of link ends lb 7484 7484 7484
kg 3395 3395 3395
With Two Assist Rams
at link ends lb n/a n/a 13001
kg n/a n/a 5897
24 in. to rear of link ends lb n/a n/a 9957
kg n/a n/a 4516

VALVE SETTINGS

Lift Cylinder Relief Valve 2850--3050 lbf/in2 (197--210 bar)

GASKET SEALER

New Holland Flexible Gasket Sealant, Part No. 82995770 (50 ml) 82995771 (300 ml)

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 3

TORQUES

= Nm
= lbf ft

Lift Cylinder Relief Valve Torque 75--90 lbf ft (102--122Nm)

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

HYDRAULIC LIFT ASSEMBLY WITH ELECTROLINK

(ELECTRONIC DRAFT CONTROL)--DESCRIPTION AND OPERATION

General In addition to providing draft control, it is also

necessary to provide a system where the
implement or hydraulic links can be maintained at
a position relative to the tractor regardless of draft
The objective of a tractor draft control system is to
on the implement. This method of maintaining the
provide a means of accurately controlling the soil
implement position is called position control.
penetration depth of a fully or semi mounted
implement. One method of providing fixed depth
control is to take advantage of the fact that draft On TS Series tractors control of implement draft
loading increases with implement depth. If a fixed can be achieved by either mechanical or electrical
implement draft is maintained a fixed implement means. This Chapter describes the operation of
depth will result, providing tractor speed and type of both position and draft control when controlled
soil being worked remain constant. electronically.

Hydraulic Lift Assembly with Electronic Draft Control 1

1. External Lift Lower Switch 5. Service Diagnostic Connector 9. Processor
2. Load Sensing Pins 6. Instrument Panel 10. Lift Control Lever
3. Hydraulic Control Valve 7. Fast Raise/Lower Switch 11. Lift Arm Position Sensing
4. Performance Monitor Radar 8. Hydraulic Control Panel Potentiometer

The principle of ElectroLink, hereinafter called The smoothness and accuracy provided during
electronic draft control, is to sense draft variations operation gives this system a clear advantage over
through two sensor pins in the lower links and using conventional mechanical systems.
a Processor translate these variations to the
Figure 1, details the principle component parts of
hydraulic system to raise and lower the links,
the hydraulic lift assembly with electronic draft
maintaining a constant draft loading.
control.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 5

Processor
The micro Processor is the management system
for the hydraulic lift assembly with electronic draft
control and is also used to control the electronic
functions of the 16 x 16 Electro Shift and 12×12
Dual Command transmissions.
The Processor (1), Figure 2, is housed in a
protective casing in the control console and
connects to the electrical harness via two multi--pin
connectors. The Processor contains no
serviceable parts and requires direct replacement
when faulty.

2
While the electronic draft control and 16 x 16
electro--shift transmission share the same
Processor both systems operate independently. It
is, therefore, possible for a tractor to be installed
wiProcessorth a but not equipped for electronic
draft control.

The Processor receives electronic signals from the

operator controls, lift arm position sensing
potentiometer and lower link load sensing pins
which it then converts to an input signal to the
hydraulic lift, solenoid operated control valve.

In addition to controlling the hydraulic system the

Processor has a self diagnostic capability. When
the Processor senses that the system is not
functioning correctly an error code is generated
ans tored in the Processor memory. For a full list
of error codes and how to retrieve them, refer to
‘‘Fault Finding and Repair’’ in this Chapter.

Load Sensing Pins

The load sensing pins sense draft variations
applied by an implement on the lower links.

Each load sensing pin, Figure 3, consists of a

hollow metal tube (1) containing a circuit board (4)
and load sensing core (2). Within the core material
are three wire coils (3) supported by metal rods.
The coils are energised by the 8.5 volt supply and
create a stable pattern of magnetic flux within the
core.

The outer casing of the pin is made from a metal

with unique electromagnetic properties. When the 3
Load Sensing Pin
metal is subjected to a shear force, which is
centered on the waisted section of the pin (5), the 1. Metal Tube
2. Load Sensing Core
natural magnetism of the pin casing changes, 3. Wire Coil (3 off)
which distorts the magnetic flux pattern of the core 4. Circuit Board
and is transformed into an electrical output signal. 5. Waisted Section
This signal which is proportional to the draft load
acting on the implement is then received by the
Processor.

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

To ensure that the load sensing pins only sense

draft forces and not forces due to the weight of the
implement, they are designed to only react to shear
forces in the horizontal plane. It is, therefore,
essential that the pin (2) cannot be incorrectly fitted
and this is achieved by using a special clamp (1)
which ensures correct installation, Figure 4.

4
Hydraulic Lift Assembly Control Valve
The hydraulic lift assembly control valve (1) is a
proportional solenoid operated valve located on
top of the hydraulic lift assembly, Figure 5. The
valve responds to pulse width modulated signals
from the Processor to direct pump pressure oil, to
and from the hydraulic lift cylinder, in direct
proportion to the degree of lift required.

5
CONTROLS

The electronic draft and position control system is

operated from a console to the right of the
operator’s seat, Figure 6. Each of the variably
adjustable controls is directly attached to a
potentiometer whose change in resistance, when
operated, is sensed by the Processor and
contributes to the input signal which operates the
hydraulic control valve.

Hydraulic Control Panel

1. Slip Limit Control (option)
2. Slip Limit ’On’ Indicator
3. Status Indicator
4. Position/Draft Sensitivity Knob 6
5. Control Valve Solenoid operating lamps
6. Drop Rate Control Knob
7. Height Limit Control

The function of each of the controls is as follows:--

The position/draft sensitivity knob (4) selects full

position control, maximum draft control or a
mixture of the two allowing selectable sensitivity in
draft control according to operating needs.

The drop rate control (6) is provided to limit the rate

of drop of the hitch and functions whenever the
implement is raised out of the ground.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 7

The height limit control (7) restricts the maximum

height the lift arms can be raised, to prevent large
implements from striking the rear of the cab or
platform. This control restricts the lift height when
either the lift control lever or external lift/lower
switches are used.

The slip limit control (1) (where fitted) limits the

amount of wheel slip. The indicator light (2) is
illuminated when the lift arms are responding to an
excessive slip condition.

The status indicator (3) is flashed when a 7

malfunction identified by the Processor occurs in
the system. The status indicator is continuously
illuminated when the hitch is disabled.

As with mechanical draft control hydraulic

systems, the raising and lowering of the lift arms is
controlled by a lever in the control console to the
right hand side of the operator’s seat, (2) Figure 8.
The lift control lever is of a low effort type having
only an electronic coupling to the hydraulic system
in the form of a potentiometer.

The raise/lower switch (1) Figure 8, enables the

operator to rapidly raise the implement to the
position set by the height limit control and to lower
the implement back down to the position set by the
lift control lever, without disturbing the settings.
8
Thus, the operator is able to raise the implement at
the headland and return the implement to the same
operating conditions.

The switch has 3 positions. To raise the implement

quickly, press the top of the switch. The implement
will raise to the height set by the height limit control.

Move the switch to the central position and the

implement will lower at the rate set by the drop rate
control knob and stop when it reaches the depth set
by the lift control lever.

Press and hold the bottom of the switch and the

implement will lower at the rate set by the drop rate
control knob, until it contacts the ground. The drop
rate and the lift control lever settings will then be
overridden and the implement will quickly
penetrate the ground, rising to the pre--set depth
when the switch is released. (The switch is
spring--loaded to return to the central position,
when released).

NOTE: The implement will not lower if ground

speed exceeds 15 MPH (24 km/h)

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

External Hydraulic Power Lift Controls

1
An external, rocker type switch (1) is provided on
each rear light assembly, Figure 9. The switches
are of a three--position designed, spring--loaded to
return to the central, off position.

WARNING: Do not stand on or near the

implement or between the implement and
tractor when operating the external hydraulic
power lift controls.

MM6
9
Before leaving the tractor to operate the external
switches:

S Move the gearshift levers to neutral.

S Disengage the P.T.O.

S Apply the parking brake.

With the engine running move the hand throttle

lever to the low idle position (fully rearwards) and
push the hydraulic lift control lever fully forward.

WARNING: Before using the external

hydraulic power lift switches, ensure that
no person or object is in the area of the implement
or 3--point linkage
Never operate the external switches while
standing:

S Directly behind the tractor or tyres.

S Between the lower links.

S On or near the implement.

WARNING: Never extend arms, legs, any

part of the body or any object into the area 1
near the 3--point linkage or implement while
operating the external switch.

Never have an assistant working the opposite set

of controls. When moving to the opposite set of
controls, move around the tractor or implement.
Do not cross between the implement and tractor.

The operator must only activate the external

switches while standing to the side of the tractor
(outboard of the rear tyres) -- see Figure 10
10

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 9

Pressing the upper part of the rocker switch (1),

Figure 11, will cause the lift linkage to raise slowly. 1
Pressing the lower part will cause the linkage to
lower. When the lower links align with the
implement, release the switch and attach the
implement to the 3--point linkage in the normal way.

To transfer control of the hydraulic power lift back

to the lift control lever, set the raise/lower switch to
the central position, pull the lift control lever fully
rearwards and push forward again, more slowly.
The ‘hitch enabled’ symbol will display in the
instrument pane, indicating that the 3--point linkage MM6
is in phase with the lift control lever.
11

IMPORTANT: When control of the 3--point linkage

is transferred back to the lift control lever, an
attached implement may raise fully and damage
the rear of the cab. Operators should be aware of
this and take appropriate action to stop raising
before full lift height is reached. Adjust the height
limit control knob as described under Position
Control Operation.

Transport Lock and Dynamic Ride Control

When transporting equipment of the 3--point

linkage, implement bounce can lead to lack of
steering control at transport speeds. With Ride
Control selected when the front wheels hit a bump,
causing the front of the tractor to rise, the hydraulic
system will immediately react to counter the
movement and minimise implement bounce to
provide a smoother ride.

To engage Ride Control, select Position Control by

turning the knob (2), Figure 12, fully
anti--clockwise. Fully depress the symbol end of
the raise/lower switch to raise the implement to the
height set by the height limit control (1).

Turn the drop rate control knob (3) fully

anti--clockwise to the transport lock position
(padlock symbol).

Ride Control will only operate at speeds above 8

kph (5MPH). When tractor speed exceeds 8 kph
(5MPH), the implement will drop by 4 -- 5 points (as 12
displayed on the instrument panel) as the hydraulic
system makes corrections to counteract
implement bounce. When tractor speed falls below
8 mph (5MPH) the implement will raise again to the
height set by the height limit control and Ride
Control will become inoperative.

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

In addition to the operator controls a series of liquid

crystal displays (LCD’s) or warning lights indicating 4 1000
1
the operating condition of the electronic draft
control system are provided within the instrument
panel.

Figure 13, illustrates the LCD displays

incorporated in the fully electronic instrument 2
panel.

Electronic Instrument Panel 13

1. Implement Position/Diagnostic Repair Code (LCD)
2. Hitch Enabled Symbol (LCD)
3. ‘Read Your Manual’ Symbol (LCD)
4. Hitch Disabled Symbol (LCD)
Figure 14, illustrates the LCD/warning light
displays incorporated in the analogue electronic
instrument panel. 3

The function of these displays are as follows:--

1
Implement Position/Diagnostic Repair Code 25

The digital display on the instrument panel

indicates the position of the lower links over a scale 30
of ‘0’ to ‘99’. A display of ‘0’ indicates that the links
are fully lowered and a display of ‘99’ indicates they 2
are fully raised. On tractors with electronic
instrument panel the hitch enabled symbol will be
Analogue Electronic Instrument Panel 14
illuminated when the hitch is in phase with the lift
control lever. 1. Implement Position/Diagnostic Repair Code
(LCD)
2. Hitch Disabled Warning Light
The ‘hitch disabled’ warning light/LCD symbol 3. ‘Read Your Manual’ Light
signifies that the lift control lever position does not
correspond to the position of the lower links and
that unintentional movement of the lower links
cannot occur. The ‘hitch disabled’ warning will
display if:--

S The lift control lever has been inadvertently

moved with the engine stopped.
S The lift control lever has been pushed fully
forward in order to transfer control of the
hydraulic power lift to the external switches.

NOTE: To put the lift control lever (2) back into

phase with the lower links position, put the raise
/lower’ switch (1), Figure 15, in the central
position, pull the lever fully rearwards and push
forward again, more slowly, to allow the lift linkage
to lower.

Re--aligning the position of the lift control lever to

the lift arms is termed ‘capturing’ the lift. 15

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 11

Position/Draft Control Schematic 16

1. Position/Draft Sensitivity Mix Control on Operator Control Panel
2. Solenoid Operated Hydraulic Control Valve
3. Implement Draft Feedback Signal from Load Sensing Pins
4. Hydraulic Lift Arm Position Feedback Signal from Lift Arm Position Sensing Potentiometer
5. Lift Control Lever
6. Processor (Computes Input Signal to Solenoid Operated Hydraulic Control Valve)

OPERATION
Figure 16, illustrates in a block schematic form the
flow of electronic signals to and from the hydraulic
system, to raise and lower the hydraulic lift in
accordance with operator position and draft control
requirements.
The electronic draft and position control system is
operated from a console to the right of the
operator’s seat.
Electronic signals to the Processor for raising and
lowering the hydraulic lift assembly in accordance
with position and draft control requirements, are
received from four main sources. These are the lift
control lever, the lift arm position sensing
potentiometer, the two load sensing draft control
pins in the lower links and the draft/position
sensitivity controls on the hydraulic control panel.
Additional signals from the drop rate and maximum
lift height controls and wheel slip control (where
fitted) also contribute towards the computation of
the input signal.
When the lift control lever (1) is operated to raise
or lower the lift arms the resistance of the 17
potentiometer (2) at the base of the lift control lever,
Figure 17, changes and is sensed by the
Processor. The computer now transmits a signal to
the appropriate raise or lower solenoid on the
hydraulic lift control valve, which directs oil to raise
or lower the hydraulic lift.

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

A position feedback signal is received from the lift

arm position sensing potentiometer (1), mounted
on the right hand lift arm, Figure 18. The control
signal from the Processor to the appropriate raise
or lower solenoid on the hydraulic lift assembly
control valve is turned ‘Off’ when the lift arms have
moved to the desired position.

In addition to raising and lowering the implement

the lift control lever also automatically generates a
draft command. The further forward the lever is
pushed the greater the draft load which is
commanded.
18

During operation of the tractor, assuming that draft of the drop rate sensitivity knob and adjusts the
control has been selected, draft forces imposed by value of the signal to the control valve lower
the implement through the lower links are sensed solenoid accordingly to maintain the desired rate of
by the two special load sensing pins. Dependent on lowering. When the implement is in the ground, the
these draft loadings electrical signals from each of drop rate control is disabled. Thus the implement
the pins are also directed to the Processor. The may be lowered to the ground in accordance with
computer averages the signals from both pins and the drop rate setting and yet still respond properly
transmits a revised pulse width modulated signal to to draft variations once the ground has been
the appropriate hydraulic control valve solenoid to contacted.
raise or lower the hydraulic lift, maintaining the
constant draft loading selected by the operator When the lift control lever is moved to the maximum
using the lift control lever. raise position the setting of the height limit control
governs the maximum height to which the hydraulic
When the position/draft selector knob is set to full lift arms can be raised.
position control, No 1 on the scale, full position
control is selected and the draft loads on the When a tractor is operated in draft control and
implement, as sensed by the lift pins, have no effect under poor traction conditions the situation can
on the control of the hydraulic lift. At the other arise where as the tyres slip, the ground speed and
extreme, when the position/draft mix knob is set to draft forces on the load sensing pins also reduce.
the maximum draft sensitivity setting, No. 8 on the The reduction in draft forces signals the Processor
scale, the draft loads on the implement have to increase the implement to a depth which can
maximum effect on the control of the hydraulic lift. ultimately stop the tractor from moving.
Intermediate setting of the position/draft mix varies
the draft sensitivity between the maximum and On tractors equipped with the ‘limited slip’ option
minimum limits. this condition is overcome by the Processor
comparing tractor ground speed and axle speed to
To increase the degree of control of the lift arms calculate wheel slip. When wheel slip exceeds the
when they are being raised to the top of their travel pre--set limit set by the operator using the slip limit
and prevent the hitch from driving hard against the control, the Processor raises the lift arms
mechanical stops, the Processor automatically and irrespective of draft loading until the wheel slip
gradually adjusts the draft control sensitivity from decreases. As long as slip is less than the limit set
that set by the operator to maximum position by the operator the lift will operate in the normal
control. Because the implement would be raised out Electronic Draft Control manner.
of the ground at this point of lift the automatic
change from draft to position control has no effect In the event of failure of either the lift control lever,
on the use of the implement. lift arm position sensing potentiometer or height
limit control potentiometer, the hydraulic lift can still
When the hydraulic lift is being lowered the be operated by the external switches on the rear
computer also takes into consideration the setting fenders.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 13

Operation Of Hydraulic Lift Assembly valve, respond to the pulse width modulated
Control Valve signals from the Processor and direct oil from the
hydraulic pump to and from the hydraulic lift
The following description on the operation of the cylinder in direct proportion to the rate of lift
hydraulic lift control valve refers to controlling the required.
lift using the lift control lever. The same principal of
valve operation, however also applies when the The solenoid on the left hand end of the valve
hydraulic lift is responding to neutral, raise or lower causes the lift arms to raise and similarly the
signals from the external fender switches or load solenoid on the right hand end causes the arms to
sensing pins in the hydraulic lower links. lower. Because the solenoids are actuated with a
variable voltage drive a controlled flow of oil to the
The solenoids on either end of the hydraulic control lift cylinder is provided.

R8--208
Electronic Draft Control Hydraulic Lift Control Valve Operation--Neutral 19
1. Pilot Spool 8. Main Spool
2. Solenoid (Raise) 9. Solenoid (Lower)
3. Return to Reservoir Port 10. Pilot Spool
4. Load Sensing Valve 11. Pump system Pressure Inlet
5. Load Sensing Line To Variable Displacement 12. Main Spool Inlet Metering Land
Pump 13. Main Spool Return To Reservoir Metering Land
6. To Hydraulic Lift 14. Pilot Pressure Inlet
7. Load Check Valve

Pump System Pressure Oil (Variable) Pilot Pressure Oil 265 lbf/in2 (18 bar)

Return to Reservoir Oil Trapped Oil

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Neutral The pilot pressure applied to the end of the main

spool moves the spool to the left directing oil from
the hydraulic pump, across the inlet metering land
When the hydraulic lift arms are held in a stationary to the load check and load sensing valves. As
position, the hydraulic lift control valve is in ‘Neutral’ pressure in the gallery feeding these valves
and the Processor is not sending raise or lower increases the load sensing valve moves to the right,
signals to the control valve solenoids. In the neutral closing the load sensing line return to reservoir port
condition the spring force applied to each end of the and allowing the pressure of the metered oil flow to
main spool holds the spool in a central position, be sensed in the load sensing line. The pressure in
preventing oil flow from the pump to the hydraulic the load sensing line is now applied to the flow
lift, Figure 19. compensating valve in the variable displacement
pump which signals the pump to increase output.
Refer to ‘‘Chapter 1 Variable Displacement
In this situation both the pilot line, which supplies oil Hydraulic Pump Assembly with Closed Centre
from the hydraulic pump at a pilot pressure of Load Sensing’’ for a description and operation of the
250--280 lbf/in2 (17--19 bar), to operate the control pump installed on tractors fitted with Electronic
valve spool and the load sensing line which senses Draft Control.
hydraulic pump demand are open to reservoir. The
hydraulic lift load check valve remains seated,
trapping oil in the hydraulic lift cylinder to maintain The resulting rise in pressure of the metered oil due
the lift arms in a stationary position. to the increase in pump output, opens the load
check valve, permitting the metered system
pressure oil to flow into the lift cylinder and raise the
arms of the hydraulic lift assembly.
Refer to the variable displacement pump section of
this Repair Manual for the description and operation
of the closed centre load sensing system. When the lift arms have moved to the desired
position, the lift arm position sensing potentiometer
on the right hand lift arm, signals the Processor to
switch off the signal to the raise solenoid. The pilot
Raising spool now moves to the right, preventing pilot
pressure from being applied to the end of the main
spool. The main spool moves back to the ‘neutral’
position, Figure 19, preventing pump pressure oil
The speed of raise of the hydraulic lift is from being applied to the load check valve.
automatically controlled by the Processor. The
following paragraphs describe the operation of the
valve in the raise sequence and is followed by a Because the main spool has now returned to the
description of how the valve controls the speed of neutral position, the load check valve closes and
raise by metering the flow of oil to the hydraulic lift the load sensing valve, under pressure of oil
cylinder. returning to reservoir, moves to the right, opening
to reservoir the load sensing line from the hydraulic
pump.
In simple terms, when the lift control lever is moved
to raise the hydraulic lift, a signal is sent to the raise
solenoid on the control valve. The armature in the The load check valve has now trapped the oil in the
solenoid reacts to the signal and the pilot spool is lift cylinder, holding the lift arms in the desired
moved to the left, allowing pilot pressure from the position, while the pressure in the load sensing line
hydraulic pump to be applied to the end of the main can ‘bleed’ off to reservoir, signalling the variable
spool, Figure 20. displacement pump to reduce output.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 15

R8--209
Electronic Draft Control Hydraulic Lift Control Valve Operation--Modulated Raise 20
1. Pilot Spool 8. Main Spool
2. Solenoid (Raise) 9. Solenoid (Lower)
3. Return to Reservoir Port 10. Pilot Spool
4. Load Sensing Valve 11. Pump system Pressure Inlet
5. Load Sensing Line to Variable Displacement 12. Main Spool Inlet Metering Land
Pump 13. Main Spool Return to Reservoir Metering Land
6. To Hydraulic Lift 14. Pilot Pressure Inlet
7. Load Check Valve

Pump System Pressure Oil (Variable) Pilot Pressure Oil 265 lbf/in2 (!8 bar)

Return to Reservoir Oil

The speed of raise of the hydraulic lift is pressure causes the main spool to oscillate and
automatically controlled by the Processor which continually ‘meter’ the flow of oil from the system
modulates the signals to the raise solenoid pressure inlet port across the main spool inlet
proportionally to the degree of raise required. metering land, Figure 20.

The modulated signal automatically and continually

varies the raise solenoid pilot spool movement and Due to the restriction and consequential pressure
consequently the pilot pressure applied to the end drop caused by the metering land, the metered flow
of the main spool. Because movement of the main of oil varies the speed of lift in accordance with the
spool is dependent on the pressure applied on its size and frequency of the modulated input signals
end face, it can be seen that the modulated pilot to the raise solenoid.

604.55.041.00 - 01 - 1998
16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

R8--210
Electronic Draft Control Hydraulic Lift Control Valve Operation--Lowering 21
1. Pilot Spool 8. Main Spool
2. Solenoid (Raise) 9. Solenoid (Lower)
3. Return to Reservoir Port 10. Pilot Spool
4. Load Sensing Valve 11. Pump system Pressure Inlet
5. Load Sensing Line to Variable Displacement 12. Main Spool Inlet Metering Land
Pump 13. Main Spool Return to Reservoir Metering Land
6. To Hydraulic Lift 14. Pilot Pressure Inlet
7. Load Check Valve

Pump System Pressure Oil (Variable) Pilot Pressure Oil 265 lbf/in2 (!8 bar)

Return to Reservoir Oil

Lowering to reservoir metering land on the main spool,

allowing the lift arms to lower at a controlled speed.
When the lift control lever is moved to lower the
hydraulic lift, a signal is sent to the lower solenoid The speed of lower on the hydraulic system is
on the control valve. As the armature in the solenoid pre--set by the operator and automatically
reacts to the signal, the pilot spool is to the right maintained by the Processor which modulates the
allowing pilot pressure from the hydraulic pump to signal to the control valve lower solenoid in
be applied to the left hand end of the main spool, accordance with the implement drop rate selected
Figure 21. As the main spool moves towards the on the operator control panel. The modulated input
right, pilot pressure is applied to the right hand face signal continually varies the lower solenoid pilot
of the load sensing valve, causing the valve to move spool movement and consequently the pressure
to the left, unseating the ball in the load check valve. applied to the end of the main spool. Because
movement of the main spool is dependent on the
The oil trapped behind the check valve can now pilot pressure applied on its end face, the main
vent to reservoir and the load sensing valve spool continually oscillates and meters the flow of
continues to move forward, unseating the load oil from the lift cylinder, across the return to
check valve poppet. The pressurised oil in the lift reservoir metering land of the main spool, giving a
cylinder now returns to reservoir across the return controlled rate of lowering.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 17

35000 -- TROUBLE SHOOTING AND CALIBRATIONS

The transmission / EDC electronic management

It should be noted that the self diagnostic capability

is generally limited to diagnosis of the electrical and
electronic circuitry and related components,
however, there are some codes, which can be
generated if pressure switch circuits are not closed
because of an actual lack of hydraulic pressure.
22
Any malfunction of the mechanical and hydraulic
components must be diagnosed using
conventional techniques, performance
characteristics and tooling, such as pressure
testing equipment. Full guidance for both electrical
self diagnosis and conventional diagnosis is
contained within this section.

Trouble--shooting and fault finding should always

Prior to detailed fault finding, items like the earth

points and Battery should be cleaned and tested to 23
ensure that they are functioning correctly.
With the use of micro--processors it is often that
this item is blamed for any malfunction but the real
truth is that this item is usually sound and that the
fault is due to poor contacts in the associated
connectors.

Each connector illustrated and identified in the

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Where the fault finding procedure requires checks

for continuity a visual inspection of the wiring
should be made prior to conducting tests to ensure
that obvious ‘mechanical’ damage has not
occurred to the harness or the connectors.

Where possible the inbuilt tractor diagnostics

should be utilised to determine the area of the fault.
The ’H’ menu mode, described in Section 55,
provides several modes to aid diagnosing faults.
One particular mode which should be used, before
any connections are split, is the H5, switch
diagnostics mode. This will provide testing of many
switch circuits, including the switch itself. If this
mode highlights a fault within a circuit then more 25
detailed fault finding can be directed towards a
particular circuit.

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

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high
range and work downwards to avoid damaging the
instrument.
Where possible it is recommended that connectors
are probed from the rear, certain connectors like
C079, C080 and C081, instrument panel
connectors, should always be probed from the
rear. Connector terminals should only be removed
using the special tools supplied in electrical repair
kit, Tool No.4FT.953 and the wires should not
require excessive pulling efforts to remove.
26
Where only front probing is practical it is
recommended that Connector test probe kit, Tool
No NH.55--125 is obtained. This provides all
connector terminal attachments for use with most
multi--meters.
IMPORTANT: Care should be used when using
the multi--meter, only use the instrument as
instructed to avoid damage to the internal elements
of the micro--processor. When checking the
continuity of wiring, sensors or switches it is
necessary to isolate the electronic
micro--processor and ensure the keystart is turned
off to prevent possible further damage. The
keystart should only be switched on and the
processor connected where specifically instructed
in the fault finding procedure.
TA60--21--01
4
If it is found necessary to clean the connectors a 27
contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains
Trichloro--ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 19

NOTES

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

The following ’H’ menu mode routines are provided

A full description of the ’H’ menu routines can be

found in Section 55.

29
It should also be noted that after installation of a
new processor or after a non volatile memory reset
operation (’H’ menu mode, H8), that the processor
defaults to a ’display all codes’ mode for 6 minutes.
If no error codes occur during this 6 minute period
the processor then reverts to normal operation. If
an error occurs during this period the processor will
continue to display ’live’ error codes until all the
errors are removed.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 21

ELECTRONIC DRAFT CONTROL ERROR CODES

Error Code Error Description Page

Code 2 Poor or no signal from tractor performance monitor radar . . . . . . .
Codes 3, 4 and 5 Speed Sensor Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes 6 and 7 Slip Control Potentiometer or Circuit Failed . . . . . . . . . . . . . . . . . . .
Code 8 Raise/Work/Lower Switch Failure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 9 Both External Lift/Lower Fender Switches are being
Operated Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes 10 and 11 Height Limit Control Potentiometer Failed . . . . . . . . . . . . . . . . . . . .
Codes 12 and 13 Drop Rate Potentiometer Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes 14 and 15 Right Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . .
Codes 16 and 17 Left Hand Load Sensing Pin or Circuit Failed . . . . . . . . . . . . . . . . .
Code 18 Both Load Sensing Pins Disconnected . . . . . . . . . . . . . . . . . . . . . . .
Codes 19 and 20 Incorrect Load Sensing Pin Reference Voltage . . . . . . . . . . . . . . . .
Codes 21 and 22 Position/Draft Sensitivity Control Potentiometer or
Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 23 Control Panel Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 24 Perform Hydraulic Lift calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code HL Height Limit Incorrectly Set to Perform Autocalibration . . . . . . . . .
Codes 25 and 26 Lift Control Lever Potentiometer Disconnected or
Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Codes 27 and 28 Lift Arm Position Sensing Potentiometer Disconnected
or Circuit Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 29 Hydraulic Control Valve Disconnected . . . . . . . . . . . . . . . . . . . . . . .
Code 30 Ground Signal to Microprocessor Open Circuit . . . . . . . . . . . . . . . .
Code 31 Chassis Harness Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 49 Wheel Speed Sensor Open/Short Circuit . . . . . . . . . . . . . . . . . . . . .
Code 53 Microprocessor 5 volt Reference Shorted to 12 volts . . . . . . . . . . .
Code 54 Microprocessor 5 volt Reference Shorted to Ground . . . . . . . . . . .
Code 57 EDC Microprocessor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 59 Microprocessor 5 volt Reference Voltage Open Circuit . . . . . . . . .
Code 63 and 65 EDC Hydraulic Valve Lower Solenoid Open/Short Circuit . . . . . . .
Code 64 and 66 EDC Hydraulic Valve Raise Solenoid Open/Short Circuit . . . . . . .
Code 67 EDC Hydraulic Valve Supply Voltage to Low . . . . . . . . . . . . . . . . . .
No Error Code Miscellaneous Hydraulic Lift Concerns . . . . . . . . . . . . . . . . . . . . . .

604.55.041.00 - 01 - 1998
22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 2

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 23

ERROR CODE 2 -- Poor or no signal from tractor performance monitor radar

Perform
Key Off
Key On

Is tractor Reconnect
performance monitor performance
radar connected? monitor radar

Disconnect radar assembly

(C068). Is there continuity Locate and
Turn keystart ON and between C68--3 and repair open
measure voltage between Fuse 9? circuit
C68--3 and C68--1.
Is battery voltage indicated?
Is there continuity
between C68--1 and
Tractor Chassis?
Disconnect processor
connector C128, and
instrument panel
connectors C079, C080,
C081. Is there an open circuit Locate and
Is there continuity between C68--3 and repair short
between Pin C128--15 tractor chassis? circuit
and C68--2?
Locate open
circuit and
repair
Is there an open
circuit between
C68--2(G) and Locate short circuit and
tractor chassis? repair

Replace radar

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 3, 4 & 5 -- Speed sensor errors

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 25

ERROR CODES 3, 4 & 5 -- Speed sensor errors

Key ON,
If Error Code 3 or 5 is drive and
displayed, perform test recheck
procedure for Error Code 2.
If Error code 4 is displayed
proceed.

Is radar correctly positioned Point radar at ground

and secure? and tighten fixing

Is the output speed

sensor correctly Retighten speed sensor
positioned and secure?

Replace output speed

sensor

604.55.041.00 - 01 - 1998
26 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 6 & 7

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 27

ERROR CODES 6 & 7 -- Slip control potentiometer or circuit failed

Key OFF,
Key ON
and
recheck

Is slip control and H8 (reset) and

radar installed recalibrate

Enter diagnostic mode H9

Channel 33 and turn slip control knob Refer to wiring diagram
fully clockwise and then fully counter and check for
clockwise. intermittent fault on
Are the values outside the range of wiring to control panel
14--84?

Remove EDC control panel and Inspect and clean

disconnect connectors C121 and C120. connectors and
While turning slip limit control, measure retest. If
resistance across male pins, C121--1 and resistance is still
C120--1 of console. incorrect replace
Does resistance vary between 90--330" ? the control panel

Turn keystart switch ON and

measure voltage across Disconnect C127.
female pins C120--1 and Is there continuity Locate and
C120--4 of vehicle harness. between C120--1 and repair open
Is the voltage approximately C127--5, then C120--4 circuit
5 volts? and C127--1?

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C121--1 and Is the circuit open circuit
C128--16? between each of the
above pins and chassis

Is there an open circuit

between C121--1 and Remove, inspect and refit Processor
C120--4, connectors, C127 and C128. If error
still occurs Reset the processor using
Repeat check between
C121--1 and C120--1? Mode H8 and recalibrate. If error still
occurs replace the processor.
Locate and repair open circuit
Is there an open
circuit between
C121--1 and Locate and repair short circuit
chassis?

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODE 8 -- In cab Raise/Work/Lower switch failure

Key OFF,
Enter Switch Diagnostics, H5. ’d0’ will be Key ON
displayed. Toggle the switch, one of the retest
following combinations will be displayed:

d3,d4,d5 -- d3,d4 -- d4,d5 -- d3 -- d4 -- d5

d3,d4,d5 d3,d4,

System okay. Disconnect Replace switch

/ reconnect switch and
wiggle test wiring.

d4,d5

Disconnect switch. Place in Disconnect

the raise position, is there processor. Check pin
Reconnect and
continuity through pins 2 & 4 No. C128--29, is
retest.
and 2 & 5? battery voltage
indicated?

Replace switch
Locate and repair short
to battery voltage on
C128--29 (TQ/P)

Disconnect switch. Is there

continuity with the switch in Replace switch
the raise position between
pins 5 & 7?

Is there continuity between Locate and repair open

C128--26 and C102--7 (TQ/W) circuit in Harness

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 29

ERROR CODE 8 -- In cab Raise/Work/Lower switch failure

Key OFF,
Key ON
d4 retest

Disconnect switch. Is there

continuity with the switch in Replace switch
the work position between
pins 5 & 2?

Is there continuity between Locate and repair open

C128--29 and C102--2 (TQ/P) circuit in Harness

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

Disconnect switch. Is there continuity

at the switch terminals between pins 2 Replace switch
& 5 in ’Work’ and 2 & 7 in ’raise’ ?

Is there battery voltage at Check harness between fuse

C102--5 (R/LG/B)? 12 and C102--5 (R/LG/B). Find
open circuit and repair.

Is there continuity between

C128--29 and C102--2 (TQ/P) Locate and repair open
and between circuit in Harness
C128--26 and C102--7 (TQ/W)?

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

604.55.041.00 - 01 - 1998
30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 9 -- Both external switches operated together

7
K/W 3
1

K/G
C C
134 135
TIA35092

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 31

ERROR CODES 9 -- Both external switches operated together

Visibly verify fender switches are Clean, fix or

functioning correctly replace switch

Is fuse 9 OK? Replace fuse 9 (if fuse still blows,

check fuse 9 wiring circuit)

Enter Mode H5. In turn Disconnect fender which does

depress and hold each not change the display. With Locate
fender switch in the raise keystart ON. Check voltage and repair
position. between green wire and chassis. open
Does the display change Is battery voltage indicated? circuit
from d0 to d2?

With the switch in the raise

In turn depress and hold Replace
position, check for continuity
each fender switch in the switch
between pins 3 & 7
lower position.
Does the display change
from d0 to d1? Disconnect
microprocessor Locate
System OK. connector C128. Is there and repair
continuity between open
C128--21 and K/W wire at circuit
switch?

Disconnect fender
which does not change Is there an open circuit Locate
the display. With between G and K/W at and repair
keystart ON. Check fender switch? short
voltage between green circuit
wire and chassis. Is
battery voltage Replace microprocessor
indicated?

With the switch in the

raise position, check Replace
for continuity between switch
pins 1 & 3

Disconnect
microprocessor Locate
connector C128. Is there and repair
continuity between open
C128--28 and K/G wire at circuit
switch?

Is there an open circuit

between G and K/G at Locate and repair
fender switch? short circuit

Replace microprocessor

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32 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 10 & 11

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 33

ERROR CODES 10 & 11 -- Height limit control potentiometer failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Channel 31 and turn Height limit control Refer to wiring diagram
knob fully clockwise and then fully and check for
counter clockwise. intermittent fault on
Are the values outside the range of wiring to control panel
14--84?

Remove EDC control panel and disconnect Inspect and clean

connectors C121 and C120. connectors and
While turning height limit control, measure resistance retest. If
across male pins, C120--5 and C120--1 of console. resistance is still
Does resistance vary between 90--330" #W/slip) or incorrect replace
180--500" (L/slip) ? the control panel

Turn keystart switch ON and

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--7 and Is the circuit open circuit
C128--31? between each of the
above pins and chassis

Is there an open circuit

between C120--7 and Remove, inspect and refit Processor
C120--4, connectors, C127 and C128. If error
Repeat check between still occurs Reset the processor using
C120--7 and C120--1? Mode H8 and recalibrate. If error still
occurs replace the processor.
Locate and repair open circuit
Is there an open
circuit between
C120--7 and Locate and repair short circuit
chassis?

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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34 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 12 & 13

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 35

ERROR CODES 12 & 13 -- Drop Rate control potentiometer failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Channel 30 and turn Drop Rate control Refer to wiring diagram
knob fully clockwise and then fully and check for
counter clockwise. intermittent fault on
Are the values outside the range of wiring to control panel
14--84?

Remove EDC control panel and disconnect Inspect and clean

connectors C121 and C120. connectors and
While turning Drop Rate control, measure resistance retest. If
across male pins, C120--2 and C120--1 of console. resistance is still
Does resistance vary between 90--330" #W/slip) or incorrect replace
90--400" (L/slip) ? the control panel

Turn keystart switch ON and

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--2 and Is the circuit open circuit
C128--9? between each of the
above pins and chassis

Is there an open circuit

between C120--2 and Remove, inspect and refit Processor
C120--4, connectors, C127 and C128. If error
Repeat check between still occurs Reset the processor using
C120--2 and C120--1? Mode H8 and recalibrate. If error still
occurs replace the processor.
Locate and repair open circuit
Is there an open
circuit between
C120--2 and Locate and repair short circuit
chassis?

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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36 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 14 & 15 -- R.H. Load Sensing Pin or Circuit Failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 37

ERROR CODES 14 & 15 -- R.H. Load Sensing Pin or Circuit Failed

Key OFF
Key ON
Is right hand load check
sensing pin
connected Reconnect pin

Check for
With no implement fitted Turn keystart switch OFF intermittent
enter diagnostic mode H9 and ON. circuit in wiring
channel 34. Is the value Is ERROR still displayed? to pin
outside the range of
42--54? Remove, inspect and refit processor connectors,
C127 & C128. ’H8’ and reset the processor. If error
Turn the keystart OFF. still occurs replace the processor.
Install New Pin (or swap
with other side). Install new pin
Is ERROR displayed?

Disconnect microprocessor connectors and both

load sensing pins, connector C48 and C47.
Check for continuity between male pins
C48--1 (LN/G) and C127--1 (LN/G) Locate and repair
C48--2 (LN/P) and C128--11 (LN/P) open circuit
C48--3(K) and C127--25(K), continuity detected?

Check for open circuit between

male pins C48--1, C48--2 and
C48--3 and an open circuit to Locate and repair
chassis between each of these short circuit
pins.
Open circuit detected?

With microprocessor connectors

disconnected, turn keystart ON. Examine harness
Test for voltage between for damage
chassis and connectors C48--2, resulting in voltage
C48--3. supply
Is voltage 0 volts?

Remove, inspect and refit

processor connectors, C127 &
C128. ’H8’ and reset the
processor. If error still occurs
replace the processor.

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38 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 16 & 17 -- L.H. Load Sensing Pin or Circuit Failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 39

ERROR CODES 16 & 17 -- L.H. Load Sensing Pin or Circuit Failed

Key OFF
Key ON
Is Left hand load check
sensing pin
connected Reconnect pin

Check for
With no implement fitted Turn keystart switch OFF intermittent
enter diagnostic mode H9 and ON. circuit in wiring
channel 35. Is the value Is ERROR still displayed? to pin
outside the range of
42--54? Remove, inspect and refit processor connectors,
C127 & C128. ’H8’ and reset the processor. If error
Turn the keystart OFF. still occurs replace the processor.
Install New Pin (or swap
with other side). Install new pin
Is ERROR displayed?

Disconnect microprocessor connectors and both

load sensing pins, connector C48 and C47.
Check for continuity between male pins
C47--1 (LN/G) and C127--1 (LN/G) Locate and repair
C47--2 (LN/P) and C128--33 (LN/P) open circuit
C47--3(K) and C127--25(K), continuity detected?

Check for open circuit between

male pins C47--1, C47--2 and
C47--3 and an open circuit to Locate and repair
chassis between each of these short circuit
pins.
Open circuit detected?

With microprocessor connectors

disconnected, turn keystart ON. Examine harness
Test for voltage between for damage
chassis and connectors C47--2, resulting in voltage
C47--3. supply
Is voltage 0 volts?

Remove, inspect and refit

processor connectors, C127 &
C128. ’H8’ and reset the
processor. If error still occurs
replace the processor.

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40 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 18 -- Both load sensing pins disconnected

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 41

ERROR CODES 18 -- Both load sensing pins disconnected

Key OFF
Key ON
check
Are both load
sensing pins Reconnect pins
connected

Visibly inspect harness to

both pins for damage. Repair or replace
Harness OK? harness as required

Remove implement if fitted.

Enter diagnostic mode H9. Turn keystart OFF and Check for
Channel 34 & 35 ON. intermittent
Are values outside the Is error still displayed? circuit in wiring
range 42--54?
Remove, inspect and refit
processor connectors, C127 &
C128. ’H8’ and reset the
processor. If error still occurs
replace the processor.

Disconnect microprocessor connectors

C128 and C127 and both load sensing
pin connectors, C48 and C47. Check
for continuity between:
C48--1 (LN/G) and C127--1 (LN/G) Locate and repair open
C48--2 (KN/P and C128--11 (LN/P) circuit
C48--3 (K) and C127--25 (K)
C47--1 (LN/G) and C127--1 (LN/G)
C47--2 (LN/LG) and C128--33 (LN/LG)
C47--3 (K) and C127--25 (K)

Remove, inspect and refit processor connectors,

C127 & C128. ’H8’ and reset the processor. If error
still occurs replace the processor.

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42 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 19 & 20 -- Incorrect load sensing pin reference voltage

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 43

ERROR CODES 19 & 20 -- Incorrect load sensing pin reference voltage

Key OFF
Key ON
check

Enter diagnostic mode

H9, Channel 9. Key OFF Remove, inspect and refit
Is the value outside Key ON processor connectors, C127 &
the range of 75--85? Is C128. ’H8’ and reset the
ERROR processor. If error still occurs
still shown replace the processor.

For both pins:

Disconnect both load Reconnect one pin at a time.
sensing pins. Turn keystart Replace the
Key OFF/Key ON --
ON and measure voltage faulty pin
Does Error Code 19 or 20
between: appear?
C48--3 and C48--1 (Ignore other pin error codes)
C47--3 and C47--1
Is voltage outside the range
of 7.5--9.0 volts? Remove, inspect and refit processor connectors,
C127 & C128. ’H8’ and reset the processor. If
error still occurs replace the processor.
Disconnect microprocessor
connectors.
Is there continuity between: Locate open circuit and
C48--3 and C127--25 repair
C47--3 and C127--25

Disconnect microprocessor
connectors and both load
sensing pin connectors C48 Locate short circuit
and C47. Is there an open and repair
circuit between tractor
chassis and C48--3 and
C47--3?

With microprocessor
connectors C127 and
C128 disconnected, turn
keystart ON and
measure for a voltage Examine harness for
between the chassis and damage resulting in
pins C48--3 (K) and voltage supply direct
C47--3 (K). Is voltage from battery.
approximately 0 volts?

Remove, inspect and refit processor connectors,

C127 & C128. ’H8’ and reset the processor. If
error still occurs replace the processor.

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44 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 21 & 22

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 45

ERROR CODES 21 & 22 -- Position/draft sensitivity control potentiometer or circuit failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Channel 30 and turn position/draft knob Refer to wiring diagram
fully clockwise and then fully counter and check for
clockwise. intermittent fault on
Are the values outside the range of wiring to control panel
14--84?

Remove EDC control panel and Inspect and clean

disconnect connectors C121 and C120. connectors and
While turning position/draft control, retest. If
measure resistance across male pins, resistance is still
C120--3 and C120--1 of console. incorrect replace
Does resistance vary between 90--330" the control panel
W/slip or 90--420" L/slip?
Turn keystart switch ON and
measure voltage across Disconnect C127.
female pins C120--1 and Is there continuity Locate and
C120--4 of vehicle harness. between C120--1 and repair open
Is the voltage approximately C127--5, then C120--4 circuit
5 volts? and C127--1?

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--3 and Is the circuit open circuit
C128--10? between each of the
above pins and chassis

Is there an open circuit

between C120--3 and Remove, inspect and refit Processor
C120--4, connectors, C127 and C128. If error
still occurs Reset the processor using
Repeat check between
C120--3 and C120--1? Mode H8 and recalibrate. If error still
occurs replace the processor.

Is there an open Locate and repair open circuit

circuit between
C120--3 and Locate and repair short circuit
chassis?

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
46 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 23 -- Control panel disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 47

ERROR CODES 23 -- Control panel disconnected Key OFF,

Key ON
retest

Are control panel connectors Reconnect

C121 and C120 connected? control panel

Examine harness of control

panel and harness from Ensure harnesses are
control panel connector to correctly connected. Is
processor. Is harness ERROR still displayed.
damaged?
Replace EDC control
Repair or replace panel (board)
harness.

604.55.041.00 - 01 - 1998
48 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

NOTES

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 49

ERROR CODE 24 --
Perform hydraulic lift calibration after replacement of lift arm potentiometer, microprocessor, lift lever
potentiometer.

Key OFF,
Key ON
retest

Is error code 24 displayed? Disconnect the lift arm potentiometer and turn
the ignition key ON. Operate the lift lever to
induce error code 27 and turn off the ignition
and reconnect the potentiometer. At the next
Disconnect the Automatic Pick key on error code 24 should be displayed.
Up Hitch (APUH) rods

Lower linkage using control lever &

connect to suitable weights (approx
200Kg) capable of overcoming any
binding within the system.

Key off the engine.

Install the diagnostic switch, Tool No.4FT.950

or start the engine with the raise/work/lower
switch depressed to enter the calibration
mode, H1.

The instrument cluster display will

show ’CAL’. Set the engine speed to
1200 +/-- 100 rpm

Set all EDC panel potentiometers

fully clockwise

Move the lift lever to the fully lowered

position

Reconnect and adjust the APUH rods. Adjust the

Pull the lever to the top of its travel
length of the rods so that when the lift is fully raised
and allow arms to fully raise. Check
using the external fender switches the lift rods are
that the display increases to 99.
slightly loose. Check that the APUH operates correctly.

Lower the control lever to 70% to 90% to start valve calibration

sequence. During calibration the linkage is automatically raised &
lowered a small amount 3 times, which takes 2--3 minutes. Each
raise & lower is accompanied by a count on the display 0--1--2.
When display indicates ”end” the calibration is complete.

Key off to store calibration values

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50 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 25 & 26 -- Lift control lever potentiometer disconnected or circuit failed

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 51

ERROR CODES 25 & 26 -- Lift control lever potentiometer disconnected or circuit failed

Key OFF,
Key ON
retest

Inspect for damage to the lift Repair/replace

control lever and potentiometer. potentiometer
Are they OK? or linkage

Enter diagnostic mode H9

Channel 29. Fully lower Refer to wiring diagram and
lever and then raise. Are check for intermittent fault to
the values outside the lift lever potentiometer
range of 27 to 83?

Disconnect potentiometer connector C149

and measure resistance between green
and orange wires from potentiometer.
Repeat test between green and black Replace potentiometer
wires. Does resistance vary between 1.28
and 2.95k" as lever is moved in both
directions

Disconnect microprocessor
Turn key switch on and Locate
C127. Check for continuity
measure voltage across male and
between male pins C149--2
pin C149--2 (K/B) and repair
(K/B) and C127--5 (LN).
C149--3 (LN/G). open
Repeat check between
Is voltage + 5 volts? circuit
C149--3 (LN/G) and C127--1
(B).
Disconnect microprocessor
connector C128. Locate
Is there an open Locate
Is there continuity between open
circuit between male and
male pins C149--1 (LN/B) circuit
pins C149--2 (K/B) repair
and C128--30 (LN/B)? and
and C149--3 (LN/G) short
repair
and an open circuit circuit
Check for open circuit to chassis between
between male pins each of these pins.
C149--1 (LN/B) and
C149--2 (K/B).
Remove, inspect and refit Processor
Repeat check between
connectors, C127 and C128. If error
C149--1 (LN/B) and
still occurs Reset the processor using
C149--3 (LN/G).
Mode H8 and recalibrate. If error still
Locate occurs replace the processor.
Check for open circuit short
between C149--1 (LN/B) circuit
and tractor chassis and
repair

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
52 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 27 & 28 -- Lift arm potentiometer sensing potentiometer disconnected

or circuit failed

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 53

ERROR CODES 27 & 28 -- Lift arm potentiometer sensing potentiometer disconnected

or circuit failed
Key OFF,
Key ON
retest

Inspect for damage to the lift arm Repair/replace

potentiometer and linkage. potentiometer
Are they OK? or linkage

Enter diagnostic mode H9

Channel 28. Fully lower Refer to wiring diagram and
lever and then raise. Are check for intermittent fault to
the values outside the lift lever potentiometer
range of 33 to 83.

Disconnect potentiometer linkage and connector

C052. Measure resistance between green and
orange wires from potentiometer.
Repeat test between green and black wires. Does Replace potentiometer
resistance vary between 0.5 and 3.5k" as lever is
moved in both directions?

Disconnect microprocessor
Turn key switch ON and Locate
C127. Is there continuity
measure voltage across and
between male pins C052--2
female pins C052--2 and repair
and C127--5.
C052--3 open
Repeat check between
Is voltage + 5 volts? circuit
C053--3 and C127--1?

Disconnect microprocessor
connector C128. Locate Is there an open Locate
Is there continuity between open circuit between male and
C052--1 and C128--8? circuit pins C052--2 and repair
and C052--3 or an open short
repair circuit to chassis circuit
Is there an open circuit between each of
between C052--1 and these pins.
C052--2.
Repeat check between
C052--1 and C052--3 ? Remove, inspect and refit Processor
connectors, C127 and C128. If error still
occurs Reset the processor using Mode
Check for open circuit H8 and recalibrate. If error still occurs
between C052--1 and replace the processor.
tractor chassis Locate
short
circuit
and
repair

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
54 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODE 29 -- Hydraulic control valve disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 55

ERROR CODE 29 -- Hydraulic control valve disconnected

Key OFF,
Key ON
retest

Are hydraulic control valve

Reconnect
connectors C217 and 218
connectors
connected.

Remove, inspect and refit Processor

Examine harness from connectors, C127 and C128. If error still
EDC control valve for occurs Reset the processor using Mode
severe damage. H8 and recalibrate. If error still occurs
Harness Damaged? replace the processor.

Repair/replace harness
as necessary.

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56 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODE 30 -- Signal ground open circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 57

ERROR CODE 30 -- Signal ground open circuit

Key OFF,
Key ON
Disconnect EDC control panel retest
connectors C121 and C120 and
microprocessor connector C127. Locate and
Is there continuity between repair open
female pins C120--4 (B) and circuit
C127--1 (B)

Is there continuity between

Locate and repair
female pins C120--1 (LN)
open circuit
and C127--5 (LN).

Measure resistance
between male pins C120--1
(G) and C120--4 (N) of Replace EDC
control panel. control panel
Is resistance approximately
300--500"

Examine
microprocessor
connector C127 for
damage to terminal pin
C127--5

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58 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 31 -- Drive line / EDC harness disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 59

ERROR CODES 31 -- Drive line / EDC harness disconnected

Key OFF,
Key ON
retest

Is chassis harness Reconnect

connected harness

Perform checks for Error Code 18

Examine harness for but do not replace microprocessor
damage. Harness at this stage of examination.
damaged? Is Error Code still displayed?

Perform checks for Error

Replace or repair Codes 27 & 28.
harness Is Error Code still
displayed?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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60 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 49 -- Wheel speed sensor open or short circuit

C020--23
5010--B 5035--LN/G 5035--LN/G 5140--TQ/N
C127--1 C046--2

C020--43
5135--T/Q 5135--T/Q
C127--6 C046--1

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 61

ERROR CODES 49 -- Wheel speed sensor open or short circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

Is the value
greater than 89 Is there an open Locate and repair
circuit on wiring open circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500"

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62 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 53 -- Microprocessor 5 volt reference shorted to 12 volt supply

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 63

ERROR CODES 53 -- Microprocessor 5 volt reference shorted to 12 volt supply

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Channel 5. Is the value greater short circuit to 12 volt
than 49 and error code 53 supply from battery or
displayed? fuse panel.
Error still displayed?
Disconnect EDC control panel
and disconnect connectors C120 Remove, inspect and refit Processor
and C121. Turn keystart switch connectors, C127 and C128. If error still
ON and measure voltage across occurs Reset the processor using Mode
female pins C120--1 and H8 and recalibrate. If error still occurs
C120--4. replace the processor.
Is voltage greater than 5 volts?

Examine harness for a

short circuit to a 12 volt
power supply from the
fuse panel or direct from
the battery.
Error still displayed?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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64 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 54 -- Microprocessor 5 volt reference shorted to ground

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 65

ERROR CODES 54 -- Microprocessor 5 volt reference shorted to ground

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Channel 5. short circuit to tractor
Is the value greater than 49 and chassis. Error still
error code 54 displayed. displayed?

Disconnect EDC control panel and

disconnect connectors C121 and Remove, inspect and refit Processor
C120. connectors, C127 and C128. If error still
Turn keystart switch ON and occurs Reset the processor using Mode
measure voltage across female H8 and recalibrate. If error still occurs
pins C120--1 and C120--4. replace the processor.
Is voltage less than 5 volts?

Disconnect
microprocessor Check for short circuit in wire
connectors C128 and from C127--5 and C120--1
C127. Check for short and tractor chassis.
circuit between C120--1 Error still displayed?
and C120--4.
Short circuit?
Remove, inspect and refit Processor
connectors, C127 and C128. If error still
Locate and repair short occurs Reset the processor using Mode
circuit H8 and recalibrate. If error still occurs
replace the processor.

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66 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 57 -- EDC Microprocessor failure

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 67

ERROR CODES 57 -- EDC Microprocessor failure

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

Check and replace fuse 14 if necessary

604.55.041.00 - 01 - 1998
68 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 59 -- Microprocessor reference voltage open circuit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 69

ERROR CODES 59 -- Microprocessor reference voltage open circuit.

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Channel 5. connector pin fault.
Is the value outside of the range At C127--5 is error still
45--53? displayed?

Disconnect EDC connectors

C120 and C121. Remove, inspect and refit Processor
Turn keystart ON. connectors, C127 and C128. If error still
Measure voltage across pins occurs Reset the processor using Mode
C120--1 and C120--4. H8 and recalibrate. If error still occurs
Is the voltage outside of the replace the processor.
range 4.5 -- 5.5 V.

Disconnect processor
connector C127. Is Locate and repair open
there continuity circuit
between C120--1 (L/N)
and C127--5 (L/N)?

Is there continuity Locate and repair open

between C120--4 and circuit
C127--1?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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70 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 63 -- EDC hydraulic valve lower solenoid Open Circuit

65 -- EDC hydraulic valve lower solenoid Short Circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 71

ERROR CODES 63 -- EDC hydraulic valve lower solenoid Open Circuit

65 -- EDC hydraulic valve lower solenoid Short Circuit
Key OFF,
Key ON
retest

Disconnect hydraulic control

valve connector C218. Measure Replace lower
coil resistance. solenoid
Is resistance approximately 8"?

Disconnect microprocessor
connector C127. Is there
continuity between C218--2 Locate and repair open
and C127--19, and C218--1 circuit
and C127--27.

With microprocessor and valve

disconnected. Is there an open
circuit between harness
connectors C218--1 and Locate and repair short
C218--2. Similarly is there an circuit.
open circuit between each of
these pins and the chassis.

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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72 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 64 -- EDC hydraulic valve Raise solenoid Open Circuit

66 -- EDC hydraulic valve Raise solenoid Short Circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 73

ERROR CODES 64 -- EDC hydraulic valve Raise solenoid Open Circuit

66 -- EDC hydraulic valve Raise solenoid Short Circuit
Key OFF,
Key ON
retest

Disconnect hydraulic control

valve connector C217. Measure Replace lower
coil resistance. solenoid
Is resistance approximately 8"?

Disconnect microprocessor
connector C127. Is there
continuity between C217--2 Locate and repair open
and C127--20, and C217--1 circuit
and C127--28.

With microprocessor and valve

disconnected. Is there an open
circuit between harness
connectors C217--1 and Locate and repair short
C217--2. Similarly is there an circuit.
open circuit between each of
these pins and the chassis.

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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74 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

ERROR CODES 67 -- EDC Hydraulic valve supply voltage too low

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 75

ERROR CODES 67 -- EDC Hydraulic valve supply voltage too low

Key OFF,
Key ON
retest

Is fuse 14 OK? Replace fuse

Enter diagnostic mode H9 Check for intermittent

channel 8. fault between fuse 14
Is value less than 35? and C127--29

Disconnect processor
connector C127. Locate and repair open
Is there battery voltage circuit
at C127--29?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

604.55.041.00 - 01 - 1998
76 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Fault Diagnostic Chart For Miscellaneous Hydraulic Lift Concerns

SYMPTON POSSIBLE CAUSE ACTION

Hydraulic lift will No pilot pressure to EDC Perform low pressure circuit tests.
not operate. hydraulic control valve. Refer to Section 35 Chapter 2

No load sensing signal. Tractors with CCLS Pump

Check load sensing valve for
sticking.
Tractors with Open Centre Gear
Pump
Examine unload valve for sticking

EDC load check valve Examine load check valve.

sticking,

Hydraulic lift will Load check valve piston Examine load check piston.
not lower. sticking.
Control valve spool sticking. Examine spool.

Lowering solenoid spool Examine solenoid spool and

sticking. torque of solenoid retaining
screws.
EDC Valve out of adjustment. Examine spool adjusters for signs
of tampering. Check valve
calibration values using
diagnostic routine H2.

Lift arms erratic, EDC valve receiving Disconnect EDC valve connector
Slow or move when electronic signal. and trace wiring fault if arms
not in operation. remain stationary.
Pilot or control valve spools Examine pilot and control valve
sticking. spools for sticking or wear.
EDC valve out of adjustment Examine spool adjusters for signs
or incorrect valve fitted. of tampering. Check valve
calibration values using
diagnostic routine H3
Check correct EDC valve fitted

Lift arms slowly Check valve leaking. Examine check valve poppet ball
drop when held in seat for wear.
raised position with Lift Cylinder safety valve Examine safety valve
engine Off. leaking
Cannot lift heavy Pump worn or lift cylinder Perform hydraulic pump flow and
loads. seals leaking. pressure tests. Refer to Section 55
Chapter 2

Unload valve sticking

(Open centre hydraulics only)

Hydraulic lift will Microprocessor incorrectly Perform memory reset and

not raise or lower to calibrated. autocalibration procedure. See
maximum limits of Error Code 24.
travel.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 77

NOTES

604.55.041.00 - 01 - 1998
78 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

HYDRAULIC LIFT COVER ASSEMBLY--OVERHAUL

REMOVAL

1. Lower lift arms.

2. Less Cab Tractors Only:

Remove platform to gain access to hydraulic
lift cover.

3. Disconnect hydraulic connections to assist

rams (5) (where fitted) and disconnect ram(s)
from lift arms, Figure 2.

4. Disconnect lift rods (2), (3) & (4) from lift arms.

5. Remove remote control valves (1).

6. Remove load sense lines (5) to remote and

hydraulic control valves, Figure 3.

7. Remove hydraulic control valve pilot pressure

feed tube (4).

8. Remove trailer brake coupler and feed tube

(1).

9. Remove assist ram feed tubes (2).

10. Remove rear axle dipstick tube retaining bolt.

11. Remove remote control valve feed and return

tubes (3).
3

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 79

12. Remove hydraulic control (EDC) valve (1).

13. Remove hydraulic top cover retaining bolts.

4
14. Disconnect connector (2) to lift arm position
sensing potentiometer (1), Figure 5.

5
15. Using suitable lifting gear remove lift cover,
Figure 6.

6
DISASSEMBLY

1. Remove four bolts (1) securing lift cylinder (2)

to cover, Figure 7.

2. Move lift arms to raised position and carefully

remove lift cylinder from locating dowels.

3. Remove lift cylinder safety valve and discard

seal. Refer to Figure 8.

NOTE: The lift cylinder safety valve is not

serviceable. 7

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80 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Hydraulic Lift Cylinder--Exploded View 8

1. Piston 5. Plug 9. Lift Cylinder
2. Ring Dowels 6. ’O’ Ring 10. ASC Valve Spool
3. Ball 7. Safety Valve 11. ‘O’ Rings (7 off)
4. Spring 8. Seal

Lift Arm Assembly--Exploded View 9

1. Lift Arm 3. Bolt 5. Washer
2. Locking Washer 4. Washer

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 81

Cross Shaft and Arm Assembly--Exploded View 10

1. Bush 4. Cross Shaft 7. Bush
2. Bush 5. Piston Rod and Arm Assembly 8. Seal
3. Seal 6. Bush

4. Discard ’O’ rings located in counterbores of oil

passages.

5. Remove ASC valve detent plug ball and

spring.

6. Remove ASC valve spool.

7. Push a soft metal rod through safety valve bore

and eject lift cylinder piston. Discard piston ‘O’
ring seal and back up ring.

8. Remove lift arms. Refer to Figure 9.

9. Withdraw cross shaft assembly components.

Refer to Figure 10.

10. If arm (2), piston rod (3) or retaining pins (1) &
(4) are worn, separate rod and arm assembly,
Refer to Figure 11. The pins are an
interference fit into the arm. To remove pins
use a suitable lever between rod and end face
of pin.

11. Where necessary, remove remaining plugs

from lift cover. Under normal circumstances
the removal of these plugs is not necessary.

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82 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

INSPECTION AND REPAIR

1. Wash all parts in suitable solvent.

2. Check oil passages are free from obstruction.

RE--ASSEMBLY AND INSTALLATION

Re--assembly and installation follows the
disassembly procedure in reverse.

A master spline machined on the cross shaft

ensures correct alignment of the both the lift arms
and piston arm during re--assembly.

During re--assembly observe the following

requirements.

S Renew all ‘O’ rings and seals.

S Install piston ‘O’ ring seal (1) closest to closed

12
end of piston and back--up seal (2) nearest
open end of piston (3), Figure 12.

S To aid installation of piston into lift cylinder and

prevent damage to the piston seals, a guide
can be manufactured to the dimensions shown
in Figure 13.

Piston Installation Guide

A. 4.126 inch (105 mm)
B. 5.25 inch (134 mm)
C. 0.12 inch (3 mm)
D. 1.62 inch (40 mm)
E. 6.0 inch (155 mm)

13
S Install piston (1) into cylinder (3) using guide (2)
as shown in Figure 14. If a guide is not avail-
able and installation is difficult a piston ring
compressor may be used to compress the
seals.

S Coat cross shaft and lip seals with grease.

S Prior to installation of the hydraulic top cover,

apply a thin bead of New Holland Gasket Seal-
ant, Part No. 82995770, to BOTH sides of the
hydraulic top cover gasket. The bead should be
continuous around the entire face of the gasket
and to a thickness of approximately 1/32 in 14
(1mm).

S Tighten all retaining bolts to the correct torque

and apply sealant to threads where specified.
See Specifications.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 83

HYDRAULIC CONTROL VALVE--OVERHAUL

REMOVAL

1. Lower hydraulic lift arms.

2. Remove panel in cab/platform floor to gain

access to hydraulic control valve (1), Figure 1.

3. Thoroughly clean the area around the valve

prior to proceeding with the removal
procedure.

4. Disconnect electrical connector to valve. 1

5. Disconnect pilot (2) and load sensing (3) lines.

6. Remove the four retaining bolts and lift the

valve from the hydraulic top cover.

DISASSEMBLY
Solenoids and Pilot Spools

1. Identify lower (1) and raise (2) solenoids, to aid

re--assembly, Figure 2.

2. Remove solenoids from valve.

3. Separate solenoid components, Figure 3.

Solenoid Components--Exploded View

1. Field Coil 7. ‘O’ Ring
2. ‘O’ Ring 8. Allen Screws
3. Plate 9. End Cap
4. Solenoid Body 10. ‘O’ Ring
5. ‘O’ Ring 11. Core
6. Ring 12. Plunger

604.55.041.00 - 01 - 1998
84 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4. Remove pilot spool (1) and spring (2) from pilot

operated valves, Figure 4.

5. Insert a 5/16 in UNF bolt (2) into end of pilot

spool (1). Pull pilot spool from housing,
Figure 5.

Main Spool

1. Using a suitable marker identify the right and

left hand adjusters in relation to the valve
housing body.

IMPORTANT: Do not disassemble or reset the

adjuster assemblies. The hydraulic control valve
adjustment is pre--set at the factory and ensures
that the spool is correctly set for the neutral
position.

Main Spool 6
2. Remove adjuster assemblies and withdraw
spool centering springs and seats, Figure 6. 1. Valve Housing
Ensure that springs and seats remain matched 2. Spool
3. Seat
with each adjuster. 4. Spring
5. Adjuster Assembly
6. Seat
7. Spring
8. Adjuster Assembly

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 85

Load Check Valve

1. Remove the load check valve plugs and
withdraw the load check valve components,
Figure 7.
NOTE: The pin, item 7, is rounded on one end.
When re--assembling the valve ensure the rounded
end of the pin is inserted into the poppet, item 2.
Load Check Valve
1. Valve Housing 6. Plug and ‘O’ Ring
2. Poppet 7. Pin
3. Ball 8. Piston
4. Guide 9. Plug and ‘O’ Ring
5. Spring

7
INSPECTION

The majority of valve failures occur because of dirt

and other foreign matter entering the valve causing
scoring and distortion. Minor imperfections can be
corrected by using fine abrasive emery cloth or fine
lapping compound. Exercise extreme care when
abrasive materials are used to ensure that all
particles are removed from the valve housing.
1. Wash all parts, except solenoids, in a suitable
solvent and dry with compressed air.

2. Inspect the valve housing, bores and spools for

evidence of scoring or damage, paying
particular attention to the condition of the
highly finished surfaces in the spool and sleeve
bores. If deep scores or serious pitting is
observed discard the valve. Remove minor
blemishes from the spools or sleeves with fine
abrasive.

3. Ensure the spools move freely in their bores.

4. Discard all ‘O’ ring seals.

RE--ASSEMBLY and INSTALLATION

Re--assembly follows the disassembly procedure
in reverse. During re--assembly observe the
following:--
S Lubricate the spools with hydraulic oil.
S Install new ‘O’ ring seals.
S Tighten all plugs and locknuts to the correct
torque. See Specifications, Section E.
S When installing the solenoids, tighten the re-
taining screws gradually in a cross corner se-
quence to a torque of 15 lbf.in (1.7 Nm). Do
Not overtorque the screws. 8
S Ensure ‘O’ ring seals (1) and (2) are correctly
located around oil galleries on mounting face
of hydraulic control valve before installing the
valve onto the hydraulic lift cover, Figure 8.

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86 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

NOTES

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 4 -- HYDRAULIC LIFT ASSEMBLY WITH

ASC SELECTOR VALVE SIZES

Colour Inches mm
Green 0.6247--0.6244 15.8674--15.8598
Yellow 0.6244--0.6241 15.8598--15.8521
Blue 0.6241--0.6238 15.8521--15.8445
White 0.6238--0.6235 15.8445--15.8369
Blue/White 0.6235--0.6232 15.8369--15.8293

CONTROL VALVE SIZES

Colour Inches mm
Orange 0.5928--0.5927 15.057--15.055
Green 0.5926--0.5925 15.052--15.050
Yellow 0.5923--0.5921 15.044--15.039
Blue 0.5921--0.5919 15.039--15.034
White 0.5919--0.5917 15.034--15.029

CONTROL VALVE BUSHING SIZES

Colour Inches mm
Green/White 1.0014--1.0012 25.436--25.430
Orange 1.0012--1.0010 25.430--25.425
Green 1.0010--1.0008 25.425--25.420
Yellow 1.0008--1.0006 25.420--25.415
Blue 1.0006--1.0004 25.415--25.410
White 1.0004--1.0002 25.410--25.405
Blue\White 1.0002--1.0000 25.405--25.400
VALVE SETTINGS
Lift Cylinder Relief Valve 197--210 bar (2850--3050 lbf/in2)
GASKET SEALER
Gasket Sealer 82995770
SPECIAL TOOLS
TOOL V.L. CHURCHILL FNH PART No
(America Only)
Control Valve Bush Installer FT. 8510 FNH 02191
Control Valve Bush Locator FT. 8510--3 FNH 10090
Extension Tool FT. 8510--1D FNH 02191
Guide and Stop Adaptor FT. 8510--1K FNH 02191
Setting Gauge FT. 8527 FT. 8527
Control valve Setting Tool FNH 00014

Lift linkage setting gauge

FT8527 dimensions

SHG35450
1

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

TORQUES

= Nm
= lbf ft

Components Nm lbf.ft

Lift Cylinder Relief Valve 102--122 75--90

Selector Support Bolts 57--76 42--56

Selector Body Turning Torque 9--14 7--10

Eccentric Shaft Locknut 20--27 15--20

Unload Valve Plug (CCLS Pump) 23--49 17--35

Yoke Retaining Nut Set Screw 27--34 20--25

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 5

FAULT FINDING

Over--Correcting or Bouncing

Symptom: Cause:
Over correcting When the hydraulic system is in neutral,
a leak exists in the trapped oil circuit.

Bouncing Due to internal linkage binding

Fully raise implement and stop engine.

Do lift arms drop?
YES NO

On tractors where the ASC valve selector linkage No hydraulic malfunction

is fitted turn ASC selector to engaged position indicated.
Arms Drop? Examine internal linkage for
YES NO binding or damage
Pay particular attention to:
Examine Examine Quadrant support
Assist ram seals ‘O’ ring seals Control rod and roller
Lift cylinder safety valve Front land on ASC valve
Lift cylinder piston seals
Lift cylinder piston
ASC valve
‘O’ ring seals

Note: On tractors not fitted with the ASC valve selector

linkage perform the checks in both the YES and NO
columns.
It should also be noted that although the ASC selector
linkage may not be fitted the ASC valve located in the lift
cylinder will be installed and must be pushed fully into its
bore.

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

No or Slow Lift
On Tractors with variable displacement CCLS hydraulic pump slow lift may
occur if there is an excessive demand on one of the hydraulic remote valves.
Slow lift will also occur on tractors with 16 x 16 transmission if the clutch pedal is
depressed when the engine speed is below 1000 rev/min.

Is ASC valve pushed fully ‘IN’?

On tractors without ASC valve linkage was the ASC valve pushed
fully into position during any recent hydraulic lift cylinder overhaul
YES

Is external linkage obstructed or

damaged?
NO

Is rear axle oil level low or incorrect grade?

Are there external oil leaks?

Attempt to lift an implement

No Lift Slow Lift

Pull out ASC valve

and turn Off engine
Pull out ASC Valve
Constant blowing of NO NO Lift Arms drop?
pressure relief valve?
YES YES

Examine Examine
Assist ram seals Assist ram seals
Lift cylinder safety valve Lift cylinder safety valve
Lift cylinder piston seals Lift cylinder piston seals
Lift cylinder piston Pressure Test Hydraulic Pump Lift cylinder piston
ASC valve Is pump output to Lift cylinder safety valve
‘O’ ring seals specification? ASC valve
‘O’ ring seals
YES

Can an implement be lifted in either position or draft control but not both?
YES NO
Examine internal hydraulic lift linkage for
binding or damage

Tractors with fixed

displacement hydraulic
pump
Tractors with variable
Move the lift control lever to the displacement CCLS
raise position and operate a hydraulic pump
remote valve to pressurise the
oil against the sealed couplers. Examine unload valve for sticking
Does the hydraulic lift raise?
YES

Examine valves in priority

valve pack for sticking

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 7

DESCRIPTION AND OPERATION

‘Top Link Sensing’ defines a hydraulic system

where draft signals applied to an implement are
sensed and transmitted mechanically via the
rocker and control yokes to the hydraulic lift draft
control mechanism by the ‘Top Link’ (2) of the
three--point linkage, Figure 1.

This method of sensing draft loadings differs from

that of the electronic draft control system where
draft forces applied to an implement are sensed
electronically using load sensing pins in the lower
lift links.

1
Implements attached to the 3 point linkage can be
operated in either ‘Draft’ or ‘Position’ control using
the levers positioned by the side of the drivers seat,
Figure 2.

The lift control lever (5) raises or lowers the

hydraulic lift to the desired position and the selector
lever (1) enables the selection of full position
control or draft control as required.

Full draft control is selected when the lever is

positioned fully forward (3) and full position control
when the lever is moved fully rearwards (2).
2

The sensitivity of draft control is adjusted by the

position of the selector lever. As the lever is moved
away from full draft control selection to full position
control the degree of draft sensitivity reduces
accordingly.

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

The Principal Of Draft Forces Applied Through The Hydraulic Linkage 3

1. Top Link (In Compression) A. Draft Forces
2. Lower Link (In Tension) B. Lower Link Pivot Point
3. Draft Control Yoke C. Tipping Force

Principals of Draft Control

Draft control, manages the working depth of soil hydraulic system maintains this draft by raising and
engaging implements in order that the implement lowering the implement within the soil accordingly.
maintains an even pull on the tractor.

When a soil engaging implement eg. a plough is When the draft force increases beyond that
lowered into the ground, the draft forces applied to selected, the compressive force on the top link
the implement as it is drawn through the soil tends pushes the yoke further into the hydraulic lift cover
to make the plough pivot about the point where it and the hydraulic system raises the implement until
attaches to the lower links, Figure 3. If the top link the required amount of draft is restored. Similarly
were removed then the plough would tip up, but due when the draft force is less than that required the
to the top link’s resistance the plough stays level in compressive force on the top link reduces allowing
the ground. This shows that there is a compressive the yoke to move out from the top cover. The
force pushing the top link against the tractor housing. hydraulic system now responds and lowers the
implement until the required draft force is again
restored.
The draft force will alter according to the depth of
work and soil type. As the draft force increases,
then so does the compressive force applied to the
top link and if the draft force decreases the top link. When position control is selected the working depth
or height of an implement relative to the tractor is
pre--set by the internal linkage in the hydraulic top
cover and maintained irrespective of changes in
implement draft. Forces sensed by the top link and
Using the selector lever, the operator can pre--set applied to the draft control mainspring in the
the required amount of draft sensitivity to be hydraulic top cover therefore have no effect on the
maintained on the implement during work and the hydraulic lift draft control mechanism.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 9

Draft Control Linkage Operation 4

(For Clarity Position Control Linkage is Not Shown)
1. Draft Control Mainspring Plunger 8. Control Rod Connector
2. Draft Control Mainspring 9. Selector Arm
3. Yoke 10. Selector Lever
4. Selector Link 11. Control Lever
5. Control Rod and Roller Assembly 12. Actuating Lever
6. Stop Pin 13. Position control Cam
7. Control Valve/Spring Assembly 14. Position Control Link

Draft Control Linkage Operation raise position. As the implement is raised and the
draft loading decreases the yoke moves rearwards
The hydraulic lift control valve, located within the allowing the control rod and roller to retract and the
hydraulic top cover, is connected mechanically to control valve to return to the neutral position.
the lift control lever and draft control linkage. This
valve directs oil from the pump to the lift cylinder, to
effect a raise condition via the unload valve or to the Should the draft loading become less than that set
reservoir for a neutral or lowering cycle. using the selector lever the yoke moves further
rearwards and the control rod and roller allows the
spring loaded control valve to move toward the
lower position. The implement is now lowered
When draft control is selected and the implement further into the ground until the selected draft
draft reaction causes the yoke to move, the reaction loading is restored and the control valve again
is transferred to the lift cylinder control valve via the returns to the neutral position.
internal linkage, Figure 4.

It can now be seen that this correction cycle

As the yoke moves the selector link similarly moves maintains the implement draft loading within the
in the same direction. Therefore as the draft load range selected with the selector lever.
increases the control rod and roller is pushed
forward against the actuating lever.
When the selector lever is moved to intermediate
positions between full draft and full position control,
The actuating lever pivots about the control lever a reduced effect on the control valve is achieved
shaft and the action of the control rod and roller whenever the top link subjects the yoke to the draft
pushing forward moves the control valve into the forces.

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Position Control Linkage Operation 5

(For Clarity Draft Control Linkage is Not Shown)
1. Draft Control Mainspring Plunger 8. Control Rod Connector
2. Draft Control Mainspring 9. Selector Arm
3. Yoke 10. Selector Lever
4. Selector Link 11. Control Lever
5. Control Rod and Roller Assembly 12. Actuating Lever
6. Stop Pin 13. Position control Cam
7. Control Valve/Spring Assembly 14. Position Control Link Roller

The intermediate positions on the selector lever actuating lever and control valve remain
have therefore been introduced to permit the unchanged unless the position of the hydraulic lift
operator to adjust the controls in order to select the control lever is moved.
system response and control characteristics best
suited to the operation being performed.
When the lift control lever is moved the actuating
Position Control Linkage Operation lever pivots on the control rod and moves the
control valve to the raise or lower position as
required.
The system of Position Control enables the working
depth or height of an implement, relative to the
tractor, to be pre--set and maintained.
As the lift arms move, the position control link roller
rides the position control cam and moves the
control rod and hence the actuating lever. When the
When the system selector lever is located in the lift arms have reached the desired position the
highest quadrant position and position control is actuating lever will have returned the control valve
selected, the control rod and roller assembly is to neutral, preventing further movement of the lift
positioned with the roller aligned with the lower end arms.
of the selector link, Figure 5.

It can now be seen that when position control is

When the rod and roller assembly is in this position selected there is a direct relationship between the
any variations in draft loading applied to the yoke height of the lift arms and the position of the lift
through the top link of the three point linkage will not control lever. The relationship being maintained by
alter the position of the control rod and roller the actuating lever, control rod, position control cam
assembly. Consequently the position of the and position control link.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 11

HYDRAULIC COMPONENTS AND CIRCUITS

R8--234

Hydraulic Circuit for Tractor with Fixed Displacement Tandem Gear Type Pump 6
and Top Link Sensing Hydraulic Lift Assembly
1. Position Control Link 13. Exhaust Valve
2. Selector Link 14. Lift Cylinder Safety Valve
3. Draft Control Mainspring 15. Auxiliary Pump Intake Filter
4. Yoke 16. Engine Mounted Auxiliary Hydraulic Pump
5. Selector Rod and Roller Assembly 17. Check Valve
6. Actuating Link 18. Combining (Sequencing) Valve
7. Pressure Relief Valve 19. Flow Control Valve
8. Steering Pump 20. Priority Valve Pack
9. Transmission Mounted Hydraulic Pump 21. Unload Valve
10. Pump Intake Filter 22. Check Valve
11. Lift Piston 23. Lift Arms
12. Control Valve

Pump Pressure Oil Trapped Oil

Suction/Return to Reservoir Oil

Figure 6 shows the hydraulic circuit and load sensing hydraulic pump or the fixed
components for the top link sensing hydraulic displacement gear type pump.
system when the tractor is fitted with a fixed
displacement hydraulic pump.

The fixed displacement pump is more commonly

When the tractor is fitted with the variable installed and must be supplemented by an auxiliary
displacement CCLS hydraulic pump the hydraulic engine mounted pump if two or more remote valves
circuit is as shown in Figure 10. are also fitted.

The reasons for the principal differences in the

circuits are as follows:-- An auxiliary engine mounted pump is never
installed on tractors with the variable displacement
CCLS pump, which is capable of providing
Tractors fitted with top link sensing may be installed sufficient flow to the hydraulic system and up to four
with either the variable displacement closed centre remote valves.

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

PRIORITY VALVE PACK

Where the tractor is fitted with the fixed

displacement hydraulic pump, a priority valve pack
is required, Figure 7. This pack, located on top of
the hydraulic lift cover, contains a set of valves
which establish pump priority and controls the flow
of oil to the lift cylinder, auxiliary equipment and
remote valves.

The individual function of each of these valves are The function of the combining valve is to:
as follows:

S Return main hydraulic pump and auxiliary

pump flows to sump when there is no remote
Flow Control Valve -- (4) Figure 7 valve demand.

This valve, located in the priority valve pack, S Direct pump flows to remote valves on demand.
controls the flow of oil to the hydraulic lift cylinder by
sensing the pressure drop through the hydraulic lift
control valve. The flow control valve ensures that S Direct a proportion of the pump flow to remote
hydraulic oil supply priority is given to the tractor valves and return surplus oil to the rear axle if
hydraulic lift demand and diverts the surplus oil to
the pump output exceeds remote valve circuit
the combining valve.
demand.

S Protect remote valve and auxiliary pump

Unload Valve -- (3) Figure 7 circuits from excess pressure.

The unload valve is operated by oil pressure as Check Valve -- (1) Figure 7
directed by the control valve and has two positions.
In the raise position the valve allows pumped oil to
flow to the lift cylinder whilst in the neutral or Two check valves are incorporated in the priority
lowering position the oil passes to the reservoir. valve pack as follows.

The first one way check valve in the auxiliary pump

supply port of the priority valve pack prevents any
Combining Valve -- (2) Figure 7 back feed from the main hydraulic pump to the
auxiliary engine mounted pump.

This valve, which is only installed when remote

valves are fitted, regulates the flow of oil in the The second check valve in the base of the priority
remote valve circuit and combines the flow of oil valve pack prevents oil flow from the lift cylinder to
from the main and auxiliary engine mounted the flow control valve during the lift cylinder
pumps. lowering, neutral or shock load conditions.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 13

Priority Valve Pack Assembly

1. Auxiliary Pump Check Valve
2. Restrictor
3. Combining Valve
4. Unload Valve
5. Flow Control
6. Lift Cylinder Check Valve

Hydraulic Lift Cylinder Exploded View 9

1. Lift Piston 9. Dowty Washer
2. ‘O’ Ring Seal 10. Control Valve Bush
3. Locating Dowels 11. Deflector
4. Ball 12. ‘O’ Ring Seal
5. Spring 13. Exhaust Valve
6. ‘O’ Ring Seal 14. ASC Valve
7. Detent Cap 15. Lift Control Valve
8. Cylinder Safety Valve

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

DESCRIPTION AND IDENTIFICATION FUNCTION

LOCATION

PRESSURE RELIEF Limits maximum pressure

VALVE in HPL system to prevent
pump overload
HPL Pump

CONTROL VALVE AND provides 4 control

BUSH positions
-- Neutral, Lowering, Slow
and Fast Raising

CHECK VALVE Controls oil flow into lift

cylinder, operates with
Priority Valve control valve
5--6 bar (70--85 lbf/in2)

EXHAUST VALVE Maintains constant

controlled lowering
Lift Cylinder

RAM CYLINDER SAFETY Protects lift cylinder from

VALVE overload with system in
neutral
Lift Cylinder 196--203 bar (2850--2950
lbf/in2)

AUXILIARY SERVICES 2 Position valve

CONTROL VALVE Inner Position --
Outer Position
Lift Cylinder

UNLOAD VALVE Operated by oil pressure

from control valve
Priority Valve Pack 4.2--21 bar (60--300
lbf/in2) Spring length
4.8cm (1.9 in)

FLOW CONTROL VALVE Multi--functional valve

operating in all HPL
Priority Pack cycles. Spring length
7.3cm (2.9 in)

COMBINING VALVE Check valve operates

with combining valve.
AUX PUMP LOAD Spring length 5.5 cm
CHECK VALVE (2.2in)

Priority Valve Pack

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 15

R8--289

Hydraulic Circuit For Tractor With Top Link Sensing Hydraulic Lift Assembly 10
and Variable Displacement CCLS Hydraulic Pump
1. Position Control Link 10. Lift Piston
2. Selector Link 11. Control Valve
3. Draft Control Mainspring 12. Exhaust Valve
4. Yoke 13. Lift Cylinder Safety Valve
5. Selector Rod and Roller Assembly 14. Check Valve
6. Actuating Link 15. Unload Valve Assembly
7. Pressure and Flow Compensating Valve 16. Unload Valve Spool
8. Pressure Regulating Valve 17. Load Sensing Line To Hydraulic Pump
9. Variable Displacement CCLS Hydraulic Pump 18. Lift Arms

Pump Pressure Oil Trapped Oil

Suction/Return to Reservoir Oil

Tractors installed with the variable displacement

CCLS hydraulic pump do not require the priority
valve pack but use a special unload valve instead,
Figure 11. The function of this single valve is to
control the flow of oil to the lift cylinder and ensure
a smooth initial lift.
The unload valve is also linked to the load sensing
line of the variable displacement pump and signals
the pump to increase or decrease output according
to hydraulic demand. Refer to Figure 16 for the
operation of this valve.
The exhaust valve also shown in both Figure 6 and
Figure 10 is spring operated and located in the
hydraulic lift cylinder. The function of this valve is
to control the flow of exhaust oil from the lift cylinder 11
and/or auxiliary equipment thereby controlling the
rate of implement drop.

604.55.041.00 - 01 - 1998
16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

HYDRAULIC OIL FLOW Pump pressure oil enters the lift cover at gallery E
TRACTORS WITH FIXED DISPLACEMENT and in neutral the flow control valve prevents oil
HYDRAULIC PUMP from entering galleries C and D.

Figure 12 to Figure 15 show the hydraulic system

oil flows for neutral, lowering. slow raise and fast
raise conditions on tractors equipped with the fixed Pump pressure oil flows up gallery E to the flow
displacement hydraulic pump. control valve and unload valve.

These illustrations also show operation of the

priority valve pack and associated valves, the The left hand end of the unload valve is open to
function of which were described on the previous sump via gallery C and the centre of the control
pages. valve.

OIL FLOW IN NEUTRAL S Pump pressure applied to the centre face of the
unload valve spool now holds the valve to the
left.
With reference to Figure 12.

S With the unload valve held to the left, gallery D

and the spring loaded end of the flow control
With the control valve in neutral the following valve are also open to sump through gallery G
functions occur:-- and the smaller internal drilling in the unload
valve.

S The oil in the hydraulic lift cylinder is trapped

and holds the cylinder in the desired position. S Pump pressure oil in gallery E now acts on the
right hand face of the flow control valve via an
internal drilling, moving the valve fully to the left,
S Pump pressure oil is directed to the combining allowing pump pressure oil to flow from gallery
valve, located in the priority valve pack on the E to F.
top of the hydraulic lift cover where it is returned
to sump or supplied to the deluxe remote
valves, if required. S If the deluxe remote valves are in neutral the
load sensing line pressure is vented to sump
through the remote valves. Pump oil in gallery
If deluxe remote valves are not fitted the combining F acts on the right hand face of the combining
valve is deleted, but the same priority valve pack valve, moving the valve to the left allowing oil
housing is still used. flow from gallery F to sump gallery G.

S The oil in the lift cylinder remains trapped in

The oil flow through the hydraulic valves with the galleries A and B by the control valve land and
control valve in neutral is as follows:-- the check valve.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 17

R8--332

Oil Flow in Neutral 12

(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil Trapped Oil

Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir

2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing) Valve 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

OIL FLOW IN LOWERING

With reference to Figure 13.

With the control valve in the lowering position the

following functions occur:--

S Pump pressure oil is directed to the combining

valve in the priority valve pack, where it is
returned to sump or supplied to the deluxe
remote valves if required.

S Oil in the lift cylinder is released to sump

through the control and exhaust valves.

Oil flow through the hydraulic valves when the

control valve is in the lowering position is as
follows:--

S Pump pressure oil flow to sump follows the

same route as described when the control valve
is in neutral, entering gallery E and flowing past
the flow control valve to the combining valve
gallery F.

S In both neutral and lowering, if there is no

deluxe remote demand the pump pressure oil
is returned to reservoir by the combining valve.

S When the control valve is moved to the right

from neutral to lowering, lift cylinder oil is
allowed to flow out of gallery A and B, across the
control valve to sump through the exhaust
valve.

S Excess lift cylinder oil flow through the exhaust

valve will force the valve down against the
spring, reducing the exhaust port aperture.

This action of reducing the exhaust port aperture

consequently controls the lowering of the lift arms
irrespective of the loading on the lift linkage.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 19

R8--333

Oil Flow in Lowering 13

(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil Trapped Oil

Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir

2. Combining Valve 6. Control Valve 11. Remote Valve Pilot Line
(Sequencing Valve) 7. Exhaust Valve (Load Sense Line)
3. Unload Valve 8. To Lift Cylinder 12. From Auxiliary Pump
4. Flow Control Valve 9. Check Valve
GALLERY A, To Lift Cylinder and Auxiliary Services GALLERY H, Auxiliary Pump Supply
Valve (where fitted)
GALLERY E, Main Pump Supply GALLERY G, Return to Sump

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

OIL FLOW IN SLOW (INITIAL) RAISING The oil flow through the hydraulic valves when the
control valve in slow raising is as follows:--

With reference to Figure 14.

S The initial movement of the lift control lever

moves the control valve from neutral to slow
When raising the hydraulic lift two conditions of raise which allows pump pressure oil in gallery
raise occur referenced to as ‘slow’ and ‘fast’ raise. E to flow via the control valve drilling to gallery
In both conditions the speed of lift is controlled by C and the left hand end of the unload valve.
the number of ports around the lift control valve
which are opened to allow pump pressure oil to be
directed to the lift cylinder. S The unload valve now moves fully to the right
due to the combined pressure in gallery C and
the spring pressure applied to the valve. In this
position the larger cross drilling in the unload
When the lift control lever is moved to the point valve connects gallery E and D.
where the hydraulic lift starts to raise slow lift is
engaged and the following functions occur:--
S Pump pressure oil flow through the unload
valve drilling is restricted to 7.6 litres/min (1.67
Pump pressure oil is directed to:-- imp gals/min, 2 US gals/min) and effects a
smooth ‘initial’ lift. The reduced pressure
(i) Lift Cylinder, or
created acts on the left hand face of the flow
(ii) Combining Valve control valve to move it to the right and the initial
oil flow to the cylinder flows via the check valve
through galleries B and A.
The position of the control valve operates the flow
control valve which gives priority to the lift cylinder
demand and diverts the surplus oil to the combining S Further movement of the control valve to the left
valve. connects Gallery E to D by uncovering a series
of ports in the bush. Increased pump oil flow
passes into Gallery D, increasing cylinder lift
speed and moving the flow control valve further
The combining valve will either return the surplus oil to the right. reducing the oil flowing from gallery
to reservoir or direct it to the deluxe remotes. E to Gallery F.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 21

R8--334TI

Oil Flow in Slow Raising 14

(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Reduced Pump Auxiliary Exhaust Oil

Pressure Oil Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir

604.55.041.00 - 01 - 1998
22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

OIL FLOW IN FAST RAISING cylinder is limited to approximately 6.7 Imp

Galls/min (8 US Galls/min 31 ltrs/min).
With reference to Figure 15

When the lift control lever is moved fully to the left S As the main hydraulic pump oil does not enter
and the flow control valve moves to the fast raise Gallery F, the combining valve moves to the
condition the following functions occur:-- right, closing the return to sump Gallery G.
However if an auxiliary pump is fitted, the
auxiliary pump oil flow will operate the
S The flow control valve gives full priority to the lift combining valve as shown in 15.
cylinder.

S Operation of the deluxe remote valves would

only be possible, at this point of the lift cycle if
an auxiliary engine mounted pump is installed. OIL FLOW FROM THE OPTIONAL ENGINE
MOUNTED AUXILIARY PUMP THROUGH THE
COMBINING VALVE
The oil flow through the hydraulic valves with the
control valve in fast raising is as follows:--
Auxiliary pump oil is used to supplement the main
pump in the supply of hydraulic oil to the remove
S The full movement of the lift control lever has valve circuit.
moved the control valve to the fast raise
position, passing the ’initial’ and ’slow’ raise
positions.
S When the remote valve circuit is actuated, a
pilot (load sensing) signal is applied to the
S All the holes in the control valve bush are now left--hand end of the combining valve which
uncovered allowing increased pump flow from moves the valve to the right, progressively
gallery E to gallery D. blocking off the connections F to G and H to G
depending on the hydraulic requirements of the
remote valves.
S The unload valve is held to the right by the
combination of spring pressure applied to the
end of the valve and oil pressure generated in S Auxiliary pump pressure oil now lifts the check
gallery C as the control valve passed through valve and joins the flow of main pump oil in the
the initial and slow raise condition. remote valve feed gallery F. Refer to Figure 15.

S Pump pressure oil flows from gallery E to D with S When the remote valve circuits are in neutral
less restriction and the pressure in gallery E, and the load sense line is vented, pump oil
gallery D and on either face of the flow control pressure in gallery F moves the combining
valve are equal. The flow control valve spring valve to the left allowing pump oil flow to return
now moves the valve fully to the right, closing directly to sump through gallery G. Refer to
off gallery E from gallery F. Figure 14.

S All main pump pressure oil is diverted to the lift S When the remote valve system is overloaded
cylinder, giving lift cylinder priority over remote and pressure in the load sense line exceeds
valves. Oil entering the cylinder flows past the 2700--2750 lbf/in2 (186--190 bar) the ball type
left hand end of the flow control valve, past the relief valve within the combining valve spool
check valve in Gallery B and into the lift cylinder operates venting the pressure applied to the left
Gallery A. hand end of the spool to sump via gallery G.
The change in pressure across the combining
valve moves the spool to the left allowing
S Due to the size of the ports in the flow control excess flow from both pumps in galleries F and
valve bush, the maximum pump flow to the lift H to be exhausted to the sump via gallery G.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 23

R8--335TI

Oil Flow in Fast Raising 15

(Tractors with Fixed Displacement Hydraulic Pump)

Main Pump Auxiliary Exhaust Oil

Pressure Oil Pump Oil

1. To Remote Valves 5. From Main Pump 10. To Reservoir

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

HYDRAULIC OIL FLOW FOR TRACTORS OIL FLOW IN RAISING

WITH VARIABLE DISPLACEMENT CCLS
HYDRAULIC PUMP
When raising the hydraulic lift two conditions of
raise occur referenced to as slow and fast raise. In
As described earlier when tractors are equipped
both conditions the speed of lift is controlled by the
with the variable displacement CCLS hydraulic load sense signal to the hydraulic pump and the
pump and top link sensing the priority valve pack
number of ports around the lift control valve which
used on tractors with the fixed displacement
are opened to allow pump pressure oil to be
hydraulic pump is replaced with the unload valve
directed to the lift cylinder.
shown in Figure 11.

S When the lift control lever is moved to the point

OIL FLOW IN NEUTRAL where the hydraulic lift starts to raise the control
valve moves from the neutral to slow lift
With Reference to Figure 16A position.

S When the control valve moves from the neutral

S When the control valve is in neutral, pump to slow raise position it also passes a stage
pressure oil is prevented from entering galleries referred to as ‘initial raising’, Figure 16C. At this
C and D. point, pump pressure oil in gallery E flows via
the control valve drilling to gallery C.
S Gallery C is open to reservoir and the sprung
loaded unload valve is held in the closed S The pressure rise in Gallery C moves the
position, preventing flow of oil from gallery E unload valve against its spring, connecting
across the unload valve to the lift cylinder gallery E, via a drilling in the unload valve, to the
gallery A. load sensing line. The flow of oil through the
unload valve drilling, signals the pump to
S The load sensing line to the hydraulic pump is produce an initial flow of oil in accordance with
open to reservoir via the dump port in the valve. the pressure drop through the drilling, ensuring
that a smooth lift is always achieved when
S The oil in the lift cylinder remains trapped in moving the lift control lever from the neutral to
galleries A and B by the control valve land and raise condition.
check valve. S The control valve after passing through the
initial to the slow and fast raise condition,
OIL FLOW IN LOWERING Figure 16D, connects Gallery E and D by
uncovering a series of ports in the control valve
bush.
With reference to Figure 16B
S The flow of oil in Gallery E can now also flow via
the control valve to Gallery D and across the
S When the control valve is moved to the right unload valve and check valve to the lift cylinder
from neutral to lowering, lift cylinder oil is Gallery A. The hydraulic lift now raises at a
allowed to flow out of gallery A into gallery B, speed in proportion to the number of ports
across the control valve to sump through the uncovered in the control valve bush.
exhaust valve.
S When the control valve reaches the fast raise
S Excess lift cylinder oil flow through the exhaust condition all the holes in the control valve bush
valve will force the valve down against the are uncovered allowing the maximum oil flow
spring, reducing the exhaust port aperture. from gallery E to Gallery D.

S This action of reducing the exhaust port S The pressure in gallery D is sensed by the load
aperture consequently controls the lowering of sense line, which signals the variable
the lift arms irrespective of the loading on the lift displacement CCLS pump to maintain output
linkage. according to demand.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 25

R8--289

Hydraulic Oil Flow For Tractors With Variable Displacement CCLS Hydraulic Pump 16
Pump Pressure Reduced Pump Exhaust Oil Trapped Oil
Oil Pressure Oil

A Neutral C Initial Raising

B Lowering D Fast Raising
1. Unload Valve Spool 5. Exhaust Valve
2. Load Sensing Line to Hydraulic Pump 6. To Lift Cylinder
3. From Hydraulic Pump 7. Check Valve
4. Control Valve

604.55.041.00 - 01 - 1998
26 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

35 114 COMPONENT OVERHAUL

PRIORITY VALVE PACK

(Tractors With Fixed Displacement
Hydraulic Pump Only)
REMOVAL
1. Fully lower hydraulic lift arms.
2. Less Cab Tractors:
Remove seat to gain access to unload valve.
3. Remove priority valve pack, Figure 17.
Priority Valve Pack Installation
(Tractors with Fixed Displacement
Hydraulic Pump)
1. Supply To Remote Valve
2. Load Sensing (Pilot) Line
3. Supply from Auxiliary Engine Mounted 17
Pump (Where Fitted)

NOTE: Ensure check valve spring and ball, item

10 and 11 in Figure 19, is not lost when remote
valve feed line is disconnected.
DISASSEMBLY
1. Remove lift circuit check valve, Figure 18. Use
a suitable hook pull to seat from housing.
Note: It is only necessary to remove seat if it is
pitted or the ‘O’ ring seal is suspected of leaking
Lift Circuit Check Valve
1. Seat and ‘O’ Ring
2. Ball
3. Spring
4. Spacer
5. Cage 18
6. ‘O’ Ring
7. Housing

2. Remove valves with reference to Figure 19 .

INSPECTION AND REPAIR

1. Wash all components in a suitable cleaning

agent such as paraffin (kerosene), mineral
spirits or a commercial cleaning solvent.

2. Examine all valves and bores for burrs and

scratches. Any minor burrs or scratches may
be removed with a fine abrasive.
Priority Valve Pack Assembly 19
3. Ensure that valves move freely in their bores. 1. Priority Valve Housing
Heavy scoring of bores will necessitate 2. Pilot Line Connector (with orifice)
installation of a new priority valve pack. 3. Combining (Sequencing) Valve
4. Spring
5. Filter
4. Renew all ‘O’ ring seals. 6. Spring
7. Unload Valve
5. Lubricate all valves with hydraulic oil prior to 8. Spring
re--assembly. 9. Flow Control Valve
10. Check Valve Ball (Auxiliary Pump Circuit)
11. Check Valve Stop and Spring
(Auxiliary Pump Circuit)

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 27

UNLOAD VALVE
(Tractors With Variable Displacement CCLS
Hydraulic Pump only)
REMOVAL
1. Fully lower hydraulic lift arms.

2. Less Cab Tractors:

Remove seat to gain access to unload valve

3. Remove unload valve assembly, Figure 20.

20
DISASSEMBLY

1. Remove unload spool, Figure 21.

Unload Valve
1. Spring
2. Unload Spool
3. Housing
4. Retaining Ring
5. Plug and ‘O’ Ring

21
2. Disassemble check valve, Figure 22.

Check Valve
1. Seat and ‘O’ Ring
2. Ball
3. Spring
4. Spacer
5. Cage
6. ‘O’ Ring
7. Housing

INSPECTION AND REPAIR

1. Wash all components in a suitable cleaning
agent.
22
2. Examine the unload valve spool and bore for
burrs and scratches. Any minor burrs or
scratches may be removed with a fine
abrasive.
3. Ensure all parts are thoroughly washed before
re--assembly. Any heavy scoring of the bore
will necessitate installation of a new unload
valve
4. Lubricate valve with hydraulic oil and
re--assemble using disassembly procedure in
reverse.
5. Renew all ‘O’ ring seals between the base of
valve housing and hydraulic lift cover.

604.55.041.00 - 01 - 1998
28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

35 110 HYDRAULIC LIFT ASSEMBLY -- OVERHAUL

REMOVAL

1. Lower lift arms.

2. Move selector lever to position control.

3. Ensure the position control marks on the

actuator align with the mark on the hydraulic lift
cover support and clamp in position using a
5/ in--18--UNC locking bolt, Figure 23.
16

Set Up Plate Locked in Position Control

1. Set Up Plate
2. Draft Control Mark on Set Up Plate
3. Position Control Mark on Support 23
4. Position Control Mark on Set Up Plate
5. Locking Bolt

4. Disconnect the control rods to the lift cover

linkage. Refer to Figure 24.

Hydraulic Lift Cover Linkage

1. Set--up Plate
2. Position/Draft Control Linkage
3. Lift Control Linkage
5. Disconnect the lever to the ASC valve (where
fitted).

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 29

8. Disconnect assist rams hoses (where fitted).

9. Disconnect assist rams and lift rods from
hydraulic lift arms.
10. Disconnect and remove remote control
valve(s).
11. Remove trailer brake coupler and feed tube
(where fitted).
12. Disconnect and remove priority valve
pack/unload valve as fitted. Refer to Figure 17
and Figure 20.

NOTE: On tractors fitted with the priority valve

pack be careful that the auxiliary pump supply
check valve spring and ball is not ejected when
disconnecting the remote valve supply tube.
13. If the hydraulic lift assembly is being removed
in order to overhaul the lift cylinder, it is
recommended that the cylinder retaining bolts
are loosened before removing the lift
assembly from the tractor. Do Not remove
these bolts.
14. Remove the lift cover retaining bolts and using
suitable lifting equipment remove hydraulic lift
assembly from the tractor, Figure 26.
26
DISASSEMBLY

1. Unscrew ASC control linkage connector (3),

pull knob (2) from lift cover and remove
selector valve stem (1), Figure 27.

NOTE: ASC valve is fitted to all units, however the

knob is only fitted on econoshift less cab (straddle
mount)
ASC Valve Selector Linkage (where fitted)
1. Selector Valve Stem
2. Knob
3. Control Linkage Connector

27
2. Disconnect and remove control valve
turnbuckle, Figure 28.

Control Valve Turnbuckle

1. Clevis Pin
2. Turnbuckle Assembly
3. Control Valve
4. Lever (Part of Control Rod, Roller
and Lever Assembly)

604.55.041.00 - 01 - 1998
30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Hydraulic Lift Cover Internal Linkage 29

1. Selector Link 5. Lift Cylinder
2. Selector Arm 6. Position Control Link
3. Control Valve Turnbuckle 7. Control Rod and Roller
4. Control Valve

3. Remove four bolts securing cylinder to lift

cover.

4. Move lift arms to raised position and carefully

remove cylinder from locating dowels. Refer to
Figure 29.

5. Remove priority/unload valve return tube (1),

Figure 30.

6. Referencing Figure 29 to Figure 36,

disassemble the hydraulic lift assembly.
30

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 31

Support Assembly 31
1. Bolt 6. Support 11. Control Rod and Roller Link
2. Nut 7. Control Rod and Roller Shaft 12. Washers (2 off)
3. Belleville Washers (5 off) 8. Selector Lever 13. Gasket
4. Locking Bolt 9. Split Pin 14. Friction Disc
5. Position and Draft Control 10. Washer 15. Body
Set--up Plate.

Control Rod, Roller and Lever Assembly 32

1. Shaft 3. Link 5. Washer
2. Lever 4. Rod and Roller Assembly 6. Seal

604.55.041.00 - 01 - 1998
32 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Eccentric Shaft and Selector Link Components

33
1. Sleeve 6. Snap Ring 10. Spacer
2. Nut 7. Cam Roller 11. Cam
3. Link 8. Spacer 12. Eccentric Shaft
4. Snap rings 9. Snap Ring 13. Washer
5. Link

Draft Control Main Spring and Plunger 34

1. Snap Ring 6. Retainer Nut 10. Bracket
2. Plunger 7. Seal 11. Spring
3. Washer 8. Yoke 12. Selector Link
4. Spring 9. Set Screw 13. Washer
5. Washer

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 33

Lift Arm Assembly--Exploded View 35

1. Lift Arm 3. Bolt 5. Thrust Washer
2. Locking Washer 4. Washer

Cross Shaft Assembly--Exploded View 36

1. Bush 4. Cross Shaft 7. Bush
2. Bush 5. Piston Rod and Arm Assembly 8. Seal
3. Seal 6. Bush

604.55.041.00 - 01 - 1998
34 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Hydraulic Lift Cylinder--Exploded View 37

1. Piston 6. Plug 11. Diffuser
2. ‘O’ Rings (7 off) 7. ’O’ Ring 12. ‘O’ Ring
3. Ring Dowels 8. Safety Valve 13. Exhaust valve
4. Ball 9. Seal 14. ASC Valve Spool
5. Spring 10. Control Valve Bush 15. Control Valve

7. Disassemble lift cylinder with reference to

Figure 37.

8. Use a soft metal rod inserted through safety

valve bore eject lift cylinder piston.

9. Discard all ‘O’ rings and seals

NOTE: The lift cylinder safety valve is not
serviceable.
10. Disassemble the control valve with reference
to Figure 38.

Lift Cylinder Control Valve

38
1. Spool
2. Spring
3. Bolt
4. Plate
5. Sleeve

11. Where necessary, remove remaining plugs

from lift cover. Under normal circumstances
the removal of these plugs is not necessary.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 35

INSPECTION AND REPAIR

1. Wash all parts in suitable cleaning agent such
as paraffin (kerosene).
2. Check oil passages are free from obstruction.
3. Examine valves and bore for wear, burrs or
scratches. Minor damage to valve may be
removed with fine abrasive.
4. If the control valve bushing requires
replacement remove the bushing using Tool
No T.8510 or FNH 02191 for North America.

The control valve bushing is colour coded and

the original size as fitted by the factory is
indicated by a colour ‘spot’ on the cylinder
casting adjacent to the control valve bore.
Always install a new bush with the same colour
code markings.
When replacing the bushing, the bush should
be lubricated and drawn through the bore,
Figure 39.
Installing Control Valve Bushing
A Bush Protrusion
1. Tool No FT. 8510 A or FNH 02191
2. Control Valve Bushing
3. Bushing locator Tool No FT. 8510--3 or
FNH 10090 39
4. Extension Tool No. FT. 8510--1A
5. Guide and Stop Adaptor Tool No T. 8510 1K

When the bush contacts the inner face of the

guide, remove guide and continue to draw
bush through the bore until the face of bush
protrudes 0.1--0.103 in (2.54--2.62 mm),
beyond the rear face of the lift cylinder (A),
Figure 40.

5. Ensure valves are thoroughly washed before

re--assembly and move freely in their bores.
Heavy scoring of the ASC valve bore
necessitates replacement of lift cylinder.

6. Where a new lift cylinder is required select

largest control valve and ASC valve spools, 40
which when lightly lubricated, will operate in
bore without binding when turned through 360!
and operated over full length of stroke.

NOTE: The control valve bushing and ASC valve

bores are colour coded only as a guide for
matching the valve to the bore. To obtain an
optimum fit a proprietary brand of metal polish may
be used to lap a slightly oversize valve into the
bore. Ensure all traces of polish are washed away
and the components are dried prior to
re--assembly. For valve sizes refer to
Specifications, Section H.

604.55.041.00 - 01 - 1998
36 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

7. If arm (2), piston rod (3) or retaining pins (1)

and (4) are worn, separate rod and arm
assembly. Refer to Figure 41. The pins are an
interference fit into the arm, to remove pins use
a suitable lever between rod and end face of
pin.

41
RE--ASSEMBLY
Re--assembly follows the disassembly procedure
in reverse.

During re--assembly observe the following:

S Renew all ‘O’ rings and seals.

S Install piston ‘O’ ring (1) and back--up seal (2)

as shown in Figure 42.

42
S To aid installation of piston (3), Figure 42 into
lift cylinder and prevent damage to the piston
seals, a guide can be manufactured to the
dimensions shown in Figure 43.

Piston Installation Guide

A. 105 mm (4.126 inch)
B. 134 mm (5.25 inch)
C. 3 mm (0.12 inch)
D. 40 mm (1.62 inch)
E. 155 mm (6.0 inch)

43
S Install piston (1) into cylinder (3) using guide (2)
as shown in Figure 44. If a guide is not
available and installation is difficult a piston ring
compressor may be used to compress the
seals.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 37

S Ensure the lift cylinder retaining bolts are

installed in the correct locations and torqued to
224--271 Nm (165--200 lbf ft), Figure 45.
S Prior to installation of the cross shaft coat the
shaft and lip seals with grease.
S The following torque procedure must be
observed when tightening the lift arm retaining
bolts.
Install the lift arms and tighten the left hand arm
retaining bolt to a torque of 27--40 Nm
(20--30 lbf ft). Lock the bolt in position with the
tab washer. Refer to Figure 35.
Raise both lift arms and tighten the right hand 45
arm retaining bolt sufficiently to allow the arms
to lower under their own weight. Lock the bolt
in position with the tab washer. Do Not over
tighten bolts as damage to the cross shaft
seals will occur.

Lift Cylinder Retaining Bolt Locations

(Viewed from Top of Hydraulic Lift Cover)
1. 76 mm (3 in) Bolt
2. 64 mm (2.5 in) Bolt
3. 57 mm (2.25 in) Bolt
4. 76 mm (3 in) Bolt withThin Bolt Head

604.55.041.00 - 01 - 1998
38 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

INTERNAL LINKAGE ADJUSTMENTS

Prior to making internal linkage adjustments
examine the linkage as follows:--
External Linkage Comonents
1. Set--up Plate
2. Position/Draft Control
3. Lift Control

46
1. Move the lift/ control and the position/draft
control levers to various positions and at each
position manually move the lift arms up and
down while checking that the internal linkage
moves freely and the components do not bind
or stick.
Internal Linkage Comonents
1. Cam Roller
2. Over Travel Spring
3. Pivot Block
4. Control Valve

47
2. With the lift arms lowered, turn the lift/lower
control counter clockwise to the raised
position, which will move the control valve
inwards.
3. Turn the position/draft control back and
forward and observe the travel of the roller
across the cam.
Internal Linkage Comonents
1. Selector Arm
2. Rod and Cam Roller Assembly
3. Washers
4. Cam

48
4. The roller should be square with the cam and
move parralell (2) and not at an angle (1)
across the cam.
5. The roller linkage can be adjusted by
shimming, Refer to Figure 31 and 32. Do not
over shim or elliminate all sideways
movement. Adjust linkage alignment and
replace worn components if required.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 39

Draft Control Mainspring Adjustment

The draft control mainspring must be checked
before carrying out any other adjustment.
1. Move lift arms (3) to fully raised position
2. Turn the lift/lower (4) and position/draft (5)
controls until the control rod and roller (1) does
not touch the cam (2) and the control valve
spool (6) is not under tension and the linkage is
free to move.

3. Screw in yoke to preload the draft control

mainspring, then unscrew the yoke to remove
any pre--load.
Draft Control Main Spring Adjustment
1. Hydraulic Lift Cover
2. Draft Control Plunger
3. Washer
4. Draft Control Main Spring
5. Washer
6. Yoke
7. Seal
8. Set Screw
9. Retainer Nut

51
4. Turn retainer nut (4) counterclockwise to
create free play in the draft control mainspring
(2), then turn clockwise until the free play has
been elliminated. The use of a screwdriver
blade (3) or feel by hand can determine when
freeplay has been eliminated.
5. Tighten the retainer nut set screw (1).

52
6. Screw the yoke (1) onto the plunger until all
free play is eliminated and ensure the hole in
the yoke is horizontal.

604.55.041.00 - 01 - 1998
40 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Draft and Position Control Adjustments

In order to complete the position and draft control
adjustments it is necessary to use a control valve
setting tool.
This tool is available as Tool No FNH 00014 or can
be manufactured to the dimensions shown in
Figure 54.
It is recommended that the tool is manufactured
from 3 mm gauge plate.
Locally Manufactured Control Valve Setting Tool
A. 20 mm (0.8 in)
B. 11.7 mm (0.46 in)
C. 12 mm (0.5 in)
54
Draft Control Adjustment
1. Ensure the draft control mainspring has been
adjusted as previously described.
2. Place lift arms (2) in fully lowered position
3. Adjust the eccentric shaft (1) until the lobe on
the eccentric is pointing into the top of the lift
cover.
NOTE:To ensure the lift cylinder piston has
reached the fully lowered position remove the
cylinder safety valve. Replace the safety valve
when piston has moved to the fully lowered
position.
55
4. Set the position/draft control set--up plate (3) in
the draft position and move the lift/lower
control until the notch on the body (2) is 1 mm
to the right of the draft control notch on the
support.
5. Check that the rod and roller assembly over
travel spring (1) is not being over compressed
as to create a gap between the pivot block and
washer. If spring is being compressed adjust
turnbuckle (4) on control valve.

56
6. Gradually reposition the position/draft control
set--up plate so that the control valve moves
aproximately 2mm further into its bore.
7. Clamp setup plate in this position with a locking
bolt.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 41

8. Move the lift arms up (1) and down and

observe the movement of the control valve (3).
9. Loosen the locking bolt and gradually move
the position of the position/draft control set--up
plate (2) until no movement of the control
valve is observed when the lift arms are raised
and lowered.
Retighten the setup plate locking bolt each time
this test for movement of the control valve is
undertaken.

10. Check the position of the control rod roller

using checking gauge (1) Tool No FT. 8527.
The distance between the top of the roller and
mounting face of the top cover should be
"1 mm of the 49.5mm (1.95 in) dimension of
the setting gauge.

If position of the roller is more than 1 mm

different than the dimension on the setting
gauge repeat the setting procedure in steps 1
to 7.
This procedure eliminates the effect of wear in
the linkage and should be used in preference
to relying on the setting gauge alone to set the
position of the roller. 59

Checking Control Rod Roller for Draft Control

1. Setting Link (Cam)
2. Control Rod Roller
3. Setting (Checking) Gauge, Tool No FT.8527
4. Control Rod

11. Using a small hacksaw, make a slot (1) in line

with the draft control mark (2) on the set--up
plate.

604.55.041.00 - 01 - 1998
42 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

12. Locate control valve setting tool (1) onto end of

the control valve bush and adjust control
valve turnbuckle until end of spool just
touches the tool. When this occurs the spool
will be set at 11.7 mm (0.46 in) from the end of
the bushing. Refer to Figure 62.
13. Apply New Holland thread sealant 82995773
to turnbuckle threads.
14. Tighten turnbuckle locknut and recheck
setting.

Control Valve Spool Setting

A. 11.7 mm (0.46 in)
1. Lift Cylinder
2. Control Valve Bushing
3. Control Valve Spool

62
Position Control Adjustment

1. Ensure lift arms are still in fully lowered

position.

2. Move the main lift lever until the notch on the

body is 1mm retarded (to the left) of the
position control notch on the support.

63
3. Loosen the locking bolt and move the
position/draft notch (2) on the set--up plate to
align with the the hacksaw slot (1) made during
draft control adjustment procedure. Re tighten
the locking bolt.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 43

1. Check the position of the control rod and roller

assembly from the top cover mounting face
using setting gauge Tool No FT. 8527.

Providing the position of the control rod roller is

within " 1 mm of the gauge dimension the
setting is correct.

If the difference is greater, repeat the draft

control adjustment to check that hacksaw
slot has been correctly positioned.
Setting Control Rod Roller for Position Control
1. Control Rod Roller
2. Cam
3. Setting Gauge, Tool No. FT.8527
4. Control Rod 65

2. Position the control valve setting tool (1) onto

the end of the control valve bush and turn the
eccentric shaft, Refer to Figure 55 until the
end of the spool just touches the end of the
tool. When this occurs the spool is set at
0.46 in (11.7 mm) from the end of the bushing.
Refer to Figure 67.

3. Tighten the eccentric shaft locknut and

recheck spool setting.

Control Valve Spool Setting

A. 0.46 in (11.7 mm)
1. Lift Cylinder
2. Control Valve Bushing
3. Control Valve Spool

604.55.041.00 - 01 - 1998
44 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

INSTALLATION

1. Apply a thin bead of New Holland gasket sealer

82995770 to BOTH sides of the hydraulic top
cover gasket. The bead should be continuous
around the entire face of the gasket and to a
thickness of approximately 1mm (1/32 in).
2. Install lift cover onto the rear axle centre
housing and tighten retaining bolts to a torque
of 135--170 Nm (100--125 lbf ft ).
3. Manually raise lift arms (engine not running)
and check that lift arms fall slowly under their
own weight. If the arms do not fall recheck the
torque applied to the lift arm retaining bolts as
described on Page 37.
4. Continue to install the lift cover, linkage and
cab/platform using the removal procedure in
reverse.
5. Reconnect the linkage and perform external
linkage adjustments as detailed in Below.

EXTERNAL HYDRAULIC CONTROL

LINKAGE

1. Ensure lift/lower control tensioning spring is

correctly fitted with shortest end of spring
attached to bracket on rear axle

68
Selector Lever Adjustment

1. Disconnect the selector lever rod at the lower

end, Refer to Figure 69.
Hydraulic Lift Cover External Linkage
1. Set--up Plate Aligned With Position Control Marks
2. Position/Draft Selector Rod
3. Lift Control Rod

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 45

2. Ensure the position control mark (3) on the

setup plate (1) aligns with the hacksaw slot (2)
on the lift control support. Use a bolt to lock the
setup plate in position.

NOTE: If the hydraulic lift was removed for

overhaul the setup plate will have been locked in
position when performing the internal linkage
adjustments.

70
3. Place the position/draft selector lever in the
position control notch. Refer to Figure 71.
Hydraulic Control Levers
1. Position/Draft Selector Lever
2. Position Control Setting
3. Draft Control Setting
4. Adjustable Stop
5. Lift Control Lever

4. Install connecting rod between position/draft

selector lever and position/draft shaft on top
cover. Tighten the locknuts to a torque of
11 Nm (8 lbf ft).
5. Remove the setup plate locking bolt.
71
Lift Control Lever Adjustment

1. Ensure the lift arms are fully lowered and lift

raise lower shaft on top cover has been turned
to the fully lowered position against the
mechanical stop.

2. Position the lift control lever 9 mm from the

fully lowered position on the cab/platform
quadrant.

3. Install connecting rod between lift control lever

and raise lower shaft on top cover. Tighten the
locknuts to a torque of 11 Nm (8 lbf ft).
72
4. Start the engine, select position control and
fully lower the hydraulic links.

5. Slowly pull on the lift lever and stop moving the

lever at the point when the lift just starts to
raise.

6. Stop the Engine and examine the alignment

of the notch on the body and the position
control notch on the support. If notches are
approximately in line then external linkage
adjustment is correct.

604.55.041.00 - 01 - 1998
46 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

7. Start engine, select draft control and fully

lower lift arms.

8. Slowly pull on the lift lever until lift arms start to

raise.

9. Stop the Engine and examine the alignment

of the notch on the body and the draft control
notch on the support of the top cover. If
notches are approximately in line then external
linkage adjustment is correct.
74
10.Start engine and check that lift arms can be fully
raised and lowered.

11. With the lift control lever in the fully lowered

position move the selector lever from position
control to draft control and check that the lift
arms do not lower. If the lift arms lower during
this check it is an indication that one of the
internal or external linkage adjustments has
been performed incorrectly.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 5 -- FIXED DISPLACEMENT GEAR TYPE PUMPS

Section Page

35 000 Specifications and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmission Mounted Fixed Displacement
Tandem Gear Type Pump -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
35 104 Transmission Mounted Fixed Displacement
Tandem Gear Type Pump -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
35 000 Engine Mounted Fixed Displacement Gear Type Pump
-- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35 104 Engine Mounted Fixed Displacement Gear Type Pump -- Overhaul . . . . . . . . . . . . . . . . . 13
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

35 000 SPECIFICATIONS AND SPECIAL TOOLS

Fixed Displacement Gear Type Pump With Integral Steering Pump

Main Hydraulic Lift Pump

Type Gear Type Pump
Minimum output @ 2100 engine rev/min
@ 2000 lbf/in2 (165 bar)
New pump 35 Ltrs/min (7.7 Imp gals/min 9.3 U.S. Gals/min)
Used pump 32 Ltrs/min (7.0 Imp gals/min 8.4 U.S. Gals/min)
Pressure relief valve setting 176--183 bar (2550--2650 lbf/in2 )
Steering Pump
Type Gear Type Pump
Minimum output @ 2100 engine rev/min
New pump 35 Ltrs/min (7.7 Imp gals/mim 9.2 U.S. Gals min )
Used pump 31 Ltrs/min (6.8 Imp gals/min 8.2 U.S. Gals/min )
Steering Motor Relief Valve Setting
2WD Tractors 138--145 bar (2000--2100 lbf/in2 )
4WD Tractors 166--172 bar (2400--2500 lbf/in2 )

Auxiliary Engine Mounted Fixed Displacement Gear Type Pump

Type Gear Type Pump

Minimum output @ 2100 engine rev/min
@ 165 bar (2400 lbf/in2 )
New pump 33 Ltrs/min (7.3 Imp gals/min 8 U.S.
Gals/min)
Used pump 23 Ltrs/min (5 Imp gals/min
6 U.S. Gals/min )

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

SPECIAL TOOLS
DESCRIPTION TOOL NUMBER
V.L. Churchill FNH Part No.
(America only)
Pressure Gauge 0--400 lbf/in2 (0--30 bar) FT. 8616 FNH 06653
Pressure Gauge 0--6000 lbf/in2 (0--414 bar) FT. 8503A FNH 02028
Adaptor--Pressure Test FT. 8503--8 FNH 0705
Adaptor--Steering Flow Test 4FT.852
(3/4’’ x 18UNS female-- 3/4’’ JIC male)
Adaptor--Steering Pressure Test 4FT.853
(11/16’’ --16UN to 7/16’’ JIC male)
Adaptor --Trailer Brake Pressure Test 4FT.854
(M18 --1.5 male to 7/16’’ JIC male)
Adaptor--Main Pump Flow/Pressure Test 4FT.858
1--14UNS Female to 1/4’’ BSP female
Adaptor--Main Pump Flow/Pressure Test 4FT.858/1
1/ ’’ BSP male to 3/ ’’ JIC male
4 4

Adaptor--Main Pump Pressure Test 4FT.858/2

1/ ’’ BSP male to 7/ ’’ JIC male
4 16
Adaptor--Steering Pump Flow Test 4FT.859
(13/16’’--16UN female to 3/4’’ JIC male)
Flowmeter MS. 820A or suitable equivalent FNH 02755
Test Hose--Pressure Testing Part No 83936707
Test Hose--Pressure Testing Part No 83926717
Adaptor--Trailer Brake Valve Part No 81862770
Plug Part No 83900652
Seal Part No 81800812
Remote Control Valve Connectors Procure through New Holland

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 3

TORQUES

= Nm
= lbf ft

Transmission Mounted Fixed Displacement Tandem Gear Type Pump

Engine Mounted Fixed Displacement Gear Type Pump

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

TRANSMISSION MOUNTED FIXED DISPLACEMENT TANDEM GEAR TYPE PUMP --

DESCRIPTION AND OPERATION

The fixed displacement gear type pump is mounted

on the right hand side of the rear transmission,
Figure 1.

The pump housing contains two gear type pumps,

mounted one behind the other. Refer to Figure 2
and Figure 3.

The front pump (2), Figure 2 (as mounted on the

tractor) supplies high pressure oil to the trailer
brakes, hydraulic lift and remote control valve
circuits and is referred to as the hydraulic lift pump.

1
If the tractor is installed with a trailer braking
system the high pressure oil from the hydraulic lift
pump flows to the trailer brake valve before
continuing onto the hydraulic lift assembly. This
ensures the braking system has priority over the
hydraulic lift circuits.

The rear pump (1), Figure 2, referred to as the

steering pump, provides oil to the hydrostatic
steering system and low pressure hydraulic
circuits.

2
The low pressure hydraulic circuits operate the
independent power take--off (PTO), four wheel
drive disengagement, electro hydraulically
operated differential lock on 12 x 12 transmissions
and the dual command cutches on the 12 x 12 and
16 x 4 transmissions.

These circuits, depending on tractor build options,

also provide lubrication to the PTO, dual power,
12 x 12 transmission synchronisers, bearings and
output shaft and 16 x 4 or 8 x 2 transmission
output shafts.

The operating pressure of these circuits is

regulated by the low pressure regulating and
lubrication circuit relief valves housed within the
PTO assembly. Refer to the PTO Section of the
Repair Manual for description and operation of
these valves. For the basic operation of the low
pressure hydraulic circuits refer to Chapter 1 in this
Section of the Repair Manual.

Both pumps share a common full flow intake filter.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 5

Cross Section of Transmission Mounted Fixed Displacement Gear Type Pump 3

1. Outlet Port to Hydraulic Lift 6. Hydraulic Lift Pump Outlet Port
2. Steering Pump Drive Gear 7. Pump Assembly Drive Gear
3. Steering Pump Driven Gear 8. Hydraulic Lift Pump Drive Gear
4. Outlet Port to PTO 9. Drive Link
5. Hydraulic Lift Pump Driven Gear 10. Pump Inlet Port (Both Pumps)

Pump Operation The fixed displacement gear type pump assembly

is supplied with oil from the rear axle centre housing
The drive for the hydraulic lift pump (front pump) is reservoir via an intake tube attached to the pump
taken via an idler gear driven from the PTO drive inlet port.
clutch hub. A drive link between both pumps,
transmits the drive through to the steering pump
(rear pump), Figure 3. When the engine is running, the PTO idler gear
drives the pump and oil is drawn through the inlet
The pump gears in both pumps revolve at the same port and intake filter into the spaces between the
speed and are in constant operation whenever the teeth of the gears within each pumping unit. As the
engine is running. Both sets of spur gears are pumping gears rotate, the oil in the spaces between
supported within the pump by aluminium bearing the gear teeth is trapped and carried between the
blocks, incorporating steel bushes with porous teeth and the pump body to the pump outlet ports,
bronze and PTFE plus lead linings. where it is discharged to the hydraulic circuits.

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

The pump inlet filter is monitored for blockage by

a vacuum switch (1) operating at a pressure of 16
in. Hg, Figure 4. The switch is also connected in
series with a low oil temperature switch (7) and
warning light. If the oil temperature is above 40!C
(104!F) and the filter is restricted, causing the
vacuum switch to operate, the warning light on the
instrument panel will illuminate.

If a tractor is fitted with the electronic instrument

cluster, an extra switch to monitor high hydraulic oil
temperature is also installed. This switch, where
fitted, is positioned in the port immediately to the
left of the low temperature switch.

The low pressure hydraulic oil supply from the Fixed Displacement Gear Type Pump Installation 4
(Tractor with 16 x 4 Transmission Shown)
steering pump is monitored by a pressure switch
(5) in the pump and operates a warning light 1. Blocked Filter Vacuum Switch
whenever the oil pressure drops below 2. Full Flow Inlet Filter with By--pass Valve
3. To Dual Power (where fitted)
75--80 lbf/in2. The light will extinguish when the oil 4. Return from Steering Motor
pressure increases to 115--125 lbf/in2. 5. Pressure Switch--Low Pressure Circuit
6. To Steering Motor
The hydraulic lift pump is protected from excessive 7. Oil Low Temperature Switch
pressures by a pressure relief valve which
operates at 2550--2650 lbf/in2 (176--183 bar). The
valve allows excess oil to return directly to sump
whenever an overload condition occurs. This valve
can be replaced without having to remove the
pump from the tractor.

Fixed Displacement Gear Type Pump Installation (Tractor with 12 x 12 Transmission Shown) 5
1. To Transmission Lubrication 7. To Electro Hydraulic Differential Lock
2. To Oil Cooler 8. To Steering Motor
3. Return from Oil Cooler 9. Return from Steering Motor
4. Oil Cooler By--Pass Valve 10. Hydraulic Lift Pump Pressure Relief Valve
5. From PTO Valve 11. To Front Wheel Drive Disengagement System
6. Hydraulic Lift Pump Output Gallery

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 7

The steering pump does not contain a pressure

relief valve and is protected by the relief valve
contained within the power steering motor.

Figure 5 shows the installation of the fixed

displacement gear type pump on a tractor fitted
with a 12 x 12 transmission. The arrows indicate
the flow of oil through the external pipework from
the steering pump within the assembly.

On tractors installed with 16 x 4 or 8 x 2

transmissions the oil cooler by--pass valve is not
fitted and oil flows directly from the PTO valve to
the oil cooler, before providing pressure lubrication
to the transmission and dual command clutches
(where fitted).

35 104 TRANSMISSION MOUNTED FIXED DISPLACEMENT TANDEM GEAR TYPE PUMP

-- OVERHAUL

Removal

1. Remove right hand rear wheel.

2. Remove rear axle drain plug, Figure 1 and

drain the oil from the rear axle assembly.

3. Disconnect all the electrical connections to the

switches mounted on the pump, Figure 2.

Fixed Displacement Gear Type Pump Installation

(Tractor with 16 x 4 Transmission Shown)
1. Blocked Filter Vacuum Switch
2. Full Flow Inlet Filter with By--pass Valve
3. To Dual Power (where fitted)
4. Return from Steering Motor
5. Pressure Switch--Low Pressure Circuit
6. To Steering Motor
7. Oil Low Temperature Switch

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

4. Disconnect and plug all hydraulic pipes

attached to the pump. Refer to Figure 2 and
Figure 3.
5. Remove pump mounting bolts and lift pump
from transmission housing.

Hydraulic Pump Installation

Tractor with 12 x 12 Transmission Shown
1. Return from Trailer Brake Valve (where fitted)
2. Blocked Filter Vacuum Switch
3. Pressure Relief Valve
4. To Four Wheel Drive (where fitted)
5. To Electro Hydraulically Operated Differential Lock
6. Feed to Trailer Brake Valve (where fitted)
3
Disassembly

1. Remove pressure relief valve from pump. The

relief valve is non adjustable and must be
replaced if away from specification.

2. Remove pump drive gear (2), Figure 4. The

gear is located on a tapered driveshaft and the
use of a soft faced mallet will be required to
loosen the gear from the shaft (1).

4
3. Remove the six pump body through bolts
(4 short and 2 long).

4. Remove end cover (1) by easing the cover

forward to clear locating dowels (3) and then
tilting cover to clear transfer tube (2), Figure 5.

5. Remove the gears and bearing blocks from the

hydraulic lift pump (front pump), Figure 7. To
ensure correct re--assembly mark both the
bearing blocks (1) and (3) and driven gear (2)
on a non critical surface, Figure 6.

5
6. Layout the components in the order of
disassembly, Figure 7. Refer to Figure 7 for
location of the seals which are positioned
between the sandwich plate and bearing block,
item 3 in Figure 7.

NOTE: The drive shaft and gear assembly is held

together with an internal snap ring, DO NOT
attempt to disassemble these parts as damage is
likely to occur to snap ring and shafts.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 9

Hydraulic Lift Pump (Front Pump) -- Exploded View 7

1. Pump Housing 7. Bolts (4 Long, 2 Short) 13. Seal
2. Steering Pump 8. Nut 14. Bearing Block
3. Bearing Block 9. Locking Washer 15. Woodruff Key
4. Driven Gear 10. Drive Gear 16. Drive Shaft and Gear
5. Transfer Tube 11. Oil Seal Assembly
6. End Cover 12. Nylon Back--Up Ring

Steering Pump (Rear Pump) -- Exploded View 8

1. Pump Body 6. Seal 11. Seal
2. Seal 7. Sandwich Plate 12. Nylon Backing Strip
3. Nylon Backing Strip 8. Seal 13. Bearing Block
4. Bearing Block 9. Nylon Back--Up Ring 14. Transfer Tube and Snap Ring
5. Driven Gear 10. Pump Housing 15. Drive Gear

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

7. Pull the steering pump (rear pump) assembly 5. Light score marks on the gear facing areas can
from the pump housing and separate the be removed using a sheet of ‘0’ grade wet or dry
components, taking care to identify the abrasive paper lubricated with paraffin on a true
orientation of the gears and bearing blocks, flat surface. Polish the affected face using light
Figure 8. pressure in a rotating motion. Journals may be
polished to achieve free movement in the body.
NOTE: A small mark on the end face of the driven
gear will assist in identification to ensure correct
re--assembly. 6. Inspect the track cut by the gear teeth in the
pump body. It is normal to see a gear track cut in
the suction side of the pump body, this is made
during the bedding in process by the pump
Inspection and Repair manufacturer. The gear track must not
however, exceed 0.004 in. (0.10 mm) depth or
continue beyond the suction half of the gear
1. Wash all components in a suitable solvent and aperture. A gear track beyond this specification
allow to dry. will necessitate the installation of a new pump.

2. Examine each bearing block thoroughly. At

major overhauls, both bearing blocks and gears
should be renewed using the service repair kit. Re--Assembly
These items are not serviced separately.
Re--assembly follows the disassembly procedure in
reverse.
3. Check bushes in bearing blocks for wear and
ensure the lubrication scrolls in the bushes are During re--assembly, observe the following
free from obstruction. requirements:--

S If the end cover locating dowels have been re-

4. Inspect the pump gears for wear or damage, moved, new dowels must be installed with
paying attention to the bearing journals, gear 2.54mm of dowel protruding from the pump
teeth and side facings. To ensure maximum housing.
pump efficiency, the width of each pair of pump
gears must be within 0.0002 in. (0.005 mm) of
each other and the gear journals within S Replace all oil seals and ‘O’ rings as provided in
0.0005 in. (0.013 mm). the seal kit.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 11

S Install washers (1) and (5) and ‘O’ ring seals (2)
and (4) to transfer tubes (3). Refer to Figure 9
for typical seal installation.
S Coat all seals and ‘O’ rings with petroleum jelly
and ensure all seals and backing strips are
correctly positioned.
S Lubricate all parts with Ambra Multi--G
hydraulic oil.
S To maintain pump efficiency it is imperative that
original gears and bearings are re--assembled
exactly as removed.
The bearing block, item 4 in Figure 8, is
manufactured with a radiused edge. During 9
re--assembly ensure that the ‘radiused edge’ is
installed at the bottom of the steering pump body
bore, Figure 10.

NOTE: Only one of the two bearing blocks used in

the steering pump is radiused on the corner edge.
Installation of the sharp edged radius block, item 13
in Figure 8, in this position will prevent correct
assembly and cause damage to the pump.

S Pack the cavity behind the end cover input

drive shaft seal with high melting point grease.

S The end cover bolts installed in the pump have

different shanks or bolt length. Install the
correct bolts in the locations shown in
Figure 11 and tighten to a torque of 37--46 lbf ft
(50--62 Nm).
Bearing Block Installation 10
S Tighten the pressure relief valve to a torque of 1. Relieved Edge
44--50 lbf ft (60--68 Nm). 2. Steering Pump Body
3. Radiused Edge
4. Radiused Edge

S Tighten the input drive gear nut to a torque of

37--41 lbf ft (50--55 Nm) and ensure the tab on
the locking washer is locked against the pump
drive gear nut.

S If the pump is not for immediate use, cap all

ports prior to storage.

Installation

Prior to installation introduce Ambra Multi--G

hydraulic oil into the pump suction port and rotate
the gears by hand.
Installation follows the removal procedure in End Cover Bolt Location 11
reverse. During installation ensure the pump to
A. Bolt M10 x 100 mm with Ground Shank
transmission housing retaining bolts are tightened B. Bolt M10 x 100 mm with Dull Black Shank
to a torque of 42--56 lbf ft (57--76 Nm). C. Bolt M10 x 115 mm with Ground Shank
D. Bolt M10 x 115 mm with Dull Black Shank
Ensure all pipe connections are tightened to the
correct torque, see Specifications.

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

35 000 ENGINE MOUNTED FIXED DISPLACEMENT GEAR TYPE PUMP

-- DESCRIPTION AND OPERATION

The Auxiliary engine mounted gear type pump,

Figure 1, where installed, is fitted on the left hand
front side of the engine and driven by the camshaft
gear.
The optional engine mounted gear type pump can
be installed on those tractors equipped with a
transmission mounted gear type pump and remote
control valves or auxiliary hydraulic equipment.
The pump supplements the existing hydraulic oil
supply provided by the transmission mounted gear
type pump to the remote control valves and/or
auxiliary equipment only.
If the remote control valves or auxiliary
equipment require additional oil flow to that
supplied by the main hydraulic pump, then oil from 1
the auxiliary pump is directed to these circuits. Any
output from the engine mounted pump that is
surplus to requirements is returned to sump using
the combining valve in the priority valve pack
situated on top of the hydraulic lift cover. Refer to
Chapter 4 for the description and operation of this
valve.
Hydraulic oil is drawn by the pump from the rear
axle centre housing through an external pipe. An
external pipe from the pump outlet port similarly
directs the oil to the priority valve pack.

Before entering the pump the oil passes through a

replaceable, full flow filter mounted on the left hand
side of the rear axle centre housing, Figure 2.

2
A cross section of the auxiliary engine mounted
pump is shown in Figure 3. The pump contains one
set of spur gears which constantly rotate drawing
oil through the inlet port. Oil on entering the pump,
fills the spaces between the teeth of each rotating
gear. As the gears continue rotating the oil is
trapped and carried between the teeth and the
pump body to the outlet side of the pump where it
is discharged to the hydraulic circuits through the
pump outlet port.
The gears in the pumps are supported in aluminium
bearings incorporating steel bushes with porous
bronze and PTFE plus lead linings.

Auxiliary Engine Mounted Pump -- Sectional View 3

1. Bearing Block
2. Driven Gear
3. Bearing Block
4. Pump Drive Gear
5. Drive Gear

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 13

35 104 ENGINE MOUNTED FIXED DISPLACEMENT GEAR TYPE PUMP

-- OVERHAUL

Removal

1. Remove inlet (1) and outlet (2) tubes to

auxiliary pump, Figure 1.

2. Remove retaining bolts (3), Figure 1 and lift

pump from engine, Figure 2.

3. Remove pump drive gear (1), Figure 3. The

gear is located on a tapered driveshaft and the
use of a soft faced mallet will be required to
loosen the gear from the shaft.

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

4. To ensure correct re--assembly observe the

position of the ‘IN’ marking on the rear end
cover (1), Figure 4.

5. Remove front and rear covers and withdraw

the pump gears and bearing blocks. Refer to
Figure 5. Take care to identify the orientation of
the gears and bearing blocks.

NOTE: A small mark on the end face of the driven

gear will assist in identification to ensure correct
re--assembly.

4
6. Remove the seal in the front end cover.

Auxiliary Pump Gears--Exploded View 5

1. Rear End Cover 11. Tab Washer
2. Through Bolts (4 off) 12. Nut
3. Seal 13. Pump Drive Gear
4. Nylon Back--up Ring 14. Woodruff Key
5. Seal 15. Seal
6. Bearing Block 16. Nylon Back--up Ring
7. Driven Gear 17. Seal
8. Pump Body 18. Bearing Block
9. Seal 19. Driveshaft and Gear
10. Front End Cover

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 15

Inspection and Repair S Coat all seals and ‘O’ rings with petroleum jelly
and ensure all seals and back ups are correctly
positioned.
1. Wash all components in a suitable solvent and
allow to dry.
S Lubricate all parts with Ambra Multi--G hydraulic
oil.
2. Examine each bearing block thoroughly for
damage or wear. At major overhauls the
bearing blocks should be renewed. S To maintain pump efficiency it is imperative that
original gears and bearings are re--assembled
exactly as removed during disassembly. The
bearing blocks are installed with their recess
3. Inspect the pump gears for wear or damage, against the gear faces and the relieved radiused
paying attention to the bearing journals, gear edges towards the outlet side of the pump.
teeth and side facings. To ensure maximum
pump efficiency the width of the pair of gears
must be within 0.0002 in. (0.005 mm) of each S Pack the cavity behind the lips of the front end
other and the gear journals within 0.0005 in. cover drive shaft seal with high melting point
(0.013 mm). grease.

4. Light score marks on the gear facing areas can

S Tighten the end cover clamping bolts to a torque
be removed using a sheet of ‘0’ grade wet or dry of 45--50 lbf ft (61--68 Nm) after lightly lubricat-
abrasive paper lubricated with paraffin on a true ing them.
flat surface. Polish the affected face using light
pressure in a rotating motion. Journals may be
polished to achieve free movement in the body.
S Tighten the drive gear retaining nut to a torque
of 30--33 lbf ft (40--45 Nm) and ensure the tab
on the locking washer is locked against the nut.

5. Inspect the track cut by the gear teeth in the

pump body. It is normal to see a gear track cut in S If the pump is not for immediate use, cap all
the suction side of the pump body, this is made ports prior to storage.
during the bedding in process by the pump
manufacturer. The gear track must not,
however, exceed 0.004 in. (0.10 mm) depth or Installation
continue beyond the suction half of the gear
aperture. A gear track beyond this specification Installation follows the removal procedure in
will necessitate the installation of a new pump. reverse.

Prior to installation on the tractor introduce hydraulic

oil into the suction port and rotate the gears by hand.
Re--assembly
During installation ensure the pump retaining bolts
Re--assembly follows the disassembly procedure in are tightened to a torque of 42--56 lbf ft (57--76 Nm).
reverse.
Tighten the inlet pipe retaining bolts to a torque of
During re--assembly, observe the following 11--15 lbf ft (15--20 Nm).
requirements.
Tighten the pump outlet pipe retaining screws to a
S Replace all oil seals. torque of 5--7 lbf ft (7--10 Nm).

604.55.041.00 - 01 - 1998
16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

PRESSURE TESTING

The following test procedure must be used to WARNING: To prevent inadvertent

confirm the efficiency and output of the fixed movement of the tractor during pressure
displacement tandem gear type and auxiliary testing the following precautions must be taken:--
engine mounted pumps installed on Series 40
Tractors. The pressure and flow values quoted in S Ensure the gear shift levers are in the neutral
this text are the minimum acceptable before position.
overhaul is required and also make allowances for
back pressure in the system. The values quoted in
the Specifications Section , are for new S If the tractor is fitted with four wheel drive, dis-
components. connect the driveshaft coupling at the front axle
pinion.

If the efficiency of the pump(s) is verified and the IMPORTANT: Before performing any flow or
hydraulic lift, remote valves, PTO or other pressure checks it is important that the oil in the rear
hydraulically operated systems are not operating axle and transmission is at an operating
correctly, reference must be made to the temperature of 75!C (170!F). This can be achieved
appropriate Parts/Chapters in the Repair Manual by installing the flowmeter as for flow testing the
which describe the fault finding, overhaul and hydraulic pump and performing steps 7 and 8 of the
pressure testing of these components. main hydraulic pump flow test.

Main Hydraulic Pump Flow and Pressure Test

1. Tractors With Trailer Brake Only:

Disconnect trailer brake valve feed tube (1)
from pump, Figure 1.

1
2. Tractors Less Trailer Brake Only:
Remove plug (1) from pump outlet port,
Figure 2.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 17

3. Install trailer brake valve adaptor (1) Part No.

81862770, Figure 3 into pump port.

On tractors with trailer brakes the adaptor is

already fitted to the pump.

Trailer Brake Valve Adaptor

1. Adaptor Part No 81862770
2. ‘O’ Ring Part No 83999938
3. ‘O’ Ring Part No 83416161
4. ‘O’ Ring Part No 83416165

3
4. Attach inlet hose (3) of flowmeter to pump
outlet port via adaptors 4FT858/1, (4) adaptor
4FT858, (5), and trailer brake adaptor, (6), and
return hose (1) into a remote valve raise port,
Figure 4.

Adaptor 4FT.858/1 (4) is provided with a 3/4 in JIC

male fitting. If the hoses on the flowmeter used are
not compatible with this size fitting a suitable
adaptor with a 1 in--14 UNS ‘O’ ring face seal
thread for attaching onto the pump test port is
required.

4
5. Set remote valve receiving oil from flowmeter
to ‘float’, Figure 5.
6. Ensure load valve (2), Figure 4 on flowmeter is
fully open.
7. Blank oil cooler with a piece of card. Start
engine and set speed to 2100 rev/min.
8. Slowly close load valve until a pressure of 2000
lbf/in2 (137 bar) is recorded on the flowmeter
pressure gauge. Run tractor until the oil is at
an operating temperature of 75!C (170!F).

5
9. Slowly close the load valve on the flow meter
until the pressure relief valve starts to operate
and the pressure gauge reading on the
flowmeter no longer increases. Record the
maximum pressure reading. The pressure
recorded should be between 2550--2650 lbf/in2
(176--183 bar).
10. If the recorded pressure was away from
specification replace the pump pressure relief
valve and re--check the pressure.
11. If the relief valve pressure is to specification,
open the load valve on the flowmeter until a
pressure of 2000 lbf/in2 (176--182 bar) is
obtained and record the pump flow.

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

The minimum flow recorded should be

8.4 U.S. Gals/min(7.0 Imp Gals/min, 34 Ltrs/min).
If the flow is less than this value the pump must be
overhauled.

Main Hydraulic Pump Pressure Test

If a flowmeter is not readily available the maximum

pump pressure can be checked by installing a
0--6000 lbf/in2 pressure gauge in place off the
flowmeter, Figure 6.

Alternatively if the tractor is not fitted with an

auxiliary engine mounted hydraulic pump the Checking Main Hydraulic Pump Pressure 6
pressure gauge can be installed directly into a
remote valve. Operation of the valve will then give 1. Adaptor 4FT. 858/2
2. Adaptor 4FT. 858
pump pressure. 3. Adaptor FT.8503--8 or FNH 00705
4. Pressure Gauge FT.8503A
1. Start tractor and set engine speed to 5. Test Hose Part No. 83936707
2100 rev/min. Observe reading on pressure
gauge.

2. Reduce the engine speed to 1200 rev/min and

again observe the pressure reading.

If the readings remain within the 2550--2650 lbf/in2

(176--183 bar) pressure specification it is an
indication that the pump does not require an
overhaul.

Trailer Brake Valve Pressure Test

If the tractor is installed with trailer brakes and the
main hydraulic pump pressure and flow test is
satisfactory, but the hydraulic lift only operates
slowly, perform the following trailer brake valve test
to determine if the concern is related to the trailer
brake valve or the hydraulic lift.
1. Connect 0--6000 lbf/in2 (0--414 bar) pressure
gauge FT.8503A to trailer brake coupler,
Figure 7.

2. Set engine speed to 1500 rev/min.

Trailer Brake Pressure Test 7
3. Depress right hand brake pedal. There should
1. Adaptor 4FT.854
be no reading on the pressure gauge. 2. Test Hose Part No. 83936707
3. Adaptor FT. 8503--8 or FNH 00705
4. Depress left hand brake pedal. There should 4. Pressure Gauge FT.8503A
be no reading on the pressure gauge. 5. Trailer Brake Coupler

5. Couple together and depress both brake

pedals. The reading on the pressure gauge
should increase as the brake pedals are
depressed harder. The pressure recorded,
depending on pedal effort, should increase up
to a maximum pressure of 2140 lbf/in2
(147 bar).

6. Release brake pedals. Pressure should

reduce to zero.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 19

Steering Pump
The following practical test will determine if the
steering pump outlet is sufficient to allow
satisfactory operation of the steering system.

Steering Test
1. Set engine speed to 1000 rev/min.
2. Turn steering quickly from lock to lock. If
steering is operating correctly the reaction of
the steering should be immediate, with no time
delay between turning the steering wheel and
movement of the wheels. At full lock the relief
valve in the steering motor should be heard to
blow and the engine speed drop to
approximately 970 rev/min.

Steering Relief Valve Pressure Test

IMPORTANT: There is no relief valve in the 1
steering pump and the following pressure test must
only be performed as specified below. Failure to
observe this precaution may result in severe
damage to the steering pump.

1. Turn steering onto full left hand lock.

2. Disconnect the left hand turn feed hose at the

steering cylinder.
3 2
3. Install a 0--6000 lbf/in2 pressure gauge FT.
60--41--024 TI
8503A, item (1), Figure 8, using adaptor
FT8503--8, item (2) Figure 8 and a locally 8
procured 7/16 JIC male adaptor, item (3),
Figure 8.
4. Start tractor and set engine speed to
2100 rev/min.

5. Using a force of approximately 5 lbf. hold

steering wheel on full left hand lock and
observe the pressure reading. The use of a
force greater than 5 lbf. at the rim of the
steering wheel may lead to slightly inaccurate
readings due to the pumping action of the
hydrostatic steering motor.

6. Reduce the engine speed to 1200 rev/min and

again observe the pressure reading.

The pressure readings after taking into

consideration system back pressure should be:--
2220--2370 lbf/in2 (153--163 bar). -- Two wheel
drive tractors.
2620--2770 lbf/in2 (180--191 bar). -- Four
wheel drive tractors.

If the steering test was satisfactory but the

pressure readings are away from specification, the
relief valve in the steering motor must be replaced.
Refer to Section 41 ‘‘Steering’’.

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Steering Pump Flow Test

1. Disconnect feed (1) and return (2) tubes to

steering motor, Figure 9.

9
2. Install flowmeter, Figure 10.

NOTE: The flowmeter used for this test must be

capable of withstanding a back pressure off
300 lbf/in 2 (21 bar).
If hoses of a different size are used with the
flowmeter, suitable adaptors with a female thread
size of 13/16 in--16 ORFS for installing onto the
pump inlet and outlet ports will be required.

3. ‘Ensure’ flowmeter load valve (1) is fully open.

IMPORTANT: If the flowmeter load valve remains

closed damage will occur to the steering pump.
Installation of Flowmeter for 10
4. Set engine speed to 2100 rev/min and slowly Steering Pump Flow Test
close the load valve until a pressure of
1. Flowmeter Load Valve
2000 lbf/in2 (138 bar) is recorded on the 2. Return Hose from Flowmeter
flowmeter pressure gauge. DO NOT increase 3. Adaptors 4FT.859
the pump pressure beyond this value. 4. Inlet Hose to Flowmeter

5. Record the pump flow.

If pump flow is less than 6.8 Imp gals/min (8.2 U.S.

Gals/min 31 Ltrs/min) the steering pump requires
overhaul.

Low and Lubrication Circuit Pressure Tests

It is important that the flow of oil on returning from

the steering motor to the tandem pump for
redistribution to the low pressure and lubrication
circuits, is regulated to the correct specification by
the pressure regulating valve and lubrication circuit
relief valve in the PTO assembly. It is, therefore,
recommended that when pressure testing the
pump the following low and lubrication circuit
pressure tests are performed.

Low Pressure Circuit Test

11
1. Remove the pressure switch (1) for the low
pressure hydraulic circuit, Figure 11.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 21

2. Install 0--400 lbf/in2 (0--30 bar) pressure

gauge, FT.8616, Figure 12.

3. Set engine speed to 2100 rev/min and observe

pressure reading. A reading of 220--260 lbf/in2
(15.2--17.9 bar) should be recorded.

Checking Low Pressure Circuit

1. Pressure Gauge FT.8616 or FNH 06653
2. Adaptor FT.8503--8 or FNH 00705
3. Test Hoses Part Nos. 83936707 and 83926717

12
Lubrication Circuit Pressure Test
Tractors with 12 x 12 Transmission only:
1. Carefully disconnect feed and return tubes to
cooler by--pass valve and using Adaptors
4FT.852 install flowmeter, Figure 13. Take
care not to damage tubes during
disconnection.
NOTE: Adaptors 4FT.852 are suitable for installing
3/ in JIC hoses to flowmeter. If hoses of a different
4
size are used with the flowmeter, suitable adaptors
with a female thread size of 3/4 in--18 UNS on one
end will be required.
2. ‘Ensure’ flowmeter load valve is fully open.
Flow Testing Steering Pump 13
3. Set engine speed to 2100 rev/min and slowly 1. Adaptor 4FT. 852
close the flowmeter load valve. Record the 2. Supply Hose To Flowmeter
pressure on the flowmeter gauge and then 3. Flowmeter Return Hose
fully open the load valve. 4. Adaptor 4FT. 852

IMPORTANT: If the flowmeter load valve remains

closed the low pressure lubrication supply to the
transmission shafts will cease with possible
damage to the transmission.
Depending on engine speed, the pressure should
be 73--123 lbf/in2 (5.0--8.5 bar). 73 lbf/in2
(5.0 bar) is the minimum operating pressure of the
lubrication circuit relief valve, located in the PTO
valve and clutch assembly.

Lubrication Circuit Pressure Test:

Tractors with 16 x 4 or 8 x 2 Transmission
only:

NOTE: The use of this method to test lubrication

circuit pressure on tractors installed with 12 x 12
transmissions may result in the readings being
influenced by the cooler by--pass valve installed on
12 x 12 transmission tractors. This would be
particularly evident if the oil temperature was below
75!C (170!F).

1. Operate the tractor and set the engine speed to

1000 rev/min. Stop the engine but do not
re--adjust the throttle.

604.55.041.00 - 01 - 1998
22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

2. Using test hose 83936707, adaptor FT.8503--8

and a suitable 7/16 in JIC adaptor, which must
be a tight fit inside the oil cooler inlet hose,
connect the 0--400 lbf/in2 pressure gauge
FT.8616 to the cooler inlet hose, Figure 14.

3. Using an assistant to start the engine, observe

the reading on the pressure gauge. Do Not run
the tractor longer than is necessary to observe
the pressure gauge reading.

The pressure recorded should be

73--123 lbf/in2 (5.3--8.5 bar), depending on engine
speed. 73 lbf/in2 (5.3--8.5 bar) is the minimum
operating pressure of the lubrication circuit relief Lubrication Circuit Relief Valve Check 14
valve located in the PTO valve and clutch (Tractors with 16 x 4 or 8 x 2 Transmission)
assembly. 1. Oil Cooler Inlet Hose
2. Hose Clamp
3. Suitable 7/16 in JIC Adaptor to Connect Test Hose
to Inlet Hose
4. Test Hose 83936707
5. Pressure Gauge FT.8616 or FNH 06653

Auxiliary Engine Mounted Pump Flow Test

NOTE: The flowmeter used for this test must be
capable of withstanding a back pressure of
300 lbf/in 2 (21 bar).

Flow Test for Tractors with Auxiliary Services

Control (ASC) Valve Option:

1. Install inlet hose (3) of flowmeter into lift

coupler of right hand inner remote control valve
and return hose (1) of flow meter into lift
coupler of right hand outer remote control
valve, Figure 15.
2. Set flow control knob (4) on remote control 15
valves to minimum flow.
3. Ensure load valve (2) on flow meter is fully
open.
4. Set engine speed to 2100 rev/min and lower lift
arms.

5. Push green handled remote control valve

operating lever (2) fully forward to ‘float’
position. (This lever operates the remote
control valve receiving oil from the flow meter),
Figure 16.

6. Pull blue handled remote control valve lever (1)

fully rearwards to cylinder extend position.
(This lever operates the remote control valve
supplying oil to the flow meter).

7. Ensure that flow meter is measuring oil flow

correctly then set remote control valve flow
knobs to maximum flow.
16

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 23

8. Turn auxiliary services control (ASC) to

engaged position, Figure 17.

9. Move the hydraulic lift control lever to the fully

raise position which will cause the pressure
relief valve in the tandem pump to operate,
diverting all the hydraulic lift pump oil to
reservoir.

10. Adjust the load valve on the flow meter until a

pressure of 2000 lbf/in2 is obtained and record
17
the pump flow. Move the lift control lever to the
fully lowered position immediately the pump
flow has been recorded.

The oil flow recorded is the output from the auxiliary

engine mounted pump. If pump flow is less than 5.0
Imp gals/min (6 U.S. Gals/min 23 Ltrs/min) the
pump must be overhauled.

11. Slowly close the load valve until the flowmeter

pressure gauge no longer increases.

Record this value which should be in the range

2550--2900 lbf/in2 (176--200 bar). This is the
operating pressure of the combining valve relief
valve, in the priority valve pack on top of the
hydraulic lift cover. If this pressure is low, overhaul
the priority valve pack as described in Chapter 4 of
this Part of the Repair Manual, before investigating
further concerns with the auxiliary engine mounted
pump.

Flow Test for Tractors Not Installed with ASC

Valve Option:

1. Remove pressure relief valve from pump (1),

Figure 18. Install plug Part No. 83900652 and
seal Part No.81800812 in place of valve.
This will return all oil from the hydraulic lift
pump to the reservoir.

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

2. Install inlet hose (3) of flowmeter into lift

coupler of right hand inner remote control valve
and return hose (1) of flow meter into lift
coupler of right hand outer remote control
valve, Figure 19.

3. Set flow control knob (4) on remote control

valves to minimum flow.

4. Ensure load valve on flow meter is fully open.

5. Set engine speed to 2100 rev/min.

19
6. Push green handled remote control valve
operating lever (2) fully forward to ‘float’
position. (This lever operates the remote 2
control valve receiving oil from the flow meter),
Figure 20.

7. Pull blue handled remote control valve lever (1)

fully rearwards to cylinder extend position.
(This lever operates the remote control valve
supplying oil to the flow meter).

8. Ensure that flow meter is measuring oil flow 1

correctly then set remote control valve flow
knobs to maximum flow. 20

9. Adjust the load valve on the flow meter until a

pressure of 2000 lbf/in2 (138 bar) is obtained
and record the pump flow.

If pump flow is less than 5.0 Imp gals/min

(6 U.S. Gals/min 23 Ltrs/min) the pump must
be overhauled.

10. Slowly close the load valve until the reading on

the flowmeter pressure gauge no longer
increases.

Record this value which should be in the range

11. Remove plug from pump and re--install the

pressure relief valve.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 6 -- HYDRAULIC TRAILER BRAKES

Section Page
35 000 Specifications and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
33 220 Trailer Brake Valve--overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

35 000 SPECIFICATIONS AND SPECIAL TOOLS

Maximum Trailer Brake Pressure 1740--2176 lbf/in2 (120--150 bar)

Brake Reservoir Oil Ambra Brake LHM (NH 610 A)

TORQUES

= Nm
= lbf ft

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

SPECIAL TOOLS
DESCRIPTION TOOL NUMBER
V.L. Churchill FNH Part No
Adaptor Trailer Brake Coupling to Test Hose 4FT.854
Test Hose--Pressure Testing 83936707
(From NH Logistics)
Pressure Gauge 0--6000 lbf/in2 (0--414 bar) FT.8503A FNH 02028
Adaptor--Pressure Gauge to Test Hose FT.8503--8 FNH 0705

DESCRIPTION AND OPERATION

Tractor and Trailer Brake Layout 1

1. Tractor Brake Fluid Reservoir A. Bleed Screw--Left Hand Brake
2. Tractor Right Hand Brake Master Cylinder B. Bleed Screw--Right Hand Brake
3. Trailer Brake Valve C. Bleed Screw--Right Hand Brake Sensing Line
4. Rear Axle Wet Disc Brakes D. Bleed Screw--Trailer Brake Valve Pilot Head
5. Trailer Brake Line Coupler E. Bleed Screw--Left Hand Brake Sensing Line
6. Handbrake
7. Tractor Left Hand Brake Master Cylinder

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 3

TS Series Tractors may be fitted with an hydraulic

valve, for the control of hydraulically operated
trailer brakes, Figure 1.

Unlike the main tractor braking system, the trailer

brakes use output from the main hydraulic pump
controlled by the trailer brake valve, to apply the
trailer brakes.

The trailer brake valve is connected in line between

the main hydraulic pump and the tractor hydraulic
circuits.

Sensing lines connected between each of the

tractor brake lines and a pilot head on the trailer
brake valve, activate the valve to direct oil supplied
by the hydraulic pump to the trailer brakes,
whenever both tractor brake pedals are depressed
simultaneously.

The trailer brake valve is connected to the trailer

brakes by means of tubing and a unique coupling
which is to the ISO/DIS 5676 standard to prevent
any coupling other than the appropriate type being
connected.

The trailer braking system has priority over the

tractor hydraulics circuits and does not affect the
function of the hydraulic system. Similarly, the
hydraulic lift, remote control valve and other
hydraulic circuits do not interfere with the function
of the trailer brakes.

The trailer braking is proportional to the effort

applied on the tractor brake pedals. Feedback is
provided by the trailer brake valve to give a sense
of ‘feel’ to the operator which aids precise braking.
The pilot head ensures trailer braking only occurs
when both tractor brake pedals are depressed
simultaneously.

The trailer braking system can be installed on

tractors with either the fixed displacement gear
type hydraulic pump, or the variable displacement
hydraulic pump with closed centre load sensing.

2
On tractors installed with the fixed displacement
gear type hydraulic pump, the valve (1) sits above
the pump and is connected by metal tubing,
Figure 2.

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

On tractors installed with the variable displacement

hydraulic pump assembly with closed centre load
sensing, the valve (2) attaches directly to the top of
the pump, Figure 3.

The valve design for both types of installation are

similar, however, the valve installed on tractors with
variable displacement closed centre load sensing
pump has a load sensing capability (1) to signal the
pump when hydraulic demand by the trailer brakes
is required. This facility is not required on tractors
with the fixed displacement gear type pump.

TRAILER BRAKE VALVE PILOT HEAD

OPERATION

The pilot head on the trailer brake valve ensures

that trailer braking only occurs when both tractor
brake pedals are depressed simultaneously. This
is achieved by ensuring that the pilot piston,
housed within the head and which activates the
trailer brake valve, only functions when both pedals
are depressed.

Brakes Not Applied

When the tractor brakes are not applied pressure

is not being applied to the pilot head sensing lines,
Figure 4.

Single Pedal Brake Application

When a ‘single’ brake pedal is depressed, pressure

is directed from the pressurised brake line to the
trailer brake valve pilot head, Figure 5. The
pressure applied through either Port ‘A’ or ‘B’,
depending on whether the left or right hand pedal
is depressed, causes the ball in the pressurised
port to seat and the piston and plunger to move
forward, pushing the opposite piston off its seat.
Because the ball in the pressurised port is firmly
seated, the pressure in the activated brake line can
not be applied to the pilot piston, so the trailer brake
valve remains in the neutral position and trailer
brakes are not activated.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 5

R8--37 R8--38
Brakes Not Applied 4 Single Pedal Brake Application 5
1. Piston 4. Ball 6. Plunger
2. Bleed Screws 5. Pilot Piston 7. Ball
3. Piston
A. Pressure from Right Hand Brake Sensing LIne B. Pressure from Left Hand Brake Sensing LIne

Tractor Brake Sensing Pressure -- Brake Applied

Tractor Brake Sensing Pressure -- Brake Not Applied

Coupled Brake Pedal Application

When both brake pedals are depressed

simultaneously, the pressure generated in the
right and left hand brake lines is also applied to
both Ports ‘A’ and ‘B’ of the brake valve pilot head.
This pressure causes the piston in each port to
move toward the other while the plunger, which
separates the two pistons, prevents the balls
within the pistons from seating, Figure 6. The
brake line pressure is then applied to the pilot
piston, causing this piston to move forward and
activate the trailer brake valve.

R8--39
Coupled Pedal Brake Application 6
1. Piston 5. Pilot Piston
2. Bleed Screws 6. Plunger
3. Piston 7. Ball
4. Ball
Tractor Brake Sensing Pressure
-- Brake Applied

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

R8--160
Trailer Brake Valve Operation -- Brakes Released 7
1. Pilot Head 6. Check Valve
2. Spring 7. Control Valve Spool Bore
3. Drilling 8. Control Spool and Plunger
4. Flow Regulating Valve 9. Pressure Relief Element
5. Restrictor 10. Pilot Piston

A. Pressure from Right Hand Brake Sensing Line E. Load Sensing Gallery
B. Pressure from Left Hand Brake Sensing Line (CCLS Pump Installation only)
C. Outlet Port to Hydraulic Circuit F. To Trailer Brakes
D. Inlet Port from Hydraulic Pump G. Return to Reservoir

Pump Pressure Zero Pressure Oil in Return to Reservoir

Oil Brake Sensing Lines (Sump) Oil

TRAILER BRAKE VALVE OPERATION held against the spring pressure to permit flow of oil
from the pump supply Port ‘D’ to the tractor
Brakes released
hydraulic system through Port ‘C’. Additionally, in
When the tractor brakes are in the released neutral the flow regulating valve while held against
position, no pressure is being exerted in the tractor the spring pressure, prevents supply oil at Port ‘D’
braking lines or on the pilot piston through Ports ‘A’ from flowing to the trailer brake check valve.
and ‘B’ and the valve assumes the neutral position,
On tractors installed with the variable displacement
Figure 7.
hydraulic pump assembly, with closed centre load
Oil from the hydraulic pump enters into trailer brake sensing (CCLS), the load sensing gallery ‘E’ is
valve Port ‘D’. A small flow of oil passes from Port provided. This gallery is not pressurised when the
‘D’, through the restrictor in the centre of the flow valve is in neutral, but when subjected to pressure,
regulating valve to the control spool, which in the signals the hydraulic pump to increase output.
neutral position permits this oil to return to reservoir Refer to Chapter 2 for description and operation of
through Port ‘G’. The oil flow through the centre of the variable displacement pump with closed centre
the regulating valve also has to pass through a load sensing.
small drilling which limits the volume of oil returning
to reservoir through Port ‘G’. On tractors installed with the fixed displacement
gear type pump the load sensing gallery ‘E’ is not
The flow of oil from the hydraulic pump on reaching required or fitted. The valve components and
the restrictor in the flow regulating valve generates operation are identical in every other respect to that
a higher pressure on the pump supply side which installed with the variable displacement load
ensures that in neutral the flow regulating valve is sensing pump.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 7

R8--161
Trailer Brake Valve -- Brakes Being Applied 8
1. Pilot Head 6. Check Valve
2. Spring 7. Control Valve Spool Bore
3. Drilling 8. Control Spool and Plunger
4. Flow Regulating Valve 9. Pressure Relief Element
5. Restrictor 10. Pilot Piston

Pump Pressure Oil Reduced Oil Flow

Brake Sensing Line Pressure Oil Return to Reservoir (Sump) Oil

Brakes Being Applied returning to reservoir through Port ‘G’. As oil from
the hydraulic pump continues to pass through the
flow regulating valve, the combination of rising oil
When both brake pedals are depressed pressure on the spring side of the valve and the
simultaneously the pilot piston moves forward spring pressure, moves the flow regulating valve to
pushing against the pressure relief element, the left.
Figure 8. As the pressure relief element moves to
the left the control spool and plunger similarly move
to the left.
The flow regulating valve now begins to restrict the
flow of oil to the tractor hydraulic system, but directs
the pump supply oil to open the check valve and
As the control spool is moved to the left the flow of pass through Port ‘F’ to apply the trailer brakes. The
oil to reservoir through Port ‘G’ is prevented in two orifice located in the end of the flow regulating valve
stages. First the connection between the trailer limits the rate at which oil can flow through the
brake line Port ‘F’ and return to reservoir Port ‘G’ is centre of the flow regulating valve to the trailer
closed and secondly, oil passing through the centre brakes. The residual output from the pump is
of the flow regulating valve is prevented from allowed to flow to the tractor hydraulic system.

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

R8--162
Trailer Brake Valve -- Brakes Held 9
1. Pilot Head 6. Check Valve
2. Spring 7. Control Valve Spool Bore
3. Drilling 8. Control Spool and Plunger
4. Flow Regulating Valve 9. Pressure Relief Element
5. Restrictor 10. Pilot Piston

Pump Pressure Oil Trapped Oil

Brake Sensing Line Pressure Oil Return to Reservoir (Sump) Oil

Brakes Held moves to the right, preventing any further pump

pressure oil from being directed over the check
valve and into the trailer brake circuit, Figure 9. The
As the pressure in the trailer brake line builds up to oil in the trailer brakes is now trapped and maintains
match the pressure applied to the tractor braking a constant braking pressure in accordance with the
system, the increase in pressure acts on the end of tractor brake pedal pressure.
the control spool plunger in opposition to that
pressure applied on the pilot piston from the tractor Any increase in the pressure applied to the brake
brake pressure line. pedals will move the control spool and plunger to
the left, causing the brake application cycle to be
When the trailer brake line pressure has increase in repeated until the pressure in the trailer brake circuit
accordance with the pressure applied by the brake increases in accordance with the pressure being
pedals, the control spool plunger moves to the right, applied to the tractor brakes.
allowing the oil trapped on the spring side of the flow
regulating valve to return to reservoir through port When the brake pedal pressure is decreased the
‘G’. Assuming a constant brake pedal pressure is control spool and plunger moves to the right
being maintained this movement of the plunger is allowing the trapped oil behind the flow regulating
not sufficient to allow the trailer brake line to valve and the oil in the trailer brake circuit to return
connect with the dump Port ‘G’. to reservoir through port ‘G’ as shown in Figure 7.
The oil is allowed to escape to reservoir until the
Because the oil on the spring side of the flow pressure in the trailer brake circuit once again
regulating valve is now open to reservoir, the valve matches the pressure applied to the brake pedals.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 9

R8--163
Trailer Brake Valve -- Brakes Applied With Maximum Brake Pedal Pressure 10
1. Pilot Head 6. Check Valve
2. Spring 7. Control Valve Spool Bore
3. Drilling 8. Control Spool and Plunger
4. Flow Regulating Valve 9. Pressure Relief Element
5. Restrictor 10. Pilot Piston

Pump Pressure Oil Trapped Oil

Brake Sensing Line Pressure Oil Return to Reservoir (Sump) Oil

Brakes Applied with Maximum Brake Pedal As pressure in the trailer braking circuit increases
Pressure to the maximum permissible limit, the trailer brake
circuit oil pressure forces the control spool and
plunger against the springs in the pressure relief
element. As the pressure relief element springs are
compressed the control spool plunger moves to the
If at any time the maximum permissible trailer right, allowing the oil trapped behind the flow
braking pressure of 1740--2180 lbf/in2 (120--150 regulating valve to return to reservoir through port
bar) is reached, for example, by pressing ‘G. The flow regulating valve can now move to the
excessively on the tractor brake pedals, an right and prevent any further pump system
increase in braking pressure is prevented by the pressure oil from being directed over the check
pressure relief element. valve to the trailer brake circuit.

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

33 220 TRAILER BRAKE VALVE

OVERHAUL

GENERAL

The trailer brake valve housing and orientation of

the pilot head (1) changes according to the type of
hydraulic pump fitted to the tractor. Figure 1 shows
the trailer brake valve for the fixed displacement
tandem gear type pump installations.

1
Figure 2 shows the trailer brake valve for tractors
fitted with the variable displacement closed centre
load sensing (CCLS) hydraulic pump. This valve
is manufactured with a special load sensing gallery
(1) and must only be used where these pumps are
fitted.
The overhaul procedure for both types of valve is
however identical.

Trailer Brake Valve Assembly

(Variable Displacement CCLS Hydraulic Pump)
1. Load Sensing Gallery
2. Pilot Head

2
REMOVAL

1. Clean area around trailer brake valve (1).

2. Disconnect hydraulic connections to valve and

allow escaping oil to drain into suitable
container. Refer to Figure 3 and Figure 4 for
the two types of installation.

3
3. Remove trailer brake valve (1).

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 11

DISASSEMBLY

Pilot Head and Piston Assembly 5

1. Pilot Head 5. Trailer Brake Valve Housing
2. Piston Housing 6. Piston
3. Seal 7. ‘0’ Ring
4. Gasket

1. Remove pilot head and withdraw piston

assembly, Figure 5.

2. Remove adaptor on end of pilot head and

remove components, Figure 6.

Pilot Head 6
1. Spring
2. Piston Seal
3. ‘0’ Ring
4. Adaptor
5. Piston Assembly
6. Plunger
7. Piston Assembly
8. Bleed Screws
9. Pilot Head
10. Piston Seal

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

3. Remove pressure relief element (1) and

control valve spool return spring (4) from valve
housing. Refer to Figure 7.

NOTE: The spring (2) and seat (3) locate within the
relief element. It is not necessary to disassemble
the pressure relief element as this is serviced as a
pre--set assembly.

7
4. Remove collar (3) retaining the control valve
spool assembly (1) and back up washer (2).
Figure 8.

NOTE: The retaining collar may be removed by

placing a 14mm nut inside the locking ring. The nut
should be of sufficient length to enable a socket
spanner to be placed over the nut to allow the collar
to be unscrewed.

5. Using a suitable rod push control valve from

housing.

8
6. Pull control valve spool assembly from spool
bore. Remove snap ring and disassemble
spool and plunger assembly, Figure 9.
Control Valve Spool Exploded View
1. ‘O’ Ring
2. Spring
3. Plunger
4. Snap Ring
5. Seal
6. Washer
7. Locating Ring
8. Spool
9. Control Spool Bore

9
7. Unscrew end cap and withdraw spring and flow
regulating valve spool. Remove snap ring and
orifice from end of spool, Figure 10.

Flow Regulating Valve

1. Clip
2. Spring
3. End Cap
4. ‘O’ Ring
5. Spool
6. Orifice
7. Snap Ring

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6 13

8. Remove check valve end cap and withdraw

spring and check valve, Figure 11. If
necessary unscrew and remove check valve
seat.

INSPECTION AND REPAIR

1. Carefully examine all components and replace

any item showing signs of wear or damage.

NOTE: Two ‘O’ ring seals are located inside the

trailer brake valve body in the control valve bore.
These seals must be carefully checked and if Check Valve Components 11
necessary replaced. 1. Trailer Brake Valve Housing
2. Check Valve Seat
3. Spring
4. End Cap
5. ‘O’ Ring Seal
RE--ASSEMBLY AND INSTALLATION 6. Check Valve
7. ‘O’ Ring Seal
1. Re--assembly and installation follows the
removal and disassembly procedure in
reverse. On re--assembly observe the
following requirements.
S Ensure all oil seals and gaskets are renewed.
S Tighten all bolts and fittings to the correct
torque. See Specifications.
2. Bleed the trailer braking system according to
the following procedure:
S Ensure the brake reservoir is full.
S Open the three bleed screws on the trailer
brake valve and also the right and left hand
brake bleed screws on the rear axle trumpet
housings.
S Couple the brake pedals together and depress
the pedals 6 times to their full stroke.
S Close all bleed screws.
S Attach transparent bleed pipes to left hand rear
axle bleed screw and insert the open end of the
pipe into a clean glass of brake fluid to New
Holland Specification NH 610 A (Ambra Brake
LHM.
S Open the bleed screw and slowly depress and
release the coupled brake pedals until no more
air is expelled with the brake fluid.
S Repeat the above procedure with the right
hand brake bleed screw.
S Repeat the above procedure with the left hand,
centre and right hand trailer brake valve bleed
screws.
S Top up the brake reservoir to the maximum fill
mark with brake fluid to New Holland
Specification NH 610 A (Ambra Brake LHM).

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

PRESSURE TESTING

1. Connect 0--6000 lbf/in2 (0--414 bar) pressure

gauge FT.8503A to trailer brake coupling,
Figure 1.

2. Set engine speed to 1500 rev/min.

3. Depress right hand brake pedal. There should

be no reading on the pressure gauge.

4. Depress left hand brake pedal. There should

be no reading on the pressure gauge.

5. Couple together and depress both brake

Trailer Brake Pressure Test 1
pedals. The reading on the pressure gauge
should increase as the brake pedals are 1. Adaptor 4FT.854
depressed harder. The pressure should 2. Test Hose Part No. 83936707
increase depending on pedal effort, until a 3. Adaptor FT. 8503--8 or FNH 00705
4. Pressure Gauge FT.8503A
maximum pressure of 2140 lbf/in2 5. Trailer Brake Coupler
(120--150 bar) is achieved.

6. Release brake pedals. Pressure should

reduce to zero.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 7 -- REMOTE CONTROL VALVES

Section Page
35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Remote Control Valves--description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

35 000 SPECIFICATIONS

Detent Regulating Valve Pressure 2150--2350 lbf/in2 (148--162 bar)

TORQUES

Flow Control Valve Plug 20 lbf ft 27 Nm

Detent Shaft Pivot Coupling 5 lbf ft 7 Nm

Detent Housing Retaining Screws 5 lbf ft 7 Nm

Priority Check Valve 5 lbf ft 7 Nm

Valve to Coupler Housing Bolts 11--15 lbf ft 15--20 Nm

Valve to Mounting Bracket Bolts 20--26 lbf ft 27--35 Nm

Remote Valve Coupler to Housing 60 lbf ft 82 Nm

THREAD SEALANT

New Holland Thread Lock and Seal, Part Number 82995773

SPECIAL TOOLS

Flowmeter VL Churchill MS820A, FNH 02755, FNH 02760

or suitable equivalent

Flowmeter Hoses Procure locally to suit Flowmeter used

Coupler Remover North America FNH 00095

Slipper Seal Installation Tool VL Churchill FT 8611

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

REMOTE CONTROL VALVES--DESCRIPTION AND OPERATION

DESCRIPTION

TS Series Tractors may be fitted with the optional

closed centre load sensing remote control valves
for the operation of external hydraulic services.

Remote valves are available to operate external

hydraulic services, eg hydraulic cylinders and
motors. Up to four remote control valves may be
installed and are located at the rear of the tractor,
Figure 1. The valves are mounted directly onto
quick release couplers which are designed to give
unrestricted flow and low back pressure.
1
On tractors with cab, the two valves are actuated
by a single joystick control (1) Figure 2, located in
a console to the right of the operator’s seat.

On tractors without cab, separate levers, (1) and

(2) Figure 3, are provided for each valve. However,
the joystick control is available as a dealer installed
accessory. Models with cab may have the optional
third and fourth valves, installed to the left of the
hydraulic top link. The levers (3) and (4) Figure 2
control valves III and IIII, respectively.

The joystick (1) and remote control valve levers (3)

and (4) each have four operating positions.
2
The joystick/levers and their respective valves are
colour coded for identification and the valves are
also numbered as shown in the following chart:

Joystick/Lever Colour Valve Position/No.

Position Code

Joystick or lever Green Right--hand outer -- I

Joystick or lever Blue Right--hand inner --II
Right--hand lever Tan Left--hand inner -- III
Left--hand lever Black Left--hand outer -- IIII

Joystick Control (where fitted)

The joystick (1) Figure 2 actuates valves I and II, 3

operating in a cross pattern. Moving the joystick
backwards and forwards in a straight line actuates
valve no. I. Moving the joystick sideways in a
straight line actuates valve No. II. Moving the
joystick diagonally will actuate both valves
simultaneously. By applying directional bias, one
valve can be made to actuate at a faster or slower
rate than the other.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 3

Move the joystick rearward from the neutral

position and the cylinder connected to valve No, I
will extend to raise the implement. Push the
joystick forward, past neutral, to retract the
cylinder. Pushing it fully forward, beyond the
’retract’ position, will select ’float’ which will permit
the cylinder connected to remote control valve No.
I to extend or retract freely, thereby allowing
equipment such as scraper blades to ’float’ or
follow the ground contour.

Move the joysitck to the left from the neutral

position and the cylinder connected to valve No. II
will extend to raise the implement. Move the
joystick to the right, past neutral, to retract the
cylinder. Moving it fully to the right, beyond the
’retract’ position, will select ’float’ which will permit
the cylinder connected to remote control valve No.
II to extend or retract freely.

The lock collar (2) Figure 4, provides selective

control of the joystick. With the lock collar pushed
fully down, the joystick is locked in neutral and
neither of the remote control valves can be
operated, either by accident or by choice.

Lift the collar up to the first, central position and the

joystick may only be moved forward or backward
to operate valve No. I. No II remote valve is locked.

If the lock collar is pulled fully up, valves I and II 4

may be operated independently or together by
moving the joystick control in the appropriate
direction.

Lever Controls (where fitted)

The levers are moved forward and backwards to

select extend, retract and float, as with the joystick
control.

Move the lever rearward from the neutral position

and the cylinder will extend to raise the implement.
Push the lever forward, past neutral, to retract the
cylinder. Pushing it fully forward, beyond the
’retract’ position, will select ’float’ which will permit
the cylinder to extend or retract freely, thereby 5
allowing equipment such as scraper blades to
’float’ or follow the ground contour.

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Joystick or Lever Controls

The float position is also used for retracting a

single--acting ram cylinder, such as when lowering
a tipping trailer, etc. (see Operating
Single--Acting Cylinders)

The extend, neutral, retract and float positions are

identified by symbols on a decal next to the joystick
and/or control levers.

A detent will hold the joystick/lever in the selected

extend or retract position until the remote cylinder
reaches the end of the stroke when the control
lever will automatically return to neutral.
alternatively, the lever may be returned to neutral
manually. The lever will not return automatically
from the float position.

A detent screw is provided on each remote control

valve and may be adjusted to vary the system
pressure required to return the lever automatically
to the neutral position.

If you wish to remove the detent, a conversion kit

is available.

NOTE: Do not hold the joystick/lever in the extend

or retract position once the remote cylinder has
reached the end of the stroke as this will cause the
relief valve to ’blow’. Forcing oil through the relief
valve for extended periods will overheat the oil and
may lead to failure of hydraulic and driveline
components.

4 1
To adjust the system pressure at which the remote
control valve lever automatically returns to neutral,
turn the screw (3) Figure 6. turning the screw
clockwise (in) will increase the pressure at which
the valve kicks out. Turning the screw
anti--clockwise (out) will decrease pressure, and
the valve will kick out more readily.
3

Each remote control valve has its own flow control

valve (4) Figure 6 and a pair of couplers. The 2
couplers are of self--sealing/locking design but will
allow remote cylinder hoses to pull free if the 6
implement should become disconnected from the
tractor. The upper (lift) coupler (1) Figure 6, is
identified by an ’extended cylinder’ symbol
moulded into the rubber dust cap. The lower (drop)
coupler (2) Figure 6, has a ’retracted cylinder’
symbol.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 5

Connecting Remote Cylinders -- adding oil, provided that the tractor is being
Figures 7 to 9 operated on level ground.

WARNING: Before connecting or

disconnecting hydraulic hoses at the remote
To connect a remote cylinder, insert the feed and/or
cylinders, stop the engine and relieve the pressure
return hose through the slit in the appropriate dust
in the circuit by moving the remote control valve
cap, ensuring it is correctly seated in the coupler.
lever(s) fully forward to the ’float’ position then back
Ensure that there is sufficient slack in the hose(s)
to neutral. Never work under or allow anyone near
to allow the tractor/implement to turn in either
raised equipment as it will drop when relieving
direction.
pressure in the system.

WARNING: Before disconnecting cylinders To equalise the pressure in the hose and tractor
or equipment ensure the equipment or couplers, start the engine and move the valve
implement is supported securely. control lever to the ’float’ position, then return it to
neutral. To disconnect, grip the hose a short
distance from the coupler, push the hose forward,
into the coupler, then quickly pull on the hose to
’pop’ the coupler free.

IMPORTANT: Before connecting remote cylinder

hoses, stop the engine and thoroughly clean the
connections to prevent oil contamination. Remote
cylinders are operated by oil drawn from the tractor
hydraulic system, therefore, always check and WARNING: Never work under equipment
replenish the hydraulic system oil after remote supported by a hydraulic device because it
cylinder equipment has been connected and cycled may drop if the control is actuated (even with the
a few times. Operating the tractor with a low oil level engine stopped) or in the event of hose failure.
may result in damage to the rear axle and Always use a secure support for equipment which
transmission components. must be serviced while in the raised position.

NOTE: When topping up the rear axle to The flow control valve (4) Figure 6, meters the flow
accommodate the requirement of remote cylinders, of oil to the remote cylinder and thus controls the
no more than 45 litres (10.0) imp. Gallons) should rate of response of the cylinder.
be added to bring the oil level up to the full mark on
the dipstick.

Turn the flow control knob anti--clockwise (hare

symbol uppermost) to increase the rate of oil flow.
Alternatively, remote cylinders with a total oil Turn the knob clockwise (tortoise symbol
capacity of up to 18 litres (4.0 Imp. Gallons) may be uppermost) to decrease the rate of flow. For flow
connected to the tractor hydraulic system without rates, see Specifications.

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Operating Double--Acting Cylinders -- Figure 7

Connect the feed hose (1) between the piston end 4
of a double--acting cylinder and the upper coupler 1
(4) on the remote control valve. Connect the
return hose (2) between the lower coupler (3) on
the same valve and the rod end of the cylinder. To
extend a double--acting cylinder, pull the control
lever towards you, to the ’raise’ position.

To retract a double--acting cylinder, push the

control lever away from you, past neutral to the
’lower’ position.
3 2
Further movement of the lever away from you will
select ’float’ which will allow the cylinder to extend
7
or retract freely. This feature is of material
assistance when carrying out work with equipment
such as scraper blades and loaders.

Operating Single--Acting Cylinders -- Figure 8

Connect the hose (1) from a single--acting cylinder
to the upper coupler (2) on the remote control
1
valve, as previously described.

To extend a single--acting cylinder, pull the control

lever toward you, to the ’raise’ position.

Manually return the lever to the neutral position to

stop the cylinder before it is fully extended or allow
the valve to return to the neutral automatically
when the cylinder reaches the end of it’s stroke. 2
To retract a single--acting cylinder, move the lever
fully away from you, to the ’float’ position. 8

IMPORTANT: Always use the ’float’ position to

lower a single--acting cylinder. The ’lower’ position
is for double--acting cylinders only.

Operating Continuous Flow Hydraulic

Equipment -- Figure 9
4 1
Continuous flow hydraulic equipment (e.g.
hydraulic motors) should be connected to remote
control valve coupler with the feed hose (2)
connected to the lower coupler (3) and the return 2
hose (1) connected to the upper coupler (4) of the
same valve.

With the remote control valve lever fully away from

you, in the ’float’ position the motor will be
stationary. The hydraulic motor will operate if the 3
lever is pulled towards you, to the ’lower’ position.
9
IMPORTANT: To stop the motor, move the lever
fully away from you, to the ’float’ position. The
motor will then slow to a halt.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 7

Observe the following to further protect the tractor

and equipment:
1

S Do not open any by--pass valve in the

equipment or motor. Use the flow control valve
to control the rate of flow or speed of the motor.

S Do not hold the remote control valve lever to

operate the equipment. If the detent will not
hold the lever, adjust the detent screw (1)
Figure 10, as previously described, check the
equipment for proper adjustment. 10

S To assure optimum hydraulic oil cooling and

prevent overheating, operate continuous flow
equipment at the highest flow setting (by use of
the flow control valve) and lowest engine speed
that will give the required machine
performance and speed.

S It is recommended that a temperature gauge,

where available, is installed in the remote
circuit when using hydraulic motors for
continuous operation. If over--heating occurs,
stop the hydraulic motor until the oil cools.
Ensure the flow control setting is at maximum
and the engine speed at a minimum,
appropriate to machine performance.

If operating conditions are normal and high

temperatures persist, install an oil cooler in the
motor return circuit. The maximum recommended
operating temperature of the oil is 110!C (230!F)

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Operating Several Remote Valves

Simultaneously or Remote Valves and
Hydraulic Lift Simultaneously

NOTE: The variable displacement pump fitted to

tractors with the closed centre load--sensing
system adjusts the oil flow according to the
individual flow control settings up to the maximum
output possible, dependent upon engine speed.
The oil flow will be relatively constant in the remote
control valve circuits if the flow control valves are
used to regulate the flow, thus providing constant
operating speed for hydraulic motors, etc., even if
engine speed varies. Maintain the engine speed
above the minimum required for simultaneous
operation of all the required circuits and vary
ground speed by selection of the appropriate gear
ration.

If operating two or more remote control valves

simultaneously or remote valves and the hydraulic
lift, all the flow control valves should be adjusted to
provide a partial flow. If not so adjusted, all the
available flow may be directed to the full flow circuit
when the pressure in that circuit is less than that of
the other circuits in use.

Bleeding Remote Cylinders

When connecting a cylinder with trapped air, i.e., a

new cylinder, one that has been out of service or
one that has had the hoses disconnected, it will be
necessary to bleed the cylinder to remove the air.

With the hoses connected to the remote control

valve couplers at the rear of the tractor, position the
cylinder with the hose end uppermost and extend
and retract the cylinder seven or eight times using
the remote control valve operating lever.

Check the rear axle oil level before and after

operating a remote cylinder.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 9

HYDRAULIC CONNECTIONS AND

COMPONENTS

Connections from the hydraulic pump to the

remote valves differ according to the type of
hydraulic pump installed on the tractor.

Tractors with Fixed Displacement Hydraulic

Pumps

Figure 11 shows the installation of a double remote

valve housing on a tractor fitted with fixed Remote Control Valve Installation 11
displacement hydraulic gear type pumps. A (Tractors with Fixed Displacement Pump)
maximum of four remote valves, however, can be 1. Supply to Remote Valve
fitted if required. 2. Load Sensing (Pilot) Line
3. Supply from Auxiliary Engine Mounted Pump
4. Priority Valve Pack (contains combining valve)
5. Remote Valve Housing
When a tractor is fitted with fixed displacement 6. Return from Remote Valve
hydraulic pumps the priority valve pack containing
the combining valve is also installed.

The hydraulic lift has priority on oil supply from the

fixed displacement hydraulic pump, with surplus
capacity directed through the combining valve, in
the priority valve pack to the remotes.

Although the oil supply from the auxiliary engine

mounted pump to the priority valve pack is via
external pipework, the supply from the main
hydraulic pump to the priority valve pack and
combining valve is through internal galleries within
the hydraulic top cover.

The combining valve operates in conjunction with

the remote valves and performs the following
functions:--

Returns main hydraulic and engine mounted

pump flow to sump (rear axle) when remotes
are in neutral.

Directs the main hydraulic and engine mounted

auxiliary pump flow, where fitted, to the deluxe
remotes when operated.

Returns surplus pump flow to sump if pump

supply exceeds demand.

Protects engine mounted auxiliary pump and

remotes from excessive pressure.

Refer to Chapter 4 for description and operation of

the priority valve pack.

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10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Tractors with Variable Displacement CCLS

Hydraulic Pump

Figure 12 shows the installation of two double

remote valve housings on tractors installed with the
variable displacement closed centre load sensing
hydraulic pump.

Tractors fitted with the variable displacement

closed centre load sensing (CCLS) hydraulic pump
do not require the priority valve pack and
combining valve, necessary for fixed displacement
hydraulic pumps installations.
Remote Control Valve Installation 12
(Tractors With Variable Displacement
CCLS Hydraulic Pump)
On tractors fitted with the variable displacement
CCLS hydraulic pump, oil required by the remote 1. Double Spool Remote Valve Housing
2. Load Sense Line Priority Check Valve
valves, flows directly from and returns to the 3. Return From Remote Valve To Hydraulic Pump
hydraulic pump housing. This is possible because 4. Feed To Remote Valve From Hydraulic Pump
output from the pump, irrespective of the hydraulic 5. Load Sense Line
circuit being operated, is continually adjusted 6. Double Spool Remote Valve Housing
according to the hydraulic demand of the tractor.

Refer to Section 35, Chapter 2 for the total

description and operation of the variable
displacement CCLS hydraulic pump assembly.

All Tractors

Irrespective of the type of hydraulic pump installed

and to ensure that pump flow is controlled by the
remote valve with the highest operating circuit
pressure, priority check valves are installed in the
load sensing lines between each individual remote
valve.

Where two individual valve housings are fitted, for

example if three or more remote valves are
installed, a check valve is fitted at the ‘Tee’ joint
between the load sense line for each valve. Refer
to item 2, Figure 12, for the typical location of the
check valve.

Where a double spool remote valve housing is

fitted a check valve is also fitted between the two
valves within the housing and is located as shown
in Figure 13, items 22/23.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 11

Double Spool Remote Control Valve 13

1. Valve Body 13. Detent Valve Spring Adjuster
2. Spool 14. Detent Balls (9 off)
3. Flow Restrictor* 15. Detent Regulating Valve Spring
4. Load Check Valve 16. Spacer
5. Flow Restrictor End Plug 17. Detent Regulating Valve
6. Flow Restrictor Control Shaft 18. Detent Housing
7. Flow Restrictor Control Knob 19. Shuttle Check Valve
8. Detent Plunger 20. Flow Control Spring
9. Spool Centering Spring 21. Flow Control Spool
10. Locknut 22. Priority Check Valve Ball (double spool only)
11. Detent Piston Spring 23. Priority Check Valve Retainer
12. Detent Piston
** The flow restrictor must be installed with the large slot positioned 1800 to that shown in illustration.

The principal components of the double spool Where a single spool remote valve is installed on a
remote control valve assembly are shown in tractor, The individual component parts are
Figure 13 and will assist in identifying the parts identical to those shown in Figure 13 for double
detailed in the oil flow diagrams used to explain the spool assemblies.
operation of the valve.

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12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

HYDRAULIC CIRCUITS

Hydraulic Oil Supply to Remote Valves for Tractors 14

Installed with Variable Displacement CCLS Hydraulic Pump
1. Supply to Remote Valve Direct from Variable 3. Lift and Drop Ports to Auxiliary Equipment
Displacement CCLS Hydraulic Pump 4. Load Sense Line Check Valve
2. Remote Control Valve Assembly 5. Load Sense Line to Hydraulic Pump

The hydraulic circuits shown in Figures 15 to 17, centering spring and passage ‘B’ is blocked by the
illustrate operation of the remote valves. These centre land of the spool.
circuits also show operation of the combining valve
used on tractors with the fixed displacement The control valve spool also isolates lift port ‘G’ and
hydraulic pump. drop port ‘H’ from supply passage ‘B’ and return oil
galleries ‘E’ and ‘F’. The oil in both ends of the lift
When studying operation of the remote valves on cylinder is, therefore, trapped.
tractors installed with the variable displacement
CCLS hydraulic pump the same principle of When the valve is in neutral galleries ‘C’ and ‘D’
operation applies but all reference to the combining connect with the return oil galleries ‘E’ and ‘F’
valve should be disregarded. allowing pressure in the load sensing lines from the
On tractors with the variable displacement CCLS valve to return to sump.
hydraulic pump, the oil supply to the remote valve
at port ‘A’ comes directly from the hydraulic pump On tractors with fixed displacement hydraulic
and the load sensing line connects directly to the pumps the combining valve moves to the left,
flow compensating valve on the pump body as against the spring, diverting oil flow from the pumps
shown in Figure 14. back to reservoir through the priority valve
assembly.
Oil Flow In Neutral On tractors with the variable displacement CCLS
hydraulic pump the flow compensating valve
With reference to Figure 15, Page 13. responds to the zero pressure in the load sensing
When the remote valves are in neutral the control line and controls the swash plate angle to maintain
valve spool is held in the neutral position by the the pre--set low pressure standby.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 13

R8--305
Single Remote Control Valve Operation--Neutral 15
Pump Pressure Oil Exhaust Oil Trapped Oil

1. Flow Control Restrictor 10. External Cylinder 18. Auxiliary Pump Supply*
2. Load Check Valve 11. Valve Body 19. Hydraulic Priority Valve
3. Check Valve Spring 12. Control valve Spool Assembly*
4. Flow Control Knob 13. Shuttle Check Valve 20. Supply to Remote Valve
5. Detent Regulating Valve 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing)
6. Detent Spool 15. Flow Control Spring Valve*
7. Detent Plunger and Spring 16. Flow Control Spool 22. Main Pump Supply via
8. Detent Balls 17. Return to Sump* Combining Valve*
9. Centering Spring

*Tractors with Fixed Displacement Hydraulic

Pump Only
For Tractors Fitted with Variable Displacement CCLS Hydraulic Pump
A = CCLS Pump Supply B = CCLS Pump Load Sensing Line

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Oil Flow In Raising and auxiliary pump pressure oil is directed to the
remote control valve inlet port ‘A’.
With reference to Figure 16.
On tractors with the variable displacement CCLS
hydraulic pump the load sensing line signals the
When the remote valve lever is moved to the raise pump to increase flow which is directed to inlet port
position, the control valve spool is moved forward ‘A’ at the pressure required to move the load
and the spring loaded detent balls engage with the connected to port G.
rear groove in the detent plunger.
Pump pressure oil flows from Port ‘A’ to passage ‘B’
Passage ‘B’ is now connected to lift port gallery ‘G’ through:--
and ‘D’ while drop port ‘H’ and gallery ‘C’ are
connected to the return to sump oil gallery E.
(i) Flow Control Spool Holes

When the remote control valve lever is initially

moved to the raise position the pressure at gallery
(ii) Load Check Valve
‘D’ is equivalent to the cylinder pressure or tractor
hydraulic back pressure whichever is the greatest.

(iii) Flow Control Restrictor

The pressure oil at gallery ‘D’ now flows to the
shuttle check valve and through the internal drilling
to: The volume of oil entering passage ‘B’ and flowing
to the lift Port ‘G’ is determined by the flow control
restrictor setting which is manually pre--set.
Detent Regulating Valve

Exhaust oil from the lift cylinder drop port ‘H’ now
Flow Control Valve Spool returns to reservoir through oil gallery ‘E’.

Load Sensing (Pilot) Line When the cylinder is fully extended, the pump
supply oil pressure increases until the detent
regulating valve opens. Pump pressure oil moves
On tractors with fixed displacement hydraulic the detent spool against the detent spring and
pumps the load sensing line pressure from gallery releases the clamping effort of the detent balls on
‘D’ acts on the end of the combining valve moving the end of the control valve spool. The centering
the valve to the right. The return to sump port in the spring now moves the spool back to the neutral
priority valve is now closed and the main hydraulic position.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 15

R8--306
Single Remote Control Valve Operation--Raising
16
Pump Pressure Oil Exhaust Oil

1. Flow Control Restrictor 10. External Cylinder 18. Auxiliary Pump Supply*
2. Load Check Valve 11. Valve Body 19. Hydraulic Priority Valve
3. Check Valve Spring 12. Control Valve Spool Assembly*
4. Flow Control Knob 13. Shuttle Check Valve 20. Supply to Remote Valve
5. Detent Regulating Valve 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing)
6. Detent Spool 15. Flow Control Spring Valve*
7. Detent Plunger and Spring 16. Flow Control Spool 22. Main Pump Supply via
8. Detent Balls 17. Return to Sump* Combining Valve*
9. Centering Spring

*Tractors with Fixed Displacement Hydraulic

Pump Only
For Tractors Fitted with Variable Displacement CCLS Hydraulic Pump
A = CCLS Pump Supply B = CCLS Pump Load Sensing Line

604.55.041.00 - 01 - 1998
16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Oil Flow In Lowering

With reference to Figure 17. On tractors with the fixed displacement hydraulic
pump the high supply line pressure from the pump
acts on the right hand end of the combining valve.
When the remote valve lever is moved to the The valve now moves against the combined spring
lowering position the spool moves rearwards
and load sensing line pressure, diverting surplus
allowing the spring loaded detent balls to engage
pump flow to sump.
with the front groove in the detent plunger.

In the lowering position, passage ‘B’ is connected The greater the restriction set by the flow control
to drop port ‘H’ and gallery ‘C’. Lift port ‘G’ is knob, the greater the difference between the supply
connected to gallery ‘D’ and return oil gallery ‘F’. line and load sense line pressures and on fixed
The connections to and from the cylinder are now displacement pump tractors the larger the volume
reversed allowing pump flow to retract the cylinder of oil returned to sump.
in a similar manner to that described for raising.
On tractors with the variable displacement CCLS
The shuttle check valve allows pressure from hydraulic pump, the low load sense line pressure
gallery ‘C’ to be sensed by the load sensing line and acting on the pump flow compensating valve
also operate the detent regulating valve and flow signals the CCLS pump to adjust pump output in
control spool as previously described. accordance with the tractor hydraulic circuit
demands.
As the flow control restrictor is rotated towards slow
flow, the flow control restrictor slot area which aligns It can now be seen that the flow control restrictor
with passage ‘B’ is reduced, restricting oil flow to enables the operator to vary the rate of flow through
passage ‘B’. The degree of restriction will cause the remote valves and consequently the speed of
supply line pressure to increase compared to load operation of the equipment attached to the
sense line pressure. remotes.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 17

R8--307
Single Remote Control Valve Operation--Lowering with Slow Flow Control Setting 17

Pump Pressure Oil Reduced Oil Flow Exhaust Oil

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Oil Flow With Cylinder Overload The combining valve now moves to the left, allowing
the auxiliary and main hydraulic pump oil flow to
return to sump, limiting maximum remote pressure
With reference to Figure 18. to 2750 lbf/in2 (192 bar).

Under normal operating conditions excessive

pressures in the remote circuits are protected by Tractors with variable displacement CCLS
the detent regulating valve which returns the control hydraulic pump:
valve spool to neutral when the external cylinder
pressure becomes excessive or the cylinder
reaches the end of its stroke. However if the Excessive pressures in the circuit are automatically
operator overrides the detent allowing the pressure protected by the pressure compensating valve in
to become excessive due to an overload condition the hydraulic pump.
the circuit is protected as follows:--
When the pressure in the load sensing line
Tractors with fixed displacement gear type approaches 2700 lbf/in2 (186 bar) the pressure
pump: compensating valve opens, allowing high pressure
oil to be directed to the swash plate servo piston.
The servo piston consequently changes the angle
When the hydraulic lift is raising and the remote of the swash plate to reduce pump flow.
valves are supplied by the auxiliary engine mounted
pump, excessive cylinder pressure acting through
the load sense line from drop port ‘H’ opens the Refer to Chapter 2 in this part of the Repair Manual
integral combining valve relief valve reducing the for the operation of the variable displacement CCLS
pressure acting on the left hand end of the valve. hydraulic pump.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 19

R8--308
Single Remote Control Valve Operation--External Cylinder Overload 18
Pump Pressure Oil Reduced Oil Flow Exhaust Oil

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Double Remote Valve Operation

With reference to Figure 19. contains radial holes, through which pump oil must
flow to reach passage ‘B’.
Two or more remote valves can be operated
simultaneously irrespective of cylinder load. If there is a large difference in the operating
pressures between the two remote valve circuits
being operated, an excessive amount of oil will
If two spools are operating a light load circuit and a attempt to flow from the pump, through the flow
heavy load circuit simultaneously, all the oil flow control spool and restrictor of the remote circuit
from the valve will attempt to flow to the light load operating at the lower pressure. This additional flow
circuit. The flow control spool will maintain pre--set results in an increased pressure being generated
flow (manual restrictor setting) to light load circuit. on the right hand face of the flow control spool.

It should be noted that in this condition the shuttle The increased pressure acting on the right hand
ball in the load sense line is pushed firmly towards face of the flow control spool moves the spool to the
the low pressure circuit, isolating the sense line left, against both the spring and lower pressure
from the remote valve operating under the lighter acting on the opposite face of the spool. As the
load condition. spool moves to the left, the flow control spool radial
holes are progressively covered restricting and
controlling oil flow from passage ‘A’ to the load
In the double remote valve operation circuit shown check valve. Excessive oil flow to the light load
in 19, passage ‘B’ is connected through the shuttle circuit is therefore prevented while maintaining a
check valve to the spring end of the flow control high supply line pressure from the heavy load
valve spool. The portion of the spool in port ‘A’ circuit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 21

R8--309
Double Remote Control Valve Operation 19
Pump Controlled Reduced Exhaust Oil
Pressure Oil Oil Flow Oil Flow
1. Flow Control Restrictor 10. External Cylinder 18. Auxiliary Pump Supply*
2. Load Check Valve 11. Valve Body 19. Hydraulic Priority Valve
3. Check Valve Spring 12. Control Valve Spool Assembly*
4. Flow Control Knob 13. Shuttle Check Valve 20. Supply to Remote Valve
5. Detent Regulating Valve 14. Load Sense Line (Pilot Line) 21. Combining (Sequencing)
6. Detent Spool 15. Flow Control Spring Valve*
7. Detent Plunger and Spring 16. Flow Control Spool 22. Main Pump Supply via
8. Detent Balls 17. Return to Sump* Combining Valve*
9. Centering Spring

*Tractors with Fixed Displacement Hydraulic Pump Only

For Tractors Fitted with Variable Displacement CCLS Hydraulic Pump
A = CCLS Pump Supply B = CCLS Pump Load Sensing Line

604.55.041.00 - 01 - 1998
22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Oil Flow In Float

With reference to Figure 20. Lift port ‘G’ and drop port ‘H’ are connected to return
galleries ‘F’ and ‘E’ allowing the remote cylinder to
float and assume any position.
The float position allows operation of single acting
cylinders when lowering under light load conditions. Galleries ‘C’ and ‘D’ are also connected to the return
oil galleries ‘E’ and ‘F’, allowing only low back
pressure to either side of the shuttle check valve.
When the remote valve lever is pushed fully forward The load sensing line is, therefore, not pressurised
to the float position, the spool is moved fully and the output from the fixed displacement pump
rearward past lowering to allow the detent balls to (where fitted) is returned to the rear axle by the
engage with the float detent plunger groove. combining valve.

On tractors with the variable displacement CCLS

The spool can only be returned to neutral manually hydraulic pump, output is adjusted automatically in
by the operator as no pressure can be generated at accordance with tractor hydraulic requirements, as
the shuttle check valve to release the detent described in Chapter 2 of this Part of the Repair
mechanism. Manual.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 23

R8--310
Single Remote Control Valve Operation--Float 20
Pump Pressure Oil Exhaust Oil Trapped Oil

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

COUPLERS

Remote Valve Coupler Operation 21

A Coupler Disconnected and Not Pressurised B Coupler Connected and Pressurised
1. Coupler Assembly 4. Probe
2. Auxiliary Equipment Hose Connector 5. Locking Sleeve
3. Hose Connector Check Valve 6. Locking Balls

Figure 21, shows a cross section through the loaded probe remains in contact with the face of the
remote couplers. check valve, Stage B, Figure 21.
Oil pressure within the coupler now pushes the
When the coupler is disconnected from the auxiliary locking sleeve rearward, forcing the locking balls
equipment, the valve is spring loaded in the closed against the end of the probe, preventing the probe
position. from moving rearwards.
With the probe locked in the forward position the
When equipment is connected and the remote hose connector check valve is held in the ‘Fully
valve pressurised, high pressure oil forces the hose Open’ position even when the remote valve is
connector check valve off its seat and the spring working at a low operating pressure.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 25

35 204 OVERHAUL

CONTROL VALVE HOUSING

REMOVAL

1. Disconnect the control linkage (2) and tubes

(1, 3 & 4), Figure 1 and remove control valve
and coupling assembly from the tractor.

1
DISASSEMBLY

1. Separate control valve (1) from coupling

assembly (2).

2
2. Remove end cap (3) with ’O’ ring (4) and
remove flow control spool (1) and spring (2)
from rear of housing, Figure 3.

3
3. Remove flow control knob (2). push restrictor
end plug (3) as far as possible into housing and
remove spiral circlip (1), Figure 4.

NOTE: The plug can only be pushed into the

housing by approximately 0.040 in (1 mm) and is
just sufficient to allow removal of the spiral circlip.

604.55.041.00 - 01 - 1998
26 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

Flow Control Restrictor 5

1. Spiral Circlip 5. Shaft 9. Restrictor End Plug
2. Knob 6. Spring 10. ‘O’ Ring
3. ‘O’ Ring 7. Load Check Valve 11. Back--up Ring
4. Back--up Ring 8. Flow Restrictor

4. Remove flow control restrictor, Figure 5.

5. Remove fixing screws and pull detent

assembly (1) with a sharp jerk from the end of
the control spool (3), Figure 6. Note the ’O’ ring
(2)

6. Using a suitable press, push end cap

sufficiently into detent housing to enable
removal of snap ring. Carefully release press
and allow the spring within the detent housing
to eject the plug, Refer to Figure 7.

6
7. Disassemble detent assembly and detent
regulating valve components taking care to
collect the nine detent balls.

8. Compress centering spring and remove detent

plunger from shaft. Refer to Figure 8.

9. Unscrew shaft from main spool.

10. To prevent damage to the housing due to paint

on the linkage end of the main control spool,
remove main spool from opposite end of
housing to that which the centering spring was
located.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 27

Detent Mechanism 7
1. Lock Nut 7. ‘O’ Ring 13. Valve
2. End Cap 8. ‘O’ Ring 14. ‘O’ Ring
3. Snap Ring 9. Back--up Ring 15. Back--up Ring
4. Spring 10. Detent Balls 16. Rod
5. Detent Spool 11. Washer 17. Spring
6. Back--up Ring 12. Detent Housing 18. Adjuster

Centering Spring Assembly 8

1. Retainer 4. Washer 6. Retainer
2. Shaft 5. Spring 7. Main Spool
3. Detent Plunger

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28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

11. Remove spiral circlip and using a small rod

withdraw shuttle check valve, Figure 9.

Shuttle Check Valve Removal

1. Shuttle Check Valve
2. ‘O’ Ring
3. Back--up Ring
4. Rod (to assist removal of valve)
5. ‘O’ Rings

9
12. Remove priority check valve, Figure 10.

Priority Check Valve

1. Ball
2. Seat
3. ‘O’ Rings

10
INSPECTION AND RE--ASSEMBLY

1. Inspect all components for wear or damage.

The main spool, flow control spool and
restrictor assembly are matched to the valve
body and are not available separately.

2. Replace all ‘O’ rings and back--up rings.

3. Re--assemble with reference to Figure 13 and

install housing ‘O’ ring seals as follows:--
Position the ‘O’ (1) ring into the detent end of
the housing, Figure 11.
11
Insert the spool (2) from the opposite end of the
housing to position shown in Figure 12, then
install remaining ‘O ring (1).

4. Apply New Holland Thread Lock and Seal, Part

No. 82995773 to the thread of the detent shaft.
Assemble centering spring and screw shaft
onto main spool, tightening to a maximum
torque of 5 lbf ft (6.7 Nm).

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 29

Double Spool Remote Control Valve 13

1. Valve Body 13. Detent Valve Spring Adjuster
2. Spool 14. Detent Balls (9 off)
3. Flow Restrictor* 15. Detent Regulating Valve Spring
4. Load Check Valve 16. Spacer
5. Flow Restrictor End Plug 17. Detent Regulating Valve
6. Flow Restrictor Control Shaft 18. Detent Housing
7. Flow Restrictor Control Knob 19. Shuttle Check Valve
8. Detent Shaft 20. Flow Control Spring
9. Spool Centering Spring 21. Flow Control Spool
10. Locknut 22. Priority Check Valve Ball (double spool only)
11. Detent Piston Spring 23. Priority Check Valve Retainer
12. Detent Piston
** The flow restrictor must be installed with the large slot positioned 1800 to that shown in illustration.

604.55.041.00 - 01 - 1998
30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

5. Re--connect the valve housing (1) to the

coupler assembly (2), ensuring that the ‘O’ ring
seals between the coupler and valve have not
been omitted. Tighten the bolts to a torque of
11--15 lbf ft (15--20 Nm).

If the remote valve couplers require overhaul refer

to Page 31. It is not necessary to remove the valve
assembly from the tractor in order to overhaul the
couplers.

14
INSTALLATION

1. Assemble the valve to the tractor tightening the

bolts to a torque of 20--26 lbf ft (27--35 Nm).

2. Reconnect the pipework and control lever

cables.

REMOTE VALVE COUPLER

DISASSEMBLY

1. Using a suitable ‘C’ spanner, Tool FNH00095

or prefabricated tool as shown in Figure 15,
unscrew coupling.

When using the tool shown in Figure 15,

engage the reduced diameter of the locking
screws into three of the round holes on the
outer diameter of the coupler and using a
standard wrench unscrew the coupler. Tool for Removing Coupler 15
1. 30 mm Socket (welded inside item 2
2. Sleeve
2. Disassemble the coupling as shown in 3. Hardened Locking Screw (3 off) made from 6 mm
Bolts
Figure 16.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 31

Remote Valve Coupler

16
1. ‘O’ Ring 8. Washer 15. Back--up Ring
2. Adaptor 9. ‘O’ Ring 16. ‘O’ Ring
3. Sleeve Assembly 10. Back--up Ring 17. Spring
4. Front Sealing Ring 11. Locking Balls 18. Locking Sleeve
5. ‘O’ Ring 12. Retaining Ring 19. Retaining Ring
6. Probe Assembly 13. Coupler Housing 20. Back--up Ring
7. Spring 14. Locking Body 21. ‘O’ Ring

3. Remove the two ‘O’ rings (3) and slipper seals

(2) from the coupler housing (1), Figure 17.

604.55.041.00 - 01 - 1998
32 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

RE--ASSEMBLY

Inspect components for wear or damage and

replace all seals which are serviced.

1. Re--assemble the coupler using the

disassembly procedure in reverse.

2. Lightly oil two new ‘O’ ring seals and install into
the coupler housing grooves.

3. Shape the new slipper seals as shown in

Figure 18 and locate inside ‘O’ ring seals. Use
a clean finger to smooth the seals into position.
18

4. Where available insert slipper seal tool No FT

8611 (1), into the housing (2) and rotate back
and forth. This operation slightly stretches and
seats the seals in order that the coupling can
be installed.

5. Lightly oil coupler and carefully install into the

housing.

NOTE: Extreme care must be exercised as the

coupler engages and slightly expands the slipper
seal. This is particularly important if the slipper seal
tool is not available.

6. Tighten the sleeve to a torque of 60 lbf ft 19

(82 Nm).

CABLE ADJUSTMENT

Adjust cable as follows:--

1. Move control lever to ‘Raise’ position and

check that control valve spool (3) is fully
extended from housing.

2. Loosen cable clamp (1), Figure 20 and slide

cable outer sleeve (2) away from valve until all
slack in the cable has been removed.

3. Tighten clamp and check for correct operation

of the valve in ‘Raise’ Neutral’ ‘Lower’ and
‘Float’ positions. 20

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7 33

PRESSURE TESTING

After servicing the detent regulating valve (1) or if

the control levers and spool are returning to neutral
prematurely, the detent regulating valve should be
tested as follows:--

1. Install inlet hose of a flowmeter (4) into lift

coupler of valve to be tested and set flow
control knob (5) to maximum flow, Figure 21.

2. Install return hose from flow meter (2) into lift

coupler of another remote valve on tractor.
21
3. Ensure load valve on flow meter (3) is fully
open.

4. Start tractor and set engine speed to

1700 rev/min.

5. Push remote control valve operating lever of

remote valve connected to flowmeter ‘Return’
hose, to ‘Float’ position, fully forward.

6. Pull lever of remote control valve to be tested,

fully rearwards, to the extend position.

7. Adjust load valve on flow meter until pressure

is at 2000 lbf/in2 (140 bar) and run engine until
hydraulic oil is at an operating temperature of
170!F (75!C).

8. With lever of remote control valve to be tested

in the cylinder extend position slowly close the
flowmeter load valve while observing the
flowmeter pressure gauge.

The pressure should steadily rise until the

detent regulating valve opens, at which point
the needle will fluctuate and the handle return
to the neutral position. Note the gauge reading
immediately prior to the needle fluctuation. The
reading should be within the specified value
2150--2350 lbf/in2 (148--162 bar).

9. If the reading is not to specification, adjust the

‘return to neutral’ pressure as follows:--

Loosen locknut on detent regulating valve.

Turn detent regulating valve adjusting screw to

change pressure setting. Half a turn of screw
is equivalent to approximately 450 lbf/in2
(32 bar).

604.55.041.00 - 01 - 1998
34 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 7

NOTES

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 8 -- ASSIST RAMS

35 000 SPECIFICATIONS

MAXIMUM LIFT CAPACITY

Tractors with Fixed Displacement Gear Type Hydraulic Pump @ 2650 lbf/in2 (183 bar)

Tractors with Fixed Displacement Gear Type Hydraulic Pump @ 2385 lbf/in2 (164 bar)

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

MAXIMUM LIFT CAPACITY

Tractors with Variable Displacement Closed Centre Load Sensing (CCLS) Hydraulic Pump
@ 2800 lbf/in2 (193 bar)

Test results to OECD criteria--links horizontal

TS90 TS100 TS110

Without Assist Rams

at link ends lb 6712 6712 n/a

kg 3045 3045 n/a

24 in. to rear of link ends lb 5190 5190 n/a

kg 2354 2354 n/a

With One Assist Ram

at link ends lb 9904 9904 9904

kg 4492 4492 4492

24 in. to rear of link ends lb 7484 7484 7484

kg 3395 3395 3395

With Two Assist Rams

at link ends lb n/a n/a 13001

kg n/a n/a 5897

24 in. to rear of link ends lb n/a n/a 9957

kg n/a n/a 4516

Tractors with Variable Displacement Closed Centre Load Sensing (CCLS) Hydraulic Pump
@ 2800 lbf/in2 (193 bar)

Test results to SAE criteria--links horizontal

Without Assist Rams TS90 TS100 TS110

24 in. to rear of link ends lb 4439 4439 n/a
kg 2014 2014 n/a

With One Assist Ram

24 in. to rear of link ends lb 6564 6564 n/a

kg 2978 2978 n/a

With Two Assist Rams

24 in. to rear of link ends lb n/a n/a 8710

kg n/a n/a 3950

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8 3

TORQUES

Single Hydraulic Assist Ram and Bracket Installation (With and Less Cab)

Double Hydraulic Assist Ram and Bracket Installation (With and Less Cab)

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4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Assist Ram Mounting Bracket

(Two and Four Post Roll Over Protection Frame)
A. Two Post Roll Over Protection Frame B. Four Post Roll Over Protection Frame

DESCRIPTION AND OPERATION

In order to increase the hydraulic lift capacity, TS

series tractors may be installed with either one or
two assist rams.

Assist rams (1), which can be either factory or

dealer installed, attach to a bracket (2) beneath the
rear axle and the end of the lift arm (3), Figure 1.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8 5

The hydraulic supply to each ram (1) and (3) is

taken from a port at the front of the hydraulic lift
cover (2), Figure 2, which connects directly with
the supply gallery to the lift cylinder.

35 116 OVERHAUL

REMOVAL

1. Fully lower lift arms.

2. Disconnect hydraulic connection to assist ram

(3).

3. Remove pin attaching assist ram to bracket

(2).

4. Remove collar on pin attaching assist ram to lift

arm (4) and withdraw ram (1) from tractor.

DISASSEMBLY

1. Grip assist ram end cap in vice and using

suitable lever unscrew cylinder, Figure 4.

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6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

2. Remove guides from end of cylinder rod,

Figure 5.

3. Slide end cap from rod and remove seal

components, Figure 6.

INSPECTION AND REPAIR

1. Replace all seals

2. Examine cylinder rod for burs, scratches and 5

distortion.

3. Examine the bearing in the eye at each end of

the assist ram and replace if worn. To remove
bearings relieve the staking around the edge of
the eye and press out using a hydraulic press.

4. When installing new bearings ensure they are

fully seated and securely staked in three
positions.

RE--ASSEMBLY

Re--assembly follows the disassembly procedure

in reverse.

1
9

8
7 6 5 4 3

Assist Ram Assembly 6

1. Piston Rod 4. Seal 7. Support Ring
2. Wiper Seal 5. Bushing 8. ‘O’ Ring Seal
3. End Cap 6. Guides 9. Cylinder Barrel

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 9 -- HYDRAULIC LIFT ASSEMBLY WITH

ELECTRONIC DRAFT CONTROL FOR TRACTORS WITH FIXED
DISPLACEMENT HYDRAULIC PUMP

Section Page
35 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
35 138 Hydraulic Control Valve -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
35 114 Priority/Unload Valve Assembly -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
35 110 Hydraulic Lift Cover Assembly -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

CAUTION: Observe the following precautions when arc welding on tractors installed with electronic draft
control
S Where possible, disconnect the part or implement to be arc welded from the tractor.
S Disconnect both battery cables from the battery. Isolate the cable ends to avoid contact with each other and
the tractor.
S Position the welder earth (ground) clamp as close to the welding area as possible.
S If welding is to be carried out in close proximity to the electronic draft control microprocessor then the
microprocessor should be removed from the tractor.
S Never allow welding cables to lay on, near or across any electrical wiring or electronic component while
welding is in progress.

35 000 SPECIFICATIONS

VALVE SETTINGS
Lift Cylinder Relief Valve 2850--3050 lbf/in2 (197--210 bar)
GASKET SEALER
New Holland Gasket Sealant Part No. 82995770 (50 ml)
82995771 (300 ml)

ASC CONTROL VALVE SIZES

Colour Inches mm
Green .6247--.6244 15.8674--15.8598
Yellow .6244--.6241 15.8598--15.8521
Blue .6241--.6238 15.8521--15.8445
White .6238--.6235 15.8445--15.8369
Blue/White .6235--.6232 15.8369--15.8293

604.55.041.00 - 01 - 1998
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

TORQUES
= Nm
= lbf ft

1
Lift Cylinder Relief Valve Torque 75--90 lbf ft (102--122Nm)

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 3

DESCRIPTION AND OPERATION

INTRODUCTION The principal differences between this system and

the electronic draft control system released for
tractors equipped with the variable displacement
The closed centre load sensing hydraulic draft closed centre load sensing hydraulic pump are as
control system described in this chapter relates to follows:--
those tractors installed with electronic draft control
and the fixed displacement hydraulic pump.

S The fixed displacement Hydraulic Pump

The location of all the components in this electronic

draft control hydraulic system are shown in Figure 3
and Figure 4.
S The priority/unload valve assembly, necessary
to interface between the fixed displacement
hydraulic pump, hydraulic lift assembly and
The principle of electronic draft control is to sense auxiliary engine mounted pump and hydraulic
variations in implement draft using a load sensing control valves where fitted.
pin in each lower link. A processor then translates
these variations into electronic signals which
operate a control valve to raise and lower the
hydraulic links and maintain a constant draft S The location of the hydraulic control valve on
loading. the tractor.

In addition to maintaining a constant draft loading

the system also provides a fully electro--hydraulic S The design of processor which is now
method of raising and lowering the hydraulic lift, connected to the system using two multi pin
eliminating the necessity for mechanical linkage connectors and also controls the functions of
between the operator controls, hydraulic control the dual command clutches on the 24x24
valve and hydraulic lift assembly. transmission.

604.55.041.00 - 01 - 1998
4 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

Electronic Draft Control Hydraulic Layout 3

1. Microprocessor* 4. Lift Control Levers
2. Rear Fender External Lift/Lower Switches 5. Operator Control Console
3. Performance Monitor Radar
* On Less Cab tractors the microprocessor is located behind the instrument console

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 5

Electronic Draft Control Component Layout 2 4

1. Instrument Panel 5. Lift Arm Position Sensing Potentiometer and
2. Lift Lever Potentiometer Electronic Draft Control Valve
3. Fixed Displacement Hydraulic Pump 6. Priority/Unload Valve Assembly
4. Load Sensing Pin

604.55.041.00 - 01 - 1998
6 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

COMPONENT DESCRIPTION

Processor
The processor, Figure 5, controls the electronic
draft control system and also controls the 24x24
transmission dual command clutches,
simultaneously but separately.
Control is maintained by sending, receiving and
interpreting signals from the other components in
the system.

5
Load Sensing Pins
The load sensing pins (2), Figure 6, sense draft
variations applied by an implement on the lower
links and transmit a signal to the processor.
The operating principal of the pin is to recognise
sheer forces in a horizontal plane, applied to the
waisted section of the pin (1) by an implements
draft. The pin does not react to vertical sheer forces
applied by the weight of the implement.

6
When the pin is subjected to implement draft forces
the magnetic field within the pin changes and the
signal to the microprocessor is changed.
To ensure the pins (2) are correctly installed and
only sense sheer forces in the horizontal plane, a
special clamp (1) guarantees correct installation,
Figure 7.

7
Hydraulic Control Valve

The hydraulic control valve, Figure 8, is a

proportional solenoid operated valve which
responds to pulse width modulation signals from
the microprocessor to direct pump pressure oil to
and from the hydraulic lift cylinder.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 7

Priority/Unload Valve Assembly

The priority/unload valve assembly, Figure 9,
contains both priority/unload and
combining/unload (sequencing) valve which
directs pump system pressure oil to either the
hydraulic control valve, remote control valves or to
sump as required.
The combining valve also directs the flow of oil from
the engine mounted auxiliary pump to the remote
valves or sump as required.

9
Lift Control Lever Potentiometer

The potentiometer (2) on the lift control lever (1),

Figure 10, is used to send a signal to the processor
to indicate the position to which the lift arms are to
be raised.

10
Lift Arm Position Sensing Potentiometer
The potentiometer (1) on the lift arm, Figure 11, is
used to send a signal to the processor to indicate
when the arms have reached the required height.
NOTE: If either the lift lever or lift arm
potentiometer fails, control of the system is
transferred to the external fender switches.

Hydraulic Control Panel 11

The electronic draft and position control system is
operated from a console to the right of the 1 2
operator’s seat, Figure 12. Each of the variably
adjustable controls is directly attached to a
potentiometer. When the control is rotated the
potentiometer resistance is varied, changing the
input signal to the processor. 6 3
Hydraulic Control Panel
1. Height Limit Control
2. Slip Limit Control (option)
3. Slip Limit ‘On’ Indicator 7
4. Status Indicator
5. Position/Draft Sensitivity Knob 4
6. Drop Rate Control Knob 5
7. EDC Valve Solenoid Indicator Lamps
12

604.55.041.00 - 01 - 1998
8 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

The function of each of the controls is as follows:--

1 2
The position/draft sensitivity know selects full
position control, maximum draft control or a
mixture of the two allowing sensitivity in draft
control according to operating needs. 6 3

The drop rate control is provided to limit the rate of

drop of the hitch and functions whenever the
implement is raised out of the ground. 7
4
The height limit control restricts the maximum 5
height the lift arms can be raised, to prevent large
implements from striking the rear of the cab or 13
platform. This control restricts the lift height when
either the lift control lever, in cab fast raise/lower
switch or external lift/lower switches are used.

The slip limit control (where fitted) limits the amount

of wheel slip. The indicator light is illuminated when
the lift arms are responding to an excessive slip
condition.

The status indicator is flashed when a malfunction

identified by the microprocessor occurs in the
system. The status indicator is continuously
illuminated when the hitch is disabled.

The electronic draft control valve solenoid indicator

lamps will illuminate when the solenoids are
activated during either raising, lamp (1) or lowering,
lamp (2).

Hydraulic Lift Controls

Raising and lowering of the lift arms is controlled by

a low effort lever in the right hand console (1),
Figure 14.

A 3 position rocker switch is also provided for rapid

raising, top of switch pressed in, and lowering,
bottom of switch pressed in. The central position
provides lowering at a rate set by the drop rate
control knob.

NOTE: The raise/lower switch will not lower the 14

implement if the tractor speed is greater than 15
MPH (24 km/h).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 9

Rear Fender External Lift Lower Switches

These externally operated switches (1) allow the

hydraulic linkage to be raised or lowered by the
operator while standing beside the tractor, so
aiding attachment and detachment of implements.

Pushing the lift lever fully forward past the fixed

stop, transfers control of the lift linkage to the rear
fender mounted switches. MM6
15

When using the external switches (1) to operate

the hydraulic lift the following precautions must be
observed.

Never operate the external switches while

standing:

S Directly behind the tractor or tyres

S Between the lower links

S On or near the implement

WARNING: Never extend arms, legs, any

part of the body or any object into the area 1
near the 3--point linkage or implement while
operating the external switch.

Never have an assistant working the opposite set

of controls. When moving to the opposite set of
controls, move around the tractor or implement.
Do not cross between the implement and tractor.

The operator must only activate the external

switches while standing to the side of the tractor
(outboard of the rear tyres) -- see Figure 16
16

604.55.041.00 - 01 - 1998
10 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

Instrument Panel
4 1000
1

Either an electronic or analogue electronic

instrument panel may be fitted to the tractor and
incorporate the following functions to advise on the
status of the hydraulic lift assembly. Refer to
Figure 17 and Figure 18.
2

Electronic Instrument Panel 17

1. Implement Position/Diagnostic Repair Code
(LCD)
2. Hitch Enabled Symbol (LCD)
3. $Read Your Manual’ Symbol (LCD)
4. Hitch Disabled Symbol (LCD)
S Implement Position Display
S Hitch enabled Symbol (Electronic instrument 3
panel only)
S Hitch Disabled Symbol 1
S Read Your Manual Symbol 25

S Diagnostic Error Code Location when retrieved

via the H--menu diagnostic mode.
30

Implement Position Display 2

The digital display indicates the position of the lift
arms on the scale of 0 (fully lowered) to 99 (fully Analogue Electronic Instrument Panel 18
raised). 1. Implement Position/Diagnostic Repair Code
(LCD)
2. Hitch Disabled Warning Light
Hitch enabled Symbol 3. $Read Your Manual’ Light

The hitch enabled symbol on the electronic

instrument panel, illuminates when the position of
the lift arms is in phase to the position of the lift
control lever.

Hitch Disabled Symbol

The hitch disabled symbol is illuminated if the lift
arms and lift control lever are out of phase.
This will occur if:--
(i) The lift control lever has been inadvertently
moved whilst the engine is stopped.
(ii) The lift control lever has been pushed fully
forward in order to transfer control of the
hydraulic lift to the external switches.
To realign the lift arms and lift lever, pull the lever
fully forward and then slowly rearward until the
hitch disabled symbol disappears. This operation
is termed ‘capturing the lift’.

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 11

Diagnostic Repair Code

Tractors installed with electronic draft control also
1000
1
have a self diagnostic fault finding capability. If a
malfunction occurs in the system, a diagnostic
repair code will be stored in the processors
memory and retrieved via the H--menu diagnostic
mode.
Refer to “Fault Finding”, for further details on error
code display and a detailed list of error codes.

Electronic Draft Control Error Code Display

(Electronic Instrument Panel Shown)

Electronic Draft Control Error Code Display

(Analogue Electronic Instrument Panel Shown)
1
25

604.55.041.00 - 01 - 1998
12 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

HYDRAULIC OPERATION AND CIRCUITS

Figure 21, illustrates in a block schematic form the fitted) also contribute towards the computation of
flow of electronic signals to and from the hydraulic the input signal.
system, to raise and lower the hydraulic lift in
accordance with operator position and draft control
requirements.

When the lift control lever is moved to raise or lower

Electronic signals to the processor for raising and the lift arms, the resistance of the potentiometer at
lowering the hydraulic lift assembly in accordance the base of the lever changes and is sensed by the
with position and draft control requirements, are processor. The processor transmits a revised
received from four main sources. These are the lift signal to the hydraulic lift control valve, which raises
control lever and the lift arm position sensing or lowers the hydraulic lift accordingly.
potentiometer, the two load sensing draft control
pins in the lower links and the draft/position
sensitivity controls on the hydraulic control panel.

As the position of the lift arms changes a feedback

Additional signals from the drop rate and maximum signal is received by the processor from the lift arm
lift height controls and wheel slip control (where position sensing potentiometer.

Position/Draft Control Schematic 21

604.55.041.00 - 01 - 1998
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 13

When the lift arms have moved to the required the control valve which adjusts the implement depth
position the control signal from the processor to the and maintains the specified draft loading.
control valve is turned ‘Off’ and the lift arms are held
in position.

When a tractor is operated in draft control and

under poor traction conditions, the situation can
arise where as the tyres slip, the ground speed and
When draft control is selected, draft forces imposed draft forces on the load sensing pins reduce. In this
by the implement through the lower links are situation the reduction in draft forces would signal
sensed by the two special load sensing pins. the microprocessor to continue increasing
implement depth to such an extent that it may
ultimately stop the tractor from moving forward.

The average of these draft load signals from each The ‘limited slip’ option prevents this situation from
pin is calculated by the processor and compared occurring and uses the processor to calculate the
with the draft control setting selected using the percentage of wheel slip by comparing the tractor
operator control panel. ground speed and axle speed.

When wheel slip exceeds the value set by the

If the implement draft begins to increase beyond the operator the control valve raises the lift arms,
range selected by the operator, the processor irrespective of draft loading, until the maximum
transmits a revised pulse width modulated signal to accepted wheel slip is restored.

604.55.041.00 - 01 - 1998
14 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

HYDRAULIC SYSTEM SCHEMATIC

The hydraulic system schematic for tractors with remote control valves and return to sump circuits as
fixed displacement hydraulic pump and electronic required.
draft control is shown in Figure 22.

The load sensing line from the control valve signals

Main hydraulic pump pressure oil flows to the the priority/unload valve to increase pump flow to
priority/unload valve assembly through internal oil the control valve whenever the hydraulic lift is
galleries in the centre housing and hydraulic top operated.
cover. A feed tube which intersects the gallery in the
top cover, also permits pump pressure oil flow to the
hydraulic control valve on the side of the tractor.
The combining valve combines the flow of main
pump oil passing through the priority/unload valve
The pilot pressure line supplies low pressure circuit with the output from the engine mounted auxiliary
oil at 220--240 lbf/in2 (15.2--16.8 bar) from the pump. This combined oil flow is used to supply the
tractor low pressure circuit for operation of the main remote valve circuits and any excess flow is
spool in the hydraulic control valve. returned to sump through the combining valve.

The priority/unload valve directs main pump system NOTE: The hydraulic lift always has priority over
pressure oil flow to either the hydraulic lift system or simultaneous operation of the remote valves.

Figure 22
Hydraulic Circuit -- Electronic Draft Control with Fixed Displacement Hydraulic Pump
1. Auxiliary Assist Rams (Where Fitted)
2. Auxiliary Engine Mounted Pump (Where Fitted)
3. Feed to Remote Valve Assembly
4. Load Sensing Line from Remote Valve Assembly
5. Combining/Unload (Sequencing) Valve
6. Blocked Filter Vacuum Switch
7. Low Oil Temperature Switch
8. High Oil Temperature Switch
9. Feed to P.T.O. Valve
10. Fixed Displacement Hydraulic Pump Assembly
11. Feed to Four Wheel Drive Valve
12. Feed to Differential Lock Valve
13. Transmission Oil Pressure Switch
14. Return from Steering Motor
15. Return from Trailer Brake Valve
16. Feed to Trailer Brake Valve
17. Feed to Steering Motor
18. Priority/Unload Valve Assembly
19. Priority/Unload Valve
20. Electronic Draft Control Valve
21. Auxiliary Services Control Valve
22. Hydraulic Lift Assembly
23. Lift Cylinder Relief Valve

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 15

Hydraulic Circuit -- Electronic Draft Control with Fixed Displacement Hydraulic Pump 22

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16 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

Hydraulic Lift in Neutral

With reference to Figure 23 Because the hydraulic control valve load sensing
line is open to sump the flow of oil from the main
hydraulic pump acts on the right hand end of the
When the hydraulic lift arms are held in a stationary priority/unload valve, causing the valve to move to
position, the hydraulic lift control valve is in ‘Neutral’ the left.
and the processor is not sending raise or lower
signals to the control valve solenoids.

All main pump oil now flows past the priority/unload

In the neutral condition the spring force applied to valve to the remote valve circuits which are also
each end of the main spool holds the spool in a supplemented with the output from the auxiliary
central position, preventing oil flow from the main engine mounted hydraulic pump.
pump through the control valve to the hydraulic lift.

When the main spool is in neutral, the right hand Pump flow in excess of any remote valve demand,
end of the load sensing valve and hence the load acts on the left hand end of the combining valve,
sensing line are open to sump. In this condition the causing the valve to move towards the right. Excess
hydraulic lift load check valve remains seated and oil flow from both the main and auxiliary pumps then
oil in the hydraulic lift cylinder is trapped maintaining flows through the combining valve to sump through
the lift arms in a stationary position. the exhaust port in the base of the housing.

Figure 23
Electronic Draft Control Operation -- Neutral
A. Hydraulic Control Valve B Priority/Unload Valve Assembly

1. Pilot Spool
2. Solenoid (Raise) 13. From Auxiliary Pump
3. Return to Sump Port 14. System Pressure From Main Pump
4. Load Sensing Valve 15. To Hydraulic Lift via Gallery in Priority/Unload Valve
5. Load Sensing Line From Hydraulic Control Valve Housing
6. To Remote Valves 16. Load Check Valve
7. Combining/Unload (Sequencing) Valve 17. Main Spool
8. Priority/Unload Valve 18. Solenoid (Lower)
9. Pump System Pressure Inlet 19. Pilot Spool
10. To Hydraulic Lift 20. Main Spool Inlet Metering Land
11. Return to Sump 21. Main Spool Return To Sump Metering Land
12. Load Sensing Line from Remote Valves 22. Pilot Pressure Inlet

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 17

R8--353
ELECTRONIC DRAFT CONTROL OPERATION -- NEUTRAL 23
A Hydraulic Control Valve B Priority/Unload Valve Assembly

Main Pump Pressure Oil Pilot Pressure Oil 220 -- 240 lbf/in2
(15.2 -- 16.8 bar)
Auxiliary Pump Oil Exhaust Oil

Trapped Oil

604.55.041.00 - 01 - 1998
18 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

Raising

With reference to Figure 24. The pressure in the load sensing line, together with
the spring pressure applied to the left hand end of
the priority/unload valve moves the valve towards
When the lift control lever is moved to the raise the right directing increased pump flow and system
position the lift control lever potentiometer sends a pressure to the hydraulic control valve.
signal to the processor and then to the raise
solenoid of the control valve.
The increase in pressure opens the load check
valve and oil passes through to the lift cylinder.
The armature in the solenoid reacts to the signal
and the pilot spool is moved to the left, allowing pilot
pressure to be applied to the right hand end of the
main spool. The rate of lift is controlled by the modulated signal
to the raise solenoid which by opening and closing
the pilot valve allows the main spool to oscillate and
continually adjust the volume of metered oil to the
The main spool moves to the left allowing pump
lift cylinder.
system pressure oil to flow past the main spool inlet
metering land to the load check and load sensing
valves.
When the hydraulic lift is being operated in draft
control the microprocessor similarly sends a signal
The flow of oil to the load sensing valve moves the to the raise solenoid whenever the implement draft
valve to the right, blocking the return to sump exceeds that set by the operator using the
gallery and allowing a sensing pressure to be draft/position control. The hydraulic lift will then
applied to the right hand end of the priority/unload raise until the required implement draft forces are
valve. restored.

Figure 24
Electronic Draft Control Operation -- Raising
A. Hydraulic Control Valve B Priority/Unload Valve Assembly

1. Pilot Spool
2. Solenoid (Raise) 13. From Auxiliary Pump
3. Return to Sump Port 14. System Pressure From Main Pump
4. Load Sensing Valve 15. To Hydraulic Lift via Gallery in Priority/Unload Valve
5. Load Sensing Line From Hydraulic Control Valve Housing
6. To Remote Valves 16. Load Check Valve
7. Combining/Unload (Sequencing) Valve 17. Main Spool
8. Priority/Unload Valve 18. Solenoid (Lower)
9. Pump System Pressure Inlet 19. Pilot Spool
10. To Hydraulic Life 20. Main Spool Inlet Metering Land
11. Return to Sump 21. Main Spool Return To Sump Metering Land
12. Load Sensing Line from Remote Valves 22. Pilot Pressure Inlet

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 19

R8--354
ELECTRONIC DRAFT CONTROL OPERATION -- RAISING 24
A Hydraulic Control Valve B Priority/Unload Valve Assembly
Main Pump Pressure Oil Pilot Pressure Oil 220 -- 240 lbf/in2
(15.2 -- 16.8 bar)
Auxiliary Pump Oil Exhaust Oil

604.55.041.00 - 01 - 1998
20 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

LOWERING

With reference to Figure 25. to continue moving to the left and unseat the load
check valve poppet.

When the lift control lever is moved to the lower

position, the lift control lever potentiometer sends a The pressurised oil in the lift cylinder can now return
signal to the processor and then to the lower to sump across the return to sump metering land of
solenoid of the control valve. the main spool allowing the arms to lower at a
controlled speed.

The armature in the solenoid reacts to the signal

and the pilot spool is moved to the right, allowing
pilot pressure oil to be applied to the left hand end of The rate of lowering is once again controlled by the
the main spool. modulated signal to the lower solenoid which by
opening and closing the pilot valve allows the main
spool to oscillate and continually adjust the volume
of metered oil returning to sump from the lift
The main spool now moves to the right allowing pilot cylinder.
pressure oil to flow to the right hand face of the load
sensing valve.

During the lowering cycle, the load sensing line to

The load sensing valve now moves to the left, the priority/unload valve is vented to sump enabling
venting the load sensing line to sump, while at the main pump system pressure to move the valve to
same time the pin on the end of the valve unseats the left.
the ball in the end of the load check valve.

Main pump pressure oil now flows past the

With the ball unseated, oil behind the load check priority/unload valve and returns to sump through
valve vents to sump enabling the load sensing valve the combining/unload valve.

Figure 25
Electronic Draft Control Operation -- Lowering
A. Hydraulic Control Valve B Priority/Unload Valve Assembly

1. Pilot Spool
2. Solenoid (Raise) 13. From Auxiliary Pump
3. Return to Sump Port 14. System pressure From Main Pump
4. Load Sensing Valve 15. To Hydraulic Lift via Gallery in Priority/Unload Valve
5. Load Sensing Line from Hydraulic Control Valve Housing
6. To Remote Valves 16. Load Check Valve
7. Combining/Unload (Sequencing) Valve 17. Main Spool
8. Priority/Unload Valve 18. Solenoid (Lower)
9. Pump System Pressure Inlet 19. Pilot Spool
10. To Hydraulic Life 20. Main Spool Inlet Metering Land
11. Return to Sump 21. Main Spool Return To Sump Metering Land
12. Load Sensing Line from Remote Valves 22. Pilot Pressure Inlet

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 21

R8--355

ELECTRONIC DRAFT CONTROL OPERATION -- LOWERING 25

A Hydraulic Control Valve B Priority/Unload Valve Assembly

Main Pump Pressure Oil Pilot Pressure Oil 220 -- 240 lbf/in2
(15.2 -- 16.8 bar)
Auxiliary Pump Oil Exhaust Oil

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22 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

35000 -- TROUBLE SHOOTING AND CALIBRATIONS

The transmission / EDC electronic management

It should be noted that the self diagnostic capability

is generally limited to diagnosis of the electrical and
electronic circuitry and related components,
however, there are some codes, which can be
generated if pressure switch circuits are not closed
because of an actual lack of hydraulic pressure.
26
Any malfunction of the mechanical and hydraulic
components must be diagnosed using
conventional techniques, performance
characteristics and tooling, such as pressure
testing equipment. Full guidance for both electrical
self diagnosis and conventional diagnosis is
contained within this section.

Trouble--shooting and fault finding should always

Prior to detailed fault finding, items like the earth

points and Battery should be cleaned and tested to 27
ensure that they are functioning correctly.
With the use of micro--processors it is often that
this item is blamed for any malfunction but the real
truth is that this item is usually sound and that the
fault is due to poor contacts in the associated
connectors.

Each connector illustrated and identified in the

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 23

Where the fault finding procedure requires checks

for continuity a visual inspection of the wiring
should be made prior to conducting tests to ensure
that obvious ‘mechanical’ damage has not
occurred to the harness or the connectors.

Where possible the inbuilt tractor diagnostics

should be utilised to determine the area of the fault.
The ’H’ menu mode, described in Section 55,
provides several modes to aid diagnosing faults.
One particular mode which should be used, before
any connections are split, is the H5, switch
diagnostics mode. This will provide testing of many
switch circuits, including the switch itself. If this
mode highlights a fault within a circuit then more 29
detailed fault finding can be directed towards a
particular circuit.

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

perform fault finding. It should be capable of
measuring resistance of at least 20,000 ohms and
measuring voltage and current. When using the
multi--meter it is good practice to select a high
range and work downwards to avoid damaging the
instrument.
Where possible it is recommended that connectors
are probed from the rear, certain connectors like
C079, C080 and C081, instrument panel
connectors, should always be probed from the
rear. Connector terminals should only be removed
using the special tools supplied in electrical repair
kit, Tool No.4FT.953 and the wires should not
require excessive pulling efforts to remove.
30
Where only front probing is practical it is
recommended that Connector test probe kit, Tool
No NH.55--125 is obtained. This provides all
connector terminal attachments for use with most
multi--meters.
IMPORTANT: Care should be used when using
the multi--meter, only use the instrument as
instructed to avoid damage to the internal elements
of the micro--processor. When checking the
continuity of wiring, sensors or switches it is
necessary to isolate the electronic
micro--processor and ensure the keystart is turned
off to prevent possible further damage. The
keystart should only be switched on and the
processor connected where specifically instructed
in the fault finding procedure.
TA60--21--01
4
If it is found necessary to clean the connectors a 31
contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains
Trichloro--ethylene, this solvent will damage the
plastic body of the connector. It is preferable to use
a cleaner with a Freon T.F. base.

604.55.041.00 - 01 - 1998
24 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

The following ’H’ menu mode routines are provided

A full description of the ’H’ menu routines can be

found in Section 55.

33
It should also be noted that after installation of a
new processor or after a non volatile memory reset
operation (’H’ menu mode, H8), that the processor
defaults to a ’display all codes’ mode for 6 minutes.
If no error codes occur during this 6 minute period
the processor then reverts to normal operation. If
an error occurs during this period the processor will
continue to display ’live’ error codes until all the
errors are removed.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 25

ELECTRONIC DRAFT CONTROL ERROR CODES

Error Code Error Description Page

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26 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 2

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 27

ERROR CODE 2 -- Poor or no signal from tractor performance monitor radar

Perform
Key Off
Key On

Is tractor Reconnect
performance monitor performance
radar connected? monitor radar

Disconnect radar assembly

Replace radar

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28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 3, 4 & 5 -- Speed sensor errors

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 29

ERROR CODES 3, 4 & 5 -- Speed sensor errors

Key ON,
If Error Code 3 or 5 is drive and
displayed, perform test recheck
procedure for Error Code 2.
If Error code 4 is displayed
proceed.

Is radar correctly positioned Point radar at ground

and secure? and tighten fixing

Is the output speed

sensor correctly Retighten speed sensor
positioned and secure?

Replace output speed

sensor

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30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 6 & 7

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 31

ERROR CODES 6 & 7 -- Slip control potentiometer or circuit failed

Key OFF,
Key ON
and
recheck

Is slip control and H8 (reset) and

radar installed recalibrate

Enter diagnostic mode H9

Remove EDC control panel and Inspect and clean

Turn keystart switch ON and

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C121--1 and Is the circuit open circuit
C128--16? between each of the
above pins and chassis

Is there an open circuit

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
32 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODE 8 -- In cab Raise/Work/Lower switch failure

Key OFF,
Enter Switch Diagnostics, H5. ’d0’ will be Key ON
displayed. Toggle the switch, one of the retest
following combinations will be displayed:

d3,d4,d5 -- d3,d4 -- d4,d5 -- d3 -- d4 -- d5

d3,d4,d5 d3,d4,

System okay. Disconnect Replace switch

/ reconnect switch and
wiggle test wiring.

d4,d5

Disconnect switch. Place in Disconnect

the raise position, is there processor. Check pin
Reconnect and
continuity through pins 2 & 4 No. C128--29, is
retest.
and 2 & 5? battery voltage
indicated?

Replace switch
Locate and repair short
to battery voltage on
C128--29 (TQ/P)

Disconnect switch. Is there

continuity with the switch in Replace switch
the raise position between
pins 5 & 7?

Is there continuity between Locate and repair open

C128--26 and C102--7 (TQ/W) circuit in Harness

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 33

ERROR CODE 8 -- In cab Raise/Work/Lower switch failure

Key OFF,
Key ON
d4 retest

Disconnect switch. Is there

continuity with the switch in Replace switch
the work position between
pins 5 & 2?

Is there continuity between Locate and repair open

C128--29 and C102--2 (TQ/P) circuit in Harness

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

Disconnect switch. Is there continuity

at the switch terminals between pins 2 Replace switch
& 5 in ’Work’ and 2 & 7 in ’raise’ ?

Is there battery voltage at Check harness between fuse

C102--5 (R/LG/B)? 12 and C102--5 (R/LG/B). Find
open circuit and repair.

Is there continuity between

C128--29 and C102--2 (TQ/P) Locate and repair open
and between circuit in Harness
C128--26 and C102--7 (TQ/W)?

Remove, inspect and refit Processor connectors, C127 and

C128. If error still occurs Reset the processor using Mode H8
and recalibrate. If error still occurs replace the processor.

604.55.041.00 - 01 - 1998
34 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 9 -- Both external switches operated together

7
K/W 3
1

K/G
C C
134 135
TIA35092

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 35

ERROR CODES 9 -- Both external switches operated together

Visibly verify fender switches are Clean, fix or

functioning correctly replace switch

Is fuse 9 OK? Replace fuse 9 (if fuse still blows,

check fuse 9 wiring circuit)

Enter Mode H5. In turn Disconnect fender which does

With the switch in the raise

With the switch in the

raise position, check Replace
for continuity between switch
pins 1 & 3

Disconnect
microprocessor Locate
connector C128. Is there and repair
continuity between open
C128--28 and K/G wire at circuit
switch?

Is there an open circuit

between G and K/G at Locate and repair
fender switch? short circuit

Replace microprocessor

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36 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 10 & 11

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 37

ERROR CODES 10 & 11 -- Height limit control potentiometer failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Remove EDC control panel and disconnect Inspect and clean

connectors C121 and C120. connectors and
While turning height limit control, measure resistance retest. If
across male pins, C120--5 and C120--1 of console. resistance is still
Does resistance vary between 90--330! "W/slip) or incorrect replace
180--500! (L/slip) ? the control panel

Turn keystart switch ON and

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--7 and Is the circuit open circuit
C128--31? between each of the
above pins and chassis

Is there an open circuit

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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38 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 12 & 13

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 39

ERROR CODES 12 & 13 -- Drop Rate control potentiometer failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Remove EDC control panel and disconnect Inspect and clean

connectors C121 and C120. connectors and
While turning Drop Rate control, measure resistance retest. If
across male pins, C120--2 and C120--1 of console. resistance is still
Does resistance vary between 90--330! "W/slip) or incorrect replace
90--400! (L/slip) ? the control panel

Turn keystart switch ON and

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--2 and Is the circuit open circuit
C128--9? between each of the
above pins and chassis

Is there an open circuit

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

604.55.041.00 - 01 - 1998
40 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 14 & 15 -- R.H. Load Sensing Pin or Circuit Failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 41

ERROR CODES 14 & 15 -- R.H. Load Sensing Pin or Circuit Failed

Key OFF
Key ON
Is right hand load check
sensing pin
connected Reconnect pin

Disconnect microprocessor connectors and both

Check for open circuit between

male pins C48--1, C48--2 and
C48--3 and an open circuit to Locate and repair
chassis between each of these short circuit
pins.
Open circuit detected?

With microprocessor connectors

disconnected, turn keystart ON. Examine harness
Test for voltage between for damage
chassis and connectors C48--2, resulting in voltage
C48--3. supply
Is voltage 0 volts?

Remove, inspect and refit

processor connectors, C127 &
C128. ’H8’ and reset the
processor. If error still occurs
replace the processor.

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42 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 16 & 17 -- L.H. Load Sensing Pin or Circuit Failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 43

ERROR CODES 16 & 17 -- L.H. Load Sensing Pin or Circuit Failed

Key OFF
Key ON
Is Left hand load check
sensing pin
connected Reconnect pin

Disconnect microprocessor connectors and both

Check for open circuit between

male pins C47--1, C47--2 and
C47--3 and an open circuit to Locate and repair
chassis between each of these short circuit
pins.
Open circuit detected?

With microprocessor connectors

disconnected, turn keystart ON. Examine harness
Test for voltage between for damage
chassis and connectors C47--2, resulting in voltage
C47--3. supply
Is voltage 0 volts?

Remove, inspect and refit

processor connectors, C127 &
C128. ’H8’ and reset the
processor. If error still occurs
replace the processor.

604.55.041.00 - 01 - 1998
44 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 18 -- Both load sensing pins disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 45

ERROR CODES 18 -- Both load sensing pins disconnected

Key OFF
Key ON
check
Are both load
sensing pins Reconnect pins
connected

Visibly inspect harness to

both pins for damage. Repair or replace
Harness OK? harness as required

Remove implement if fitted.

Disconnect microprocessor connectors

Remove, inspect and refit processor connectors,

C127 & C128. ’H8’ and reset the processor. If error
still occurs replace the processor.

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46 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 19 & 20 -- Incorrect load sensing pin reference voltage

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 47

ERROR CODES 19 & 20 -- Incorrect load sensing pin reference voltage

Key OFF
Key ON
check

Enter diagnostic mode

For both pins:

Disconnect microprocessor
connectors and both load
sensing pin connectors C48 Locate short circuit
and C47. Is there an open and repair
circuit between tractor
chassis and C48--3 and
C47--3?

Remove, inspect and refit processor connectors,

C127 & C128. ’H8’ and reset the processor. If
error still occurs replace the processor.

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48 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 21 & 22

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 49

ERROR CODES 21 & 22 -- Position/draft sensitivity control potentiometer or circuit failed

Key OFF,
Key ON
and
recheck

Enter diagnostic mode H9

Remove EDC control panel and Inspect and clean

disconnect connectors C121 and C120. connectors and
While turning position/draft control, retest. If
measure resistance across male pins, resistance is still
C120--3 and C120--1 of console. incorrect replace
Does resistance vary between 90--330! the control panel
W/slip or 90--420! L/slip?
Turn keystart switch ON and
measure voltage across Disconnect C127.
female pins C120--1 and Is there continuity Locate and
C120--4 of vehicle harness. between C120--1 and repair open
Is the voltage approximately C127--5, then C120--4 circuit
5 volts? and C127--1?

Disconnect processor Is there an open circuit

connector C128. between C120--1 and Locate and
Is there continuity C120--4? repair short
between C120--3 and Is the circuit open circuit
C128--10? between each of the
above pins and chassis

Is there an open circuit

Is there an open Locate and repair open circuit

circuit between
C120--3 and Locate and repair short circuit
chassis?

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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50 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 23 -- Control panel disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 51

ERROR CODES 23 -- Control panel disconnected Key OFF,

Key ON
retest

Are control panel connectors Reconnect

C121 and C120 connected? control panel

Examine harness of control

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52 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

NOTES

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 53

ERROR CODE 24 --
Perform hydraulic lift calibration after replacement of lift arm potentiometer, microprocessor, lift lever
potentiometer.

Key OFF,
Key ON
retest

Lower linkage using control lever &

connect to suitable weights (approx
200Kg) capable of overcoming any
binding within the system.

Key off the engine.

Install the diagnostic switch, Tool No.4FT.950

or start the engine with the raise/work/lower
switch depressed to enter the calibration
mode, H1.

The instrument cluster display will

show ’CAL’. Set the engine speed to
1200 +/-- 100 rpm

Set all EDC panel potentiometers

fully clockwise

Move the lift lever to the fully lowered

position

Reconnect and adjust the APUH rods. Adjust the

Lower the control lever to 70% to 90% to start valve calibration

Key off to store calibration values

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54 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 25 & 26 -- Lift control lever potentiometer disconnected or circuit failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 55

ERROR CODES 25 & 26 -- Lift control lever potentiometer disconnected or circuit failed

Key OFF,
Key ON
retest

Inspect for damage to the lift Repair/replace

control lever and potentiometer. potentiometer
Are they OK? or linkage

Enter diagnostic mode H9

Channel 29. Fully lower Refer to wiring diagram and
lever and then raise. Are check for intermittent fault to
the values outside the lift lever potentiometer
range of 27 to 83?

Disconnect potentiometer connector C149

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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56 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 27 & 28 -- Lift arm potentiometer sensing potentiometer disconnected

or circuit failed

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 57

ERROR CODES 27 & 28 -- Lift arm potentiometer sensing potentiometer disconnected

or circuit failed
Key OFF,
Key ON
retest

Inspect for damage to the lift arm Repair/replace

potentiometer and linkage. potentiometer
Are they OK? or linkage

Enter diagnostic mode H9

Channel 28. Fully lower Refer to wiring diagram and
lever and then raise. Are check for intermittent fault to
the values outside the lift lever potentiometer
range of 33 to 83.

Disconnect potentiometer linkage and connector

Remove, inspect and refit Processor connectors,

C127 and C128. If error still occurs Reset the
processor using Mode H8 and recalibrate. If error
still occurs replace the processor.

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58 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODE 29 -- Hydraulic control valve disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 59

ERROR CODE 29 -- Hydraulic control valve disconnected

Key OFF,
Key ON
retest

Are hydraulic control valve

Reconnect
connectors C217 and 218
connectors
connected.

Remove, inspect and refit Processor

Repair/replace harness
as necessary.

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60 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODE 30 -- Signal ground open circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 61

ERROR CODE 30 -- Signal ground open circuit

Is there continuity between

Locate and repair
female pins C120--1 (LN)
open circuit
and C127--5 (LN).

Measure resistance
between male pins C120--1
(G) and C120--4 (N) of Replace EDC
control panel. control panel
Is resistance approximately
300--500!

Examine
microprocessor
connector C127 for
damage to terminal pin
C127--5

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62 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 31 -- Drive line / EDC harness disconnected

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 63

ERROR CODES 31 -- Drive line / EDC harness disconnected

Key OFF,
Key ON
retest

Is chassis harness Reconnect

connected harness

Perform checks for Error Code 18

Examine harness for but do not replace microprocessor
damage. Harness at this stage of examination.
damaged? Is Error Code still displayed?

Perform checks for Error

Replace or repair Codes 27 & 28.
harness Is Error Code still
displayed?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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64 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 49 -- Wheel speed sensor open or short circuit

C020--23
5010--B 5035--LN/G 5035--LN/G 5140--TQ/N
C127--1 C046--2

C020--43
5135--T/Q 5135--T/Q
C127--6 C046--1

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 65

ERROR CODES 49 -- Wheel speed sensor open or short circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500!

Is the value
greater than 89 Is there an open Locate and repair
circuit on wiring open circuit

Check the
resistance of the
sender. Is the Replace sender
resistance
approximately
2,500!

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66 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 53 -- Microprocessor 5 volt reference shorted to 12 volt supply

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 67

ERROR CODES 53 -- Microprocessor 5 volt reference shorted to 12 volt supply

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Examine harness for a

short circuit to a 12 volt
power supply from the
fuse panel or direct from
the battery.
Error still displayed?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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68 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 54 -- Microprocessor 5 volt reference shorted to ground

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 69

ERROR CODES 54 -- Microprocessor 5 volt reference shorted to ground

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Channel 5. short circuit to tractor
Is the value greater than 49 and chassis. Error still
error code 54 displayed. displayed?

Disconnect EDC control panel and

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70 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 57 -- EDC Microprocessor failure

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 71

ERROR CODES 57 -- EDC Microprocessor failure

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

Check and replace fuse 14 if necessary

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72 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 59 -- Microprocessor reference voltage open circuit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 73

ERROR CODES 59 -- Microprocessor reference voltage open circuit.

Key OFF,
Key ON
retest

Enter diagnostic mode H9 Inspect for intermittent

Channel 5. connector pin fault.
Is the value outside of the range At C127--5 is error still
45--53? displayed?

Disconnect EDC connectors

Disconnect processor
connector C127. Is Locate and repair open
there continuity circuit
between C120--1 (L/N)
and C127--5 (L/N)?

Is there continuity Locate and repair open

between C120--4 and circuit
C127--1?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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74 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 63 -- EDC hydraulic valve lower solenoid Open Circuit

65 -- EDC hydraulic valve lower solenoid Short Circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 75

ERROR CODES 63 -- EDC hydraulic valve lower solenoid Open Circuit

65 -- EDC hydraulic valve lower solenoid Short Circuit
Key OFF,
Key ON
retest

Disconnect hydraulic control

valve connector C218. Measure Replace lower
coil resistance. solenoid
Is resistance approximately 8!?

Disconnect microprocessor
connector C127. Is there
continuity between C218--2 Locate and repair open
and C127--19, and C218--1 circuit
and C127--27.

With microprocessor and valve

disconnected. Is there an open
circuit between harness
connectors C218--1 and Locate and repair short
C218--2. Similarly is there an circuit.
open circuit between each of
these pins and the chassis.

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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76 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 64 -- EDC hydraulic valve Raise solenoid Open Circuit

66 -- EDC hydraulic valve Raise solenoid Short Circuit

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 77

ERROR CODES 64 -- EDC hydraulic valve Raise solenoid Open Circuit

66 -- EDC hydraulic valve Raise solenoid Short Circuit
Key OFF,
Key ON
retest

Disconnect hydraulic control

valve connector C217. Measure Replace lower
coil resistance. solenoid
Is resistance approximately 8!?

Disconnect microprocessor
connector C127. Is there
continuity between C217--2 Locate and repair open
and C127--20, and C217--1 circuit
and C127--28.

With microprocessor and valve

disconnected. Is there an open
circuit between harness
connectors C217--1 and Locate and repair short
C217--2. Similarly is there an circuit.
open circuit between each of
these pins and the chassis.

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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78 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

ERROR CODES 67 -- EDC Hydraulic valve supply voltage too low

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9 79

ERROR CODES 67 -- EDC Hydraulic valve supply voltage too low

Key OFF,
Key ON
retest

Is fuse 14 OK? Replace fuse

Enter diagnostic mode H9 Check for intermittent

channel 8. fault between fuse 14
Is value less than 35? and C127--29

Disconnect processor
connector C127. Locate and repair open
Is there battery voltage circuit
at C127--29?

Remove, inspect and refit Processor

connectors, C127 and C128. If error still
occurs Reset the processor using Mode
H8 and recalibrate. If error still occurs
replace the processor.

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80 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 9

Fault Diagnostic Chart For Miscellaneous Hydraulic Lift Concerns

SYMPTON POSSIBLE CAUSE ACTION

Hydraulic lift will No pilot pressure to EDC Perform low pressure circuit tests.
not operate. hydraulic control valve. Refer to Section 35 Chapter 2

No load sensing signal. Tractors with CCLS Pump

Check load sensing valve for
sticking.
Tractors with Open Centre Gear
Pump
Examine unload valve for sticking

EDC load check valve Examine load check valve.

sticking,

Hydraulic lift will Load check valve piston Examine load check piston.
not lower. sticking.
Control valve spool sticking. Examine spool.

Lowering solenoid spool Examine solenoid spool and

sticking. torque of solenoid retaining
screws.
EDC Valve out of adjustment. Examine spool adjusters for signs
of tampering. Check valve
calibration values using
diagnostic routine H2.

Unload valve sticking

(Open centre hydraulics only)

Hydraulic lift will Microprocessor incorrectly Perform memory reset and

not raise or lower to calibrated. autocalibration procedure. See
maximum limits of Error Code 24.
travel.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 81

35 138 HYDRAULIC CONTROL VALVE -- OVERHAUL

REMOVAL
NOTE: The following procedure describes the
removal of both the hydraulic control valve and
manifold. It is not necessary to remove the
manifold from the tractor if only the valve is being
serviced.
1. Fully lower hydraulic lift arms
2. Disconnect electrical connector to control
valve.
3. Disconnect pilot (1), load sensing (5), system
pressure inlet (3) and hydraulic lift feed (4)
tubes at control valve (2), Figure 34.
34
4. Remove valve bracket retaining bolt (1) and
pull valve and manifold (2) from tractor,
Figure 35.
5. Separate control valve from manifold,
Figure 36, and note the location of all ‘O’ ring
seals.

Hydraulic Control Valve and Manifold 36

1. Return to Reservoir Tube 5. Connector
2. Connector 6. Control Valve
3. Connector 7. Manifold
4. Connector

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82 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

DISASSEMBLY

Solenoids and Pilot Spools

1. Identify lower (1) and raise (2) solenoids, to aid

re--assembly, Figure 37.

2. Remove solenoids from valve.

37
3. Separate solenoid components, Figure 38.

Solenoid Components -- Exploded View

1. Allen Screws 7. Field Coil
2. Piston 8. Body
3. Core 9. Plate
4. Plunger 10. ‘O’ Ring
5. ‘O’ Ring 11. End Cap
6. Plate

38
4. Remove pilot spool (1) and spring (2) from pilot
operated valves, Figure 39.

39
5. Insert a 5/16 in UNF bolt (2) into end of pilot
spool (1). Pull pilot spool from housing,
Figure 40.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 83

Main Spool

1. Using a suitable marker identify the right and

left hand adjusters in relation to the valve
housing body.

IMPORTANT: Do not disassemble or reset the

adjuster assemblies. The hydraulic control valve
adjustment is pre--set at the factory and ensures
that the spool is correctly set for the neutral
position.

2. Remove adjuster assemblies and withdraw

spool centering springs and seats, Figure 41. Main Spool 41
Ensure that springs and seats remain matched 1. Valve Housing 5. Adjuster Assembly
with each adjuster. 2. Spool 6. Seat
3. Seat 7. Spring
4. Spring 8. Adjuster Assembly

Load Check Valve

1. Remove the load check valve plugs and

withdraw the load check valve components,
Figure 42.

NOTE: The pin, item 7, is rounded on one end.

When re--assembling the valve ensure the rounded
end of the pin is inserted into the poppet, item 2.

Load Check Valve 42

1. Valve Housing 6. Plug and ‘O’ Ring
2. Poppet 7. Pin
INSPECTION 3. Ball 8. Piston
4. Guide 9. Plug and ‘O’ Ring
5. Spring
1. Wash all parts, except solenoids, in a suitable
solvent and dry with compressed air.

2. Inspect the valve housing, bores and spools for

3. Ensure the spools move freely in their bores.

4. Discard all ‘O’ ring seals.

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84 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

RE--ASSEMBLY and INSTALLATION

Re--assembly follows the disassembly procedure

in reverse. During re--assembly observe the
following:--

S Lubricate the spools with hydraulic oil.

S Install new ‘O’ ring seals.
S Tighten all plugs and locknuts to the correct
torque. See Specifications.
S When installing the solenoids, tighten the
retaining screws gradually in a cross corner
sequence to a torque of 15 lbf.in (1.7 Nm). Do
Not over torque the screws. 43
S Ensure ‘O’ ring seals (1) and (2) are correctly
located around oil galleries on mounting face of
hydraulic control valve before installing the
valve onto the hydraulic lift cover, Figure 43.

35 114 PRIORITY/UNLOAD VALVE ASSEMBLY -- OVERHAUL

REMOVAL

1. Fully lower hydraulic lift arms

2. Less Cab Tractors:

Remove seat to gain access to unload valve.

3. Remove panel in cab/platform floor to gain

access to priority/unload valve assembly.

4. Thoroughly clean area around valve prior to

proceeding with removal procedure.
44
5. Disconnect hydraulic connections to valve: (1)
Remote valve feed, (2) remote valve pilot line,
(3) supply from auxiliary pump, (4) supply from
control valve to hydraulic lift, (5) load sense
line.

NOTE: Be careful that check valve spring and ball

is not ejected when disconnecting the remote valve
supply tube.

6. Remove retaining bolts and lift valve assembly

from lift cover.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 85

DISASSEMBLY

NOTE: The connectors are installed against spring

pressure and must be removed with care.

Disassembly with reference to Figure 45 and

Figure 46.

Auxiliary Pump Check Valve

1. Ball
2. Spring
3. Check Valve Stop

Priority/Unload Valve Assembly

1. Housing
2. Combining/Unload Valve
3. Filter
4. Spring -- Unloaded Length 73.4 mm (2.89 in)
5. Plug
6. Connector
7. Spring -- Unloaded Length 137 mm (5.39 in)
8. Priority/Unload Valve

46
INSPECTION AND REPAIR

1. Wash all components in a suitable cleaning

agent such as paraffin (kerosene), mineral
spirits or a commercial cleaning agent.

2. Examine all valves and bores for burrs and

scratches. Any minor burrs or scratches may
be removed with a fine abrasive.

3. Ensure valves move freely in their bores.

Heavy scoring or bores will necessitate
installation of a new priority/unload valve
assembly.

4. Inspect the orifice in the end of the

priority/unload valve connector (1), Figure 47.

This connector receives the signal from the

electronic draft control valve load sensing line
and if blocked will prevent operation of the
valve resulting in a no/slow hydraulic lift.

5. Ensure the valve springs are not broken or

damaged.

6. Renew all ‘O’ ring seals.

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86 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

RE--ASSEMBLY

1. Lubricate all components with hydraulic oil.

2. Replace all ‘O’ ring seals.

3. Ensure the seals in the priority/unload valve

housing are not dislodged during installation
onto the tractor (1) and (2), Figure 48.

48
4. Tighten the valve to top cover mounting bolts
to a torque of 42--56 lbf ft (74--46 Nm).

5. Securely tighten all connections.

35 110 HYDRAULIC LIFT COVER ASSEMBLY -- OVERHAUL

REMOVAL

1. Lower lift arms.

2. Less Cab Tractors Only:

Remove platform to gain access to hydraulic
cover.

3. Where fitted turn auxiliary services control

knob to engaged position and disconnect
linkage at lift cover (3).
49
4. Disconnect hydraulic connections to assist
rams (where fitted) and disconnect rams (5)
from lift arms, Figure 50.

5. Disconnect lift rods (2) (3) and (4) from lift

arms.

6. Remove remote control valves (1).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 87

7. Remove hydraulic control valve (2), Figure 51,

as previously described in “Control Valve
Overhaul”.

8. Remove feed tube from hydraulic top cover to

control valve (1).

51
9. Disconnect and remove lift arm position
sensing potentiometer (1), Figure 52.

52
10. Disconnect tube connections at priority/unload
valve assembly and remove tubes from tractor.

1. Remote Valve Feed Tube

2. Remote Valve Pilot Line
3. Supply from Auxiliary Pump
4. Supply from Hydraulic Control Valve to Hydraulic
Lift
5. Load Sense Line from Hydraulic Control Valve

NOTE: Be careful that check valve spring and ball

is not ejected when disconnecting the remote valve
supply tube.

53
11. Remove trainer brake coupler and feed tube.

12. Remove assist ram feed tube.

13. Remove priority/unload valve assembly.

14. If the hydraulic lift assembly is being removed

in order to overhaul the lift cylinder, it is
recommended that the cylinder retaining bolts
are loosened before removing the lift
assembly from the tractor. Do Not remove
these bolts.

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88 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

15. Using suitable lifting gear remove lift cover,

Figure 54.

NOTE: For clarity, illustration shows lift cover

removal with platform removed. The cover can
however be removed with the cab in situ. When
removing the cover, with cab in situ, the lifting gear
should be positioned beneath the lift arms taking
care not to damage the small bracket on the right
hand arm.

54
DISASSEMBLY

1. Where fitted pull ASC valve to engaged

position. Unscrew control linkage connector
(3), pull knob (2) from lift cover and remove
selector valve stem (1), Figure 55.

55
2. Remove four bolts (1) securing lift cylinder (2)
to cover, Figure 56.

3. Move lift arms to raised position and carefully

remove lift cylinder from locating dowels taking
care not to damage the ASC valve spool.

56
4. Remove priority/unload valve assembly return
tube (1), Figure 57.

5. Remove lift cylinder safety valve and discard

seal. Refer to Figure 58.

NOTE: The lift cylinder safety valve is not

serviceable.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 89

Hydraulic Lift Cylinder -- Exploded View 58

1. Piston 5. Plug 9. Lift Cylinder
2. Ring Dowels 6. ‘O’ Ring 10. ASC Valve Spool
3. Ball 7. Safety Valve 11. ‘O’ Rings (7 off)
4. Spring 8. Seal

Lift Arm Assembly -- Exploded View 59

1. Lift Arm 3. Bolt 5. Washer
2. Locking Washer 4. Washer

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90 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

Cross Shaft and Arm Assembly -- Exploded View 60

1. Bush 4. Cross Shaft 7. Bush
2. Bush 5. Piston Rod and Arm Assembly 8. Seal
3. Seal 6. Bush

6. Remove ASC valve detent plug ball and spring

and withdraw valve spool.

7. Push a soft metal rod through safety valve bore

and eject lift cylinder piston. Discard piston ‘O’
ring seal and back up ring.

8. Remove lift arms. Refer to Figure 59.

9. Remove ASC valve detent plug ball and

spring.

10. Withdraw cross shaft assembly components.

Refer to Figure 60.

11. If arm (1), piston rod (3) or retaining pins (1)

and (4) are worn, separate rod and arm
assembly. Refer to Figure 61. The pins are an
interference fit into the arm. To remove pins
use a suitable lever between rod and end face
of pin.

12. Where necessary, remove remaining plugs

from lift cover. Under normal circumstances
the removal of these plugs is not necessary.
61

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 91

INSPECTION AND REPAIR

1. Wash all parts in suitable solvent and replace

all ‘O’ ring seals.

2. Examine ASC valve and mating bore for wear,

burrs or scratches. Minor damage to valve may
be removed with fine abrasive. Ensure valve is
thoroughly washed before re--assembly.
Ensure valve moves freely in bore. Heavy
scoring of bore necessitates replacement of lift
cylinder.

3. Check oil passages are free from obstruction.

4. Where a new lift cylinder is required select

largest ASC valve spool which when lightly
lubricated, will operate in bore without binding
when turned through 360# and operated over
full length of stroke.

NOTE: The ASC valve is colour coded only as a

guide for matching the valve to the bore. To obtain
an optimum fit a proprietary brand of metal polish
may be used to lap a slightly oversize valve into the
bore. Ensure all traces of polish are washed away
and the components are dried prior to
re--assembly. For control valve sizes refer to
Specifications.

RE--ASSEMBLY AND INSTALLATION

A master spline machined on the cross shaft
ensures correct alignment of both the lift arms and
piston arm during re--assembly.
Re--assembly and installation follows the
disassembly procedure in reverse while observing
the following requirements.
S Renew all ‘O’ rings and seals.
S Install piston ‘O’ ring seal (1) closest to closed
end of piston and back--up seal (2) nearest
open end of piston (3), Figure 62.

62
S To aid installation of piston into lift cylinder and
prevent damage to the piston seals, a guide
can be manufactured to the dimensions shown
in Figure 63.

Piston Installation Guide

A. 4.126 inch (105 mm)
B. 5.25 inch (134 mm)
C. 0.12 inch (3 mm)
D. 1.62 inch (40 mm)
E. 6.0 inch (155 mm)

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92 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

S Install piston (1) into cylinder (3) using guide (2)

as shown in Figure 64. If a guide is not
available and installation is difficult a piston ring
compressor may be used to compress the
seals.

64
S Ensure the lift cylinder retaining bolts are
installed in the correct locations and torque to
165--200 lbf ft (224--271 Nm), Figure 65.

Lift Cylinder Retaining Bolt Locations

(Viewed from Top of Hydraulic Lift Cover)
1. 3 in (76 mm) Bolt
2. 2.5 in (64 mm) Bolt
3. 2.25 in (57 mm) Bolt
4. 3 in (76 mm) Bolt with Thin Bolt Head

65
S Prior to installation of the cross shaft coat the
shaft and lip seals with grease.

S The following torque procedure must be

observed when tightening the lift arm retaining
bolts.

S Install the lift arms and tighten the left hand arm
retaining bolt to a torque of 20--30 lbf ft (27--40
Nm). Lock the bolt in position with the tab
washer. Refer to Figure 65.

S Raise both lift arms and tighten the right hand

arm retaining bolt sufficiently to allow the arms
to lower under their own weight. Lock the bolt
in position with the tab washer. Do Not over
tighten bolts as damage to the cross shaft
seals and washers will occur.

S Prior to installation of the hydraulic top cover,

apply a thin bead of New Holland gasket sealer,
Part No. 82995770, to BOTH sides of the
hydraulic top cover gasket. The bead should be
continuous around the entire face of the gasket
and to a thickness of approximately 1/32 in
(1mm).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9 93

S Install lift cover onto the rear axle centre

housing and tighten retaining bolts to a torque
of 100--125 lbf ft (135--170 Nm).
S Manually raise lift arms (engine not running)
and check that lift arms fall slowly under their
own weight. If the arms do not fall recheck the
torque applied to the lift arm retaining bolts.
S Continue to install the lift cover, linkage and
cab/platform using the removal procedure in
reverse.
S Tighten all retaining bolts to the correct torque
and apply sealant to threads where specified.
See Specifications.

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94 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER -- 9

NOTES

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 1

SECTION 41 -- STEERING
Chapter 1 -- Hydrostatic Steering System

CONTENTS
Section Description Page

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
41 204 Steering Motor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steering Column -- Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
41 216 Two Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Four Wheel Drive Steering Cylinder -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

604.55.041.00 - 01 - 1998
2 SECTION 41 -- STEERING -- CHAPTER 1

41 000 SPECIFICATIONS

HYDROSTATIC SYSTEM 2WD 4WD

Pump specifications

Minimum Pump Output

Litres/min. 31.0 31.0
Imp.Galls/min 6.8 6.8
U.S. Galls/min. 8.2 8.2

Steering Motor Displacement 125cc/revolution 150cc/revolution

Relief Valve Maximum Differential 145 Bar 170 Bar

Pressure Setting 2100 lbf.in2 2465 lbf.in2

Absolute Gauge Pressure 153--163 Bar 180--190 Bar

2220--2370 lbf.in2 2620--2770 lbf.in2

TWO WHEEL DRIVE AXLE

Maximum Steering angle 55!

Steering Wheel Turns (Lock to Lock) 3.4

Cylinder Double Acting Balanced

Short Wheel Base Long Wheel Base

Turning Radius with Brakes 3.27 m 3.53 m

Turning Radius less Brakes 3.66 m 3.88 m

Toe--out 0--13 mm 0--13 mm

FOUR WHEEL DRIVE AXLE

Maximum Steering angle 55!

Steering Wheel Turns (Lock to Lock) 4.7

Cylinder 2 off Double acting Unbalanced

Turning Radius with Brakes 3.45

(4WD disengaged)

Turning Radius less Brakes 4.04

(4WD disengaged)

Toe--In 13mm

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 3

41 000 TIGHTENING TORQUES

A. Steering Cylinder C. Steering Motor 1

B. Variable Displacement/Tandem Gear Pump

Steering General Nm Lbf.ft.

Steering Wheel Retaining Nut 23.0 17.0
Front Wheel Nut 2WD 133.0 98.0
Front Wheel Nut 4WD 475.0 350.0
Motor End Cover 23.0 17.0
Cylinder Ball--joint to Extension 43.0 32.0
Cylinder Ball--joint to Axle 176.0 130.0
Cylinder Ball--joint Clamps 43.0 32.0
Cylinder Ball--joint Nuts 176.0 130.0
Cylinder Extension Tube to Cylinder 271.0 200.0
Column to Frame Bolt 23.0 17.0
Cylinder, Tube End Pin Retaining Bolt (4WD) 23.0 17.0
41 000 SPECIAL TOOLS

DESCRIPTION NEW HOLLAND V.L.CHURCHILL

TOOL NUMBER TOOL NUMBER
Pressure Gauge (0--6000 lb/in2) 292870 FT8503A
Roto--glyd Seal Installer 294056 --
Adaptor (Gauge to Hose) FT8503--8
Test Hose Part No. 83936707
Adaptor (Test hose to tractor tube) 7/16 JIC Male x 9/16 JIC Male

604.55.041.00 - 01 - 1998
4 SECTION 41 -- STEERING -- CHAPTER 1

41 000 -- DESCRIPTION AND OPERATION

Hydrostatic Steering System Component Layout -- CCLS Pump Model 2

1. Transmission Oil Cooler 7. Transmission / Rear Axle Lubrication Line
2. Left Hand Turn Hose 8. Steering Pump Output Line
3. Steering Cylinder 9. Steering Motor
4. Right Hand Turn Hose 10. Seering Return / Lubrication Line
5. Cooler Outlet Line 11. Oil Cooler Outlet Line
6. Cooler Bypass Valve

All models have fitted as standard, hydrostatic The steering motor is similar across the vehicle
steering systems that are powered when the engine range and is bolted to a bracket within the steering
is running by hydraulic pumps mounted on the rear console and connected to the steering column by a
axle. splined shaft.

There are two types of steering pump used The steering column is adjustable for varying
depending on whether the hydraulic system has a angles of tilt on all models.
closed centre or open centre system.

On two wheel drive units the steering cylinder is

Both open and closed centre hydraulic systems fixed at one end to the front axle beam and at the
incorporate a steering pump as part of the hydraulic other to an eye on the spindle steering arm.
pump assemblies. The closed centre system has a
unique suction filter, whereas the open centre
system shares a combined function filter. On four wheel drive units two steering cylinders are
used, one for each wheel. The cylinders are fixed at
one end to the axle casing and the piston end to
The pumps, driven by the P.T.O. idler gear, steering arms from the swivel housings.
pressurise the steering column operated steering
motor. The pressurised oil from the steering motor
drives the axle mounted double acting steering The pressure relief valve for the system is
cylinder (2WD), or twin cylinders (4WD). contained within the steering motor itself.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 5

G41003
Steering Operation Schematic -- Neutral Position 3
1. Metering Unit 6. Return via Cooling and 9. Control Valve Spool
2. Check Valve Lubrication 10. Suction Valves (2WD Only)
3. Non Return Valve 7. Pressure Relief Valve 11. Bias Valve (2WD Only)
4. Pump 8. Control Valve Sleeve 12. Steering Cylinder/s
5. Filter

Suction Oil Return Oil

(Restricted by cooling and Lubrication)
Trapped Oil Pump Oil

OPERATION Suction valves, item 10 Figure 3, only used on two

wheel drive models, prevent cavitation in the
steering cylinder as oil is transferred from a small
Oil is drawn from the rear axle and into the pump
area to a large area when the steering motor is in
through a filter, pressurised by the rotation of the
the neutral position.
gears, and expelled through the pump outlet port to
the steering motor, via a resonance damper filter The system is fully hydrostatic and as such there is
which reduces the noise from the system and no mechanical connection between the steering
smooths the output from the pump. The column and the steering wheels.
pressurised oil when received at the steering motor
is directed to the steering actuating cylinder when Neutral Position
the steering wheel is turned.
With the steering wheel held still, the leaf springs in
The steering motor incorporates a metering unit the steering motor return and hold the spool and
which regulates the volume of oil supplied to the sleeve in the neutral position. This ensures no more
cylinder so that it is proportional to the angular oil is supplied to the steering cylinder, Figure 3. The
movement of the steering wheel. The metering unit trapped oil is, however, allowed to transfer between
in combination with the check valve also allows the the left and right turn sides of the cylinder/s,
steering to be operated MANUALLY without allowing the wheels to react to the ground to provide
pressurised oil being supplied from the pump. feedback for the driver.

604.55.041.00 - 01 - 1998
6 SECTION 41 -- STEERING -- CHAPTER 1

G41004
Oil Flow Schematic 4
A-- Right Hand Turn B-- Left Hand Turn
Suction Oil Pressure Supply
Metering Unit Supply Metered Oil To Steering Cylinder
Return Oil (Restricted by cooling and Lubrication)

Right Hand Turn Manual Right Turn

When the steering wheel is turned the movement of In the event of a power steering pump failure or loss
the control valve spool in its sleeve forms a series of of oil pressure, the power steering system can be
passages. During right turns the oil flows through the operated manually. Turning the steering wheel
sleeve along a groove in the valve spool and into a rotates the metering unit rotor and forces oil into the
passage in the steering motor housing which leads rod side of the power steering cylinder.
to the metering unit, Figure 4.
On the suction side of the metering unit, return oil
The metering unit is turned by the drive shaft and flows from the cylinder and is drawn through the
directs oil along another set of passages in the spool check valve to feed the metering unit.
and sleeve and into the steering cylinder. Return oil
from the other side of the cylinder is directed through Manual Left Turn
the valve spool and sleeve to a return passage in the
housing. Turning the steering wheel rotates the metering unit
rotor which forces oil into the piston side of the power
steering cylinder.
Left Hand Turn
When additional oil supply is required, as in making a
When turning the wheel to the left oil flows along the left turn, additional oil is drawn from the power
sleeve and operates in a similar manner as steering reservoir through the check valve to the
described in right hand turn, Figure 4. metering unit.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 7

41 000 -- FAULT FINDING

IMPORTANT: When effecting a repair the cause must be corrected to avoid a repeat failure.

PROBLEM POSSIBLE CAUSE REMEDY

No steering or excessive effort 1. Air in system 1. Check for loose connections

to steer or damaged tubing. Purge
system of air.

2. Steering system relief valve 2. Check system pressure.

sticking/faulty

3. Worn pump 3. Inspect and repair.

4. Leaking steering cylinder 4. Inspect and repair.

5. Broken or damaged steering 5. Inspect and replace as

column coupling required.

6. Damaged or worn metering 6. Inspect and replace as

unit required.

Steering wanders 1. Excessive play in steering 1. Inspect and replace as

linkage joints required.

2. Leaking steering cylinder 2. Inspect and repair.

3. Damaged or worn metering 3. Inspect and replace as

unit required.

Drift to Left, Two Wheel Drive 1. Bias valve faulty 1. Replace or repair
only

Front wheels surge when 1. Leaking steering cylinder 1. Inspect and repair.
steering
2. Damaged or worn metering 2. Inspect and replace as
unit required

604.55.041.00 - 01 - 1998
8 SECTION 41 -- STEERING -- CHAPTER 1

41 000 -- SYSTEM TESTING

When the hydrostatic steering system is in

operation, the pressure of oil supplied by the
steering pump, item (1), Figures 5 and 6, to the
steering motor, can rise towards the maximum
setting of the steering motor relief valve, which is
145--170 bar (2100--2465 lbf/in2) depending on
tractor model.

Item (2), figures 5 and 6 show the return from the

steering motor

The pressure of oil, however, on leaving the

steering motor and returning via the oil cooler to the
16×16 transmission and PTO clutch lubrication
circuits, is limited to a maximum pressure of 7 bar 5
(100 lbf/in2) by the lubrication circuit relief valve,
located within the transmission control valve.

Differential Pressure
(Tractors with Tandem Gear Pump)

Differential pressure is the difference in pressure

between the supply and sump ports on the steering
motor. Measured (gauge) pressure is equal to the
relief valve setting plus system back pressure.

System back pressure varies between 8.3 and

18.6 bar (120 and 270 lbs/in2) depending on
hydraulic system.

The flow of oil on leaving the steering motor returns

to the pump body for distribution to the low
pressure and lubrication circuits. The pressure of
oil returning from the steering motor is regulated at 6
a pressure of 15.2 -- 16.6 bar (220--240 lbf/in2) by
the low pressure regulating valve in the PTO clutch
assembly at 2100 revs/min. As the pressure is
regulated, excess oil in the low pressure circuit
flows through the regulating valve, into an adjacent
lubrication circuit relief valve which limits the
pressure of oil in the lubrication circuit to 5.0--5.7
bar (72--83 lbf/in2) at 4.5 ltrs/min (1.1 gpm).

Steering Pump
There is no relief valve in the steering/low pressure
pump. The following practical test will determine if
steering pump output is sufficient to allow
satisfactory operation of the steering system.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 9

Steering Test -- All Models

1. Set engine speed to 1000 rev/min.

2. Turn steering quickly from lock to lock. If

7
Steering Relief Valve Pressure Test

IMPORTANT: There is no relief valve in the 1

steering pump and the following pressure test must
only be performed as specified below. Failure to
observe this precaution may result in severe
damage to the hydraulic pump.

1. Turn steering onto full left hand lock.

2. Disconnect left hand turn feed hose at steering

cylinder. 3 2
60--41--024 TI
8
3. Install a 0--6000 lbf/in2 pressure gauge
FT. 8503A, item 1, Figure 8, using adaptor
FT8503--8, item 2, Figure 8 and a locally
procured 7/16 JIC male x 9/16 JIC male
adaptor, item 3, Figure 8.

4. Using kit 292870 install adaptor 293874 and

291318 into the place of the banjo fitting of the
steering hydraulic cylinder.

5. Start tractor and set engine speed to

1450 rev/min. Turn steering wheel to the left
with a pull of approximately 22 N (2.25 kgf,
5 lbf) and observe the pressure reading.

NOTE: The use of a force greater than 5 lbf. at the

rim of the steering wheel may lead to slightly
inaccurate readings due to the pumping action of
the hydrostatic steering motor.

If the steering test was satisfactory but the

pressure readings are away from specification the
relief valve in the steering motor must be adjusted.

The pressure reading should be:--

153--163 bar (2220--2370 lbf/in2) for 2WD tractors

180--191 bar (2620--2770 lbf/in2) for 4WD tractors

6. If the system pressure is not to specification

proceed to Relief Valve Adjustment.

604.55.041.00 - 01 - 1998
10 SECTION 41 -- STEERING -- CHAPTER 1

1
13
2
12
3

9 B 10
T
11

8 7 A 6

Steering Motor Relief Valve Adjustment 9

1. Plug Cylinder 9. Size 10 ORS Swivel Running
2. Steering Shaft 6. Fabricated Hose for Pump Tee
3. Relief Valve Supply to Steering Motor 10. Pressure Gauge 0--500lbf.in2
4. Fabricated Steering Motor 7. Pressure Gauge 0--5000lbf.in2 11. Size 6 ORS Blanking Cap
Output Hose 8. Size 8 ORS Swivel Running 12. Spring
5. Tractor Tubes to Steering Tee 13. Adjuster

Relief Valve Adjustment -- All Models steering bracket, as detailed previously in this
Chapter, and remove from the tractor.
With reference to Figure 9. 2. Fabricate suitable test hoses to connect from
the tractor pressure and return tubes. Connect
NOTE: To adjust the steering system relief valve it the hoses into locally procured tee pieces and
is necessary to remove the steering motor from the install pressure gauges. Start the engine and
steering bracket, to gain access to the hexagon idle between 1450 and 1500 rev/min. Run the
headed adjusting screw. tractor until the transmission oil reaches normal
working temperature of approximately 68!C
1. Disconnect the steering motor from the (155!F).

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 11

3. With the engine running, turn the steering Gauge ‘A’ 162 bar (2350 lbf.in2) minus Gauge ‘B
motor shaft to obtain full lock. The pressure 17 bar (250 lbf.in2) =
gauge reading at point ‘A’ should read 162 bar 145 bar (2100 lbf.in2on 2WD models
(2350 lbf.in2) on 2WD models and 190 bar (2750 Gauge ‘A’ 190 bar (2750 lbf.in2) minus Gauge ‘B
lbf.in2) on 4WD models. The gauge pressure at 17 bar (250 lbf.in2) =
point ‘B’ should be in the region of 17 bar (250 142 bar (2500 lbf.in2) on 4WD models
lbf.in2).
4. To establish actual (differential) pressure 5. If the pressure readings are not correct, reset
subtract gauge ‘B’ reading from the gauge ‘A’ the adjuster (item 13), 9, using an 8mm
reading. The differential pressure should be to hexagon key. Half a turn on the adjuster
the specification of: equates to approximately 200 lbf.in2 (13.8 bar).

41 204 -- STEERING MOTOR - OVERHAUL

5 15 16
14
17 1
18
19

13
12
11
10

5 2

3
9

5
8
7

6 5 4
60--41--001 TI

Steering Motor 10
1. Pin 8. Manifold Plate 14. Spring
2. Centering Springs 9. Drive Shaft 15. Complete Assembly
3. Retaining Bolts 10. Retainer 16. Ball
4. Dowel Pin Bolt 11. Ball 17. Pin
5. ‘O’ Ring Seal (Kit) 12. Relief Valve Seat 18. Thrust Bearing and Washers
6. End Plate 13. Relief Valve (Kit items) 19. Spacer
7. Rotor and Stator Assembly

604.55.041.00 - 01 - 1998
12 SECTION 41 -- STEERING -- CHAPTER 1

NOTE: Parts/Motors are common between the two

steering pumps, with the exception of items
7,10,12 and 13, Figure 10.

Removal

1. Position the tractor on a hard level surface and

apply the parking brake.

2. To gain access to the steering motor :--

Raise and remove the engine hood
Remove the steering column consoles
Remove the cab access panels
Remove the cab to engine fire wall.

3. Disconnect the four supply/return tubes and

‘O’ ring seals from the steering motor and cap
the ends of the tubes.

4. Remove the roll pin from the drive collar to

separate the steering shaft, Figure 11.

5. Remove the four bolts at the base of the

steering column and slide the steering motor
from the upper section of the steering column,
Figure 11.

6. Remove the steering motor from the front of

the cab through the engine compartment.
60--41--018 TI
11
Dlsassembly
1. With the steering motor connectors removed
note position of the non return valve, see
Figure 21.
2. Hold the steering motor securely in a vice using
a tube connector as shown in, Figure 12.

NOTE: The position of the pin bolt must remain the

same on re--assembly.

3. Remove the end plate bolts, end plate and ‘O’

ring, Figure 12.
60--41--002 TI
12
4. Remove metering unit, valve plate and ‘O’ ring
seals, note mating surfaces for correct
re--assembly, Figure 13.

60--41--003 TI
13

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 13

5. Lift out rotor drive-shaft, Figure 14.

60--41--004 TI
14
6. Unscrew the check valve retainer, Figure 15
and shake out the check and suction valves.

60--41--005 TI
15
7. Remove the relief valve assembly, Figure 16.

IMPORTANT: The relief valve must be set to the

correct pressure setting on re--assembly. Follow
the correct procedure as detailed under the
heading ‘Pressure relief valve setting’, of this
Chapter.

60--41--006 TI
16
8. Remove the inner and outer valve sleeves,
bearings and thrust washer, Figure 17.

NOTE: When removing spool and sleeve ensure

drive pin is in a horizontal position so that it cannot
fall into an internal gallery and make removal
difficult.

60--41--007 TI
17

604.55.041.00 - 01 - 1998
14 SECTION 41 -- STEERING -- CHAPTER 1

9. Once spool is disassembled from the body

ensure oil seal is removed, Figure 18.

60--41--008 TI
18

IMPORTANT: Upon re--assembly ensure washer,

item 1, Figure 19 is installed with chamfer towards
the valve sleeve. 1

10. Remove the control valve spool and sleeve,

Figure 19.

60--41--009 TI
19

11. Remove centering springs, Figure 20.

NOTE: Arrangement of the leaves must remain the

same upon re--assembly.

12. Remove drive pin, Figure 20.

13. Push inner sleeve from outer sleeve.

60--41--010 TI
20
14. Remove ‘O’ ring and back-up ring.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 15

9
TI

Hydrostatic Steering Components 21

1. Thrust Washers and Bearing 7. Bolts 12. Metering Unit
2. Drive Pin 8. Control Valve 13. Distributor Plate
3. Retaining Ring 9. Drive Link 14. Check Valve Bolt
4. Relief Valve 10. ‘O’ Ring 15. Non Return Valve
5. Control Valve Spool 11. End Plate 16. Housing
6. Suction Valves

Inspection

1. Wash all parts in a suitable solvent to remove

any foreign particles and dry with a clean lint
free cloth or compressed air.

2. Inspect valve sleeves for, damage or wear.

Minor burrs or scratches can be removed with
a fine abrasive. Ensure all parts are thoroughly
cleaned prior to re-assembly.

3. Check leaf springs for damage. Replace if

necessary.

4. Discard all ‘O’ ring seals and replace with new

seals on re-assembly.

604.55.041.00 - 01 - 1998
16 SECTION 41 -- STEERING -- CHAPTER 1

Re-Assembly

1. Assemble inner and outer sleeves so that the

leaf spring slots align.

2. Install the drive pin, Figure 22.

60--41--010 TI
22
3. Install the leaf springs and push fully into
position, Figure 23.

60--41--012 TI
23
4. Install leaf spring retainer, and bearing, Figure
24.

NOTE: The inner bearing race must be positioned

with the chamfer side facing the spool, Figure 19.

60--41--009 TI
24
5. Apply a light coating of hydraulic oil onto the
sleeve item 2 and insert into the steering motor
body, item 3, Figure 25.

6. Coat the ‘O’ ring and back-up ring, item 4,

Figure 25, with hydraulic fluid and position
them onto the seal installer guide.

-- Use New Holland special tool No. 294056 to

install oil seal type roto--glyd.

60--41--013 TI
25

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 17

7. Position the seal guide tool into the sleeve and

push down with a twisting action, Figure 26.

8. Remove tools once the seal has seated.

60--41--014 TI
26
9. With the seal installed in the motor body refit
control valve, Figure 27.

NOTE: Ensure that the Drive is in a horizontal

position to aid re--assembly.

60--41--015 TI
27
10. Once the control valve is seated correctly refit
the check and suction valves, Figure 28.

11. Screw the check valve down to just below the

surface of the housing.

60--41--005 TI
28
12. Refit the ‘O’ Ring and place the end plate in
position.

60--41--016 TI
29

604.55.041.00 - 01 - 1998
18 SECTION 41 -- STEERING -- CHAPTER 1

Metering Unit Reassembly

1. To aid reassembly install the control valve into

the housing so that the drive pin is
perpendicular to the front face of the housing.

2. Install drive link into the steering motor body,

Figure 30, ensuring that the link engages
correctly over the drive pin.

60--41--004 TI
30
3. Assemble the metering unit rotor and stator
and install new lightly greased ‘O’ rings to
either side of the stator, Figure 31.

4. Assemble the rotor and stator onto the drive

link.

5. Install the end plate and bolts, ensure the pin

bolt(1) is fitted in position ‘7’. Tighten the bolts
in two steps, first to 8 lbf.ft (10.8 Nm) and then
to 21 lbf.ft (28.4 Nm) in sequence as shown,
Figure 32.
60--41--003 TI
31
6. Install the relief valve assembly, items 1, 2 and
3 Figure 1., leaving the plug, item 4 out until
after the relief valve has been adjusted. 6 4

7. Check to ensure the motor turns freely without 1 2

binding.
1
IMPORTANT: The relief valve must be set to the 7
correct pressure setting after the motor has been 3
re--assembled. Follow the correct procedure as 5
detailed under ‘Pressure relief valve setting’, of this
Chapter.

32
8. After the relief valve has been correctly set
re--install the steering motor onto the mounting
bracket and tighten the securing bolts to a
torque value of 10--15 lbf ft(13--20Nm).

4
9. Reconnect the steering hoses, tighten to a
torque value of 10--15 lbf ft (13--20Nm).

10. Purge the air from the system by operating the 1

steering system from lock to lock until the 2
system functions correctly.
3
60--41--006 TI
33
1

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 19

STEERING COLUMN REMOVAL and

INSTALLATION

NOTE: The component parts of the steering

column as listed are serviced separately.

Removal

1. Remove the steering wheel, if required.

2. Remove the lower steering column cover

complete with multi--function switches.
60--41--028 TI
34
3. Remove the upper steering column cover.

4. Remove the instrument console side panels.

5. Remove the four securing bolts securing the

column to the frame, Figure 34.

6. Lift the column clear of the steering shaft and

clear of the instrument console, Figure 35.

7. Remove the pin from the spacer at the bottom

of the column and remove the steering shaft
and spacer, Figure 36. 60--41--027 TI
35
Inspection

1. Inspect the steering shaft universal joint and

lower rubber coupling. Replace if any free play
is evident.

2. Inspect the column assembly, if damaged or

the bushes are worn a new assembly will be
required.

Installation 60--41--025 TI
36
1. Place spacer and steering shaft onto the
steering motor and install pin.

2. Carefully place the steering column through

the instrument console and over the steering
shaft, ensuring flat sides are aligned.

3. Replace the securing bolts at the top of the

column. Tighten to 23 Nm (17 lbf.ft).

4. Refit the upper and lower column covers and

shuttle switch if fitted.

5. Refit the instrument console panels.

60--41--026 TI
6. Refit the steering wheel. 37

604.55.041.00 - 01 - 1998
20 SECTION 41 -- STEERING -- CHAPTER 1

41 216 TWO WHEEL DRIVE STEERING CYLINDER -- OVERHAUL

Removal

1. Stand the unit on a hard level surface and

position the front wheel in the straight ahead
position.

2. Disconnect flexible pipes, cap the open pipe

ends.

NOTE: Position of flexible pipes and orientation of

connectors must be the same upon re--assembly.
38
3. Remove retaining nuts (3) and separate ball
joints (1) from track rod/axle (2), Figure 38

Disassembly

1. Drain the cylinder of all oil. Cap the ports.

2. Loosen the clamp bolts (1) and remove ball

joint assemblies (2), Figure 39.

3. Install suitable fittings into the cylinder ports to

enable the cylinder to be clamped in the jaws of
a vice.

IMPORTANT: Do not clamp directly around the

cylinder barrel, as damage may occur.

4. Using a ‘C’ spanner (2) unscrew the extension

tube (1) and gland assembly, Figure 40

5. Withdraw gland and piston/rod assembly from

the cylinder.

6. Remove all seals.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 21

Inspection

1. Wash all components in a suitable solvent and

air dry.

2. Inspect all parts for damage/wear. Minor

nicks/burrs can be removed with an abrasive
stone.

3. Inspect ball--joints for free play. Replace as

necessary.

41
Re--Assembly

1. Install a new ‘O’ Ring (3), piston seal (4) and

wear rings (1) onto the piston (2), Figure 41

2. Install new rod seals (3) in the glands (1),

ensure sealing lip faces towards oil pressure.
Install new back--up rings (5), ‘O’ rings (4) and
rod wipers (2), Figure 42.

42
3. Lubricate seals and slide the gland assembly
(2) onto the piston rod (1), Figure 43.

43
4. Place cylinder barrel (2) in a vertical position
and insert the piston/rod (1) and gland
assembly (3), Figure 44

NOTE: Installation of the piston seal on top of the

‘O’ ring requires special care. Allow the seal to
contract naturally before installing the piston and
rod assembly into the cylinder.

5. Screw gland into barrel until fully seated.

604.55.041.00 - 01 - 1998
22 SECTION 41 -- STEERING -- CHAPTER 1

Installation

1. Installation of steering cylinder and track

control rods is the removal procedure in
reverse.

2. Screw anchor end ball joint into extension

tube. Unscrew ball joint a fraction of a turn and
ensure the connectors are positioned as,
Figure 45. Tighten the clamp to 43.0 Nm (32.0
lbf.ft) 4.4 kgf m.
45

3. Compress the cylinder rod until the piston

bottoms in the cylinder.

4. Assemble the anchor end ball joint to the track

rod axle (2), Figure 46 and tighten to 176 Nm
(130 lbf ft), 18.0 kgf m.

5. Position right hand wheel in the full right hand

lock position.

6. Extend cylinder rod from the fully compressed 46

position by 4.0 -- 10.0 mm. (0.15 -- 0.4 in).

7. Adjust the piston rod ball joint to align with lug

on tract rod. Install joint (1), Figure 46, and
tighten to 173 Nm (130 lbf ft) 18.0 kgf m.

8. Position front wheels in the straight ahead

position, adjust track rod to achieve a toe--out
of 0 -- 13.0 mm (0 -- 0.5 in.) measured on the
wheel rim at hub height (A minus B), Figure
47.

9. Purge the air from the system by starting the

engine and turning the wheels from lock to lock 47
several times. Repeat until steering operates
correctly.

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 23

48
Steering Cylinder Assembly
1. Piston and Rod Assembly 5. Dust Washer 9. Seal Kit items*
2. Cylinder 6. Clamp Bolt 10. Nut
3. Extension Tube 7. Clamp 11. Track rod end
4. Track Rod End 8. Nut 12. Clamp Bolt
* Seal Kit Consists of:--
Rod Seals and Bushing
Piston Seals
Gland Seals

604.55.041.00 - 01 - 1998
24 SECTION 41 -- STEERING -- CHAPTER 1

41 216 FOUR WHEEL DRIVE STEERING CYLINDERS -- OVERHAUL

Removal and Installation

1 2

7
6

Steering Cylinder Installation -- Four Wheel Drive 49

1. Pivot Pin 5. Circlip
2. Pivot Pin 6. Spacer
3. D Shaped Washer 7. Spacer
4. Spacer

1. Stand the unit on a hard level surface and

position the front wheel in the straight ahead
position.

2. Disconnect flexible pipes, cap the open pipe

ends and remove hose clamps.

NOTE: Position of flexible pipes and orientation of

connectors must be the same upon re--assembly.

3. Remove the snap ring retaining the steering

arm to the cylinder piston pivot pin, item 6,
Figure 49 and remove the pivot pin.

4. Remove the steering cylinder fixed end pivot

pin retaining bolt and withdraw the pivot pin,
item, 1, Figure 49. Remove the cylinder from
the vehicle.

5. Installation is the reversal of the removal

procedure

Steering Stop Adjustment

1. Turn the wheels to full lock and adjust steering

stop to ensure tyres or mudguards do not touch
the side of the tractor and that the steering
cylinders have not reached the end of their
travel 50

604.55.041.00 - 01 - 1998
SECTION 41 -- STEERING -- CHAPTER 1 25

Steering Cylinder Overhaul -- Four Wheel Drive

1 2

8
3

6 4

Steering Cylinder Assembly -- Four Wheel Drive 51

1. Cylinder 5. Cylinder Rod
2. Wiper Seal 6. Gland and Seal Assembly
3. Retaining Ring 7. Piston
4. Gland Nut 8. Nut

1. Using appropriate ‘C’ spanner, unscrew and

remove the gland nut.

2. Using a punch, push the steering cylinder

gland into the cylinder and remove the wire
locking ring.

3. Pull the rod and gland assembly from the

cylinder.

52
4. Remove the nut from the cylinder rod and
disassemble to replace seals.

5. Inspect the bore of the cylinder and replace if

scored.

6. Reassemble the cylinder in the reverse to

disassembly, lubricating all components as
assembled. Replace all seals supplied in the
service seal kit.

NOTE: The seal located in the centre of the gland is

replaceable.
53

604.55.041.00 - 01 - 1998
26 SECTION 41 -- STEERING -- CHAPTER 1

NOTES

604.55.041.00 - 01 - 1998
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 1

SECTION 44 -- FRONT AXLE

Chapter 1 -- Two Wheel Drive Axle

Section Page

44 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
44 101 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
44 101 Front Axle--overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

44 000 SPECIFICATIONS

TORQUES

lbf ft

LUBRICANT

Hub bearing grease to Specification NH710A (Ambra GR9).

604.55.041.00 - 01 - 1998
2 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

DESCRIPTION AND OPERATION

Two Wheel Drive Axle Assembly 1

1. Telescopic Axle Extension 4. Support Pin
2. Wheel Hub and Spindle 5. Front Support
3. Centre Beam 6. Track Control Rod Assembly

The two wheel drive front axle consists of a hollow The axle is equipped with hydrostatic steering as
centre beam with telescopic axle extensions and standard using a cylinder connected between the
spindle assemblies at each end, Figure 1. axle beam and track control rod assembly.

The centre beam, telescopic extensions and track

control rod are machined to provide a series of holes
The centre beam is attached to the support using a allowing the track of the axle to be varied in 4 in
single pin, allowing radial movement of the axle (102 mm) steps between 56 in (1422 mm) and 84 in
about the centre line of the tractor. (2134 mm) depending on the tractor model.

604.55.041.00 - 01 - 1998
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 3

ADJUSTMENTS

TRACK WIDTH ADJUSTMENT

1. Apply the handbrake and place blocks at the

front and rear wheels.

2. Jack up the front axle (2) and place on axle

stands.

3. Remove axle extension (3) securing bolts (1),

Figure 2.

4. Remove locating bolts from both ends of track 2

rod, Figure 4.

5. Set the left and right hand axle extensions to Standard Axle
the required track as indicated in the following Track Setting Securing Bolt
tables. Locations
in. mm Refer to 2
56 1422 A C
60 1524 B D
64 1626 C E
68 1727 D F
72 1829 E G
76 1930 F H
80 2032 G J
84 2134 H K

NOTE: The track settings shown are approximate. Tobacco Axle (North America Only)
The front wheel discs are off--set relative to the Track Setting Securing Bolt
centre line of the rim. The track settings in the table Locations
are with the dished side of the wheel nearest the in. mm Refer to 2
axle hub. If the front wheels are reversed on the
hubs the track settings shown in the tables will be 68 1727 A C
increased by approximately 4 in. (100 mm). 72 1829 B D
76 1930 C E
80 2032 D F
84 2134 E G
88 2235 F H
92 2337 G J
96 2438 H K

604.55.041.00 - 01 - 1998
4 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

6. Install the axle extension securing bolts and

tighten to a torque of 300 lbf ft (407 Nm).

7. Position both wheels straight ahead and install

the track control rod locating bolts, Figure 4.
Tighten the bolts to a torque of 110 lbf ft
(150 Nm) and their locknuts to 55 lbf ft
(75 Nm). Re--check all torque settings after 50
hours of operation.

Track Control Rod -- Left Hand End

1. Drillngs
2. Locating Bolt and Locknut
3. Clamp Bolt
4. Threaded Section

FRONT WHEEL TRACK ADJUSTMENT

After resetting the track width, the front wheel

‘Toe--Out’ may require adjustment. For correct
operation, the front wheel toe--out should be
0--0.5 in. (0--13 mm).

1. Position the front wheels in the straight ahead

position and measure the distance between
the wheel rims at hub height at the front of the
wheels. Position B, Figure 3.

2. Rotate both wheels 180!, to eliminate wheel

rim run out errors and check the
measurements at the rear of the wheels in
position A, Figure 3.

3. Calculate the toe--out measurement by

subtracting dimension A from dimension B.

3
NOTE: If the toe out is correctly adjusted,
Dimension A should be up to 0.5 in (13 mm)
greater than dimension B.
Where necessary adjust tracking as follows:
4. Remove locating bolt from left hand end of
track rod (2), Figure 4.

5. Slacken clamp bolt (3) and turn threaded

section (4) of track rod in or out until toe--out is
correct when the locating bolt is re--inserted.

6. Tighten the locating bolts to a torque of

110 lbf ft (150 Nm) and their locknuts to
55 lbf ft (75 Nm).
4

604.55.041.00 - 01 - 1998
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 5

44 101 FRONT AXLE--OVERHAUL

Hub and Spindle Assembly 5

1. Spindle 4. Outer Bearing 7. Castellated Nut
2. Grease Retainer 5. Split Pin 8. Washer
3. Inner Bearing 6. Grease Retaining Cap 9. Hub

The wheel hubs spindles and extensions can be 2. Inspect hub inner and outer bearings and cups.
serviced without removing the axle from the tractor. If damaged they should be replaced as an
It is only necessary to remove the axle in order to assembly, ensuring that the new cups seat
replace the bushes in the centre beam. correctly against the shoulders in the wheel
hub.
For overhaul of the steering cylinder refer to Section
41 Steering Systems.
RE--ASSEMBLY
HUB AND BEARING OVERHAUL
1. Position grease retainer and inner bearing on
spindle.
REMOVAL 2. Pack the hub and bearing with grease to
Specification NH710A (Ambra GR9)
1. Use a suitable jack or hoist to support the
tractor and remove wheel. 3. Install hub, outer bearing, washer and
castellated nut.
2. Remove hub grease retaining cap and
castellated nut, Figure 5. 4. Tighten castellated nut to a torque of
20--30 lbf ft (27--40 Nm)
3. Pull hub assembly from spindle and separate
components. 5. Rotate hub clockwise 3--6 revolutions.
6. Further tighten the retaining nut to a torque of
INSPECTION AND REPAIR 45--55 lbf ft (61--74 Nm) and install a new split
pin.
1. Clean all components using a suitable cleaning 7. Pack the outer bearing with grease and install
agent such as paraffin (Kerosene). the cap.

604.55.041.00 - 01 - 1998
6 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

SPINDLE OVERHAUL
REMOVAL

1. Use a suitable jack or hoist support the tractor

and remove wheel.

2. Using a thread file (2) clean the threads (1) at

the top of the spindle, Figure 6.

6
NOTE: The threads are deformed during assembly
to act as a locking device on the spindle arm
retaining nut.

3. Disconnect track control rod assembly from

spindle arm (1), Figure 7.

4. Using a suitable puller remove spindle arm and

felt washer (2), Figure 7.

7
5. Remove spindle, thrust bearing (1) and spacer
(2), Figure 8.

8
INSPECTION AND REPAIR
1. Clean all components using a suitable cleaning
agent such as paraffin (Kerosene).

2. Inspect the spindle bearing surfaces, thrust

bearing and washer for wear or damage.

3. Inspect the spindle bushes in the top and

bottom of the axle telescopic extensions. If
worn remove extension from tractor and
replace bushes.

4. Inspect track control rod ball joints.

604.55.041.00 - 01 - 1998
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 7

RE--ASSEMBLY
1. Position spacer on wheel spindle. Ensure
chamfered edge of spacer faces down,
Figure 9.
2. Position bearing on spindle with manufacturers
name facing upwards.
3. Pack spindle thrust bearing with grease to
specification NH710A (Ambra GR9) and install
on spindle.
4. Install spindle into axle extension. Ensure
spindle rotates freely in the bushes.
5. Install a new felt dust seal
9
6. Position arm onto the spindle ensuring the
marks on both the arm and spindle are aligned
(1), Figure 10.

7. Tighten the spindle nut to a torque of

360--440 lbf ft (488--597 Nm). To prevent the
nut from loosening during normal operation
deform the protruding thread adjacent to the
nut.

10
8. Reconnect track control rod and tighten ball
joint (1), Figure 11, to the correct torque of:--
133--170 lbf.ft (180--236 Nm)

9. After re--assembly check front wheel track

adjustment. Refer to Page 4.

11
AXLE CENTRE BEAM AND FRONT SUPPORT
OVERHAUL

REMOVAL

1. Position the front wheels straight ahead.

2. Disconnect and remove steering cylinder.

3. Raise the front of the tractor and position safety

stands under the engine and remove front
wheels.

4. Support axle centre beam assembly to remove

weight from support pin.

604.55.041.00 - 01 - 1998
8 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

5. Remove locking plate (3), Figure 12.

6. Drive the pin (1) from the support and carefully

lower axle (2) from front support (4).

12
INSPECTION AND REPAIR
1. Inspect bushes and pin, replacing if worn or
damaged.

2. Replace thrust washers.

3. Replace support pin locking plate.

4. Inspect front support for signs of cracks.

RE--ASSEMBLY

1. Install axle (3) onto front support (2) ensuring

thrust washers (1 & 5) are positioned at both
ends of axle pivot pin bore, Figure 13.

2. Tighten support pin (4) retaining bolts to a

torque of 52--66 lbf ft (70--90 Nm) and bend
locking plate tabs against bolt heads.

13
NOTE: On tractors fitted with the long wheel base
option (2), ensure the axle pivot pin trunnion (4) to
front support (1) retaining bolts are tightened to a
torque of 254--317 lbf ft (345--430 Nm) and locked
in position with a locking plate (3). Figure 14.

3. Reconnect steering cylinder and bleed

steering system of air as described in Section
41, Steering Systems.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 1

SECTION 50 -- AUXILIARY UNITS

Chapter 1 -- AIR CONDITIONING

CONTENTS

Section Description Page

50 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding and System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Leak Testing, Charging, Discharging and System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . 31
Component Overhaul (excluding compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
50 200 Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
50 200 Compressor Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

50 000 SPECIFICATIONS

Refrigerant Specification New Holland Specification 82000810 (R134a)

Refrigerant Charge 1.5 kg (3.31 lbs)

Compressor Oil Specifications New Holland Specification 82008750 (PAG Type)

(ISO 100 Viscosity)
Sanden SP20

Refrigerant Oil Capacity

(Compressor and system) 186 cc--228 cc
Cooling capacity @ 22! C -- 49! C (75! F -- 120!F) ambient. 4.5 kW Typical
(Actual capacity dependent on system control operator settings)

Combined High/Low Pressure Switch (Mounted Adjacent to Compressor)

Low Pressure Switch
On 2.06 bar (29.9 lbf/in2)
Off 1.96 bar (28.4 lbf/in2)

High pressure switch

On 21 bar (299 lbf/in2)
Off 26 bar (384 lbf/in2)
Low Pressure Cut Out Switch (Mounted in Cab Roof)
On 2.3 bar (34 lbf/in2)
Off 0.7 bar (10 lbf/in2)
Temperature Cycling Control Switch
Switch Setting On Off
Minimum Cooling 21! C 18! C
Maximum Cooling 5! C 2! C

COMPRESSOR
Manufacturer and Type Sanden SD7H15 (model 7865)
Compressor Clutch and Pulley Air Gap 0.4--0.8 mm (0.016 and 0.031")
Drive Belt Tension Automatic Belt Tensioner

604.55.041.00 - 01 - 1998
2 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

TORQUES
Compressor Cylinder Head Bolts 24.5--26.5 Nm (18--19.5 lbf.ft)
Compressor Clutch Front Plate retaining Bolt 11.0--14.0 Nm (8--10 lbf.ft)
Self--sealing Couplings small 40--54 Nm (29--40 lbf ft)
large 54--68 Nm (40--50 lbf ft)
Compressor Mounting Bolts 20.5--25.5 Nm (15--19 lbf.ft)
SPECIAL TOOLS
Certified Refrigerant Recover,Recycling and Recharge Equipment suitable for the type of refrigerant gas used
on tractor are required when servicing air conditioning systems.
This special equipment is available through recognised suppliers of air conditioning equipment. Refer to the Tool
supplier for details on the latest equipment available for servicing the air conditioning system.
Vacuum/charge Portable system New Holland Tool No.294030
Recovey/recharge Portable system New Holland Tool No.294048
Evaporator and condenser cleaner New Holland Tool No.293831
Expansion valve tape New Holland Tool No.293826
Electronic Gas Leak Detector New Holland Tool No.294036
Manifold Gauge Set (Where required) OTC/V.L Churchill Ltd Part No FNH00172
Quick Release Coupling Tool New Holland Tool No.295031
COMPRESSOR TOOLS:
Sanden SDH715 KIt OTC/V.L Churchill Ltd Part No. NH.50--100

SAFETY PRECAUTIONS # Never discharge refrigerant into the

atmosphere. When servicing air conditioning
units a certified refrigerant recovery unit
operated by a certified technician must be
WARNING used.
Before overhauling an air conditioning system # When discharging the refrigerant in the system
read and observe the following Safety make sure you are operating in well--ventilated
PrecautionsIf a repair or replacement becomes premises with good air circulation and far away
necessary, ensure that only certified Air from open flames.
Conditioning technicians are employed, using
approved equipment to effect repairs. Do not # When charging and discharging the system
attempt to disassemble the air conditioning always wear goggles and take suitable
system, It is possible to be severely frostbitten precautions to protect the face in general and
or injured by escaping refrigerant. the eyes in particular, from accidental spillage
of the refrigerant fluid.
# The oil and refrigerant mixture inside the air
conditioning system is pressurized.
IMPORTANT: Do not allow refrigerant to escape Consequently, never loosen fittings or tamper
into the atmosphere. with lines unless the system has been properly
Refrigerant must be handled with care in order to discharged.
AVOID HAZARDS. # Before loosening any connection, cover the
fitting in question with a cloth and wear gloves
Undue direct contact with liquid refrigerant can and goggles in order to prevent refrigerant
produce freezing of skin and eyes. from reaching the skin or eyes.
Keep the refrigerant container and air # In the event of an accident, proceed as
conditioning system away from flame or heat follows:--
sources, the resulting pressure increase can
cause the container or system to explode. If the refrigerant has reached the eyes, wash
them immediately with copious amounts of
If in direct contact with open flames or heated sterilised water or mains pressure tap water
metal surfaces, the refrigerant will decompose and transfer to hospital for immediate medical
and produce products that are toxic and acidic. help.

Make sure to comply with the following If the refrigerant has touched the skin, wash
indications and simple precautions to avoid any with cold water and transfer to hospital for
risk of injury: immediate medical help.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 3

PRINCIPALS OF AIR CONDITIONING

The function of the air conditioning system is to

improve the operator’s comfort by cooling the air
temperature inside the cab and reducing the
humidity level.
This temperature control is achieved by absorbing
the heat within the cab into a refrigerant and then
allowing the heat absorbed by the refrigerant to be
transferred to the outside air
In order to achieve this heat transfer the following
principals of heat generation and transfer are
applied within the air conditioning system. 60--50--001 TI
1

1. When two bodies of different temperature

come together heat is transferred from one to
another. On air conditioning systems an
evaporator is used to hold the low temperature
refrigerant which absorbs the heat from the air
within the cab.

2. When a gas is pressurised the temperature of

the gas will rise. In air conditioning systems the
increase in pressure is achieved using a
compressor.
60--50--002 TI
2
3. When a gas is cooled it will condense into a
liquid. In the air conditioning system a
condenser is used to cool the gas and the
resulting liquid is stored in a receiver dryer.

4. When a liquid is atomized through an orifice,

the temperature of the resultant vapour will
drop. The low temperature of the atomized
liquid will then absorb heat from its
surroundings. On air conditioning systems the
refrigerant is atomized using an expansion
valve.

60--50--003 TI
3
It can now be seen that the principal components of
an air conditioning system are:--
# Refrigerant
# Evaporator
# Compressor
# Condenser
# Receiver Dryer
# Expansion Valve
Figure 5, uses the examples above to illustrate the
air conditioning cycle. 60--50--004 TI
4

604.55.041.00 - 01 - 1998
4 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

2 1

O
C

60--50--005 TI

Air Conditioning Principal of Operation 5

1. Expansion Valve -- Atomizes Liquid Refrigerant Before Passing to Evaporator
2. Evaporator-- Absorbs Heat From Air In Cab
3. Compressor -- Compresses and Raises Temperature Of Refrigerant Gas
4. Condenser, Evaporator and Dryer -- Converts Refrigerant from Gas to a Liquid

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 5

LOW PRESSURE SIDE HIGH PRESSURE SIDE

EXPANSION VALVE

LOW TEMPERATURE
HIGH PRESSURE LIQUID
FILTERED AND MOISTURE REMOVED
LOWER TEMPERATURE
LOW PRESSURE
ATOMIZED LIQUID
RECEIVER DRYER

LOWER TEMPERATURE
EVAPORATOR HIGH PRESSURE LIQUID

CONDENSER

WARM
LOW PRESSURE VAPOUR
HIGH TEMPERATURE
HIGH PRESSURE VAPOUR

COMPRESSOR
HEAT FROM INSIDE CAB HEAT MOVES TO OUTSIDE AIR
MOVES TO REFRIGERANT FROM REFRIGERANT

Air Conditioning Flow Diagram 6

Figure 6, shows in schematic form the flow of As liquid refrigerant passes through the metered
refrigerant through the five major components of orifice in the expansion valve the refrigerant
an air conditioning system. Refer to, Figure 7, for changes from a high pressure liquid to a low
the location of these components on the tractor. pressure atomized liquid with a lower temperature.

Refrigerant is drawn into the compressor as a cool, This low pressure, low temperature, atomized
low pressure vapor which is compressed and then liquid enters the evaporator coils and absorbs heat
pumped out as a hot, high pressure vapor to the from the cab warm air blown across the coils and
condenser. fins by the cab blower motor. The refrigerant now
changes from a cold low pressure atomized liquid
to a warm low pressure vapor and leaves the
As the hot, high pressure vapor passes through the evaporator outlet, moving to the suction (low
condenser core it gives off heat to the cooler pressure) side of the compressor to repeat the
outside air, being drawn past the fins by the engine cycle.
cooling fan.
As this heat loss is taking place, moisture
By giving off heat to the outside air, the vapor is (humidity) in the cab air will condense on the
condensed to a liquid which moves under high outside of the evaporator and drain off as water
pressure to the receiver dryer where it is stored through the drain hoses attached to the evaporator
until released to the evaporator by the temperature drain pan, thereby reducing the humidity level of
sensing expansion valve. the cab.

604.55.041.00 - 01 - 1998
6 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Air Conditioning Component Layout

A. Blower Motor, Expansion Valve and Evaporator C. Compressor 7
B. Quick Release Self Sealing Couplings D. Condenser and Receiver Dryer

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 7

SYSTEM COMPONENTS -- DESCRIPTION

AND OPERATION

Refrigerant

To achieve the absorption and the release of heat

which is, in essence, the function of an air
conditioning system, requires the use of a suitable
“refrigerant” - a liquid that has a relatively low
temperature boiling point, plus certain desirable
safety and stability features.

The refrigerant used in the air conditioning system

is refrigerant R-134a.

NOTE: To help protect the environment legislation

has been introduced in most territories banning the
release into the atmosphere of
refrigerants,including R134a. All service
procedures contained in this manual can be carried
out without the need to release refrigerant into the
atmosphere.

In order to prevent the incorrect type of refrigerant

being charged to the system the service valves
fitted to the tractor and necessary to connect up
refrigerant recovery, evacuation and
recycling/recharging equipment will be of two
different sizes as recognised and specified by the
air conditioning industry.

WARNING
R--134a refrigerant is not compatible with R--12
refrigerant. Do not attempt to replace R134a re-
frigerant with R--12 refrigerant or test the system
using gauges or equipment previously used with
R12 as damage to the system will result.

R-134a refrigerant is stable at all operating

temperatures and able to absorb great quantities
of heat.

The boiling point of R-134a is -22! C (-15! F) at

atmospheric pressure.

If the pressure is increased, R-134a will readily

vaporize to absorb heat at temperatures between
-11.7! C (11! F) at 1.9 bar (27.5 lbf/in2) and 0!C
(32! F) at 42 lbf/in2 (2.9 bar) in the evaporator.

At higher pressures, R-134a will condense and

give off heat at temperatures between 48! C (118!
F) at 12.4 bar (180 lbf/in2) and 58! C (136! F) at
15.85 bar (230 lbf/in2 ) in the condenser.

604.55.041.00 - 01 - 1998
8 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

6
5 4 3

TA6050007

Air Conditioning Refrigerant Compressor 8

1. Electro--magnetic Clutch 4. Wobble Plate 7. Discharge Chamber
2. Clutch Bearing 5. Piston 8. Cylinder Head
3. Cam Rotor 6. Suction Chamber 9. Static Gear

Compressor Pump Refrigerant is drawn in on the downward stroke of a

The tractor air conditioning unit compressor pump piston through the reed valves located either end of
is mounted on the left hand side of the engine and is the cylinder assembly. Refrigerant enters the
belt driven by the crankshaft pulley, Figure 7. cylinder assembly through a gallery in the outer
circumference of the cylinder assembly.
The compressor separates the low and high
pressure sides of the system and is basically a The upwards stroke of the piston compresses the
pump which has two functions: refrigerant and expels it through another reed valve
into an inner gallery in the cylinder assembly and
(1) To raise the refrigerant temperature by out into the refrigerant circuit.
compression to a higher degree of temperature
than the ambient (outside air) temperature. The compressor is lubricated with a Polyalklene
Glycol (PAG) oil. This oil is totally miscible with the
(2) To circulate the required volume of refrigerant refrigerant and is carried around the refrigerant
through the system. circuit.

The refrigerant compressor is a seven cylinder The compressor is activated by an

wobble plate unit housed in a die cast aluminium electro-magnetic clutch which functions to engage
housing. or disengage the compressor as required in the
operation of the air conditioning system.
Drive to the wobble plate is from the pulley, through
the electro magnetic clutch to the main driveshaft. The clutch is primarily activated by the:--
Attached to the driveshaft is a cam rotor which
oscillates the wobble plate. The wobble plate is # Temperature cycling control switch
prevented from rotating by a static gear engaging
with teeth formed in the face of the plate. The seven # Combined high/low pressure cut--out switch
pistons are connected to the wobble plate by rods
# Low pressure cut--out switch
located in ball sockets.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 9

Air Conditioner Temperature Cycling Control

Switch

The air conditioner temperature cycling control

switch is mounted on the left hand side of the
evaporator housing and close to the expansion
valve, Figure 9.

60--50--009 TI
9

The switch is a device which turns the compressor

clutch on and off to maintain a constant average
evaporator temperature and senses the
evaporator temperature using a thermistor
positioned within the evaporator fins, Figure 10.

The temperature cycling control switch compares

the voltage of the thermistor, which is dependent
on the temperature of the evaporator, with the
voltage across the potentiometer of the ‘in cab’
temperature control switch.

The switch upon comparing the two voltages

determines whether the compressor clutch should 60--50--010 TI
be switched ‘on’ or ‘off’ in order to maintain the
desired in cab temperature control. 10

Low Pressure Cut-out Switch

The low pressure switch, Figure 11, is in the

evaporator outlet line and located in the cab roof
next to the evaporator and temperature cycling
control switch.
60--50--011 TI
The purpose of the switch is to shut off the
compressor pump in the event of low pressure in 11
the refrigerant system.

Low refrigerant pressure may occur due to a faulty

expansion valve, icing up of the expansion valve
orifice or refrigerant loss. Low refrigerant pressure
may result in damage to the compressor pump.

The low pressure switch is factory set and cannot

be adjusted.

604.55.041.00 - 01 - 1998
10 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Combined High/Low Pressure Cut--out

Switch

The combined high/low pressure switch, (1) Figure

12, is located in the condenser inlet line from the
compressor. The switch shuts off the compressor
pump in the event of a restriction in the high
pressure line or excessively low pressure due to
lack of refrigerant in the system.

Loss of refrigerant in the system will result in

insufficient cooling and lubrication and continuous
operation will cause damage to the compressor
pump.

12
System Pressure Relief Valve

A relief valve is located at the discharge port on the

compressor, (1) Figure 13. This allows the system
refrigerant to be discharged into the engine bay
(atmosphere) instead of in the cab, if the system
pressure became such that a hose might fail in the
cab and cause injury to the operator. This
secondary safety feature will only operate in
extreme conditions, for example, if the high
pressure cut out switch were to fail, or in the event
of an engine fire.

13
Condenser And Receiver Dryer
The condenser, (1) located at the front of the
tractor, Figure 14, consists of a number of turns of
continuous coil mounted in a series of thin cooling
fins to provide a maximum of heat transfer in a
minimum amount of space.
The condenser receives the hot, high pressure
refrigerant vapour from the compressor. The hot
vapour passes through the condenser coils and
outside air is pushed through the condenser by the
engine cooling fan.
Heat moves from the hot refrigerant vapour into the
cooler outside air flowing across the condenser
coils and fins. 14
When the refrigerant vapour reaches the pressure
and temperature that will induce a change of state,
a large quantity of heat is transferred to the outside
air and the refrigerant changes to a high pressure
warm liquid.
The warm liquid refrigerant continues onto the
receiver/drier where it is filtered and desiccated, to
remove any moisture, before passing through an
outlet line to the thermostatic expansion valve.
The receiver/dryer(2) stores the liquid refrigerant to
be sure a steady flow to the thermostatic expansion
valve is maintained under widely different
operating conditions.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 11

The drier section contains a desiccant (Molecular

sieve) to absorb any moisture within the system
and a filter prevents the entry of foreign particles.

NOTE: Any moisture in the air conditioning system

is extremely harmful. Moisture not absorbed by the
dehydrator will circulate with the refrigerant and
droplets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the
refrigerant flow and stop the cooling action.
Moisture will also react with refrigerant R-134a and
the lubricant to form a corrosive acid.

The desiccant can only absorb a limited amount of

moisture before reaching saturation point.
Because of this, after any system component
replacement or repairs requiring entry into the
system, the receiver/dryer should be replaced.

Expansion Valve

The expansion valve, Figure 15, is located next to

the evaporator, in the pressure line leading from the
receiver/dryer and performs the following
functions:

1. METERING ACTION -
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to
a low pressure, lower temperature atomized 60--50--013 TI
liquid.
15

2. MODULATING ACTION -
A thermostatically controlled valve within the
expansion valve body controls the volume of
liquid refrigerant passing through the orifice
and makes sure the refrigerant is fully
vaporized within the evaporator. Liquid
refrigerant would damage the compressor
reed valves or freeze the pistons.

3. CONTROLLING ACTION -
The valve responds to changes in the cooling
requirements. When increased cooling is
required, the valve opens to increase the
refrigerant flow and when less cooling is
required the valve closes and decreases the
refrigerant flow.

604.55.041.00 - 01 - 1998
12 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Expansion Valve - Operation

All of the needed temperature sensing and

pressure sensing functions are consolidated into
this basic unit and no external tubes are required
for these purposes.

The refrigerant from the condenser and receiver

dryer enters the thermostatic expansion valve as a
high pressure warm liquid. Upon passing through
the ball and spring controlled metering orifice, the
pressure and temperature of the refrigerant is 60--50--014 TI
reduced and the refrigerant leaves the 16
thermostatic expansion valve as a low pressure,
lower temperature atomized liquid.

The atomized liquid now passes through the

evaporator where it absorbs heat before returning
via the expansion valve to the compressor as a
warm Low pressure vapour.

There are two refrigerant passages in the valve.

One passage is in the refrigerant line from the
condenser to the evaporator and contains the ball
and spring type orifice valve. The other passage is
in the refrigerant line from the evaporator to the
compressor and contains the valve’s temperature
sensing element.

Liquid refrigerant flow from the condenser and

receiver dryer is controlled by a push-rod forcing
the orifice valve ball off its seat and the spring
exerting pressure on the ball to keep it on its seat.

During stabilized (vehicle shutdown) conditions,

the pressure on the bottom of the expansion valve
diaphragm rises above the pressure on the top of
the diaphragm allowing the valve spring to close
the orifice.

When the system is started, the pressure on the

bottom of the diaphragm drops rapidly, allowing the
orifice to open and meter atomized liquid
refrigerant to the evaporator where it begins to
vaporize.

Suction from the compressor draws the vaporized

refrigerant out of the evaporator and back through
a gallery in the top of the valve which passes the
temperature sensor.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 13

The temperature sensor reacts to variations in

refrigerant gas pressure returning from the 1
evaporator. When heat from the passenger
compartment is absorbed by the refrigerant the
pressure of the gas increases causing a differential 2
pressure above and below the temperature sensor
diaphragm. The diaphragm reacts to this pressure
differential and a push rod forces the ball in the
expansion valve orifice further off its seat. This
reaction allows an increase in the atomized
refrigerant to flow through the valve, to the
evaporator, so that more heat can be absorbed by
the air conditioning system.
60--50--015 TI
17
Similarly when the temperature of the gas returning
from the evaporator decreases the pressure of the
gas decreases. This causes the diaphragm to react
accordingly and allow the ball in the orifice to move
closer towards its seat thus reducing the flow of
refrigerant through the valve to the evaporator.

Evaporator

The evaporator, Figure 17, is located in the cab

roof and consists of a number of turns of
continuous coils mounted in a series of thin cooling
fins to provide a maximum of heat transfer in a
minimum amount of space.

Low temperature refrigerant in the evaporator

absorbs heat from the hotter air in the operator’s
compartment, thereby cooling the air.
60--50--016 TI
18
Blower Fan

The blower fan, (2) Figure 17, draws warm air from
outside the cab through the intake filters, Figure 18
and forces it across the evaporator before entering
the cab through louvered vents.

The blower motor is controlled by a three-speed

switch, figure 19. The switch uses a variable
resistor to change the fan speed.

High blower speed provides the greatest volume of

circulated air, however, a slower speed will allow
the air to contact the cooling fins and coils of the
evaporator for a longer period resulting in the warm
air giving up more heat to the cooler 60--50--017 TI
refrigerant.Therefore, the coldest air temperature 19
is obtained when the blower fan is operated at the
lowest speed.

604.55.041.00 - 01 - 1998
14 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

FAULT FINDING AND TESTING THE AIR Preliminary Fault Finding

CONDITIONING SYSTEM
Always conduct the preliminary fault finding checks
before performance testing the system.

General 1. Run the engine at 1000-1200 rev/min for 10

minutes with the air conditioner set at maximum
cooling and the blower on high speed.

Overhaul of the air conditioning system should only

be undertaken by a certified specialist refrigeration
engineer using a comprehensive air conditioning 2. Check that the heater temperature control is
test kit, including a gas leak detector, suitable for switched OFF.
R134a refrigerant gas.

3. Close the heater shut--off valve on the rear of

the inlet manifold.

WARNING 4. Check that the blower fan is operating at all

speeds.
Before dismantling an air conditioning system for
repair the gas within the system must be dis-
charged and recovered using a certified recov-
ery unit designed for the type of refrigerant gas
used in the system. 5. Check that the compressor clutch engages
when the temperature control switch is turned
NEVER release refrigerant gas into the atmo- from “OFF” to “ON” position. A clicking sound
sphere. indicates the clutch is engaging. If the clutch
fails to operate it may indicate an electrical
ALWAYS wear safety goggles and gloves when problem in the high low pressure cut out
servicing any part of the air conditioning system. switches or malfunction of the electric drive
clutch on the compressor.

6. Check the engine cooling fan is drawing cool air

through the condenser
To prevent the entry of any foreign material,
observe the following points:

7. Check the compressor drive belt tension.

# Ensure all tools, gauges, hoses and
replacement parts are kept clean and dry and
are suitable for the type of refrigerant gas used
in the system. 8. Check the condenser core and grid is clean and
free of obstruction.

# Clean all hoses and fittings before

disconnecting. Cap or plug all openings when
disconnected. 9. Check the cab air filters are clean and free of
obstruction.

# When adding lubricating oil to the system

always uncap and re-cap the oil container
immediately before and after use. Always 10. Check the evaporator fins are not plugged or
ensure the oil remains free of moisture. excessively dirty.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 15

Attaching Manifold Gauge Set to the Tractor 20

1. Low Side Gauge 6. Test Hose to Low Side Service Connector
2. High Side Gauge 7. Shut-off Valve
3. Shut-off Valve 8. Low Pressure Side Service Valve
4. Test Hose to High Side Service Connector 9. High Pressure Side Service Valve
5. Center Hose (Not Used)

Performance Testing The Air Conditioning Operating Precautions

System
IMPORTANT: Always ensure the shut--off valves
are closed (turn clockwise until seated) during all
test operations.
The manifold gauge set is the most important tool
used in testing and servicing the air conditioning In the closed position, refrigerant circulates around
system. the valve stems to the gauges. Therefore, when the
manifold gauge set is connected into a system,
It should be noted however that for those dealers pressure is registered on both gauges.
who posses the latest design level of refrigerant # NEVER open the HIGH SIDE shut off valve
recovery, recycling and recharging station these when the system is operating.
gauges are an integral part of the machine.
# ALWAYS open the LOW SIDE shutoff valve
when adding refrigerant.
The following instructions for performance testing
the air conditioning system is based on the use of Attaching The Gauge Set To The Tractor
the gauge set shown in Figure 20. The principal of
operation is however similar when testing the
system using a recovery and recharging station WARNING
with integral gauges. To avoid personal injury, stop the tractor engine
during connection of the manifold gauge set.

When using this type of equipment always consult 1. Check that the gauge set shut off valves are
the manufacturers operating instructions. closed (turned fully clockwise).

604.55.041.00 - 01 - 1998
16 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

2. Connect the high side gauge hose (normally 3. Turn the heater temperature control ‘off’
red) to the high pressure side service valve and
the low side gauge hose (normally blue) to the
low pressure side service valve on the tractor, 4. Operate the system at maximum cooling, with
Figure 20. Ensure the hose connections are the blower fan at high speed for 10 minutes to
fully tightened. stabilize all components.

5. Check the manifold low pressure gauge

IMPORTANT: Prior to connection of the manifold reading is within the specified range of
gauge set, identify the suction (low pressure) and approximately 4-36 lbf/in2 (0.28-2.48 bar)
discharge (high pressure) service gauge ports. (0.28-2.53 kgf/cm2).
The high pressure service valve is always in the
line from the compressor to the condenser.
6. Check the manifold high pressure gauge
The high and low pressure service valves on the reading and compare the reading to the
tractor are spring loaded valve and will be pressure indicated on the pressure
automatically opened when the test hose is temperature chart below.
connected.

7. Measure and compare the temperature of

NOTE: The test hose must incorporate a valve conditioned air entering the cab through the
depressor to actuate this type of valve. louvered air vents with the ambient air at the
air intake filters on the outside of the cab.

The service valves have a protective cap. This cap If the system is operating correctly the
must be removed for test gauge connections and conditioned air entering the cab should be
replaced when service operations are completed. 6--9! C (10--15! F) cooler than the ambient
temperature of the outside air.
Test Procedure
8. If it is confirmed that the system is not
After the manifold gauge set has been connected operating correctly refer to the fault diagnostic
and before pressure tests can be made, the system charts and performance test gauge reading
must be stabilized as follows: examples on the following pages for possible
corrective action.
1. Re--check that both the high and low side shut
off valves on the manifold gauge set are fully
closed. WARNING
A significant amount of refrigerant vapour may
2. Apply the parking brake, check the gear shift have condensed to a liquid at the service fitting at
levers are in neutral and close the cab windows the high side of the compressor. Use a cloth or
and doors. other protective material when disconnecting the
manifold hose from this fitting to prevent personal
3. Run the engine at 1000-1200 rev/min. injury to hands and face.

APPROXIMATE HIGH PRESSURE GAUGE READINGS

Ambient Air Temperature High Pressure Gauge Reading

Degrees F Degrees C bar kgf/cm2 lbf/in2
80 27 10.0/11.6 10.3/11.8 147/168
85 29 11.2/12.7 11.4/12.9 162/184
90 32 12.3/13.8 12.5/14.0 179/200
95 35 13.3/15.2 13.6/15.5 194/221
100 38 14.5/16.7 14.8/17.0 210/242
105 41 16.0/18.3 16.3/18.6 231/265
110 43 17.3/20.0 17.7/20.3 252/289

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 17

PERFORMANCE TEST DIAGNOSIS

Gauge Readings:-- Low Pressure - Low
High Pressure - Low

PROBLEM POSSIBLE CAUSES CORRECTION

Evaporator air not cold Low refrigerant charge. Perform leak tests and repair

(Refer to Example 1) Evacuate system

Charge system, re--test system

Evaporator air warm Extremely low refrigerant Perform leak tests and repair
charge.
Evacuate system
Charge system, re--test system

Evaporator air cool but not Expansion valve not permitting Check expansion valve as
sufficiently cold . sufficient flow. follows:
Low pressure switch cutting Stuck valve
out Set a max. cooling
Expansion valve to
evaporator tube shows Low pressure gauge should
drop slowly
considerable condensation
or frost. If expansion valve is defective:
Too cold to touch
Discharge system
Replace expansion valve
Evacuate system
Charge system
Re--test

604.55.041.00 - 01 - 1998
18 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - High
High Pressure - High

PROBLEM POSSIBLE CAUSES CORRECTION

Evaporator air warm Improper operation of condenser Inspect for dirty condenser
Liquid line hot (condenser restricting air flow and cooling
outlet to expansion valve Overcharged with refrigerant
tube) Check operation of condenser
Air in system cooling fans. Repair or replace
High pressure switch as needed.
cutting out Check for overcharge as follows:
Stop the engine. Recover and
recycle the charge using correct
recovery equipment.
Recharge the the system with
the correct quantity of
refrigerant, replacing any lost
lubricant. Recheck performance
of air conditioning system.

Evaporator air not cold Expansion valve allowing too much Check expansion valve as
refrigerant to flow through the follows:
evaporator Set for Maximum cooling.
Low pressure gauge should drop
slowly

If expansion valve is defective:

Discharge System
Replace Expansion Valve
Evacuate System
Charge System
Re--test

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 19

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - Low

High Pressure - High

PROBLEM POSSIBLE CAUSES CORRECTION

Insufficient cooling Restriction in liquid line Discharge the system
Replace the receiver/drier
Inspect all lines and tubing from
compressor outlet to expansion
valve.
Replace if needed.
Evacuate the system
Charge the system
Re--test

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - High

High Pressure - Low

PROBLEM POSSIBLE CAUSES CORRECTION

Evaporator air not cold Internal leak in compressor. (reed Discharge the system
valves, gasket, worn or scored Replace the compressor
piston rings or cylinder) Evacuate the system
Charge the system
Re--test

604.55.041.00 - 01 - 1998
20 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - Normal
High Pressure - Normal

PROBLEM POSSIBLE CAUSES CORRECTION

Insufficient cooling Low System low on charge Air or Perform leak test
pressure reading does not moisture present in system Discharge system
fluctuate with changes in Repair leaks
temperature control switch Replace receiver/drier
(pressure should drop until Check oil level
compressor cycles) Evacuate system
Evaporator air not cold. Charge the system
Re--test

PERFORMANCE TEST DIAGNOSIS CHART

Gauge Readings:-- Low Pressure - High

High Pressure - Normal

PROBLEM POSSIBLE CAUSES CORRECTION

Compressor cycles “on” Defective temperature control Stop engine and shut off A/C
and “off” too frequently (thermostatic) switch Replace temperature control
switch
Re--test system and check
compressor cycling

EXAMPLES OF MANIFOLD GAUGE

READINGS AND INTERPRETATIONS

The following examples show typical low and high

pressure gauge readings obtained when
performance testing the air conditioning system
with an ambient temperature of 35! C (95! F).

The recommended corrective action is based on a

similar fault as identified in the performance test
diagnosis charts.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 21

PERFORMANCE TEST EXAMPLE 1

7 1

6 2

5 4 3
60--50--019

Performance Test Example 1 21

1. High Side Low 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

1. Leak test the system.

Little or no cooling.
2. Repair leaks. (Discharge and recover the
CAUSE: refrigerant from the system; replace lines or
components).

Refrigerant slightly low. 3. Check compressor oil to ensure no loss.

4. Evacuate the system.

CONDITIONS*
5. Charge the system.
Low side pressure too low. 6. Performance test the system.
Gauge should read 1--2 bar (15-30 lbf/in2).
DIAGNOSIS: System refrigerant is low. May be
caused by a small leak.
High side pressure too low.
Gauge should read 13.3--14.8 bar *NOTE: Test procedure based upon ambient
(194--215 lbf/in2). temperature of 35!C (95! F). For proper high side
gauge reading for other ambient temperatures,
refer to the pressure temperature chart.
Evaporator air not cold.

604.55.041.00 - 01 - 1998
22 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST EXAMPLE 2

7 1

6 2

5 4 3
60--50--020

Performance Test Example 2 22

PROBLEM: CORRECTIVE PROCEDURES

Insufficient cooling. 1. Leak test the system.

CAUSE: 2. Discharge and recover the refrigerant from the

system.
Refrigerant excessively low.
3. Repair leaks.
CONDITIONS*
4. Check compressor oil to ensure no loss.
Low side pressure very low. 5. Evacuate the system.
Gauge should read 1--2 bar (15-30 lbf/in2)
6. Charge the system.
High side pressure too low. 7. Performance test the system.
Gauge should read 13.3--14.8 bar
(194--215 lbf/in2). DIAGNOSIS: System refrigerant is extremely low.
A serious leak is indicated.
Evaporator air warm. *NOTE: Test procedure based upon ambient
temperature of 95! F. For proper high side gauge
Low pressure switch cutting out reading for other ambient temperatures, refer to
the pressure temperature chart.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 23

PERFORMANCE TEST EXAMPLE 3

7 1

6 2

5 4 3
60--50--021

Performance Test Example 3 23

1. High Side Normal 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side Low
4. Not Used

PROBLEM: CORRECTIVE PROCEDURES

1. Leak test the system. Give special attention to

Insufficient cooling. the compressor seal area.

2. Discharge and recover the refrigerant from the

CAUSE: system.

3. Repair leaks.
Air in system.
4. Replace the receiver/dryer.

CONDITIONS* 5. Check compressor oil to ensure no loss.

6. Evacuate the system.

Low side pressure reading does not change when
compressor cycles “on” and “off”. 7. Charge the system.

8. Performance test the system.

High side pressure slightly high or slightly low. DIAGNOSIS: Air or moisture in system. System
Gauge should read 13.3--14.8 bar not fully charged.
(194--215 lbf/in2).
*NOTE: Test procedure based upon ambient
temperature of 35!C (95! F). For proper high side
gauge reading for other ambient temperatures,
Evaporator air not cold. refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
24 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST EXAMPLE 4

7 1

6 2

5 4 3
60--50--022

Performance Test Example 4 24

PROBLEM: Evaporator air not cold.

Insufficient cooling.
CORRECTIVE PROCEDURES

CAUSE:
1. Replace the compressor.

Compressor malfunction.
DIAGNOSIS: Internal leak in compressor caused
by worn or scored pistons, rings, or cylinders.
CONDITIONS*

Low side pressure too high. Gauge should read

1--2 bar (15-30 lbf/in2). *NOTE: Test procedure based upon ambient
temperature of 35!C (95! F). For proper high side
gauge reading for other ambient temperatures,
High side pressure too low. Gauge should read refer to the pressure temperature chart.
13.3--14.8 bar (194--215 lbf/in2).

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 25

PERFORMANCE TEST EXAMPLE 5

7 1

6 2

5 4 3
60--50--023

Performance Test Example 5 25

1. High Side High 5. Low Side Hose Connected to
2. High Side Hand Valve Closed Low Side Service Connector
3. High Side Hose Connected to 6. Low Side Hand Valve Closed
High Side Service Connector 7. Low Side High
4. Not Used

PROBLEM: 3. If engine is overheating replace engine

thermostat and radiator pressure cap.
Insufficient or no cooling. Engine overheats in
some cases. At this point, operate the system and check its
performance. If still unsatisfactory, proceed as
CAUSE: follows:--

Condenser not functioning properly. 4. Discharge and recover the refrigerant from the
system.
CONDITIONS*
5. Remove the condenser and clean and flush it
to ensure a free flow of refrigerant. Or, if the
Low side pressure too high. Gauge should read condenser appears to be unduly dirty or
1--2 bar (15-30 lbf/in2 ). plugged, replace it.
High side pressure too high. Gauge should read 6. Replace the receiver/dryer.
13.3--14.8 bar (194--215 lbf/in2).
7. Evacuate the system, and recharge it with the
Liquid line hot. correct quantity of refrigerant.
Evaporator air warm. 8. Performance test the system.
High pressure switch cutting out.
DIAGNOSIS: Lack of cooling caused by pressure
CORRECTIVE PROCEDURES that is too high on the high side, resulting from
improper operation of condenser. (Refrigerant
1. Check belt. Loose or worn drive belts could charge may be normal or excessive).
cause excessive pressures in the compressor
head.
*NOTE: Test procedure based upon ambient
2. Look for clogged passages between the temperature of 35!C (95! F). For proper high side
condenser fins and coil, or other obstructions gauge reading for other ambient temperatures,
that could reduce condenser airflow. refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
26 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST EXAMPLE 6

7 1

6 2

5 4 3
60--50--024

Performance Test Example 6 26

PROBLEM: CORRECTIVE PROCEDURES

Insufficient or no cooling. 1. Discharge and recover the refrigerant from the

system.

CAUSE: 2. Replace the receiver/dryer.

Large amount of air in system. 3. Evacuate the system.

CONDITIONS* 4. Charge the system.

5. Performance test the system.

Low side pressure too high. Gauge should read
1--2 bar (15-30 lbf/in2). DIAGNOSIS: Air in system. This, and the
moisture in the air, is contaminating the refrigerant,
causing the system to operate improperly.
High side pressure too high. Gauge should read
13.3--14.8 bar (194--215 lbf/in2). *NOTE: Test procedure based upon ambient
temperature of 35!C (95! F). For proper high side
gauge reading for other ambient temperatures,
Evaporator air not cool. refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 27

PERFORMANCE TEST EXAMPLE 7

7 1

6 2

5 4 3
60--50--025

Performance Test Example 7 27

1. High Side High 5. Low Side Hose Connected to Low Side Service
2. High Side Hand Valve Closed Connector
3. High Side Hose Connected to High Side Service 6. Low Side Hand Valve Closed
Connector 7. Low Side Hide
4. Not Used

PROBLEM: Operate the system at maximum cooling.

Insufficient or no cooling. Check the low side gauge. The pressure

should drop slowly.
CAUSE:
2. If the test indicates that the expansion valve is
Improper operation of thermostatic expansion defective, proceed as follows:
valve (stuck open)
Discharge and recover the refrigerant from the
system.
CONDITIONS*
Replace the expansion valve.
Low side pressure too high. gauge should read
1--2 bar (15-30 lbf/in2). Evacuate the system.
High side pressure too high. Gauge should read Charge the system.
13.3--14.8 bar (194--215 lbf/in2).
Performance test the system.
Evaporator air warm.
DIAGNOSIS: Thermostatic expansion valve is
Evaporator and suction hose (to compressor) allowing too much refrigerant to flow through the
surfaces show considerable moisture.
evaporator coils. Valve may be stuck open.

CORRECTIVE PROCEDURES *NOTE: Test procedure based upon ambient

temperature of 35!C (95! F). For proper high side
1. Check for sticking expansion valve as gauge reading for other ambient temperatures,
follows:-- refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
28 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST EXAMPLE 8

7 1

6 2

5 4 3
60--50--026

Performance Test Example 8 28

PROBLEM: Insufficient cooling. Operate the system at maximum cooling.

CAUSE: Improper operation of thermostatic Check the low side gauge. The pressure
expansion valve (stuck closed). should drop slowly.

2. If the procedure outlined in Step 1 shows that

CONDITIONS* the expansion valve is defective, proceed as
follows:
Low side pressure too low (zero or vacuum).
Gauge should read 1--2 bar (15-30 lbf/in2). Discharge system

High side pressure low. Gauge should read Replace expansion valve
13.3--14.8 bar (194--215 lbf/in2).
Evacuate the system.
Evaporator air cool, but not sufficiently cold.
Charge the system.
Evaporator inlet pipe surface shows considerable
moisture or frost. Performance test the system.
Low pressure switch cutting out. DIAGNOSIS: Expansion valve is not permitting a
sufficient flow of refrigerant. May be caused by
valve stuck in restricted or closed position.
CORRECTIVE PROCEDURES
*NOTE: Test procedure based upon ambient
1. Place finger on expansion valve to evaporator temperature of 35!C (95! F). For proper high side
tube. If too cold to touch, proceed as follows: gauge reading for other ambient temperatures,
refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 29

PERFORMANCE TEST EXAMPLE 9

7 1

6 2

5 4 3
60--50--027

Performance Test Example 9 29

PROBLEM: CORRECTIVE PROCEDURES

Insufficient cooling. 1. Discharge and recover the refrigerant from the

system.
CAUSE:
2. Replace the liquid lines, receiver/dryer, or
Restriction in high side of system. other obstructed components.

CONDITIONS* 3. Evacuate the system.

4. Charge the system.

Low side pressure too low. Gauge should read
1--2 bar (15-30 lbf/in2). 5. Performance test the system.
High side pressure too low. Gauge should read
13.3--14.8 bar (194--215 lbf/in2).
DIAGNOSIS: Restriction in the liquid line and/or
NOTE: A normal or high reading of the high side receiver/dryer resulting in a “starved” evaporator
pressure gauge under these conditions indicates (compressor moving refrigerant from the
the system is overcharged or the condenser or evaporator faster than it can enter).
receiver/dryer is too small.
*NOTE: Test procedure based upon ambient
Evaporator only slightly cool. temperature of 95! F. For proper high side gauge
reading for other ambient temperatures, refer to
Liquid line and receiver/dryer are cool to touch and the pressure temperature chart.
show frost or considerable moisture.

604.55.041.00 - 01 - 1998
30 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

PERFORMANCE TEST EXAMPLE 10

7 B A 1

6 2

5 4 3
60--50--028

Performance Test Example 10 30

PROBLEM: CORRECTIVE PROCEDURES

Compressor cycles (cuts in and out) too rapidly.

1. Stop the engine and shut off A/C system.
CAUSE:
2. Replace thermostatic switch with switch of
Thermostatic switch defective. same type.

CONDITIONS*
3. Make sure the switch’s temperature sensor is
Low side pressure readings too high during both installed in the same position and depth (in
“on” and “off” compressor cycles and between evaporator core) as previous.
cycles. Readings should be:
4. Performance test the system.
0.8--1.0 bar (12-15 lbf/in2) - cycle “off”

2.5--2.7 bar (36-39 lbf/in2) - cycle “on”

DIAGNOSIS: Defective thermostatic switch.
1.7--1.9 bar (24-27 lbf/in2) - between cycles
*NOTE: Test procedure based upon ambient
High side pressure normal. Gauge should read temperature of 35!C (95! F). For proper high side
13.3--14.8 bar (194--215 lbf/in2). gauge reading for other ambient temperatures,
refer to the pressure temperature chart.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 31

LEAK TESTING, DISCHARGING and

CHARGING THE AIR CONDITIONING
SYSTEM

Leak Testing

To perform a leak test if refrigerant leakage is

suspected, use an electronic leak detector, Figure
31 following manufacturer’s instructions.

Electronic leak detectors use flashing lights or

sound to alert the operator to a leak. If the leak
detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the
60--50--029 TI
manufacturer’s instructions before use.
31
When using a leak detector, keep in mind that a
very slight amount of leakage in the compressor
pulley area is normal and does not necessarily
indicate a repair is required.

When a leak is located, follow these steps.

# Discharge the system using a certified freon

recovery system.
# Repair the leak.
# Evacuate the system.
# Partially charge system with 400 grammes
(14 ozs) of refrigerant.
# Check system for leaks.
# Fully charge the system.
Always check the system for leaks as a final test
after evacuating and before recharging. Refer to
Evacuating the system.

Discharging The System

Legislation has been introduced banning the

release of refrigerant into the atmosphere.

Whenever overhauling the air conditioning system

or performing other tasks which require the air
conditioning system to be dismantled it is
necessary to discharge the refrigerant gas before
commencing repair.

Before you can dismantle an air conditioning

system for repairs, you must discharge and
recover the refrigerant using a certified recovery
unit in accordance with the manufacturers
instructions.

Figure 32 shows a combined refrigerant recovery,

evacuation and recycling/charging station. This
equipment removes R--134a refrigerant from the
air conditioning system, recycles and recharges all
in one hook up. The unit is designed to be used with
the manifold gauge set built into the control panel. 60--50--030 TI
32

604.55.041.00 - 01 - 1998
32 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Connecting Recovery Evacuation and recycling/Charging Station to the Tractor 33

1. High Side Service Valve (Red Hose)
2. Built In Manifold Gauge Set
3. Recovery/Recharging Unit
4. Low Side Service Valve (Blue Hose)

Other recovery systems are available where the 2. Set up the recovery unit following
manifold gauges are not an integral part of the manufacturer’s instructions. Ensure that the
machine. When this type of equipment is used a units red (high side) hose is connected to the
separate manifold gauge set must be used. high side fitting and the blue (low side) hose to
the low side fitting, Figure 33.
NOTE: If a unit requiring the manifold gauge set is
The following is a summary of the steps for being used, the low and high sides of the manifold
discharging the system using a recovery/recycling set are connected to the low and high sides of the
unit tractor air conditioning system. The hose from the
recovery unit is then connected to the manifold
centre port. Refer to Figure 34.
WARNING 3. To recover refrigerant, open both high and low
side valves on the control panel or the valves
Never discharge refrigerant gas into the atmos
phere. Always wear safety goggles and gloves on the manifold gauge set if being used, Figure
when working with refrigerant. Only use 34.
authorised refrigerant tanks. 4. Open the valves labeled “gas” and “liquid” on
the recovery unit refrigerant tank, Figure 35.
5. Plug in the units power cord
IMPORTANT: Always follow the manufactures 6. Operate the recovery system in accordance
instructions when operating recovery equipment. with the manufacturers instructions.

1. Run the vehicle’s air conditioning system for a The compressor will shut off automatically when the
few minutes. recovery is complete.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 33

FLUSHING THE SYSTEM

A B
7 1

6
Air conditioning systems may occasionally
become contaminated with solid particles. This 2
contamination may be the result of allowing dirt to
enter the system while it was open, from aluminum 5
corrosion or sludge, or from disintegrated
compressor reed plates. Contamination of this
nature can result in plugged evaporators, 4 3
condensers and expansion valves. 60--50--032 TI
Manifold Gauge Set 34
1. High Side Gauge
2. High Side Shut--off Valve
3. High Side Hose
4. Centre Service Hose
Contaminated systems must be flushed with a 5. Low Side Hose
special flushing solvent to remove the unwanted 6. Low Side Shut--off Valve
material. Prior to flushing, the system must be 7. Low Side Gauge
discharged as described in “Discharging the
System”.

Each individual component must be flushed after

disconnecting every hose fitting.

The compressor and expansion valve can not be

flushed, therefore, the compressor should be
disassembled and cleaned or replaced and the
expansion valve should be replaced. When
flushing the system always replace the
receiver/drier.

NOTE: Never use any solvent for flushing an air

conditioning system other than a special flush
solvent made specifically for air conditioning
systems. Always follow the manufacturer’s
recommendations and directions for using the
flushing equipment and solvent.
60--50--033 TI
35

Re--assemble and evacuate the system to remove

air and moisture as described in “Evacuating the
System”.

604.55.041.00 - 01 - 1998
34 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

EVACUATING THE SYSTEM 1. If the manifold gauge set FNH00172 is being

used connect the low and high sides of the
IMPORTANT: A system in which the refrigerant manifold to the low and high sides of the tractor
has been recovered to facilitate repairs, must be air conditioning system as described for
evacuated before new refrigerant is installed. discharging the system.

Air and moisture are removed by evacuating the Connect the manifold centre hose to the
system using a vacuum pump. vacuum pump suction port as per the
manufacturers instructions.

The automatic recycling, recharge and evacuation Fully open both the low and high side gauge
stations or evacuating and charging stations shutoff valves.
available throughout the air conditioning industry
incorporate a vacuum pump within the assembly. If 2. If a combined recovery/evacuation unit is to be
this type of equipment is not available a separate used attach the unit to the air conditioning
vacuum pump and manifold gauge set must be system in accordance with the manufacturers
used. instructions. Be sure to read all installation and
operating instructions carefully before starting
As the system is evacuated the boiling point of any the unit.
moisture within the system is similarly lowered. As
the vacuum increases the boiling reduces to below
that of the ambient temperate and the moisture is 3. After starting the evacuation cycle, note the
subsequently boiled away. low side gauge to be sure the system pulls
down into a vacuum.

The relationship of system vacuum to the boiling

temperature at which the water vapor is removed 4. Time the evacuation for a minimum of 20
from the system is as follows: minutes from the point when lowest vacuum is
attained.

5. When the low side gauge attains the lowest

steady vacuum, stop the evacuation process.
System Vacuum Temperature
NOTE: The vacuum pump achieves ultimate
In Cm. of !F !C vacuum with the vented exhaust valve closed.
Mercury Mercury
28.0 71.0 100 38 6. Check the system by closing the gauge
28.9 73.4 80 27 shut--off valves, turning the vacuum pump off
29.4 74.6 60 16 and noting the low side gauge reading. A loss
of more than 2" (5 cm) of vacuum in 5 minutes
29.7 75.4 40 5
indicates either a leak or moisture in the
29.8 75.7 20 -7 system.
29.9 75.9 0 -18

7. If the gauge needle remains stationary and the

vacuum is maintained for 3-5 minutes, close
both the high and low side manifold hand
valves, turn off and disconnect the center hose
from the pump. The system is now ready for
charging.

NOTE: For every 1000 feet (305 m) above sea 8. If a leak is detected, charge the system with
level, the vacuum gauge reading must be approximately 14 ozs (400 g) of refrigerant,
corrected by adding 1" (2.54 cm) of mercury to see charging the system and identify leak
compensate for the change in atmospheric using a leak detector.
pressure.

IMPORTANT: Be sure the system is completely 9. Once the leak is located discharge and recover
discharged as refrigerant will damage the vacuum the refrigerant in the system, repair the leak,
pump. then repeat the evacuation procedure.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 35

CHARGING THE SYSTEM 5. If the refrigerant charge will not completely

transfer to the air conditioning system, recover
IMPORTANT: Be sure there are no leaks in the and recharge the system.
system and the system has been fully evacuated.
Observe all safety recommendations when 6. Close the high and low side valves on the units
handling refrigerant R-134a, see “Precautions control panel, or manifold gauge set if being
when Handling Refrigerant R-134a” in this Section. used and test the air conditioning as detailed in
Performance Testing The Air Conditioning
1. Ensure the charging unit is correctly connected System on Page 15.
to the tractor air conditioning system in
accordance with the manufacturers
instructions. NOTE: After charging a system use the following
start up procedure to ensure the lubricating oil is
2. If a charging unit, in conjunction with the properly dispersed around the system:
manifold gauge set is used, open the high and
low side hand valves on the manifold.
3. Charge the system with 1.4kg (3.1lbs) of S Ensure air conditioning is switched OFF.
refrigerant as per the manufacturers
instructions.
S Start the engine and bring speed down to idle.
4. If the charging rate becomes very slow close
the high side valve, start the tractor and set
engine speed to idle. Turn ‘ON’ the air S Turn the air conditioning ON and allow system
conditioning so that the compressor can pull to operate for at least one minute before in-
the remainder of the refrigerant into the system. creasing engine speed.

Connecting Recovery Evacuation and Recycling/Charging Station to the Tractor 36

1. High Side Service Valve (Red Hose)
2. Built In Manifold Gauge Set
3. Recovery/Recharging Unit
4. Low Side Service Valve (Blue Hose)

604.55.041.00 - 01 - 1998
36 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

COMPONENT OVERHAUL (EXCLUDING

COMPRESSOR)
GENERAL

WARNING
Before disconnecting components in the air
conditioning system the refrigerant gas must be
discharged and recovered using a certified
recovery system. Refer to Discharging the
system on Page 31. Do Not discharge the gas
into the atmosphere.

If an air conditioning component is to be replaced

during a system overhaul it is necessary to drain
any refrigerant oil that has collected in the
component being replaced into a clean calibrated
container.
A volume of clean refrigerant oil equivalent to that
removed from the replaced component must then
be added to the new item before being installed
onto the tractor.
Upon completion of the repair evacuate,
recharge, leak test and performance test the
system to ensure correct operation.

EXPANSION VALVE

The expansion valve is not a serviceable item and

must be replaced if defective.

1. Fully discharge the air conditioning system.

2. Remove roof access hatch and evaporator

cover plate to gain access to the valve, Figure
37.
60--50--013 TI

37
3. To gain access to the expansion valve spring
lock couplings partially lift the evaporator core
from its position in the cab roof.

4. Disconnect the two spring lock couplings to the

expansion valve.

5. Remove Allen screw securing the inlet and

outlet connections to the valve, Figure 38 and 60--50--036 TI
pull valve from tubing. 38

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 37

6. Replace the ‘O’ ring seals and lubricate with

refrigerant oil prior to installing the valve using
disassembly procedure in reverse, Figure 39.

7. Evacuate, leak test and recharge the system.

60--50--037 TI
39
EVAPORATOR

1. Close the heater shut--off valve on the rear of

the inlet manifold, Figure 40.

2. Turn the cab heater temperature control to

maximum heat.

40
3. Apply a clamp to the heater return hose at the
left side of the engine. Disconnect the hose
and drain the heater system of coolant, Figure
41.

4. Discharge and reclaim refrigerant gas using

certified recovery systems.

5. Remove the black cover plate to reveal

evaporator assembly.
60--50--038 TI
41
6. Partially lift evaporator and heater core from
plastic housing to improve access to hoses,
Figure 42.
7. Remove temperature cycling control
thermocouple, Refer to Figure 43.
8. Disconnect tubing to expansion valve.
9. Disconnect heater hoses and remove
evaporator and heater core assembly.
10. Check the evaporator assembly fins for
damage. Straighten fins if necessary.
11. Clean the evaporator core of all foreign
material to be sure it is free of obstructions. 60--50--015 TI
42

604.55.041.00 - 01 - 1998
38 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

12. Check the evaporator assembly for indications

of refrigerant leakage. If damage or leaks are
evident, replace the evaporator core.
13. If a new evaporator is to be installed drain the
refrigerant oil in the evaporator into a clean
calibrated container. Measure the quantity of
oil obtained and add the same quantity of new
refrigerant oil directly into the replacement
evaporator core.
14. Install evaporator using disassembly
procedure in reverse.
15. Evacuate, leak test and recharge the system.
60--50--010 TI

43
AIR CONDITIONER TEMPERATURE CYCLING
CONTROL SWITCH

1. Remove the black evaporator cover plate.

2. Partially lift evaporator and heater core and

remove temperature cycling control switch
thermistor from left hand end of evaporator,
Figure 44.

60--50--010 TI
44
3. Carefully pull and disconnect the switch wiring
connector from beneath the plastic housing
which holds the evaporator and blower motor
assembly. Refer to Figure 50.

4. Remove temperature cycling control switch,

Figure 45.

60--50--009 TI
45
LOW PRESSURE CUT--OUT SWITCH

1. With the engine ‘Off’ check continuity across

the switch contacts, Figure 46. If the switch
shows ‘Open Circuit’ replace as detailed
below.

NOTE: The switch can be replaced without

discharging the system.

2. Remove switch, Figure 46, by unscrewing

from self sealing schrader valve.

3. Replace with new switch and connect to 60--50--011 TI

harness.
46

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 39

BLOWER MOTOR and FAN ASSEMBLY

The blower motor can if required be removed

without discharging the system as follows:--

1. Remove the cab heater temperature control

knob, Figure 47 and then unscrew the control
shaft retaining nut.

60--50--017 TI

47
2. Remove the 3 head lining studs situated close
to the air louvre vents inside the front of the
cab.

3. Raise the cab roof and withdraw the heater

control mechanism, Figure 48, from the
control panel.

4. Remove the visible screws which attach the

motor to the plastic air conditioning housing in
the cab roof.
60--50--039 TI
48
5. Remove the 2 retaining bolts from the plate
which covers the evaporator and then remove
the 2 bolts securing the plastic evaporator
housing to the cab roof.

6. Carefully lift the front of the plastic evaporator

housing and turn the complete assembly over
towards the rear of the cab Refer to Figure 49
and Figure 50.

NOTE: Take care not to damage hoses during this

operation or spill any water onto the cab roof.
If the cab heater hoses restrict movement of the
housing drain the heater assembly and disconnect
60--50--015 TI
the hoses.
49

7. Disconnect the motor wiring connector block.

8. Remove the remaining motor securing screws

and withdraw motor.

9. Re--assembly follows the disassembly

procedure in reverse. During re--assembly
ensure the 4 drain hoses are reconnected to
the plastic air conditioning housing, Figure 50.
60--50--040 TI

604.55.041.00 - 01 - 1998
40 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

RECEIVER DRYER and CONDENSER

The receiver/dryer, (2) Figure 51, cannot be

overhauled and must be replaced as an assembly.
The receiver/dryer assembly should be replaced if
it is suspected that moisture is in the system.

The receiver dryer must also be replaced if the

system has been discharged and the air
conditioning joints disconnected.

1. Discharge and reclaim refrigerant gas using

certified recovery systems.

2. Slide condenser, (1) Figure 51, to side of

tractor.

3. Separate the air conditioning tube spring lock

couplings to the receiver dryer.

4. Remove the dryer from the tractor.

5. Disconnect the connections to the condenser.

51
6. Cap and plug all fittings to prevent any dirt
entering the system.

7. Remove condenser from tractor.

8. Inspect the condenser assembly fins for

damage and be sure they are not plugged.

9. Check the condenser for signs of leakage. If

the condenser is damaged or leaking, install a
new condenser assembly.

10. Drain the refrigerant oil from the receiver dryer

into a clean calibrated container. Measure the
quantity of oil obtained and add the same
quantity of new refrigerant oil directly into the
new item.

11. If the condenser is to be replaced, drain the

refrigerant oil from the condenser into a clean
calibrated container. Measure the quantity of
oil obtained and add the same quantity of new
refrigerant oil directly into the new condenser.

12. Soak new tubing connector ‘O’ rings in clean

refrigerant lubrication oil and install onto tubing

13. Install condenser and a new receiver dryer.

14. Evacuate, leak test and recharge the system.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 41

COMPRESSOR HIGH LOW CUT--OUT

SWITCH

1. With the engine ‘Off’ check continuity across

the switch contacts, (1), Figure 52. If the
switch shows ‘Open Circuit’ replace as
detailed below.

NOTE: The switch can be replaced without

discharging the system.

52
2. Remove switch by unscrewing from self
sealing schrader valve.

3. Replace with new switch and connect the

harness.

CAB AIR FILTERS

1. Before servicing the filters, switch off the

blower and close the roof hatch, all windows
and one door. Slam the final door closed and
the resulting back pressure will dislodge most
of the loose dirt from the underside of the
filters.

2. Remove filter element(s), Figure 53 and

clean by blowing with compressed air not
exceeding 2 bar (30 lbf/in2). 60--50--016
53
Blow the dust from the upper surface through
the element to the underside. Hold the nozzle
at least 12 in (300 mm) from the element to
prevent damage to the paper pleats.

3. Clean both filter chambers with a damp, lint

free cloth.

4. Replace the filter elements with the rubber seal

uppermost and re--install the covers.

604.55.041.00 - 01 - 1998
42 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

COMPRESSOR -- OVERHAUL

Compressor Removal

1. Discharge and reclaim refrigerant gas using

certified recovery systems. Record the amount
of oil discharged as (X).

2. Disconnect tubing to compressor.

3. Disconnect wiring connector to compressor

clutch.

4. Disconnect drive belt, remove the four

mounting bolts and remove compressor from 54
tractor.

5. Drain the refrigerant oil from the old

compressor into a clean calibrated container.
Measure and record the quantity of oil as (Y).
This information is required during installation
of the new or overhauled unit.

NOTE: It is necessary to rotate the compressor

drive shaft several times to completely expel all
the oil.

Compressor Installation
1. Installation is the reversal of the removal but
the following points should be noted:--
# Torque the mounting bolts to 40--51Nm 55
(29--38lbf.ft).

NOTE: It is recommended that a new receiver /

drier assembly is installed after any system
component replacement or any repair that requires
entry into the system.

# Drain the oil from the new compressor to be

fitted into a clean container, or if the old
compressor is to be refitted, obtain a new can
of refrigerant oil.
# Calculate the amount of oil to be installed as,
(x)+(y). Add this quantity of the new oil into the
fill port on top of the compressor.
NOTE: Refer to the following page regarding Oil
Level Measurement to determine if the system
oil quantity is correct.

After charging a system use the following start up

procedure to ensure the lubricating oil is properly
dispersed around the system:
56
# Ensure air conditioning is switched OFF.
# Start the engine and bring speed down to idle.
# Turn the air conditioning ON and allow system
to operate for at least five minutes before
increasing engine speed.

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 43

Oil Level measurement (on vehicle)

Oil level in the compressor should be checked

when a system component is removed or
replaced or when an oil leak is suspected.

Use the following procedure to determine if the

oil quantity is correct.

1. Start the engine and allow to idle. Switch on air

conditioning and run the compressor for 10
minutes.
1
2. Recover the refrigerant from the system, very
slowly so as not to lose any oil.

3. Carefully remove the oil filler plug. Turn the

armature retaining nut to allow full insertion of
the oil dipstick (1) Figure 57, supplied with kit
NH.50--100.

57
4. Remove the dipstick and count the notches
covered by the oil. An acceptable level of oil is
when 5--7 notches are covered.

5. Add or subtract oil through the filler plug to

obtain the correct level.

6. Ensure the filler hole seat and filler plug seal

are clean and not damaged and Install the oil
plug. Tighten to 15--25Nm (11--18lbf.ft).

Oil Retained in System Components

After replacement of individual system Typical oil amount

components it will be necessary to add some oil to Component
the system to make up the amount lost in the fl.oz. cc
removed component. The table, on the right, Evaporator 2.0 60
shows some typical volumes for the components. It
is, however, still recommended that the on vehicle Condenser 1.0 30
oil level measurement procedure, described Receiver / drier 0.5 15
above, is carried out after a new component has
been installed to establish correct oil quantity. Hoses 0.3 10

604.55.041.00 - 01 - 1998
44 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Preliminary Inspection

1. Rotate the compressor shaft. Use a suitable + --

socket on the hub centre bolt or by hand using A

the rubber dampers.

If severe roughness is felt while rotating the

hub, the compressor should be disassembled.

2. Using a 12 volt battery check current drawn by

the field coil which should be between 3.6-- 4.2
Amps.
TA605057
59
Very high current readings indicate a short
circuit in the field coil and no current reading
indicate an open circuit. Replace coil with
either fault. Resistance of the coil using an
ohmmeter should be approximately 3.0$ at
20!C.
A poor earth (ground) connection of the field
coil will result in a low voltage.
3. Ensure clutch is disengaged and rotate pulley
by hand. If roughness in the bearing is felt, it
will be necessary to replace the pulley and
bearing as an assembly.
TA605058
60
Clutch Disassembly

Removal

All clutch servicing should be done with the com-

pressor removed from the vehicle:
1. Support the compressor. If using a vice, do not
hold on to the housing.
2. Remove the cover on the front of the clutch
plate.
3. Using the front plate tool hold the clutch plate
stationary and remove the retaining nut from 6050092TAG
the end of the shaft. Figure 61.
61

4. Place a thread protector over the end of the

driveshaft and using a puller remove the clutch
front plate, Figure 62.

6050093TAG
62

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 45

5. Carefully remove the bearing dust cover, if

fitted.

TA605088

63
6. Remove the clutch shims

TA605062
64
7. Remove the shaft key

TA605063

65
8. Remove the pulley bearing external snap ring

TA605064
66

604.55.041.00 - 01 - 1998
46 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

9. With a shaft protector over the exposed shaft,

use a suitable puller to remove the clutch
pulley.

6050094TAG

67
10. Inspect the pulley bearing for wear and replace
where necessary.

TA605066
68
11.Remove the field coil wire retaining clip.

TA605067
69
12. Remove the field coil retaining snap ring and lift
the coil from the housing.

TA605068
70

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 47

Clutch Reassembly

1. Install the field coil, ensuring that the lug on the

compressor housing locates in the cut out on
the back of the coil housing, secure with the
snap ring.

TA605071
71
2. Position the pulley on the housing hub.

TA605069
72
3. Using a suitable adaptor that rests firmly on the
inner race of the pulley bearing, tap the pulley
onto the front hub of the compressor.

TA605070
73
4. Install the bearing snap ring.

5. Replace the original shims, key and a new

bearing dust cover.

TA605064
74

604.55.041.00 - 01 - 1998
48 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

6. Install the clutch front plate and using a

suitable adaptor, tap into position.

TA605073
75
7. Replace the retaining nut and tighten to a
torque of 18Nm (13lbf.ft).

6050092TAG
76
8. Check the clearance between the clutch front
plate and pulley. This should be consistent
around the circumference and be between
0.4--0.8mm (0.016--0.031in.)

9. If the air gap is not consistent, lightly pry up on

the counter weighted front plate at the low
spots or lightly tap down at the high spots.

TA605074
77
10. If the clearance is not within specification the
shims under the front plate, Figure 78, should
be added to or subtracted from until the correct
clearance is obtained.

NOTE: New shims are available in sizes 1.00,

0.50 and 0.13 mm, (0.040, 0.020 and 0.005 in.).

TA605062

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 49

Shaft Seal Replacement

The refrigerant must be discharged from the
system and the compressor removed from the
vehicle prior to replacing the shaft seal.
Removal
1. Remove the clutch front plate, as detailed in
steps 1 to 7 of clutch disassembly.

2. Using a suitable lever or pair of snap ring pliers,

remove the felt ring.

TA605076

79
3. Remove the shaft seal retaining snap ring.

TA605075
80
4. Insert the seal remover/installer tool. Twist the
tool to engage the slots in the seal. Pull up to
remove. Discard the seal.

NOTE: If seal remover tool is not available, insert

a suitable piece of hooked wire into the seal slot
and pull out seal.

6050095TAG
81
Installation
1. Thoroughly clean the seal cavity in the hub.
Use ‘lint free’ cloth only.

2. Position the seal protector over the driveshaft.

TA605077
82

604.55.041.00 - 01 - 1998
50 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

3. Ensure the shaft seal ‘O’ ring is installed onto

the seal assembly.

TA605079

83
4. Dip the new seal assembly in clean refrigerant
oil and attach to the seal remover/installer tool.

5. Insert the new seal fully into the hub.

NOTE: If remover/installer tool is not available,

position the seal squarely in the hub and tap
gently until fully seated.

TA605080
84
6. Install the seal snap ring. If the snap ring has a
beveled edge this should face outwards.

TA605082
85
7. Install a new felt seal and gently tap into
position.

8. Remove the shaft protector and position the

shims over the shaft.

9. Reinstall the clutch front plate as described in

clutch reassembly.

TA605083
86

604.55.041.00 - 01 - 1998
SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 51

CYLINDER HEAD SERVICING

Disassembly

1. Drain the refrigerant oil from the compressor

into a clean calibrated container. Measure and
record the quantity of oil obtained. This
information is required during installation of the
new or overhauled unit.
TA605084
87
2. Remove the six cylinder head bolts and using a
hide mallet, gently tap the cylinder head free.
The use of a gasket scraper may also be
required to free cylinder the cylinder head from
the compressor body.

3. If the valve plate and/or cylinder head are to be

reused, carefully remove the gasket using a
suitable scraper.

TA605085

88
4. Gently pry the valve plate free from the cylinder
block and remove the gasket.

5. Inspect the valve plate for damage.

Reassembly

1. Coat the top of the valve plate with clean

refrigerant oil and reassemble the cylinder
head using the reverse of the disassembly
procedure. TA605086
89
2. When installing the gaskets and valve plate
ensure they are correctly positioned over the
locating pins in the cylinder block.

3. Install the cylinder head bolts and tighten using

the sequence shown in Figure 90. Torque
initially to 20Nm (14lbf.ft) then finally to 32Nm
(24 lbf.ft).

4. When the overhaul is complete add to the

compressor a volume of oil equivalent to that
drained prior to disassembly. TA605087

604.55.041.00 - 01 - 1998
52 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

NOTES

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
SECTION 55 -- ELECTRICAL SYSTEM

Chapter 1 -- Electrical Introduction

CONTENTS

Section Description Page

55 000 Electrical Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 100 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 512 Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 000 System Precautions For Battery Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
55 510 Various Cab Switches -- Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
55 510 Clutch Pedal and Brake Pedal Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
55 100 Temporary Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

55 000 ELECTRICAL EQUIPMENT SPECIFICATIONS

Alternator 12v. 100 amp -- with cab

12v. 55 amp -- less cab

Regulator Integral with alternator

Battery Minimum maintenance type -- 12v. 800 cca

Dual battery option -- with cab

Starting motor Positive engagement, solenoid operated

Cold starting aid Thermostart (with electric timer)

Block heater optional

Bulb rating and type: Headlights 60/55W -- H4

Position lights 5W -- R5W
Work lights 55W -- H3
Turn signals 21W -- P21W
Stop/tail lights 21/5W -- P21/5W
Licence plate lights 10W -- R19/10

604.55.040.00- 01-- 1998

2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
55100 ELECTRICAL SYSTEM AND FUSES

The electrical system of all tractors consists of

various wiring harnesses, instrument clusters, and
switches. A micro--processor is also used to control
the 16x16 transmission, the 12x12 Dual Command
transmission and Electronic Draft Control where
fitted.

There are three instrument clusters available,

Electronic Instrument Cluster (EIC),
Analogue/Electronic Instrument Cluster (AEIC) and
an Analogue Instrument Cluster (AIC).

The Key start switch has five positions:

1. Thermostart

2. ‘Off’

3. Accessory ‘on’

4. Warning lamp and instruments ‘on’

5. Start
1

There are two battery options.

Standard 1 x 800 CCA, Figure 2.

Optional 2 x 800 CCA (with cab only) A

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 3
There are two alternator options:

55 Amp Standard less cab

100 Amp Standard with cab

There is one starter motor specification with two

manufacturers supplying:

3
Bosch 3.1Kw / Iskra 3.1Kw

Fuses and Relays

The Main Distribution Panel (MDP), or fuse box, is 4

located behind the right hand instrument cluster
console side panel.

For primary protection the main supplies from the

starter solenoid are fed through Maxi--Fuses. These
are heavy duty fuses ranging from 30 to 60 amps and
are located behind the left hand instrument cluster
5
console side panel.

6 maxi fuses are used on with cab models, Figure 6.

Tractors with cab

Fuse No. Rating Colour
1 50A Red
2 60A Blue
3 30A Green
4 60A Blue
5 30A Green
6 40A Amber
6
604.55.040.00- 01-- 1998
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
4 maxi fuses are used on less cab models, Figure 7.

Tractors without cab

Fuse No. Rating Colour
1 30A Green
2 30A Green
3 30A Green
4 30A Green

The maxi fuses for with cab tractors protect the

circuits shown in the right hand column: Maxi Fuse 1 To ignition relay and supplying Fuses
(50 Amp) 9/14/15/16/17/18/21

To ignition switch and supplying fuses

Maxi Fuse 2
8/10/11/12/13/20/22
(60 Amp)
and Thermostrt Module (Fuse 19)

Maxi Fuse 3 Turn switch and supplying fuses

(30 Amp) 1/2/3/4

Maxi Fuse 4 Fuses 5/6/7

(60 Amp) (Worklamps)

Maxi Fuse 5 Fuses 23/24

(30 Amp) (Accessories)

Maxi Fuse 6 40 Amp Implement Sockets

(40 Amp)

The maxi fuses for less cab tractors protect the

circuits shown in the right hand column:
Maxi Fuse 1
(30 Amp)

Maxi Fuse 2
(30 Amp)

Maxi Fuse 3
(30 Amp)

Maxi Fuse 4
(30 Amp)

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 5

Relay Function Relay Function

A Diff--lock (12x12 only) III Not Used
B Worklamp Relay -- Front (Roofline) IV Remote Valve Module
C Worklamp Relay -- Rear (Roofline) V & VI Power take--off Module
D Worklamp Relay -- Lower Front VII Thermostart Module
E Worklamp Relay -- Lower Rear VIII Front Intermittent wipe
F Busbar (Fuel Shut Off Relay) IX Rear intermittent wipe
G Diff--lock (12x12) X Blank
H Not Used XI & XII Flasher module
I Ignition Relay
II Accessory Socket

No. Amps. Circuit

No. Amps. Circuit
14 10 EDC
1 15 Headlamp -- Main
15 15 Stoplamps/4wd/Diff. lock
2 15 Headlamp -- Dip
16 25 Air conditioning/Heater Fan
3 15 Sidelamp -- Right Hand
4 15 Sidelamp -- Left Hand Wiper Washer/Front Wiper/Rear
17 20
Wiper/Console Lamp
5 10 Worklamp -- Front (Low)
6 15 Worklamp -- Rear (Fenders) 18 10 Turn Indicators
7 20 Worklamp -- Front & Rear (Cab Roof) 19 25 Thermostart
8 10 Fuel Shut--Off 20 5 Processor ’Keep Alive Memory’ (KAM)
9 10 Gauges/External Switches 21 5 P.T.O.
10 15 Hazard Lights
22 5 Radio/Implement socket switch & relay
Horn/Headlamp Flasher/Cigar
11 30 Accessories/Interior lamp/Radio
Lighter/Roof Beacon 23 20
KAM/EIC buzzer
12 10 EDC
24 10 Interior Light
13 15 Transmission solenoids

604.55.040.00- 01-- 1998

6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Micro Processors

The tractor can have a maximum of 2 processors

(including an Electronic Instrument Cluster, where
fitted). With the transmission/EDC processor
connected to the instrument cluster by a serial link for
cluster display.

Electronic Instrument Cluster

16x16 transmission / 12x12 Dual Command

Transmission processor and EDC, where fitted,
processor.

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 7

CAB CONTROLS (Op. No.55 512)

The information on the following pages identifies, P.T.O. controls -- Figure 14 to Figure 16.
locates and briefly describes the function of the
controls and instruments located in the cab. Some of Differential lock and four wheel drive -- Figure 17
the features shown may not be fitted to your tractor and Figure 18.
or may not be available in your country.
Hydraulic controls (top link sensing) -- Figure 19.

Electronic Draft Control -- Figure 20 to Figure 22.

INSTRUMENT PANELS

4 1 5 1

P
P

15 40
80 100
120
540
15 540 20
540 540 20 1000
0
10 1000

10 C
80 100
40 120
25 0 25
5 C 5

0 30 0 30
000 000
0 00 0 0 0

3 2 4 3 2
MM12 MM13

Figure 5 -- Analogue Instrument Panel Figure 6 -- Analogue/Electronic Instrument Panel

1. Warning and indicator lights 1. Warning and indicator lights
2. Engine coolant temperature gauge 2. Liquid crystal display panel
3. Fuel gauge 3. Proofmeter
4. Proofmeter 4. Fuel gauge
5. Engine coolant temperature gauge

Refer to Chapters 4 and 3 of this Section for full details

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 11
INSTRUMENT PANELS

1000

ON/OFF SETUP RESET RESET

Figure 7 Electronic Instrument Panel

1. Warning and indicator lights 3. Central display panel (LCD)
2. Tractor Performance Monitor (LCD) 4. Function buttons
5. Bargraph display (LCD)

Refer to Chapter 2 of this Section for full details

CAB ROOF-MOUNTED CONTROLS

Figure 8 -- Roof-mounted Controls

1. Console light -- illuminates when tractor lights are
turned on.
2. 3-speed blower control
3. Air conditioner temperature control (where fitted)
4. Heater temperature control

Refer to the Operators Manual for complete

operating instructions.

604.55.040.00- 01-- 1998

12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
TRANSMISSION CONTROLS

Figure 9 -- 12 x 12 Transmission Controls Figure 10 -- 24 x 24 Transmission Controls (Dual

1. Range lever (3 ranges)
Command option)
2. Hand throttle lever 1. Direct drive button
3. Shuttle lever 2. Main shift lever (4 ratios)
4. Main shift lever (4 ratios) 3. Range lever (3 ranges)
4. Shuttle lever
5. Hand throttle lever
6. ‘Dump’ switch
7. Underdrive button

Refer to the Operators Manual for complete operating instructions.

TRANSMISSION CONTROLS RIGHT-HAND ‘B’ PILLAR

Figure 11 -- 16 x 16 transmission Controls Figure 12 -- Right-hand ‘B’ Pillar (tractors with

1. Range lever (4 ranges)
cab)
2. Main shift lever (4 ratios) 1. Clock
3. Shuttle lever 2. Rear windscreen wipe/wash switch (where fitted)
4. Illuminated gear display
5. Hand throttle lever
6. ‘Dump’ switch
7. Powershift down button
8. Powershift up button

Refer to the Operators Manual for complete operating instructions.

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 13
ELECTRICAL POWER PANEL P.T.O. CONTROLS

Figure 13 -- Electrical Power Panel Figure 14 -- P.T.O. Switch (tractors with cab)
1. Switch (power to screw terminals (4) and to external 1. P.T.O. indicator lamp
40 amp socket) 2. Push button
2. Implement status socket 3. P.T.O. selector knob
3. Live, 2--pin, 8 amp socket
4. 40 amp screw terminals Press the central button and lift knob to engage the P.T.O.
5. Cigar/cigarette lighter Press the knob to disengage.

Refer to the Operators Manual for complete operating instructions.

P.T.O. CONTROLS

1 2

Figure 15 -- P.T.O. Switch (tractors without cab) Figure 16 -- P.T.O. Controls (right-hand console
1. P.T.O. indicator lamp -- rear)
2. Push button 1. P.T.O. range selector lever
3. P.T.O. selector knob 2. Safety lock collar -- lift collar to move lever.

Press the central button and lift knob to engage the P.T.O.
Press the knob to disengage.

Refer to the Operators Manual for complete operating instructions.

604.55.040.00- 01-- 1998
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
DIFFERENTIAL LOCK AND FOUR WHEEL DRIVE

Figure 17 -- Differential Lock and Four Wheel Figure 18 -- Differential Lock and Four Wheel
Drive (tractors with cab) Drive (tractors without cab)
1. Differential lock switch 1. Four wheel drive switch
2. Four wheel drive switch 2. Differential lock switch
3. Fast raise switch (Electronic Draft Control only)

Refer to the Operators Manual for complete operating instructions.

HYDRAULICS CONTROLS -- HYDRAULICS CONTROLS --

TOP LINK SENSING ELECTRONIC DRAFT CONTROL

5 1

4 3 2

Figure 19 -- Hydraulic Controls -- Top Link Sensing Figure 20 -- Hydraulic Control Panel (tractors
with cab only)
1. System selector -- ease to the right, then move back- 1. Slip limit control knob (with radar option)
ward for Position Control or forward for Draft Control 2. Slip limit on indicator light (with radar option)
2. Position Control setting 3. Malfunction warning light
3. Draft Control setting 4. Position/Draft sensitivity knob
4. Adjustable stop 5. 3-point linkage movement indicators
5. Lift control lever 6. Drop rate control knob
7. Height limit control knob

Refer to the Operators Manual for complete operating instructions.

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 15
HYDRAULICS CONTROLS -- ELECTRONIC DRAFT CONTROL

MM6

Figure 21 -- Hydraulic Controls (tractors with cab Figure 22 -- External Power Lift Control
only) 1. Fender-mounted raise/lower switch -- press top to raise
1. Fast raise switch (with Electronic Draft Control only)* 3-point linkage, press bottom to lower.
2. Lift control lever
3. Adjustable stop

* Press top of switch to raise 3-point linkage, hold bottom

of switch to lower quickly. Central position allows
implement to lower at rate set by drop rate knob.

Refer to the Operators Manual for complete operating instructions.

55 000 -- PROTECTION OF ELECTRICAL SYSTEMS DURING CHARGING OR WELDING

PRECAUTIONS ! Position the welder earth (ground) cable clamp as
To avoid damage to the electronic/electrical sys- close to the welding area as possible and ensure
tems, always observe the following: a good earth.

! Never allow welding cables to lay on, near or

1. Never make or break any of the charging circuit across any electrical wiring or electronic compo-
connections, including the battery connections, when nent while welding is in progress.
the engine is running.
6. Always disconnect the negative cable from the
batteries when charging the batteries in the tractor
2. Never short any of the charging components to
with a battery charger.
earth (ground).

WARNING: Batteries contain sulphuric acid.

3. Do not use a slave battery of higher than 12 volts
In case of contact with skin, flush the af-
nominal voltage.
fected area with water for five minutes. Seek medical
attention immediately. Avoid contact with the skin,
4. Always observe correct polarity when installing eyes or clothing. Wear eye protection when working
the batteries or using a slave battery to jump start the near batteries.
engine. Follow the instructions in the operator’s
manual when jump starting the tractor. Connect IMPORTANT: Failure to disconnect the two earth
positive to positive and negative to negative. (ground) cable connections at the battery prior to
charging the batteries or welding on the tractor or
5. Always disconnect the earth (ground) cable from attached implement will result in damage to the
the batteries before carrying out arc welding on the electronic and electrical systems.
tractor or on any implement attached to the tractor.
604.55.040.00- 01-- 1998
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
SWITCH REMOVAL AND REPLACEMENT
(Op. No. 55 510)

Switch removal and replacement such as the hazard

warning light type of switch, (1), Figure 41, are best
removed from behind the switch, although it is
possible to prise the switch out from the front,
damage may occur to the paint or plastic of the
console.

To remove and replace any of the roof console 41

switches, (heater controls), it is necessary to remove
the front panel of the cab roof. Pull of the knob and
remove the nut and washer from the switch, from
inside the cab and withdraw the switch from the top of
the cab.

Key Start Switch -- Removal and Replacement

1. Disconnect the tractor battery.

2. Remove the steering column covers.

3. Disconnect the wiring connector to the harness,

remove the nut (1) securing the switch (2) Figure
42, to the cover and withdraw.

4. Replacement is the reversal of the removal

procedure.
42

Multi Function Stalk Switches -- Removal and

Replacement

1. Disconnect the tractor battery.

2. Remove the steering column covers (1) Figure

43.

3. Disconnect the wiring connector (2) Figure 43, to

the harness from the switch and remove the
screws retaining the switch to the column
bracket.

4. Replacement is the reversal of the removal

procedure. 43
604.55.040.00- 01-- 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 17
P.T.O. Switch Replacement -- Figure 45

1. Remove the right hand B--Pillar trim, (1), Figure

44.

2. Unscrew and remove the yellow knob.

3. Remove the nut securing the switch to the trim 44

withdraw the switch from the trim and disconnect
the wiring, noting the positions for reassembly.

4. Replacement is the reversal of removal.

Handbrake Switch Replacement -- Figure 46

1. Ensure the handbrake (1) is applied.

2. Disconnect the wiring connector (3) to the

harness from the switch.

3. Remove the two split pins (2) retaining the switch

and withdraw the switch from the bracket. 46

4. Replacement is the reversal of removal.

604.55.040.00- 01-- 1998

18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Clutch Pedal Switch adjustment
(16x16 and 12x12 Dual command
Transmissions) Op No. 55 510

Install the diagnostic tool, 4FT.950, into the

diagnostic connector. Turn the key start ‘on’ and
select mode HA.

Depress the clutch pedal and listen for the ‘click’ of

the switch. Note the number displayed. Release the
pedal slowly until the switch ‘clicks’ again and 47
observe the number displayed.

The switch should operate between 8--14.

If the switch operation is outside the range, adjust the

switch by loosening the switch retaining screws and
sliding in the slots until correct adjustment is
obtained.

Brake Pedal Switches Adjustment

Locate a 2.5mm (0.10 inch) thick gauge bar between

the switch and brake pedal. Loosen the switch
retaining screws.

Push the switch towards the brake pedal to the limit

of the plunger travel whilst ensuring that the pedal
remains stationary. Tighten the retaining screws and
remove the gauge. Repeat for the other switch. 60--33--020 TI

After adjustment ensure that both switches can be

heard operating and operating simultaneously.

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 19
Temporary Wiring Harness Repair
(Op No 55 100)

The following method to repair wiring is a temporary

expedient only. Wiring should be replaced as soon
as possible. Replacement of temporary repaired
cables with new is particularly important if the tractor
is to be used for spraying as chemicals can enter the
repaired area, travel up the cable and damage
electrical components. Do not attempt to repair the
wire on any system sensors as these are sealed and
should only be replaced with a new component.

NOTE: When conducting a cable repair it is 50

important that only RESIN CORED SOLDER is
used. Use of other types of solder may result in
further cable damage.

To carry out a temporary repair, proceed as follows:--

1. Locate damaged portion of cable then cut away

outer protective cover on both sides of the dam-
aged area, Figure 50.

2. Peel back the cable from both ends of the dam-

aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13
mm (1/2 inch) of insulation from the wires. Do not
cut away any wire strands.

3. Using a suitable solvent, clean about 2 inches 51

(50 mm) from each cover end. Clean the grey
cable cover and the individual leads.

4. Twist two bare leads together for each damaged

lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape,
Figure 51.

5. Wind a layer of vinyl insulation tape up to the grey

cable cover at each end of the repair section.
Make a paper trough, Figure 52, then apply sili-
con rubber compound (non hardening sealant)
over the repaired section up to the cover ends.
Sufficient sealant must be used to fill the ends of
the cut away area.
52
604.55.040.00- 01-- 1998
20 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
6. Allow the compound to cure then cover the area
with insulating tape taking the tape well over
each end of the repair. An overlap of at least 2
inches (50 mm) of tape at each end is necessary,
Figure 53.

7. Check to ensure the repair is satisfactory and se-

cure the repaired cable so that repeat damage is
avoided.
53

NOTE: This is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.

604.55.040.00- 01-- 1998

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 2 -- Electronic Instrument Cluster

CONTENTS
Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Programming central LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Programming performance monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault code charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1000

ON/OFF SET- RE- RE-

UP SET SET

1
The Electronic Instrument Cluster consists of five
distinct areas:

1. Indicator and Warning Lamps

2. Tractor Performance Monitor

3. Central Display

4. Function Buttons

5. Tractor Condition Bar Graph

604.55.041.00 - 01 - 1998
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

AREA 1: INDICATOR AND WARNING LAMPS

Condition Indicator/ Central Audible Alarm

Warning Lamp Display
1 Engine Coolant Temperature High ON STOP CRITICAL
2 Engine oil pressure ON STOP CRITICAL
3 Battery voltage Low ON --
4 Air filter restriction ON NON CRITICAL
5 Thermostart ON --
6 Park brake And Brake/Clutch Fluid Low
-- Ignition On Park Brake Applied FLASHING --
-- Ignition On Brake/Clutch Fluid Low FLASHING --
-- Engine Running Tractor Moving FLASHING CRITICAL
Park Brake Applied
-- Key Off Park Brake Released FLASHING CRITICAL 2 min
7 Transmission/Rear Axle. Hydraulic Oil ON CRITICAL
Temperature
8 Variable Displacement Pump
-- Steering filter Blocked ON --
-- Charge Pump Filter Blocked FLASHING NON CRITICAL
Tandem Gear Pump
-- Steering/Hydraulic Filter Blocked ON --
9 Transmission Lubrication Low pressure ON CRITICAL
10 Low Trailer Brake Pressure (Italy only) FLASHING CRITICAL
11 Left turn indicator FLASHING --
12 Trailer One Turning FLASHING --
13 Trailer Two Turning FLASHING --
14 Headlights Main Beam ON --
15 Side Lights ON --
16 Direct Drive (Dual Command Transmission Only) ON --
17 Underdrive (Dual Command Transmission Only) ON --
18 4WD ON --
19 Differential Lock ON --
20 1000 PTO Speed Selected ON --
1000 PTO Speed Selected and Overspeeing ON FLASHING
5 sec ON
21 Right Hand Indicator FLASHING --

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 3

AREA 2: TRACTOR CONDITION BAR

GRAPHS
CRITICAL ALARMS

COOLANT TEMPERATURE HIGH

With engine running:

Critical audible alarm, stop and left hand display will
flash.
The tractor performance monitor will also go blank.
With engine off, key on:
The left hand display continues to display 3
maximum bars and coolant symbol.

ENGINE OIL PRESSURE LOW

With engine running:

Critical audible alarm, stop and left hand display will
flash. Alarm pressure function will vary with engine
speed.

OIL PRESSURE RPM ALARM

Bar lbf/in2 Less than 500 OFF
0.6 8 500--1500 ON
1.1 16 1500--2000 ON
1.7 24 2000--3000 ON
4
The tractor performance monitor will also go blank.
With engine off, key on:
The left hand display continues to display minimum
bars and oil pressure symbol.
NOTE: If both coolant and oil pressure alarms are
activated together, both symbols, high and low
symbols and all 12 segments of left hand display
flash.

FUEL LEVEL LOW

Display and alarm are activated as bargraph

changes from:--

3 to 2 Segments
2 to 1 Segment

Or when Key switched on (with low fuel).

5 second non critical alarm.

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4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

AREA 3: CENTRAL DISPLAY

BATTERY VOLTAGE

Digital display indicating to nearest 0.1volt.

Alarm system activated if voltage is less than 10

volts or above 16 volts. The 5 second and 10
second alarm will sound and the battery voltage
sign will flash.

ENGINE HOURS

Digital display of actual hours of engine running,

automatically selected when Key Start switch
turned ’ON’.

Readouts 0--1000 hours in 0.1 increments and

above 1000 hours in 1 hour increments to
maximum 9999 hours.

Recorded hours are stored in the permanent

memory and not affected by battery removal.

ENGINE RPM

Digital display to nearest 10 rpm.

Display automatically selected on engine start up.

Permanent 18 segment rpm bargraph display

indicates 800--2500 rpm in 100 rpm steps.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 5

GROUND SPEED

Digital display of ground speed km/h or mph

(programming). In ’ERPM’, display will
automatically select ground speed over 20 km/h
(12.4 MPH).

Ground speed provided by Radar (if fitted) or

transmission speed sensor.

Ground speed calibration must be correct to

provide accurate ground speed.

9
GROUND SPEED CALIBRATION SETUP

Ground speed calibration number is related to the

rear wheel rolling radius (under load) for tractors
less Radar. The calibration number is programmed
into the centre display using digit select and set
buttons.

For tractors with Radar the calibration number is

4018.

10
Should tyres of a different size be fitted, then the
Static Calibration Number
computer module may be recalibrated to display a Loaded Radius 12×12 16×16
more accurate ground speed mm in. Transmission Transmission

622 24.5 9997 7630

635 25.0 9798 7477
648 25.5 9605 7330
660 26.0 9421 7190
673 26.5 2943 7054
686 27.0 9072 6923
699 72.5 8907 6797
711 28.0 8748 6676
724 28.5 8594 6559
737 29.0 8446 6446
749 29.5 8303 6337
762 30.0 8165 6231
Using the table select the required calibration
775 30.5 8031 6129
number. 787 31.0 7902 6030
800 31.5 7776 5934
813 32.0 7654 5841
826 32.5 7537 5752
838 33.0 7423 5664
851 33.5 7312 5580
864 34.0 7204 5498
876 34.5 7100 5418
889 35.0 6998 5341
902 35.5 6900 5266
914 36.0 6804 5192

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ALTERNATIVE CALIBRATION PROCEDURE

Start engine and enter ground speed calibration
mode.

Measure suitable 122 m (400 ft) course. Drive over

course, touch speed button at start and end of
course.

Number displayed is new CALIBRATION number,

turn off Key Start switch to enter into memory.

11
SERVICE ALERT SETUP

The next service alert is indicated by the hourmeter

symbol flashing for up to 10 hours when the service
is due.

The warning can be cancelled by pressing the

hourmeter and ground speed function buttons
together.

12
To enter the program press and hold the hour
function button for 3 seconds, (1) Figure 13.

13
To program the next service alert use the digit set
(3) and digit select, (2) Figure 14, function buttons.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 7

Power Take Off Display -- non--shiftable P.T.O.

Touch button (3) and the ’PTO 540 legend (1) will 7 1
display, together with the P.T.O. speed in the main
LCD (7). If the 1000 rev/min P.T.O. shaft is in use
touch the selector button again and the ’PTO 1000’
legend (2) will display together with a digital display 6 2
of P.T.O. speed.

Power Take Off Display -- shiftable P.T.O. 5 3

With shiftable P.T.O. the P.T.O. display, when
selected will automatically show the P.T.O. speed 4
set by the position of the P.T.O. speed change ON/OFF

lever, even if the P.T.O. knob is in the disengaged

position. If 1000 rev/min P.T.O. is selected, the 15
PTO 1000’ indicator light will also illuminate.
In both non--shiftable and shiftable P.T.O. the
speed is calculated by the EIC using a pre--set
constant and engine speed.

Transmission Gear Display -- Figure

The lower LCD (6) provides a permanent display of
the gear selected, provided the key--start switch is
on.

AREA 4: TRACTOR PERFORMANCE

MONITOR

AREA PER HOUR

Area per hour being worked based on last 5

seconds of operation.

Display will read .0 if either the implement is raised

or the tractor is stopped.

16
AREA

Total accumulated area (since last display reset).

Area accumulation is automatically switched ’OFF’
or ’ON’ when the implement is raised or lowered in
work, or manually by touching the ON/OFF
(ground speed button).

Area display can be set to ZERO by holding down

AREA function button for 3 seconds.

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8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

SLIP (WITH RADAR OPTION ONLY)

Wheel slip percentage (%).

Based on difference between radar (ground speed)

sensor and transmission (wheel speed) sensor
signals.

To ’zero’ slip, hold down SLIP function button for 3

seconds (alarm tone) while tractor speed is less
than 16 km/h (10 mph).

18
TRACTOR PERFORMANCE MONITOR SETUP

1 IMPLEMENT WIDTH

Hold Set Up button to enter programming mode

and display implement width.

Use digit select and digit set buttons to revise width

setting.

Units:
M = metric ; FT = imperial

19
2 SLIP ALARM

Touch Set Up button to display slip alarm* setting

(where Radar fitted).

Use digit set and select buttons to revise slip alarm

setting.

Set display to ’0’ ’0’ if alarm not required.

*Units without Radar will show AREA PRESET.

20
3 AREA PRESET

Touch Set Up button to display area accumulation

reading.

Use digit select and set buttons to preset area

reading.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 9

TRACTOR PERFORMANCE MONITOR SETUP

4 DISTANCE MEASUREMENT

22
Touch Set Up button to enter distance measuring
mode.

(M or FT will be displayed indicating metric/imperial

units).

To measure travelled distance in this mode use

ON/OFF switch to start and stop display.

5 SETTING METRIC OR IMPERIAL UNITS

23
Touch Set Up button to display units ’M’ or ’FT’.

Touching either reset button will change the units

displayed.

To exit programming mode hold down Set Up

button until the display changes to AREA/HOUR
display.

604.55.041.00 - 01 - 1998
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

Hitch Enabled Sumbol (with Electronic Draft

Control only)

The hitch enabled symbol (1) is displayed to advise

the operator when the 3--point linkage is in phase
with the hydraulic lift control lever. See
’ELECTRONIC DRAFT CONTROL’.

ON/OFF SETUP RE- RE-

SET SET

Hitch Position Display (with Electronic Draft

Control only)

The display (2) advises the operator of the position

of the lower links (and implement) by means of
numbers ranging from ’0’ (fully lowered position) to
’99’ (maximum lift height). See ’ELECTRONIC
DRAFT CONTROL.

Hitch Disabled Symbol (with Electronic Draft

Control only) ON/OFF SETUP RE- RE-
SET SET

25
The hitch disabled symbol (3) is displayed when
the 3--point linkage is out of phase with the
hydraulic lift control lever. See ’ELECTRONIC
DRAFT CONTROL.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 11

AREA 5: FUNCTION KEYS

1 Engine Oil Pressure 8 Engine RPM Digital Readout

2 Fuel Tank Level 9 Ground Speed
3 Engine Coolant Temperature 10 PTO RPM 540/1000
4 Battery Voltage 11 Area/Hour
5 Engine Hours 12 Area Worked
6&7 Programming & Diagnostic Functions 13 Slip %

The liquid crystal displays are selected by touching

the appropriate touch sensitive function buttons as
shown above.

An audible bleep confirms each function button

command.

The selected displays are shown on the previous

pages.

The function buttons are disabled during critical

and non--critical alarm sequences.

604.55.041.00 - 01 - 1998
12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

EIC SERVICEABILITY

Removing Electronic Instrument Cluster

Rear Cover removed

Bulb replacement

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 13

FAULT CODE CHART

ERROR CODES

The Electronic Instrument Cluster (EIC) features These error codes appear when any one of the
an integral fault diagnosis system which displays listed errors occurs. The alarm sounds
error codes on the LCD as shown in the following continuously for a critical alarm and for 5 seconds
Table. with a non critical alarm.

EIC DISPLAY
SENSOR COND T ON ALARM
Less han 500 rev m n More han 500 rev m n
Error Code No
O Sende
C ca
Sho o G ound Open C cu
O Sende
C ca
Sho o a +ve Vo age
Fue Sende
Non C ca
Sho o Ea h G ound
Fue Sende
Non C ca
Open C cu o Sho o a +ve Vo age
Ax e S a Sende
Non C ca
Sho o Ea h G ound
Ax e S a Sende
Non C ca
Open C cu o Sho o a +ve Vo age
Coo an Tempe a u e Sende
Non C ca
Sho o Ea h G ound
E ec on c D a Con o e o
Se a L nk Fa u e
T ansm ss on e o
Se a L nk Fa u e
Ba e y Ca b a on e o

S p A a m S p cons an
Non C ca
W d h and Se v ce Hou s check
Coo an Tempe a u e Sende
C ca
open c cu o sho ed o a +ve Vo age
Eng ne Shu down e o

Non EIC Errors -- only displayed Read Your Manual (RYM)

in the Diagnostic Memory.

604.55.041.00 - 01 - 1998
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ERROR CODE 1 -- Engine Oil Pressure Sender Short or Open Circuit

Turn keystart OFF and

disconnect connector C003
from sender

Short Signal Out, FM--31--Y/S Does Error Code

and +5, FM--2014--G/K, pins on disappear and oil
connector C003 pressure display indicate
Is Error Code 1 still maximum?
displayed?

At connector, C003,
measure voltage between Replace
Check for faulty cable between cable
C001--S--FM2014--G/K/C081--5--CM2014--G/K, +5 and Ground pins
C001--A--FM31--Y/S/C081--6--CM31--Y/S and Is voltage approx. 5v?
C001--J--FM2095--G/W/B /
C081--9--CM2095--G/W/B,
Is cable O.K? Replace
sender
Replace Replace
EIC cable

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 15

ERROR CODE 2 -- Engine Oil Pressure Sender Short to +ve Voltage

Disconnect connector C003

from sender

Using a suitable multi--meter Substitute

test for a voltage at each of the Inspect instrument Instrument panel
three terminals, with the keystart panel connectors. Are for one of known
ON. There should only be +5V connectors okay? performance.
at FM2014--G/K and 0V at the
remaining pins. Are voltage
readings correct? Repair connector as
required.
Disconnect engine
harness at connector
C001. Test voltage at Trace and repair faulty
C001--A--CM31--Y/S, wiring between connector
C001--S--CM2014--G/K C001 and connector
and C081
C001--J--CM2095--G/W/B
. Are voltages correct?

Trace and repair wiring

in Engine harness

604.55.041.00 - 01 - 1998
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ERROR CODE 3 -- Fuel Tank Level Sender Short to Earth/Ground

ERROR CODE 4 -- Fuel Tank Level Sender Open Circuit or Short to +12V

Inspect level sender, are the

connectors on the terminals clean Repair/replace and recheck
and tight?

Disconnect wires from sender unit

and connector C079 from the
instrument panel. With a suitable Locate and repair open circuit in sender
multi--meter, check ground wire
C022--RM2095--G/W/B to ground. Is
resistance <10! "

Check the terminals of the sender to Remove sender, repair/replace and

ground. Is a short to ground indicated ensure there is no short to ground on
on either terminal? reassembly

Check the operation of the sender. Is

the resistance within the range: Renew sender
Full 30! and Empty 250! ?

Check C022--RM29--G/B to ground.

Is a short to ground indicated? Trace and repair fault in wiring

Check between C022--RM29--G/B Trace and repair open circuit fault in

and C079--16. Is resistance <10! ? wiring

Inspect instrument
panel connectors. Are Substitute instrument panel for one of
connectors okay? known performance and recheck.

Repair connector as
required.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 17

ERROR CODE 5 -- Axle Speed Sender Short Circuit

ERROR CODE 6 -- Axle Speed Sender Open Circuit

Disconnect EDC and

transmission processor
connector C127 and wheel
speed connector C046. Test
wiring between C127--6 and
C046--RM5135--TQ. Is a short or
open circuit indicated?

Reconnect the Trace and

two connectors repair/replace
carefully. Check fault in wiring
that they are
correctly fitted
and recheck. Is
error code 5 or 6
still displayed?

With the sender

installed check for
a short circuit to
ground on each
sender terminal or
for an open circuit
of the sender.
Replace sender if
either condition is
indicated.

604.55.041.00 - 01 - 1998
18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ERROR CODE 7 -- Coolant Temperature Sender Short Circuit

Remove the connector, C012, from the

sender. Ensure the end of the wire is not
contacting any metallic part. Turn keystart Renew sender and
ON, engine OFF recheck function.
Is Error Code 7 displayed?

Remove the instrument panel, disconnect

plug C079. Disconnect the signal wire Locate and repair
from the sender. Measure the resistance short circuit in signal
between pins C079--8--CM39--G/U and wire
C079--7--CM57N--B
Is the resistance less than 5000!?

Replace instrument cluster with one of

known performance

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 19

ERROR CODES 8 and 9 Communications Error

The Electronic Draft Control module and the electronic transmission control (processor) send their disply
information over a two wire serial communications connection.

Communications errors (8&9) occur when the message received by the instrument panel is not correct. This
can be caused by an intermittent connection on the signal wires (LN/O orLN/TQ). If these errors are
accompanied by reports of intermittent or blank displays in the transmission or hitch position areas, then the
circuit wires should be investigated for open circuits, short circuits and intermittent connections.

LN/O C128--35
C080--19
EIC LN/TQ
EDC/TRANS.
C080--20 C128--14

ERROR CODE 10 -- Memory Retention Error of Battery Calibration Constant

Compare the voltage display of instrument panel to a voltmeter reading at the battery. If the readings differ
by more than 2.0 volts, then replace instrument panel and recheck.

ERROR CODE 11 -- Memory Retention Error of Operator Setting for Slip Alarm, Slip
Zero Reference Constant, Implement Width and Service Hours

If Error Code 11 persists then replace the instrument panel.

Re--programme the constants listed above using the instructions detailed earlier in this Section. Turn
keystart OFF and re--check the programmed values. If the values are not correct then replace the
instrument panel

604.55.041.00 - 01 - 1998
20 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ERROR CODE 12 -- Coolant Temperature Sender Short Circuit

Inspect the connection at connector C012

at the sender. Rectify poor
Are the terminal and connector clean connection and
and do they fit together firmly? recheck function

With the connector removed from the

Remove the connector C012 from the sender measure the resistance between the
sender and hold it firmly against a good sender terminal and body
ground Is the resistance between 80! (hot) and
Does the display indicate Code 7? 800! (cold) ?

Remove the instrument panel, disconnect Sender has poor

connector C079. At the sender ,earth the signal Renew sender and
ground to engine. recheck function.
wire and measure the resistance between Remove sender and
C079--8--CM39--G/U and C079--7--CM57N--B clean threads
Is the resistance less than 10!?

Clean the connector pins with Find and repair an open circuit fault in wiring
contact cleaner spray Apply a between connectors C079--8 (instrument panel)
dielectric grease. Reconnect and connector C012 (sender)
plugs to the instrument cluster
and turn keystart switch on
Does the cluster function Install a new Instrument Panel and recheck
correctly? function.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 21

ERROR CODE 13 -- Engine Shut--Down Output Short to a + Voltage

Figure 1

Remove the Fuel Shut--Off relay (F) from

the fuse panel. Measure the resistance of Renew relay
the relay coil at terminals 85 and 86.
Is resistance less than 95 !?

Remove instrument panel, disconnect connector

C081. With relay removed, measure resistance Locate and repair
between harness pins C081--8--2080--O/R and short in circuit
C081--7--2070--O/U/B between C081 and
Is resistance showing open circuit ? Relay F holder

Check instrument panel

connectors if okay Install a new
Instrument Panel

604.55.041.00 - 01 - 1998
22 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

Common Test Procedure for ALL of the Switch Circuits Connecting to Ground

Disconnect the harness at the Check the ground path of the switch and
sender/switch, and connect signal wire to recheck function.
ground Is the resistance to ground less than
Is the warning light illuminated? 10 !?

Unplug wiring harness from instrument Renew the switch

cluster. Ground the signal wire at and recheck
switch/sender and measure resistance function.
between the signal pin and the tractor
frame at the panel connector Locate
Is resistance less than 10 !? and repair
open
circuit in Check and clean
Clean wiring harness to instrument signal wire connectors. Is
cluster connector pins with contact spray switch
Reconnect the plugs to instrument panel functioning?
Remove the signal wire at the switch and
connect to ground
Is the warning light illuminated? Locate and
repair the open
circuit
Renew
the
warning
bulb

Is the
warning
light
illuminated?

Renew the Instrument Panel

and recheck function

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 23

Instrument Cluster Inoperative

No display on instrument cluster when the keystart switch is turned on.

Ensure the gear levers are in the neutral

position.Turn the keystart switch to crank
Charge the
the engine
battery
Is the battery sufficiently charged to
crank the engine?

Turn keystart off. Remove Fuse 9 from

the fuse box. Renew fuse
Is fuse blown? and recheck
function.

Remove the instrument cluster. Clean wiring loom to instrument cluster

Disconnect plug C079. Turn keystart connector pins with contact spray. Rejoin
switch on and measure voltage between connector C079 and switch ignition on.
C079--57N--B and C079--CM1003A--G Does instrument cluster display?
terminals
Is approximately 12v measured?
lnstall a new central
Digital Display
Turn keystart switch on and measure Module into the
voltage between connector terminal instrument cluster
C079--CM1003A--G and the battery and recheck
negative (ground) terminal. function.
Is approximately 12v measured?

Fault in ground wiring Fault in 12V power wiring

Locate and repair locate and repair

604.55.041.00 - 01 - 1998
24 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

DIAGNOSTIC MEMORY

To enter diagnostic memory mode hold down digit

set button during key ’ON’ and self test sequence.

Touching the digit set button will cycle the display

through the memory.

The error codes will appear on the appropriate

display, together with engine hours recorded.
Typical examples are illustrated.

The memory can be erased by holding down the

digit set button for 10 seconds (while in diagnostic
memory mode).

To exit mode touch any other display and function

button.

The cluster stores up to 10 diagnostic error codes

in a permanent memory. The stored ’Services
History’ can be displayed by entering the
Diagnostic Memory Mode.

When in this mode, touching the digit set button will

cycle the display through the stored memory. 32

When 10 error codes are already stored, further

error codes occurring will cancel the oldest error
code in the memory or update the hours if that code
is already stored.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 25

INSTRUMENT PANEL BYTE LEVELS

To set bytes, press and hold the battery function

button and turn key to ON (Engine off). The display
will show

’0’ ’7’
’7’ = Byte number
’0’ or ’1’ = Function

Use the DIGIT SELECT function switch to select next Byte (15 -- 0).

Use the DIGIT SET function switch to select function of Byte (’0’ or ’1’).

BYTE No.

7 EDC Gain -- Both should be switched to ’0’.

6
5 Reserved -- No effect whether switched to ’0’ or ’1’.
4
3 Bar Graph Displays -- Both should be switched to ’1’.
2
1 Units : Imperial ’1’ : Metric ’0’.
0 Panel Type -- should be switched to ’1’.
15
14
13
Reserved -- No effect whether switched to ’0’ or ’1’.
12
11
10
9 Radar Normally switched to ’0’
If switched to ’1’ the Tractor Performance Monitor display will be blank when radar
not fitted.

8 PTO Switched to ’0’.

Engine Speed Constant − depress Engine Speed function switch.

Constant = 017.1

604.55.041.00 - 01 - 1998
26 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

NOTES

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- Analogue Electronic Instrument Cluster

CONTENTS

Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3
1

80 100
40
120
540
15 540 20 1000
0

C 10

25
5

0 30
0 0 0 0 0 0

2
4

The Analogue Electronic Instrument Cluster

consists of four distinct areas:

1. Indicator and Warning Lamps

2. Tractor Condition Gauges

3. Main Tachometer

4. LCD Displays

604.55.041.00 - 01 - 1998
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

AREA 1: INDICATOR AND WARNING LAMPS

Condition Indicator/Warning Audible Alarm

Lamp
1 Not Used -- --
2 Engine Oil Pressure ON --
3 Battery Voltage Charge Low ON --
4 Air Filler Restriction ON --
5 Thermostart ON --
6 Park Brake + Clutch/Brake Fluid level
-- Key On Park Brake ON FLASHING --
-- Low Brake/Clutch Fluid level FLASHING --
-- Key Off Park Brake OFF -- CRITICAL 2 min
7 Not Used --
8 Variable Displacement Pump
-- Steering Filter Blocked ON --
-- Charge Pump Filter Blocked FLASHING --
Tandem Gear Pump
-- Steering/Hydraulic Filter Blocked ON --
9 Transmission Lubrication Low Pressure ON --
10 Low Trailer Brake Pressure (Italy Only) FLASHING CRITICAL
11 Left Turn Indicator FLASHING --
12 Trailer One Turning FLASHING --
13 Trailer Two Turning FLASHING --
14 Headlights Main Beam ON --
15 Side Light ON --
16 Direct Drive (Dual Command Tractors Only ON --
17 Indirect Drive (Dual Command Tractors Only ON --
18 4WD ON --
19 Differential Lock ON --
20 1000 PTO Speed Selected ON --
1000 PTO Speed Selected And Over Speeding FLASHING --
5 sec ON
21 Right Turn Indicator FLASHING --

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 3

AREA 2: TRACTOR CONDITION GAUGES

The Analogue panel has two gauges:

Coolant Temperature

Fuel Level

AREA 3 : MAIN TACHOMETER

The central display is the tachometer showing

engine speed and the correct engine speeds for
540/1000 PTO operation, as well as economy 540.

Also in this area is the proof meter for engine hours.

604.55.041.00 - 01 - 1998
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

AREA 4 : LCD DISPLAYS

Area 4 is the liquid crystal display, which is split into

the upper and lower sections. 20 1000

25
MPH
km/h

6
Upper Digital Display
Unit with Electronic Draft Control (EDC), the
3--point linkage position is indicated ’0’ (Fully 20 1000 1
lowered position) to ’99’ (Maximum lift height)

Unit with a 16×16 transmission without EDC, the 25

transmission ratio will appear. MPH
km/h

Error codes also appear in the upper display when 30

retrieved.

7
Lower Digital Display
The lower LED provides a permanent display of
ground speed (in MPH or Km/h) which can be 20 1000
changed depending on market.
The hitch disabled warning light illuminates when
the 3--point linkage position is out of phase with the
25
MPH
hydraulic lift lever. km/h

30
1

8
Calibrating the Instrument Panel
Road Speed Units
S Press and hold in the shuttle ’dump’ button(3)
and turn the key--start switch to ON. Release
the button.
S Press the up--shift or downshift button (1 or 2)
to change from MPH to km/h or vice--versa.
S Turn the key--start switch off to enter the
selected setting into the memory.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 5

Road Speed Calibration

Mark out a distance of 122 m (400 feet) on a dry,

firm, level and straight piece of ground.

-- Press and hold the shuttle ’dump’ button (3).

Start the engine.

10
-- Release the button.

-- The current radius of the rear tyres in

millimetres will be displayed.

11
-- Select a transmission ratio as follows:
24×24 transmission -- gear 2, range 3
16×16 transmission -- high range 1--4 gear

-- As the centre of the front tyres passers over the

mark press and release the upshift button. The
display will change to Run.

-- As the centre of the front tyres passes over the

finish line, press and release the downshift 12
button. The new rear tyre radius will appear in
the display.

-- To enter the new calibration No. turn off the

key--start switch.

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Alternative Calibration Procedure

Using the H6 Menu Mode via the diagnostic lead

will allow the actual radius of the wheel in
millimetres to be selected

13
Install the diagnostic lead and select H6.

The current radius will be displayed in millimetres.

14
By depressing the transmission upshift button a
larger radius may be selected

15
By depressing the transmission downshift button a
smaller radius may be selected.

Use the buttons to select the value closest to the

actual radius.

Key off and disconnect the diagnostic lead. This

will store the settings in the memory.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 7

SERVICEABILITY

Instrument Cluster removed.

17
Rear cover removed.

18
Bulb replacement.

As well as the bulbs, the gauges and liquid crystal

displays can also be replaced separately.

604.55.041.00 - 01 - 1998
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 4 -- Analogue Instrument Cluster

CONTENTS

Section Description Page

55 100 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 418 Servicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1
4

540
15 540 20 1000

10
80 100
40 120

25 0

5 C

0 30
0 0 0 0 0 0

2
3

The Analogue Instrument Cluster has four

display areas:
1. Indicator and Warning Lamps
2. Fuel Level
3. Main Tachometer Display
4. Engine Temperature

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2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

AREA 1: INDICATOR AND WARNING LAMPS

Condition Indicator/ Warning Audible

Lamp Alarm
1 Not Used -- --
2 Engine Oil Pressure ON --
3 Battery Voltage Charge Low ON --
4 Air Filter Restriction ON --
5 Thermostart ON --
6 Park Brake and Clutch/Brake Fluid Level
-- Key on Park Brake ON FLASHING --
-- Low Brake/Clutch Fluid Level FLASHING --
-- Key off Park Brake OFF -- CRITICAL 2 min
7 Not Used -- --
8 Variable Displacement Pump
-- Steering Filter Blocked ON --
-- Charge Pump Filter Blocked FLASHING --
Tandem Rear Pump
-- Steering/Hydraulic Filter Blocked ON --
9 Transmission lubrication low pressure ON --
10 Low Trailer Brake Pressure (Italy only) FLASHING CRITICAL
11 Left Turn Indicator FLASHING --
12 Trailer one turning FLASHING --
13 Trailer two turning FLASHING --
14 Headlights main beam ON --
15 Side Light ON --
16 Direct Drive (Dual command transmission only) ON --
17 Underdrive (Dual command transmission only) ON --
18 4WD ON --
19 Differential Lock ON --
20 1000 PTO Speed Selected ON --
1000 PTO Speed Selected and Over Speeding ON--FLASHING --
5 secs ON
21 Right Turn Indicator FLASHING --

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 3

Fuel Level

Tachometer

Displays engine speed and indicates correct

speeds for 540/1000 PTO operation.

Coolant Temperature

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4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SERVICABILITY (OP. 55 418)

Removing Analogue Instrument Cluster.

Rear cover removed.

Bulb replacement.

As well as the bulbs, the gauges can also be re-

placed seperately.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 5 -- Starting System

CONTENTS

Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 201 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

55 000 SPECIFICATIONS

Starter Type
Bosch 3.1 Kw

Maximum No Load Current Draw at 12.0 volts

and 8000 rev/min. 80 amps

Minimum Brush Length 7.00 mm (0.28 in)

Minimum Commutator Diameter 42.5 mm

Maximum Armature Shaft End Play 0.4 mm (0.015 in)

TORQUE SPECIFICATIONS

lbf.ft Nm

Starting motor to Engine Block Retaining Bolts 25 34

Solenoid Cable nuts 5 7
Starting Motor End Housing Nuts 7 10
Solenoid Retaining Bolts 4 5

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2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

OPERATION

The type of starting system is dependant on the At this point one end of the ‘pull--in’ coil is connected
transmission installed in the tractor. All systems to battery positive through the starter switch while
consist of a key start switch, heavy duty wiring, the other end is connected to positive through the
starter motor and solenoid assembly, and a starting solenoid contacts. The ‘pull--in’ coil is thus
relay, these are the components of the basic circuit by--passed, drawing no current and the ‘hold--in’ coil
which is used on the mechanical transmission. alone keeps the solenoid plunger engaged.

The 3.1 Kw rated motor is a four pole four brush The starter incorporates a single set of contacts and
type starter with integral solenoid and positive a two piece solenoid plunger which completely
engagement drive assembly. closes the contacts even if the pinion and ring gear
teeth are misaligned. When this happens, an
engagement spring is compressed which forces the
pinion into full engagement as soon as the starter
begins to turn.

The integral solenoid incorporates two windings

connected in parallel. One winding is the low
resistance ‘pull--in’ coil, grounded through the
motor, while the other is the high resistance
‘hold--in’ coil grounded via the solenoid body.
When the key start switch is released, power to the
solenoid and motor is removed. The solenoid return
spring acting through the pivoted linkage
mechanism pulls the drive pinion out of mesh and
reopens the solenoid contacts.

When the key start switch is closed with the

transmission in neutral the solenoid coils are
energised and the solenoid plunger is magnetically
attracted into the solenoid core. This movement,
transmitted through a pivoted linkage mechanism
forces the drive pinion into mesh with the flywheel Incorporated in the drive pinion assembly is a roller
ring gear. At ring gear to pinion abutment, the clutch device. This device prevents the armature
solenoid plunger closes a set of contacts to give a from rotating excessively if the pinion remains in
direct feed from the battery to all four field coils, mesh with the flywheel ring gear after the engine
providing full power to the starting motor. has started.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 3

16×16 Transmission Start Inhibitor Switch

12×12 and 12×12 Dual Command Start Inhibitor

Switch.

8×2 Transmission Start Inhibitor Switch

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4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

FAULT FINDING

Engine Does Not Turn Over When Key Start Is Operated, Transmission In Neutral
Is the battery Charge or replace
fully charged? NO battery. Does engine
turn over OK?

Inspect starter circuit wiring. Are all

connections tight, is the battery Repair wiring
negative to ground connection O.K, are as required
any wires broken or frayed, possibly
causing a short circuit?

Is the engine Investigate

seized? engine failure

Operate key start switch, is there Can the Suspect faulty

+12v at the starter solenoid input solenoid be motor windings,
wire (white/red stripe) heard brushes or
‘clicking’? mechanical
failure
Suspect faulty starter solenoid,
remove starter and inspect
Inspect starter relay, operate key
start switch, can the relay be Replace relay
felt/heard operating?

Remove connector to relay is there

+12v on pin 4, (white/red stripe wire) Replace relay
when the key start switch is operated?

Inspect wiring to start inhibitor switch, are Reconnect wiring

wires connected? NO
to switch

Check operation of switches, Replace switch

NO
are switches O.K.?
Check continuity of the
Is there +12v on the white/yellow white/red wire from clutch
wire to the start inhibitor switch? switch to pin 4 at starter
relay connector.
Is there continuity of white/yellow wire from clutch
NO Repair/replace
switch to key start switch, connector pin 6?
wiring

Do the displays in the instrument panel Check the main feed to the key
NO start switch from the battery.
illuminate when the key start is operated?
Pin 1 of key start connector.

Inspect the key start switch, if wiring

to switch is O.K. replace switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 5

STARTER SYSTEM TESTING ON TRACTOR

For easier and rapid diagnosis and for most
conclusive test results, it is recommended that a
battery--starter tester (high rate discharge tester)
incorporating a 0--20 volt voltmeter and a 0--500
amp ammeter be used to diagnose starting system
problems.

When using test equipment follow the manufactur-

ers recommended test procedures. If test equip-
ment is not available the following test procedure,
using a standard 0--20 volt voltmeter and 0--500
amp ammeter can be used to determine the correct
operation of the starter without removing it from the
engine.

Before testing:

! Check that the battery is fully charged.

! Check the complete starting system wiring

circuit for frayed or broken wires or loose
terminal connections.

! Check the engine is not seized.

Starter Motor Circuit Current Draw

1. Disconnect the Battery (3) ground (negative)

cable from the battery.

2. Disconnect the battery positive cable from the

starter solenoid. Connect the ammeter(1)
positive lead to the battery positive terminal
and the negative lead to the solenoid input
terminal.

3. Reconnect the battery ground (negative) cable

to the battery negative terminal.

4. Connect the voltmeter(2) positive lead to the

battery positive terminal and the voltmeter 4
negative lead to the battery negative terminal.

5. Disconnect the wire from the fuel injection

pump shut off solenoid.

6. Crank the engine while observing the

voltmeter and ammeter readings. The voltage
should remain steady at around 12 volts with
between 250--300 amps being drawn.

! If the current draw is within specification the

starting motor (4) is functioning correctly. If the
voltage drops during the test proceed to
‘Starting System Circuit Resistance’.

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

! If the current draw is greater than specified,

check the circuit as outlined below. If the
starting system circuit tests are satisfactory
the starting motor is defective and must be
disassembled to determine the cause.

! If the current draw is less than specified, the

starting motor is defective and must be
disassembled to determine the cause.

Starting System Circuit Resistance

(Voltage Drop)

If there is an excessive current draw the circuit

should be checked by recording voltage drops
across the individual components in the circuit

IMPORTANT: Disconnect the fuel injection pump

fuel shut off solenoid wire.

Battery Positive Cable:

1. Connect the voltmeter positive lead to the V

battery positive terminal.

2. Connect the voltmeter negative lead to the

starting motor solenoid battery terminal.

3. Crank the engine while observing the

voltmeter reading. If the voltage exceeds 0.2
volts, check and tighten the cable connections.
Recheck the voltage, if still excessive install a
new cable.
60-- 55-- 002 mm
5

Starting Motor Ground Connections:

1. Connect the voltmeter positive lead to the

starting motor frame.

2. Connect the voltmeter negative lead to the

engine block.

3. Crank the engine while observing the

voltmeter reading. If the voltmeter reading
exceeds 0.2 volts check the ground
connections between the starting motor flange
and the rear engine plate.
60-- 55-- 003 mm
6

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 7

Battery Ground Cable:

1. Connect the voltmeter positive lead to the

engine block. V
2. Connect the voltmeter negative lead to the
battery negative terminal.

3. Crank the engine while observing the

voltmeter reading. If the reading exceeds 0.2
volts, check and tighten the ground cable
connections. Recheck the voltage, if it is still
excessive install a new ground cable.
60-- 55-- 004 mm
7

STARTER MOTOR REMOVAL AND

INSTALLATION (OP. 55 201)

1. Disconnect the battery ground (negative)

cable from the battery.

2. Remove the protective cover from the solenoid

assembly and disconnect the positive cables
to the solenoid and the solenoid coil feed wire.

3. Remove the three starting motor mounting

bolts and remove the starting motor.

4. Installation is the reverse of the removal

procedure.
8

604.55.041.00 - 01 - 1998
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Starter Motor -- Exploded View 9

1. Stud and Bolt Kit 11. Housing Assembly
2. End Cap 12. Solenoid Assembly
3. Collar and Ring Assembly, Drive Thrust 13. Solenoid Hardware Kit
4. Brush End Plate Assembly 14. Lever Assembly
5. Brush Assembly 15. Brush Spring
6. Brush Assembly 16. Brush Holder Assembly
7. Field Coils and Housing Assembly 17. Washer
8. Armature 18. Nut
9. Centre Bearing Plate 19. Drive Assembly
10. Bushing

DISASSEMBLY 3. Remove the three screws from the front

housing assembly and withdraw the solenoid
With reference to Figure 9. assembly. Note that the plunger will remain in
the drive engagement lever.

1. Support the starting motor in a soft jawed vice.

4. Remove the solenoid plunger from the drive
engagement lever by gripping the plunger and
2. Disconnect the thick braided wire from the field lifting up the front end and releasing it from the
coil housing to the solenoid assembly. drive engagement lever.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 9

5. Remove the two end housing nuts and the two

screws retaining the end cap and brush plate to
the end housing. Remove the ‘C’ clip and
armature shaft end play shims and withdraw
the end housing, leaving the brush gear on the
commutator. Remove the thin metal washer
from the commutator end of the armature.
6. At this stage of disassembly inspect the
brushes and commutator. Check for sticking
brushes. If necessary, clean brushes and
brush channels with a petrol moistened cloth.
Check brushes for wear. If worn below the
minimum length specified, of 7.00mm, it will be
necessary to replace the complete starter
motor.

NOTE: The brushes are not serviced separately..

They are spot welded into position and not
intended to be replaced during the starter motors
service life.

7. Withdraw the motor casing from the armature

and drive end bracket.
8. Withdraw the drive engagement lever pivot pin
from the drive end housing.
9. Remove the drive assembly and inner plate
retaining snap ring from the armature shaft by
driving the securing thrust collar squarely off
the snap ring with a suitable diameter tube and
then levering the snap ring from the groove.
10. Withdraw the armature and drive assembly.

RE--ASSEMBLY

1. Re--assembly of the starting motor follows the

disassembly procedure in reverse.
Prior to installation, the armature end play must be
checked and the starting motor no load function
must be tested.

Checking the Armature End Play:

1. Secure the starting motor in a vice equipped

with soft jaws and attach a dial indicator to the
drive end housing flange. Locate the dial
indicator pointer on the end of the armature
shaft.
2. Lever the armature fully forward and zero the
dial indicator. Lever the shaft fully rearwards
and record the gauge reading.
3. The gauge reading should not exceed 0.4mm
(0.015in). If the reading is greater, inspect the
armature assembly and the brush end plate
assembly for wear. Replace worn components
as required and recheck the end play.

604.55.041.00 - 01 - 1998
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Starting Motor No--Load Test:

NOTE: A fully charged battery and a battery starter

tester (high rate discharge tester) with a carbon pile
(variable load resistor) should be used to perform
this test.

1. Secure the starting motor in a vice equipped

with soft jaws.

2. Connect the battery negative cable (4) to the

starting motor mounting flange.

3. Connect a short jumper lead (6) between the

solenoid battery and solenoid switch terminals. 10

4. Connect a voltmeter (3) positive lead to the

battery positive terminal, the voltmeter
negative lead to the battery negative terminal,
the ammeter (1) positive lead to the battery
positive terminal and the ammeter negative
lead to the solenoid battery or starting motor
terminal.

5. Hold a hand tachometer (5) on the end of the

armature shaft. Actuate the starting motor by
adjusting the carbon pile (2) to give 11.7 volts.
When the armature rotates between 7500 and
8500 rev/min. the maximum current draw
should not exceed 160 amperes.

6. If the starting motor does not perform to

specification, check for grounded field coils, a
rubbing armature or a distorted armature shaft.

BENCH TESTS

Armature
1. The commutator face should be clean and free
from burnt spots. If necessary remove any
burnt spots using fine glass paper, not emery
cloth. Finally clean the commutator with a
petrol moistened cloth.
2. If it is necessary to skim the commutator
ensure the diameter is not reduced below the
minimum specified diameter of 42.5mm.
Following skimming the commutator should be
polished with a fine glass paper and then wiped
clean with a petrol moistened cloth.
NOTE: Do not cut into the commutator metal when
recutting insulation slots.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 11

3. Armature insulation can be checked by

connecting an ohmmeter between the
commutator segments and the armature shaft.
There should be an infinity reading, i.e, no
continuity.

4. To test the armature for short circuits it is

necessary to use suitable armature testing
equipment, the only alternative is to check the
armature by substitution.

5. If there is evidence that the armature

circumference has been in contact with the
pole pieces, then the armature bearings are
probably excessively worn. First check that the
11
pole pieces are tight and that the armature runs
true in a lathe, then if necessary renew the
armature bearings.

Field Coils

1. To test the insulation of the field coils connect

an ohmmeter in turn between each of the field
winding brushes and a clean unpainted part of
the housing. There should be no reading, i.e,
no continuity.

2. To test the field winding continuity connect an

ohmmeter in turn between each of the field
winding brushes and the main feed terminal
(thick braided wire). A reading of 1 M" should
be indicated.

3. If a fault is indicated in the field windings it will

be necessary to replace the complete field 12
coils and housing assembly.

Bearing Bushes

1. Inspect the bushes in the brush end plate

assembly and pinion drive end housing for
wear. Install the armature shaft and observe

the free play, replace bushes where free play

appears excessive. Inspect the field poles for
signs of rubbing by the armature which may
also have been caused by worn bushes.
Drive Pinion Assembly
1. Check the operation of the roller clutch. The
pinion should rotate clockwise only. If the
pinion is stuck or rotates in both directions, or if
the pinion teeth are damaged install a new
drive assembly.

If damaged pinion teeth are evident, check the fly-

wheel ring gear teeth as described in Section 10,
Engine Systems.

604.55.041.00 - 01 - 1998
12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- Charging System

CONTENTS

Section Description Page

55 000 SPECIFICATIONS

Alternator Type
A127--55 A127--1R

Polarity Negative Ground

Nominal Voltage 12.0 v
Maximum Rev/Min. 15,000 18000
Maximum Output 55 Amps 100 Amps
Regulator Controlled Voltage 13.6 -- 14.4 v
Rotor Field Winding Resistance 2.9! 2.6 !
Stator Field Winding Resistance 0.2! 0.075 !
New Brush Length 20.0 mm
Minimum Brush Length 5.0 mm
Brush Spring Pressure 1.3--2.7 N (4.7--9.8 oz)

TORQUE SPECIFICATIONS

lbf.ft Nm

Alternator Through Bolts 4.0 5.5

Pulley Retaining Nut 52.0 70
Rectifier Attaching Screws 3.0 4.0
Regulator and Brushbox Screws 2.0 2.7
Terminal Nuts 2.0 2.7

604.55.041.00 - 01 - 1998
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Description and Operation

Magnet Marelli (Lucas) A127 type alternators are

fitted to all models. Used in 55 Amp form with an
external cooling fan and in 100 Amp form with an
internal cooling fan. The alternator is mounted at
the front of the engine and is driven from a
crankshaft pulley via a ‘poly vee’ drive belt. The
alternators feature integral regulators.

100 Amp Alternator

1. Earth (Ground) Connection
2. Engine Speed Sensor Connection (W Terminal)
3. Warning Lamp (D+ terminal)
4. Output Connection (B+ Terminal)
5. Protective Terminal Sleeve

5 3 4
55 Amp Alternator
1. Earth (Ground) Connection
2. Engine Speed Sensor Connection (W Terminal) 2
3. Warning Lamp (D+ terminal)
4. Output Connection (B+ Terminal)
5. Protective Terminal Sleeve

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 3

1
7 8 9
6

A
B+
B
D+

W
C + 2

--
3

5 4

Alternator Charging Circuit 3

A To Starter Motor 1. Starter Solenoid 6. Stator Output Windings (55 Amp
B To Starter Relay 2. Battery Alternator)
C Speed Sensor Terminal to: 3. Rotor Field Winding 7. Rectifier Pack
Diagnostic Plug, to Module 4. Regulator 8. Charge Indicator Lamp
Instrument Cluster and 5. Alternator Frame 9. Key Start Switch
Transmission/EDC Processor.

Alternator Operation This direct current is fed back to supplement the

current flowing through the rotor field winding.

With reference to Figure 3.

This action results in an ever increasing magnetic
influence of the rotor along with an associated rapid
When the key start switch is turned on a small cur- rise in generated output current and voltage.
rent flows from the battery through the rotor field
wiring. The circuit is made via the charge indicator
warning lamp, alternator terminal ‘D+’ the rotor field During the rise in generated output voltage (re-
winding, the alternator regulator and ground. flected at the ‘D+’ terminal) the brilliance of the
warning lamp is reduced and when the voltage at
the ‘D+’ terminal equates to that at the battery side
At this stage the warning light is illuminated and the of the warning light the lamp is extinquished.
rotor partially magnetised.

The voltage continues to rise until the predeter-

When the engine is started and the partially mag- mined regulated voltage level is reached.
netised rotor revolves within the stator windings a
3--phase alternating current is generated. A con-
stant portion of the generated current is converted In the event of drive belt breakage the voltage will
to direct current by the three field diodes incorpo- not build up within the alternator and so the charge
rated in the rectifier pack. indicator light will remain on to indicate failure.

604.55.041.00 - 01 - 1998
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Fan Belt Tensioner 4

A. Fan Belt with Air Conditioning B. Fan Belt less Air Conditioning

1. Air Conditioning Compressor (optional) 6. Water Pump Pulley

2. Idler Pulley only with (Air Conditioning) 7. Alternator
3. Crankshaft Pulley 8. Torque Wrench
4. Tensioner Assembly 9. Tensioner Attaching Bolt
5. Idler Pulley

SYSTEM TESTING AND FAULT FINDING

Service Precautions Preliminary Checks
To avoid damage to the components of the
Prior to electrical testing thoroughly inspect the
alternator charging system, service precautions
charging and electrical system.
must be observed as follows:
Check all leads and connections for continuity and
" NEVER make or break any of the charging tightness.
circuit connections, including the battery, when
the engine is running. 1. Check the battery
" NEVER short any of the charging components Using a hydrometer check the individual battery
to ground. cells. The battery should be at least 70% charged
and in good condition.
" ALWAYS disconnect the battery ground cable
(negative) when charging the battery on the 2. Check the drive belt
tractor using a battery charger.
Inspect the alternator drive belt and pulley,
" ALWAYS observe correct polarity when ensuring that both are clean, free from oil and
installing the battery or using a slave battery to grease and in good condition.
start the engine. The alternator drive belt is automatically tensioned
by a spring tensioner mounted at the front of the
CONNECT POSITIVE TO POSITIVE AND engine, shown in Figure 4. If the the belt tension is
NEGATIVE TO NEGATIVE
suspect, check the tensioner assembly as follows:

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 5

Fan Belt Tensioner Removal If the warning lamp is not fully illuminated check the
bulb. If the bulb is not the cause of the fault carry out
the Alternator wiring connections test as detailed
1. The fan belt should be removed in the following under ‘initial tests’ in this section.
manner. Place a lever with 1/2 inch square
drive attachment into the 1/2 inch square hole If the warning lamp is illuminated start the engine
of the tensioner arm and rotate the lever and run above idling speed. The lamp should go
clockwise. Remove the fan belt from the pulley out.
and allow the tensioner to return to its
untensioned position once the belt has been If the lamp does not go out, stop the engine and
removed. remove the wire from the D+ terminal. If the lamp
now goes out a faulty alternator component is
2. Remove the tensioner from the pump by indicated. Conduct the ‘Alternator components
loosening and removing the centre attaching tests’ as detailed in this section.
bolt, item 6 Figure 4.
If the warning lamp remains illuminated, check for a
short circuit to earth (ground) between the ‘D+’
cable end and the warning lamp.
Inspection and Repair
INITIAL TESTS
1. Checking of the tensioner assembly operation
should be carried out, with the tensioner
assembly still attached to the front plate fuel The initial tests may be performed without
injection pump gear cover. To check the spring removing any of the charging circuit components
load, place a ‘‘break back” torque bar pre--set from the tractor and enable the following items to
to, 52 -- 63 lbf. ft (70 -- 85 Nm) (7.1 -- be checked:
8.7 kgf.m), into the pulley arm 1/2 inch squre
drive hole. Raise the lever up through an arc of " Alternator wire connections
20# maximum. If the torque bar does not
‘‘break” within the range a new tensioner
assembly is required. " Alternator charging current and controlled
voltage
2. Ensure the tensioner pulley rotates freely by
hand. If not replace with new parts. " Alternator charging circuit volt drops

" Alternator maximum output performance

Re--Assembly
Test equipment required:
1. Fit a new pulley to the assembly if required,
and torque the attaching bolt to, 34.5 --
44 lbf.ft (46.5 -- 60 Nm), (4.7 -- 6.1 kgf.m) " Voltmeter (0--30 volts moving coil type

2. To re--assemble the arm assembly, position " Millivoltmeter (0--1 volt)

the tensioner on to the front plate fuel injection
pump gear cover, fit the mounting bolt through
the assembly, and torque the bolt to, 34.5 -- " Ammeter (0--110 Amperes moving coil type)
44 lbf.ft (46.5 -- 60 Nm), (4.7 -- 6.1 kgf.m).
" 1.5 Ohm 110 Amperes variable load resistor
3. Refitment of the fan belt is the reverse of the
removal procedure, but ensure the ‘‘Poly V’’ NOTE: Most commercial test equipment incorpo-
belt, is positioned correctly onto all of the rates several testing devices within a single unit .
pulleys.
Use such equipment in accordance with the manu-
facturers instructions.

3. Check the Warning Lamp 1. Alternator Wiring Connections Test

Turn on the key start switch and check that the With reference to Figure 5.
warning lamp is fully illuminated.

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

1. Disconnect the battery

4
2. Disconnect the B+(2) and D+(3) terminals from 1
the alternator.
+ V --
3. Reconnect the battery and turn the key start on
but do not start the engine. Connect a
3
voltmeter(4) between each terminal and earth
(ground), (1). Battery voltage should be
registered.

If battery voltage is not registered a continuity fault

in the external cable circuitry must be traced and
remedied, refer to the circuit diagram shown in 2
Figure 3.
5
4. Connect the D+ terminal, warning lamp
(brown/yellow) wire, to earth (ground). The
warning lamp should illuminate.

5. Disconnect the battery and reconnect the

removed alternator cable connections to the
alternator.

NOTE: If the warning lamp fails to illuminate when

the cable is reconnected to the alternator, a fault is
indicated in the alternator regulator or rotor circuits.
Ensure that the D+ terminal is clean and then con-
duct the alternator component tests as detailed in
this section.

2. Charging Current And Controlled Voltage

Tests

With reference to Figure 6.

1. Ensure all tractor electrical components are 4

switched off and the key start switch is in the
‘off’ position. 3
2. Disconnect the battery negative terminal and 1
disconnect the B+ terminal(4) of the alternator.
-- + -- +
3. Connect an ammeter(1), between the
removed (brown) cable(3) and the B+ 2
alternator terminal. V A
6
4. Connect a voltmeter(2) between the alternator
B+ terminal and earth (ground)
5. Reconnect the battery. Start and run the
engine at 2000 rev/min. and observe the
ammeter and voltmeter readings.
The voltmeter should register in excess of battery
voltage and when the ammeter reading falls below
10 Amperes the voltmeter reading should stabilise
at 13.6--14.4 volts.
If the voltmeter reading exceeds 14.4 volts the
alternator regulator must be replaced as described
in this section. (when a new regulator has been
installed conduct tests 4 and 5).

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 7

If the voltmeter reading is below 13.6 volts a faulty

alternator component or a high resistance fault in
the external connections of the charging system is
indicated.

If the ammeter registers zero amperes a faulty

alternator component is indicated. Turn off the
engine and conduct the ‘alternator component
tests’ as detailed in this chapter.

3. Charging Circuit Volt Drop Tests

4
(a) Insulated--Side Volt Drop Tests
-- +
With reference to Figure 7.
V 5
Ensure the key start switch is in the ‘off’ position. 1
1. Disconnect the battery negative cable and
disconnect the B+ cable(1) from the alternator -- 2
-- +
2. Connect a millivoltmeter(4) between the A
battery positive terminal and the B+ cable(5). 3
(Positive side to cable).
7
3. Securely connect an ammeter(2) between the
B+ terminal of the alternator and the B+ cable
(negative side to cable)
4. Reconnect the battery negative cable and
connect a variable load resistor(3), with the
slider in the minimum current draw position
(maximum resistance), across the battery
terminals.
5. Start the engine and increase the speed to
2000 rev/min.
6. Slowly increase the current loading of the
resistor (decrease resistance) until the
ammeter registers 55 or 100 Amperes
depending on alternator type.
7. Observe the millivoltmeter reading which
should not exceed 400 millivolts.

If the reading is in excess of 400 millivolts, a high

resistance fault is indicated in the external circuitry.

If the required alternator output cannot be achieved

and the millivoltmeter reading is less than 400 mil-
livolts, then a faulty alternator component is indi-
cated. Conduct the‘ alternator component tests’ as
detailed in this section.

8. Stop the engine.

604.55.041.00 - 01 - 1998
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

(b) Ground--Side Volt Drop Test

With reference to Figure 8.

9. Ensure the key start switch is in the ‘off’ -- +

position. V
5
10. The circuit is the same as that used in the 4 1
previous test except for the millivoltmeter(4)
which is now connected between the battery
-- 2
negative terminal and the alternator frame -- +
(negative side to frame).
A
3
NOTE: Ensure the variable load resistor(3) is in the
8
minimum current draw position (maximum resis-
tance).

11. Start the engine and increase the speed to

2000rev/min.

12. Slowly increase the current loading of the

resistor (decrease resistance) until the
ammeter(2) registers 55 or 100 Amperes
depending on alternator type.

13. Observe the voltmeter reading which should

not exceed 200 millivolts.

If the reading is in excess of 200 millivolts a high

resistance fault is indicated in the external circuitry.

If the required alternator output cannot be achieved

and the millivoltmeter reading is less than 200
millivolts then a faulty alternator component is
indicated. Conduct the alternator component tests
as detailed in this section.

14. Stop the engine.

4. Alternator Maximum Output

Performance Test
4
With reference to Figure 9.
-- +
1. Ensure the key start switch is in the ‘off’
position. V 5
1
2. Disconnect the battery negative cable and
disconnect the B+ cable (5) from the alternator. -- 2
-- +
3. Securely connect an ammeter(2) between the
A
B+ terminal(1) of the alternator and the B+
cable (negative side to cable). 3

4. Connect a voltmeter(4) between the alternator 9

B+ terminal and earth (ground).

5. Reconnect the battery, start and increase the

engine speed to 2000 rev/min.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 9

6. Slowly increase the the current loading of the

resistor(3) (decrease resistance) until the
ammeter registers either 55 or 100 Amperes
depending on alternator type.

7. Observe the voltmeter reading which should

not fall below 13.6 volts

If the reading falls below 13.6 volts a faulty

alternator component is indicated. Conduct the
‘alternator component tests’ as detailed in this
section.

ALTERNATOR COMPONENT TESTS

The component tests which should only be
conducted if the INITIAL TESTS have indicated a
faulty alternator component, will enable the
following items to be checked:
" Regulator
" Rotor Field Winding Continuity
" Brushes and Springs and Rotor Slip Rings
NOTE: The component tests detailed previously
may be performed with the alternator installed on
the tractor. Testing of the other alternator compo-
nents will necessitate removal of the alternator
from the tractor. Refer to the ‘Overhaul’ section of
this Chapter.

IMPORTANT: Prior to removal of the alternator ca-

bles from the alternator ensure that the key start
switch is in the ‘off’ position and the battery nega-
tive cable is disconnected.
Test equipment required:
" 12 volt battery
" Multimeter
" 2.2 Watt Test Lamp

1. Regulator and Rotor Field Circuit Test

With reference to Figure 10. --

1. Disconnect all of the alternator cables.

2. Connect a 12 volt battery and a 2.2 Watt test

lamp(2) in series between the D+(1) and the 2
alternator frame (negative side to frame).

3. The test lamp should illuminate.

If the test lamp is not illuminated a fault is indicated

in the rotor circuit. Check brushes, slip rings and 1
continuity of rotor field windings.
10
If examination indicates these parts to be
satisfactory the regulator may be suspect.

604.55.041.00 - 01 - 1998
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

2. Rotor Field Winding Continuity Test

With reference to Figure 11

1. Remove the regulator and brushbox assembly
as described in this chapter.

2. Connect an ohmmeter(3) between the two slip

rings(2). The resistance should read 2.6 ohms
at 20#C.

If the resistance is outside of the specification

renew the rotor(1) as detailed in the following
overhaul section.

11
3. Brushes--and--Springs and Rotor Slip
Rings
5 mm
1. Remove the regulator and brushbox assembly
as described in this Chapter.
2. Ensure the brushes and slip rings are clean
and check for freedom of movement of the
brushes in the brushbox moulding.
3. Check the brush spring pressure with a push
type spring gauge and record the spring
pressure when the brush end face is flush with
the moulding. Install a new regulator and
brushbox assembly if the pressure is less than
specified.
12
If the visible length of the brushes(1) in the free
position is less than 0.25 in. (5mm) this is a
probable cause of open circuit in the field circuit
and the regulator and brushbox assembly should
be renewed, Figure 12.

NOTE: The brushes are an integral part of the

regulator and brushbox assembly and cannot be
replaced as individual items.

55 301 ALTERNATOR OVERHAUL AND

COMPONENT TESTING
Alternator Removal
With reference to Figure 13
1. Disconnect the battery negative cable.
2. Disconnect the four cables from the rear of the
alternator.
3. Remove the alternator drive belt in the
following manner. Place a lever with socket
attachment, onto the tensioner retaining bolt
and gently lever the tensioner up, Figure 4.
Remove the fan belt from the pulley, and allow 13
the tensioner to return to its untensioned
position once the belt has been removed.
4. Remove the alternator arm(2) and the lower
mounting through bolts and remove the
alternator(1) from the engine bracket(3).

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 11

100 Amp Alternator Components 14

1. Rectifier and Housing Assembly 4. Stator and Housing Assembly 7. Regulator and Brushbox
2. Pulley Retaining Nut 5. Rotor Assembly Assembly
3. Spacer 6. End Cover

Disassembly -- 100 Amp Alternator 3. Using a suitable soldering iron, unsolder the six
wires from the stator to rectifier.

With reference to Figure 14 4. Remove the three nuts securing the two halves
of the outer casing. Mark each half of the
casing to aid reassembly and carefully pull the
casing apart, it may be necessary to gently tap
1. Remove the three nuts securing the plastic end the casing on the mounting lugs.
cover.

5. Remove the nut securing the pulley to the rotor

2. Remove the nut securing the blue wire to the shaft and withdraw the rotor from the casing.
warning lamp terminal and disconnect the
wire. Remove the two bolts and two nuts
securing the regulator and brushbox
6. It is not necessary to remove the rectifier from
assembly, withdraw the assembly from the
the casing as these are serviced as one unit.
alternator.

604.55.041.00 - 01 - 1998
12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

55 Amp Alternator Components 15

1. Rectifier assembly 5. Front End Housing 8. Regulator and Brushbox
2. Pulley Retaining Nut 6. Stator assembly
3. pulley 7. Rotor 9. Rear End Housing
4. Cooling Fan

Disassembly -- 55 Amp Alternator 6. Gently tap the rear face of the alternator front
end bracket to separate the front end bracket
and rotor assembly from the rear end bracket,
With reference to Figure 15. stator and rectifier assembly.

1. Remove the four nuts securing the terminal

7. Remove the nuts, washers and insulators from
block to the alternator.
the stud terminals on the alternator rear end
bracket and the two rectifier retaining screws.
2. Remove the nut from the temperature sensor Remove the stator and rectifier from the rear
terminal block. end bracket.

3. Remove the three securing bolts and withdraw 8. Unsolder the stator leads from the tags on the
the regulator/brushbox assembly. rectifier, using a pair of pliers as a heat sink to
prevent the diodes from overheating.
4. Unscrew and remove the remaining three nuts
from the alternator through bolts. With a soft
mallet tap the threaded end of the through bolts 9. Remove the nut, washer, pulley, fan and
to release the spline at the hexagon head end. spacer from the rotor shaft.

5. Mark the alternator front end bracket, stator

10. Press the rotor shaft out of the front end
and rear end bracket to ensure correct
bracket bearing.
alignment on reassembly.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 13

COMPONENT TEST

Rectifier Assembly -- Diode Testing 100 Amp

Alternator

With reference to Figure 16.

1. Test each of the nine diodes separately, using a
multimeter with a diode check facility or a
multimeter set on the resistance scale.

16
2. Connect one test lead onto the lower plate(3)
and the other to the diode pin(1).
On a multimeter(2) with the diode check
facility, note if a reading of 0.49 (volts) is
shown. Reverse the test lead connections.
The meter should indicate 0.49 (volts) during
one half of the test and 0 volts with the leads
reversed. Repeat this test on all nine diodes. If
any one diode fails this test it will be necessary
to replace the rectifier and housing assembly.

3. Where only an ohmmeter is available repeat

the above test observing the following results,
0 ohms with leads in one direction and when
the test leads are reversed a reading of
between 900--1000K!$ again if any one diode
fails this test it will be necessary to replace the
rectifier and housing assembly%

Rectifier Assembly -- Positive / Negative

Diode Testing 55 Amp Alternator

With reference to Figure 17. Test each of the six

diodes separately as follows:

1. Connect a multimeter(2) in series with one of

the diodes. One test lead is applied to the diode
connecting pin(1) and the other lead to the
plate into which the diode is mounted.

2. Note the resistance shown on the multimeter.

Reverse the test lead connections.

3. The multimeter should indicate an open circuit

(infinity ohms) during one half of the test only. If 17
any one diode fails this test the complete
rectifier will need replacing.

604.55.041.00 - 01 - 1998
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Rectifier Assembly -- Field Diode Testing 55

Amp Alternator

With reference to Figure 18. Test each field diode

separately as follows:

1. Connect a multimeter(2) in series with the field

diode module. Apply the negative test lead to
the D+ terminal connection(1) and the other
lead in turn to each of the field diode
connections(3).

2. Note the resistance shown on the multimeter.

Reverse the test lead connections.

3. The multimeter should indicate an open circuit 18

(infinity ohms) during one half of the test only. If
any one diode fails this test the complete
rectifier will need replacing.

Rectifier Insulation 100 Amp Alternator

With reference to Figure 19.

1. Check the insulation of the rectifier to the

casing. With an ohmmeter (2), connect the test
leads between the alternator casing(3) and the
positive plate of the diodes(1). An infinity
reading should be displayed, therefore
indicating an open circuit. If a resistance of any
kind is indicated, i.e, a short circuit, the rectifier
and housing assembly should be replaced.

Stator Test -- Winding Continuity

100 Amp Alternator Figure 1 1

With reference to Figure 20.

1. Connect the ohmmeter(2) test leads between

A
the pairs of wires, A, B and C. There should be
a small resistance of 0.1!, between each pair B
of wires. If a resistance higher than this is
C
registered it will indicate a possible break -- +
within the winding, i.e, an open circuit. A lower
reading, for example 0.0! will indicate a short
circuit within the winding. If any one of the three !
pairs of wires fail the test a new stator(1) and 2
housing assembly will be required.
20

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 15

Stator Test -- Winding Continuity

55 Amp Alternator 1

With reference to Figure 21

1. Connect the ohmmeter(3) test leads between A

the A, B and C wires(2). There should be a B
small resistance of 0.1!, between each of the
wires. If a resistance higher than this is C
registered it will indicate a possible break -- +
within the winding, i.e, an open circuit. A lower
reading, for example 0.0! will indicate a short !
circuit within the winding. If the test proves 3 2
unsatisfactory a new stator(1) and housing
assembly will be required. 21

Stator Test -- Insulation

100 Amp Alternator

With reference to Figure 22.

1. Check the insulation of each pair of windings to

each other and then each pair to the alternator
casing. There should be no continuity between
the three pairs of windings and no continuity to
the casing. If any ohmmeter(2) reading other -- +
than open circuit is indicated in any test it will be
necessary to replace the stator(1) and housing ! 1
assembly. 2
22
Stator Test -- Insulation
55 Amp Alternator 1

With reference to Figure 23

1. Check the insulation of each winding to the

alternator casing. There should be no A
continuity between the winding and the casing.
B
If any ohmmeter(2) reading other than open
circuit is indicated it will be necessary to C
replace the stator(1) assembly. -- +

Rotor Test ! 2

Prior to performing component tests on the rotor 23

the following slip ring inspection should be carried
out.

1. Ensure the slip rings are clean and smooth. If

necessary the slip rings may be cleaned with a
petrol moistened cloth. If the slip rings are
burnt and require re--finishing use very fine
glass paper (not emery cloth) and wipe clean.

NOTE: Ensure the re--finishing glass paper is suffi-

ciently fine to produce a highly polished slip ring
surface otherwise excessive brush wear will occur.

2. If the slip rings are excessively worn a new

rotor must be installed.

604.55.041.00 - 01 - 1998
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Rotor Field winding Continuity

with reference to Figure 24

1. Connect an ohmmeter(3) between the two slip

rings(2). The resistance should read 2.6 ohms
at 20#C.

If the resistance is outside of the specification

renew the rotor(1).

24
Rotor Field Winding Insulation

With reference to Figure 25.

1. Using an ohmmeter(3) test between each of

the slip rings(2) and the rotor poles(1). An
infinity reading should be indicated in each
case. If any resistance reading is indicated the
rotor assembly must be replaced.

25
INSPECTION AND REPAIR

1. Inspect the rotor poles and stator for signs of

rubbing. Areas of rubbing indicates possible
worn bearings, misaligned housings or a bent
rotor assembly shaft.

NOTE: Both end bearings of the 100 Amp alterna-

tor and the front bearing of the 55 Amp alternator
are not serviced separately. It will be necessary to
either obtain a new rectifier and housing or stator
assembly to renew worn bearings.

26
2. Inspect the roller bearing(1) of the 55 Amp
alternator located in the rear (slip ring) end
bracket(2) for wear and damage

3. If bearing replacement is necessary support

the housing (rear end bracket) and using a
suitable size mandrel carefully drive out the
bearing, Figure 26.

4. Clean and examine all components.

5. Press the new bearing(2) into the housing(1).

The bearing should be positioned .020--.028in
(0.50--0.70mm) proud of the inner face of the
bearing boss as shown at item (3), Figure 27.
27

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 17

RE--ASSEMBLY

1. Re--assembly of the alternator follows the

disassembly procedure in reverse.

On reassembly of the 55 Amp alternator observe

the following:

" To avoid misalignment of the end brackets,

install the stator assembly in the drive end
bracket then assemble the slip ring end
bracket to the stator laminations.

INSTALLATION

1. Installation of the alternator is the removal

procedure in reverse.

On installation observe the following:

" Ensure the battery ground (negative) cable is

disconnected from the battery when installing
the alternator.

" Adjust the alternator drive belt as previously

described in this Chapter.

604.55.041.00 - 01 - 1998
18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

NOTES

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 7 -- BATTERY

CONTENTS
Section Description Page

55 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 300 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Common Causes of Battery Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

55 000 SPECIFICATIONS

Standard
Capacity (Ampere hour at 20 hour rate) 107

Cold Cranking Ampere Rating 800

Voltage 12

Cells 6

Ground Terminal Negative

55 000 DESCRIPTION AND OPERATION ! To furnish current when the electrical demands
exceed the alternator output.

All tractor models feature one 12 volt, negative ! To support quiescent loads from radio and
ground, ‘maintenance free’ lead calcium (Pb--Ca) micro processor memory.
type batteries, of six cell construction.
The battery is constructed in such a manner that
NOTE: ‘Maintenance Free’ means that under nor- each cell contains positive and negative plates
mal charging conditions the battery does not loose placed alternatively next to each other. Each posi-
water from the electrolyte. Conditions that may tive plate is separated from a negative plate by a
cause water loss include prolonged charging above non--conducting porous envelope separator. If any
14.4volts where gassing occurs as it approaches of the positive plates should make contact with
full charge. This can be caused by a faulty charging negative plates within a cell, the cell will short circuit
system or boost/recovery charging equipment. and suffer irreparable damage. All of the positive
plates are welded to a bus--bar, forming a positive
The battery is mounted on the right hand side of the terminal and all of the negative plates are welded to
unit under the cab steps (with cab models) or under a similar bus--bar forming a negative terminal.
the platform on less cab models.
Each positive plate is composed of a lead grid with
The battery has four major functions: lead peroxide pasted into the grid openings. The
negative plates are composed of a lead grid with
! To provide a source of current for starting, spongy lead pasted into the grid openings.
lighting and instrumentation.
! To help control the voltage in the electrical The plates are submerged in a liquid electrolyte
system. solution of diluted sulphuric acid.

604.55.041.00 - 01 - 1998
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

REMOVAL AND INSTALLATION OP. 55 300

Top Battery

1. Lift up step (with cab) re--fit pin.

2. Remove battery tray lock pin and swing battery

tray out.

3. Remove cover.

4. Remove battery securing strap. 1

5. Remove earth clamp and positive lead from

the battery.

6. Using the lifting handles remove battery.

Installation

1. Installation of the battery is the removal

procedure in reverse, observing the following
points:

! Ensure that the battery is clean and dry and

that the vent caps are fully installed. Smear the
terminals with petroleum jelly (vaseline or
equivalent), do not use conventional
lubricating greases as these can promote
electrolytic corrosion.

! Ensure the battery tray and clamps are clean

and free from stones or small objects which
may puncture the battery casing.

! Ensure that the battery terminal polarity is

correct and that the terminal connections are
sufficiently tight, but not overtightened.

! The radio, if fitted, will lose its stored

information and will require re--programming. It
should be noted that on models with electronic
instrument panel and micro--processors, that
these components will not lose their memories,
i.e, electronic draft control and transmission
calibrations will not be affected.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 3

BATTERY MAINTENANCE AND TESTS Table 1

Specific Gravity Efficiency of a Fully

Temperature Charged Battery
The specific gravity of the battery electrolyte
indicates the state of charge. Fully charged the 25.0"C (77.0"F) 100%
specific gravity of the electrolyte is 1.280 minimum --4.5"C (23.9"F) 82%
at 25"C. --24.0"C (--11.2"F) 64%
--27.5"C (--17.5"F) 58%
Alternatively the approximate state of charge can
--31.0"C (--23.8"C) 50%
be measured by using an accurate digital volt
--34.5"C (--30.1"C) 40%
meter (+/-- 0.01V) as follows:--
--37.5"C (--35.5"C) 33%
Less than 10.5V Battery un--serviceable*
Less than 11.8V Battery discharged
Less than 12.3V Battery 1/2 charged Maximum battery life will be obtained if the correct
Better than 12.6V Battery fully charged care and periodic inspection is given. It is
important that output capacity should not be
* See note under tests for possible recovery of a exceeded by constant and excessive overloading
mildly sulphated battery. and that charging requirements are maintained.

Servicing The Battery

WARNING
Battery voltage to be taken with the battery
unloaded and:-- Batteries contain sulphuric acid and during
A) After the battery has rested unloaded for at least charging generate a highly explosive mixture of
4 hours. hydrogen and oxygen gases.
B) If the vehicle has recently run or battery has ! Never use equipment that generates flames
recently been charged, switch on headlamps for 2 or sparks in order to control electrolyte level
minutes.
! Do not remove the battery cover plugs without
protection for eyes and hands.

When a battery discharges, sulphuric acid in the When servicing a battery the following steps
electrolyte combines chemically with the plates should be observed:
and this action lowers the specific gravity of the
solution. 1. Maintain the electrolyte to the recommended
level of 17 mm (0.67 in.) above the plates. If
this is not observed the acid will reach a high
concentration that will damage the separators
A battery hydrometer will determine the specific and impair the performance of the plates.
gravity of the electrolyte in a cell and the amount of
unused sulphuric acid in the solution is a measure
of the degree of charge of that cell. 2. Use only distilled or de--mineralised water, do
not overfill and never use tap water or water
from a rain barrel or other source.

The lower the temperature at which a battery is 3. Always keep the battery at least 75% charged
required to operate, the more necessary it is that otherwise the plates will become sulphated
the battery is maintained in a fully charged and loss of efficiency will result with possible
condition. For example a battery with a low specific damage from freezing at low temperatures.
gravity of 1.225 at 27"C (80"F) will operate the
starting motor at warm ambient temperatures but
may not, due to lower battery efficiency at a low 4. Avoid overcharging the battery as excessive
temperature. charging will create high internal heat that will
cause plate grid deterioration and produce
water loss.

Table 1 shows the effect of temperature on the 5. When fast charging ensure the battery
efficiency of a typical battery. temperature does not exceed 50"C.

604.55.041.00 - 01 - 1998
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

6. Do not add sulphuric acid to a cell unless the 7. When using a fast or high rate of charge
electrolyte has been lost through spilling. carefully follow the manufacturers instructions.
Before replenishing ensure the solution is at High rate charging raises the temperature of
the correct specific gravity. A slow charge is the the electrolyte and unless the charger is
only method to be employed to fully charge a equipped with an automatic time or
battery. A high rate charger can be used to temperature device, the electrolyte
quickly boost the battery capacity but this must temperature could exceed 50"C , which may
be followed by a slow charge rate to bring the cause violent battery gassing and damage to
battery to full capacity. internal components.

Dry Charged Batteries 8. Re--check the level of electrolyte in each cell

and add distilled water as necessary.
1. Remove the battery cell vent plugs.
2. Fill each cell to the recommended level with WARNING
electrolyte of 1.260 specific gravity.
When a battery is being charged an explosive gas
Dry charged batteries must be prepared for service is produced. Do not smoke or use an exposed
as follows: flame when checking the electrolyte level and
ensure the charger is switched off before
NOTE: The electrolyte must be diluted sulphuric connecting or disconnecting to avoid sparks which
acid preferably at a temperature of 21" --32"C could ignite the gas.
(70" --90"F).
3. After filling, allow the battery to stand for 15 Recharging Deeply Discharged Batteries
minutes then re--check the electrolyte level
and top up if necessary. The recommended method to recharge a
maintenance free Pb--Ca battery is to use a
4. Charge the battery for 4 hours at a rate of 5--8 constant voltage charger. For deeply discharged
amperes and check that all cells are gassing batteries a 48 hours charging period at 16volts is
freely. recommended, with current limitation, (47.5A for
5. Install the battery cell vent plugs. 107Ah).
This system is self regulating: high current is
delivered at the beginning (when battery voltage is
low), lower and lower current is then absorbed
when battery reaches full charge (and its voltage is
Charging The Battery high).
If only constant current chargers are available it is
Before charging a battery: recommended to use the current levels and times
shown Table 2 below. The figures are intended for
1. Thoroughly clean the battery casing and cell deeply discharged batteries. If the battery is only
covers with dilute ammonia or hot water and 50% discharged use one half of the time listed
clean the terminals. (slow charge programs). For other states of
discharge reduce proportionally the time of charge.
2. Check the level of the electrolyte in each cell Whenever possible use the slowest charge
and, if below plates, add distilled water to bring program to increase the battery’s life.
above plate level. If when charging the battery, violent gassing or
spewing of electrolyte occurs, or the battery case
feels hot (50"C or greater), reduce or temporarily
halt charging to avoid damaging the battery.
Normal (Top--up) Charging
Table 2 Battery Type
1. With a slow charger use a rate of 3 to 6
amperes for the time necessary to bring the
battery to full charge. This may take 36 hours 107Ah
or more if the battery is heavily discharged. A (800 cca)
severely sulphated battery might not accept a
charge. When the battery is fully charged the Slow Charge 25hrs at 5A
cells will gas freely and the specific gravity will Programs 12.5hrs at 10A
remain constant. Remove the charger after
three consecutive hydrometer readings taken Fast charge 7hrs at 18A
at hourly intervals indicate that the specific Program
gravity has stopped rising. (emergencies only)

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 5

Tests
Corrected Corrected
Before commencing battery tests check the battery Specific Specific Average
for clogged vents, corrosion, raised vent plugs or State of Gravity Gravity Battery
a cracked case. Charge @15"C @25"C Voltage
Test equipment required:
100% 1.295 1.287 12.76
1.253 1.246 12.52
! Hydrometer 75%
50% 1.217 1.210 12.30
25% 1.177 1.170 12.06
! Battery starter tester (High rate discharge 1.137 1.130
Discharged 11.84
tester)

! Thermometer
NOTE: Specific gravity should not vary more than
! Battery Charger 0.025 points between cells.

Specific Gravity: This test will determine the 4. If the specific gravity is 1.280 or more the
state of battery charge. battery is fully charged and in good operating
condition.
1. With the float in the vertical position take the 5. Should the corrected specific gravity be below
reading. 1.280, charge the battery and inspect the
charging system to determine the cause of the
2. Adjust the hydrometer reading for electrolyte low battery charge.
temperature variations by subtracting 4 points NOTE: If distilled water has recently been added
(0.004 specific gravity) for every 5.5"C (10"F) the battery should be recharged for a short period
below the temperature at which the otherwise accurate hydrometer readings will not be
hydrometer is calibrated and by adding 4 obtained.
points (0.004 specific gravity) for every 5.5"C If the battery has been charged under static
(10"F) above this temperature. conditions, denser electrolyte will accumulate at
the bottom of the cells. The battery should be
shaken periodically to mix the electrolyte, this will
The following examples are calculated using a improve the charge rate and provide a more
hydrometer calibrated at 30"C (86"F). accurate hydrometer reading when tested.

Performance Test: The performance test is to

determine if the battery has adequate capacity to
Example 1:
turn the engine. The voltage reading obtained is
Temperature below 30"C (86"F)
used to determine the battery condition. Prior to
Electrolyte temperature 19"C (66"F)
testing, ensure the electrolyte level is correct and
Hydrometer reading 1.270
the open circuit voltage is 12.5V or more. The
Subtract 11.0 x 0.004 0.008
battery may be tested on or off the tractor.
5.5
Corrected specific gravity = 1.262
1. Set the current control switch of the battery
starter tester (high rate discharge tester) to the
‘off’ position and the voltage selector switch
equal to, or slightly higher than, the rated
Example 2: battery voltage. Connect the tester positive
Temperature above 30"C (86"F) leads to the battery positive terminal and the
Electrolyte temperature 40"C (104"F) negative leads to the negative battery terminal.
Hydrometer reading 1.220
Add 10.0 x 0.004 0.007
5.5 2. Turn the current control knob until the ammeter
Corrected specific gravity = 1.227 reading is half the CCA rating of the battery
and take the voltage reading.

! If the reading is 9.6 volts or more after 15

3. Use the following table to determine the state seconds, the battery has an acceptable output
of charge. capacity and will readily accept a normal
charge.

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

! If however the reading is below 9.6 volts, the ! If the total voltage is over 15.5 volts the battery
battery is considered unsatisfactory for service is unsatisfactory and is probably sulphated or
and should be test charged as described worn out and should be replaced.
below.

NOTE: A mildly sulphated battery can be

recovered by using a multiple battery type charger,
with an open circuit upper voltage limit of 50 volts.
Owing to the high resistance of a sulphated battery,
it will primarily require a high voltage setting to
overcome the resistance of the sulphation. initially
CAUTION: Do not leave the high discharge load on there may be no visible acceptance of the charge.
the battery for periods longer than 15 seconds. After a few minutes of inactivity a small charge will
be apparent, followed by a rapid increase in the
charge rate. The charge rate must not exceed 14.0
amperes or the electrolyte temperature 50"C.
When the ampere rate has stabilised, reset the
volts until the charge rate is a steady 5 amperes.
Continue at this rate until the electrolyte specific
gravity stops rising at approximately 1.275--1.280
at 20"C (68"F), this can take up to 48 hours of
charging. Stand the battery for 24 hours and then
conduct the capacity test detailed previously.
Test Charging: This test is designed only for
batteries that have failed the previous capacity
test.

! If the total voltage is under 15.5 volts, test the

1. Attach the battery starter (high rate discharge specific gravity of each cell and re--charge the
tester) positive leads to the battery positive
battery to the following scale:
terminal and the negative leads to the battery
negative terminal.

2. Connect the battery charger positive lead to

the battery positive terminal and the negative
lead to the battery negative terminal. Specific Gravity Fast charge up to:

1.150 or less 60 minutes

3. Turn the charger timer past a ‘3 minutes’ 1.151 to 1.175 45 minutes

charge indication and then back to the ‘3
minutes’ mark. 1.176 to 1.200 30 minutes

1.201 to 1.225 15 minutes

(Slow charge only)

4. Set the charging rate as close as possible to 40

amperes.

NOTE: When battery problems are experienced

5. After 3 minutes at this fast charge take the the fan belt tension and the complete charging
voltmeter reading.
system should be checked.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 7

Common Causes of Battery Failures 5 Crystal growth occurs whenever batteries are
left discharged. High temperatures and
1 Internal open circuit. extended discharged periods increase this
condition. At room temperature after one week
2 Internal short circuit. the battery is unlikely to recover on the vehicle.
Recharge will require a higher constant
voltage. After 3 weeks the battery will have
3 Loss of electrolyte. suffered permanent degradation and the
procedure detailed previously for charging a
4 Separation of active materials from grids. ‘Deeply Discharged’ battery should be
followed.

5 Accumulation of sulphate crystals too large to

disperse.
When fully charged, batteries have a long shelf life.
The lead calcium type battery self discharges at
These failures are normally caused by the 3% per month. This means that it will take 16
following: months to drop to 50% charged. On the tractor the
1 Failure of inter cell components. quiescent load is about 50mA. To predict rundown
on a static vehicle this should be added as
approximately 8Ah per week.
2 Excessive crystal growth may puncture the
separators and cause short circuits.

3 Excessive over charging (charging system It is worth stressing that when cranking, if a battery
malfunction, boost/recovery techniques with starts to fade, it is beneficial to stop and allow two
high voltage, operation in very high
minutes for the battery to recover. The recovery
temperatures.
time should be increased as the temperature
decreases.
4 Freezing of electrolyte.
A fully charged battery does not freeze until
--65"C. A 50% charged battery freezes
between --17"C and --27"C. Fully discharged With the dual battery set up, an old battery should
electrolyte freezes at --3"C to --11"C. not be used with a new one. One battery will always
Excessively high boost charging and gassing fail first. If the battery has given the service life
will also cause separation of active materials expected, change both batteries. If one has failed
from the grids. Separation destroys the early, i.e, through manufacturing defect, then it is
chemical function of the battery. acceptable to replace just one battery.

604.55.041.00 - 01 - 1998
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

NOTES

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

SECTION 55 -- ELECTRICAL CIRCUITS

Chapter 8 -- Wiring Diagrams
CONTENTS

Description

Wiring diagram references

How to use the linear wiring diagrams

Symbols

Component identification and wiring diagram location key

Wire identification key

Electroshift and Dual Command System Diagrams

Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10--360

With cab Electroshift with EDC
With cab Dual Command with EDC
With cab Dual Command Less EDC

Circuit 1--A Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10--360

Less Cab Electroshift
Less Cab Dual Command

Circuit 1--B Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10--360

With Cab Synchro--Command

Circuit 1--C Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10--360

Less Cab Synchro--Command

Circuit 1--D Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10--360

Less Cab Econoshift

Circuit 2 Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . . 370--720

With cab Electroshift with EDC, part 1

Circuit 2--A Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . . 370--720
With cab Dual Command with EDC , part1

Circuit 2--B Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . . 370--720
With cab Dual Command Less EDC, part 1

Circuit 2-- C Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . . 370--720
Less Cab Electroshift, part 1

Circuit 2--D Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . . 370--720
Less Cab Dual Command, part 1

Circuit 3 Transmission and EDC Processor (C128 Black Connector) . . . . . . . . . . . . . . . . . . 730--1080

With cab, Electroshift and Dual Command with EDC, part 2

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Circuit 3--B Transmission and EDC (C128 Black Conncetor)
With cab, with Dual Command Less EDC, part 2 . . . . . . . . . . . . . . . . 730--1080

Circuit 3--C Transmission and EDC (C128 Black Conncetor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730--1080

Less Cab Electroshift, part 2
Less Cab Dual Command, part 2

Circuit 4 Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1090--1440

With cab, Electroshift with EDC, part 1

Circuit 4--A Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1090--1440
With cab, Dual Command With EDC, part 1

Circuit 4--B Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1090--1440
With cab, Dual Command Less EDC, part 1

Circuit 4--C Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1090--1440
Less Cab, Electroshift, part 1

Circuit 4--D Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1090--1440
Less Cab, Dual Command, part 1

Cicuit 5 Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1450--1800

With cab, Electroshift With EDC, part 2

Circuit 5--A Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1450--1800
With cab, Dual Command With EDC part 2

Circuit 5 B Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1450--1800

With cab, Dual Command Less EDC part 2

Circuit 5 C Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1450--1800

Less cab, Electroshift, part 2

Circuit 5 D Transmission and EDC Processor (C127 Red Connector) . . . . . . . . . . . . . . . . . . 1450--1800

Less cab, Dual Command, part 2

Circuit 6 EIC and AEIC Instrument Clusters and associated sensors (C079) . . . . . . . . . . 1810--2170
With cab Electroshift with EDC
With Cab Dual Command With EDC
With cab Dual Command Less EDC

Circuit 6--A AEIC and AIC Instrument Clusters and associated sensors (C079) . . . . . . . . . . 1810--2170
With Cab Synchro--Command

Circuit 6--B AEIC Instrument Cluster and associated sensors (C079) . . . . . . . . . . . . . . . . . . . 1810--2170
Less Cab Electroshift
Less Cab Dual Command

Circuit 6--C AEIC and AIC Instrument Cluster and associated sensors (C079) . . . . . . . . . . . 1810--2170
Less Cab Synchro--Command

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Circuit 6--D AIC Instrument Cluster and associated sensors (C079) . . . . . . . . . . . . . . . . . . . . 1810--2170
Less Cab Econoshift

Circuit 7 EIC and AEIC Instrument Clusters and associaited sensors (C080) . . . . . . . . . . 2180--2530
With Cab Electroshift With EDC

Circuit 7--A EIC and AEIC Instrument Clusters and associated sensors (C080) . . . . . . . . . . 2180--2530
With cab Dual Command with EDC

Circuit 7--B EIC and AEIC Instrument Clusters and associated sensors (C080) . . . . . . . . . . 2180--2530
With cab Dual Command Less EDC

Circuit 7--C AEIC Instrument Cluster and associated sensors (C080) . . . . . . . . . . . . . . . . . . . 2180--2530
Less cab Electroshift

Circuit 7--D AEIC and AIC Instrument Clusters and associated sensors (C080) . . . . . . . . . . 2180--2530
With cab Synchro--Command

Circuit 7--E AEIC and AIC Instrument Clusters and associated sensors (C080) . . . . . . . . . . 2180--2530
Less cab Dual--Command

Circuit 7--F AEIC and AIC Instrument Clusters and associated sensors (C080) . . . . . . . . . . 2180--2530
Less cab Synchro--Command

Circuit 7--G AIC Instrument Cluster and associated sensors (C080) . . . . . . . . . . . . . . . . . . . . 2180--2530
Less cab Econoshift

Circuit 8 EIC Instrument Clusters only (C081) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2540--2890

With cab Electroshift with EDC
With Cab Dual Command With EDC
With cab Dual Command Less EDC

Circuit 9 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900--3260

With cab Electroshift with EDC
With cab Dual Command with EDC
With cab Dual Command Less EDC

Circuit 9--A Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900--3260

With Cab Synchro--Command

Circuit 9--B Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900--3260

Less Cab Electroshift
Less Cab Dual Command

Circuit 9--C Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900--3260

Less Cab Synchro--Command

Circuit 9--D Four Wheel Drive and 16x4 Dual Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2900--3260
Less Cab Econoshift

Circuit 10 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270--3620

With cab Electroshift with EDC
With cab Dual Command with EDC
With cab Dual Command Less EDC

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Circuit 10--A Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270--3620
With Cab Synchro--Command

Circuit 10--B Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270--3620

Less Cab Electroshift
Less Cab Dual Comand

Circuit 10--C Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270--3620

Less Cab Synchro--Command

Circuit 10--D Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270--3620

Less Cab Econoshift

Circuit 11 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3630--3990

With cab Electroshift with EDC
Less Cab Electroshift

Circuit 11--A Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3630--3990

With cab Dual Command with EDC
With cab Dual Command Less EDC
Less Cab Dual Command

Circuit 12 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000--4360

With cab Electroshift with EDC, part1
With cab Dual Command with EDC, part1

Circuit 12--A Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000--4360

With cab Dual Command Less EDC, part1

Circuit 12--B Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000--4360

Less cab Electroshift Less EDC
Less cab Dual Command Less EDC

Circuit 13 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4370--4730

With Cab Electroshift with EDC, part2
With cab Dual Command with EDC, part2

Circuit 13--A Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4370--4730

With cab Dual Command Less EDC, part2

Circuit 14 Indicator & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4740--5100

With cab Electroshift with EDC
With cab Dual Command with EDC
With cab Dual Command Less EDC

Circuit 14--A Indicator & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4740--5100

With Cab Synchro--Command

Circuit 14--B Indicator & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4740--5100

Circuit 19A--21A Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6220--7290

With Cab Synchro--Command

Circuit 19B--21B Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6220--7290

Less Cab Electroshift
Less Cab Dual Command
Less Cab Synchro--Command

Circuit 19C--21C Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6220--7290

Less Cab Econoshift

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

HOW TO USE THE LINEAR WIRING DIAGRAMS

The wiring diagrams have been drawn in a linear
style. This means that the complete TS Tractor
wiring has been drawn over a number of pages.

There are a number of guides to help assist in

reading and understanding the wiring diagrams.

1. Wiring diagram contents. All diagrams (1) are

located on the right hand page, A3 fold outs are
used on the larger circuits. The front page of the
A3 fold outs have the circuit description, and the
line reference range indicated. Located on the
left hand page (2) is the key of components used
(3) on the adjacent wiring diagram, (And brake
down of the function of the terminals of relevant
component). On the bottom of the page (4) is the
wire colour code chart, and in the left hand corner
(5) the line reference range it refers to.

2. Every component and connector has its own

reference number.

3. Every wire has a code assigned to it (1) this code

refers to its function, the code is not marked on
the actual wire. A key of all wire codes can be
found at the rear of this section letters (2), (3) and
(4) indicate the wire colour. The first letter (2)
indicates the main wire colour. The second letter
(3) indicates tracer wire colour, the third letter (4)
indicates the band colour, for example wire
reference (5) and number 57 is a earth wire,
letter (6) B indicates its a solid black wire.

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
4. Each component and connector pin appears
only once in the electrical drawings and has its
own location point on the page.

5. The wiring diagrams are drawn in sections.

However where a single component is used in a
number of circuits such as a processor or multi
function switch, it is drawn either on its own or on
the circuit which it influences the most.

6. The wiring is drawn between three lines two

across the top of the page and one at the bottom
of the page.

The upper most line (1) marked with +30 is the

constant live line.
Below the +30 line is the +15 (2) which is the
ignition key on live line.
On the lower part of the page (3) a line is marked
with numbers increasing by ten (10--20--30,
etc.). This is the line used to reference wires and
components.

7. In the first top left hand corner is the serial

number (1) of the machine that the drawing
applies to. If there is a change to the wiring, new
diagram is added and the serial number range it
applies to is indicated.

8. In the top right hand corner is the model type (1)

of the machine which the diagram applies to.

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

Example

The above drawing shows a basic circuit drawn over

two pages.

Power comes in from the ignition on live line +15

through fuse F3, which is located at point 230.

Power comes to switch S10. If the switch is operated,

power continues up and stops with an arrow (1) and a
number. The arrow indicates the wire continuing to
another page. The Number 780 refers to the line
reference where it appears on a new page. Note the
line reference directly below the wire being traced ie.
260. Following the line reference until 780 is found.
Using either the index or following the page
reference line. When 780 is located on the reference
line the number 260 will be observed at the top of the
page. Note the arrow points back to the previous part
of the circuit. From this point follow the wire down to
solenoid EV6. The diagram now indicates that power
goes to ground.

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

Symbols

Fuse

Relay

Elector--Valve/solenoid

Motor

Earth point

Sensor

Potentiometer

Lamp

Resistor

Speaker

Connector pin

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
UNIVERSAL SYMBOLS

Thermostart Roof Transmission

starting aid Horn beacon oil pressure
switch

P.T.O. solenoid
Alternator Radio
charge
FWD
engaged
Creeper solenoid
Turn signals gears switch
Fuel level
sender
Accessory
Front wind- socket
screen Slow or
Automatic wash/wipe
Fuel shut-off low setting
switch
solenoid
Implement
Rear wind- socket
Fast or high
screen setting
Engine oil wash/wipe
pressure switch switch
& sender
Ground %age
speed slip
Blower motor
Heater fan
Engine coolant
temperature
sender
Hitch raise
Differential solenoid
Air conditioner lock solenoid
compressor

Tractor lights
Rear axle Hitch lower
Air filter oil tempera- solenoid
blocked sensor ture switch

Headlamp

Parking Hazard Hitch height

brake switch warning switch limit (rear)
Work lamps

Stop Brake fluid Variable Remote

lamps level control valve

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
SYMBOL DRAWING DESCRIPTION
LOCATION

(A) PROCESSORS,
MODULES AND PANELS

A 1810--2890 ELECTRONIC INSTRUMENT CLUSTER

A001 370--1800 TRANSMISSION AND EDC PROCESSOR
A002 3850 GEAR SHIFT DISPLAY MODULE
A003 4470 EDC PANEL
A004 6500 RADIO

(B) SENSORS, SENDERS

AND POTENTIOMETERS

B1 2670 ENGINE OIL PRESSURE SENSOR

B2 1990 ENGINE COOLANT TEMPERATURE SENSOR
B3 2110 FUEL TANK SENDER
B4 2640 RADAR
B5 1230 AXLE SPEED SENSOR
B18 3840 CLUTCH PEDAL POTENTIOMETER
B6 4460 HEIGHT LIMIT POTENTIOMETER
B7 4460 SLIP LIMIT POTENTIOMETER
B8 4460 DROP RATE POTENTIOMETER
B9 4460 DRAFT/POSITION POTENTIOMETER
B10 4680 ROCKER SHAFT POTENTIOMETER
B11 4710 QUADRANT LEVER POTENTIOMETER
B12 4620 DRAFT PIN LEFT
B13 4650 DRAFT PIN RIGHT
B14 6510 TEMPERATURE CONTROL POTENTIOMETER
B15 6530 SPEAKER
B16 6470 SPEAKER
B17 6230 HORN

(C) SPECIAL CONNECTORS

C225 7130 SPLICE CONNECTOR

(E) MISCELLANEOUS

E1 6390 AIR CONDITIONING COMPRESSOR CLUTCH

E2 6610 INTERIOR LIGHT
E3 6830 CONSOLE LIGHT

(F) FUSES

F1 5130 HEAD LAMP MAIN 15A

F2 5180 HEAD LAMP DIP 15A
F3 5320 SIDE LAMP RH 15A
F4 5420 SIDE LAMP LH 15A
F5 5820 WORK LAMP FRONT LOW 10A
F6 5530 WORK LAMP REAR FENDER 15A
F7 5610 WORK LAMP FRONT AND REAR CAB ROOF 20A
F8 230 FUEL SHUT OFF SOLENOID 10A
F9 1910 GAUGES AND EXTERNAL SWITCHES 10A
F10 4760 HAZARD LIGHTS 15A

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
SYMBOL DRAWING DESCRIPTION
LOCATION
F11 4850 HORN, FLASHERS, CIGAR LIGHTER,
ROOF BEACON. 30A
F12 4020 EDC 10A
F13 1700 TRANSMISSION SOLENOIDS 15A
F14 1630 EDC 10A
F15 3210 STOP LAMPS, 4WD, DIFF. LOCK 15A
F16 6240 AIR CONDITIONING HEATER FAN 25A
F17 5960 WIPER WASHER, FRONT WIPER,
REAR WIPER CONSOLE LAMP 20A
F18 4750 TURN INDICATORS 10A
F19 340 THERMOSTART 25A
F20 1650 PROCESSOR ‘KEEP ALIVE MEMORY’ (KAM) 5A
F21 3300 PTO 5A
F22 6390 RADIO, IMPLEMENT SOCKET SWITCH AND
RELAY 5A
F23 6400 ACCESSORIES, INTERIOR LAMP, RADIO KAM,
EIC BUZZER. 20A
F24 7160 INTERIOR LIGHT 10A

(H) LAMP AND LIGHTS

H1 3580 PTO LAMP
H2 4450 EDC STATUS LAMP
H3 4480 SLIP LAMP
H4 4460 RAISE LAMP
H5 4460 LOWER LAMP
H6 4990 FRONT INDICATOR LAMP LH ISO
H7 5010 FRONT INDICATOR LAMP RH ISO
H8 4970 REAR INDICATOR LAMP LH ISO
H9 5030 REAR INDICATOR LAMP RH ISO
H10 5050 FRONT INDICATOR LAMP LH NASO
H11 5090 FRONT INDICATOR LAMP RH NASO
H12 5070 REAR INDICATOR LAMP LH NASO
H13 5100 REAR INDICATOR LAMP RH NASO
H14 5140 HEAD LAMP LH
H15 5170 HEAD LAMP RH
H16 5350 FRONT SIDE LAMP LH
H17 5380 FRONT SIDE LAMP RH
H18 5430 REAR BRAKE/TAIL LAMP LH
H19 5340 REAR BRAKE/TAIL LAMP RH
H20 5560 LICENCE PLATE LIGHT TOP RH
H21 5540 LICENCE PLATE LIGHT TOP LH
H22 5400 LICENCE PLATE LAMP LOWER
H23 5690 UPPER FRONT WORK LAMP LH
H24 5790 UPPER FRONT WORK LAMP RH
H25 5690 LOWER FRONT WORK LAMP LH
H26 5790 LOWER FRONT WORK LAMP RH
H27 5520 UPPER REAR WORK LAMP LH
H28 5580 UPPER REAR WORK LAMP RH
H29 5610 LOWER REAR WORK LAMP LH
H30 5630 LOWER REAR WORK LAMP RH

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
SYMBOL DRAWING DESCRIPTION
LOCATION

(G) CHARGING

G1 10 BATTERY
G2 100 ALTERNATOR

(K) RELAYS

K 6670 IMPLEMENT SOCKET RELAY

K1 80 IGNITION RELAY
K2 170 STARTER RELAY
K3 4780 FLASHER UNIT RELAY
KXI+XII 4940 FLASHER MODE RELAY
KA 3020 DIFF LOCK RELAY (12X12 ONLY)
KB 5820 FRONT WORK LAMP RELAY
KC 5530 REAR WORK LAMP RELAY
KD 5680 LOWER FRONT WORK LAMP RELAY
KE 5600 LOWER REAR WORK LAMP RELAY
KF 220 ENGINE SHUT DOWN RELAY
KG 3020 DIFF LOCK RELAY (12X12 ONLY)
KH 3030 FOUR WHEEL DRIVE LAMP RELAY (8X2 ONLY)
KV+VI 3460 PTO RELAY
KII 6390 ACCESSORY SOCKET RELAY
KIV 6950 REMOTE VALVE RELAY
KVII 330 THERMOSTART RELAY
KVIII 6000 INTERMITTENT FRONT WIPER RELAY
KIX 6070 INTERMITTENT REAR WIPER RELAY

(M) MOTORS

M1 50 STARTER MOTOR
M2 6030 FRONT WIPER MOTOR
M3 6100 REAR WIPER MOTOR
M4 5940 WASHER MOTOR
M5 6190 WASHER MOTOR
M6 6330 BLOWER MOTOR
M7 6920 AIR SEAT

(MF) MAXI FUSE

MF1 20 TO IGNITION RELAY AND SUPPLY TO

FUSE 9/14/15/16/17/18/21.
MF2 20 TO IGNITION SWITCH AND SUPPLYING
FUSES 8/10/11/12/13/20/22. AND
THERMOSTART MODULE FUSE 19
MF3 4860 TURN SWITCH AND SUPPLYING FUSES 1/2/3/4.
MF4 5530 WORK LAMPS FUSES 5/6/7.
MF5 6400 ACCESSORIES FUSES 23/24.
MF6 6720 40 AMP. IMPLEMENT SOCKET.

(P) CLOCKS

P1 6860 CLOCK SPARE

P2 6890 CLOCK

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
SYMBOL DRAWING DESCRIPTION
LOCATION

(R) RESISTORS

R1 340 THERMOSTART COIL

R2 230 FUEL INJECTION PUMP WAX MOTOR
R3 6280 BLOWER SPEED RESISTOR
R4 6260 CIGAR LIGHTER
R5 6340 BLOWER SPEED RESISTOR

(S) SWITCHES

S1 320 IGNITION SWITCH

S2 160 START INHIBITOR SWITCH
S3 1850 ENGINE OIL PRESSURE SWITCH
S4 2470 LOW CHARGE PRESSURE SWITCH (CCLS)
S5 2310 HYDRAULIC OIL TEMP. SWITCH
S6 2290 HYDRAULIC FILTER BLOCKED SWITCH
S7 2210 STEERING PRESSURE SWITCH
S8 2240 TRANSMISSION PRESSURE SWITCH
S9 2280 TRANSMISSION OIL TEMPERATURE SWITCH
S10 2370 HAND BRAKE SWITCH
S11 2340 BRAKE FLUID LEVEL SWITCH
S12 2050 AIR FILTER VACUUM SWITCH
S13 2940 FWD SWITCH
S14 3040 DIFFERENTIAL LOCK SWITCH
S15 3120 DIFFERENTIAL LOCK ENGAGEMENT
LIGHT SWITCH
S16 3150 BRAKE SWITCH RIGHT HAND
S17 3190 BRAKE SWITCH LEFT HAND
S18 3340 PTO SWITCH
S19 3500 SEAT SWITCH
S20 3320 540/1000 PTO SPEED SWITCH
S21 3710 CLUTCH PEDAL SWITCH
S22 3670 CREEPER SWITCH
S23 3740 SHUTTLE DUMP SWITCH
S24 3750 UP SHIFT SWITCH
S25 3760 DOWN SHIFT SWITCH
S26 3770 HIGH RANGE SWITCH
S27 3780 LOW RANGE SWITCH
S28 3790 1--4 RANGE SWITCH(16x16) / HI--MED SW. (24X24)
S29 3800 5--8 RANGE SWITCH
S30 4160 RAISE WORK SWITCH
S31 4260 FENDER SWITCH LEFT
S32 4300 FENDER SWITCH RIGHT
S33 4880 INDICATOR SWITCH
S34 4790 HAZARD SWITCH
S36 5810 FRONT UPPER LAMP SWITCH
S37 5670 FRONT LOWER LAMP SWITCH
S38 5520 REAR LAMP SWITCH
S39 5870 FRONT WIPER AND WASHER SWITCH

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
SYMBOL DRAWING DESCRIPTION
LOCATION

S40 6160 REAR WIPER AND WASHER SWITCH

S41 6390 AIR CON HIGH LOW PRESSURE SWITCH
S42 6390 AIR CON LOW PRESSURE CUT OUT SWITCH
S43 6490 AIR CON TEMP. EXCHANGE CONTROL SWITCH
S44 6260 BLOWER SPEED SWITCH
S45 6600 INTERIOR LIGHT DOOR SWITCH
S46 6620 INTERIOR LIGHT DOOR SWITCH
S47 6670 40 AMP. TERMINAL AND EXTERNAL
40 AMP. 4 PIN POWER SWITCH
S48 6280 BEACON SWITCH
S49 6950 REMOTE VALVE SWITCH
S50 3670 TRANSMISSION OIL PRESSURE SWITCH
S51 3780 1st / 2nd SWITCH
S52 3800 3rd / 4th SWITCH
S53 230 THERMO SWITCH FOR WAX MOTOR
S54 2900 DUAL COMMAND SWITCH (8X2 MODEL ONLY)
S55 2280 HYDRAULIC FILTER SWITCH (8X2 MODEL ONLY)
S56 3600 PTO INHIBITOR SWITCH (8X2 MODEL ONLY)

(X) POWER SOCKETS

XI 6650 40 AMP. SCREW TERMINAL

X2 6640 ACCESSORY SOCKET
X3 6730 IMPLEMENT STATUS SOCKET
X4 6740 TRAILER SOCKET
X5 6680 FOUR PIN 40 AMP. SOCKET
X6 6290 ROOF BEACON SOCKET LH
X7 6330 ROOF BEACON SOCKET RH

(Y) SOLENOID VALVES

Y1 210 FUEL SHUT OFF SOLENOID

Y2 250 ELECTRIC FUEL PUMP
Y3 2980 FWD SOLENOID
Y4 3080 DIFFERENTIAL LOCK SOLENOID
Y5 3540 PTO SOLENOID
Y6 3990 CREEPER SOLENOID
Y7 3910 PWM VALVE 1
Y8 3930 PWM VALVE 2
Y9 3950 PWM VALVE 3
Y10 3970 PWM VALVE 4
Y11 4190 RAISE SOLENOID EDC VALVE
Y12 4210 LOWER SOLENOID EDC VALVE
Y13 6960 REMOTE VALVE SOLENOID
Y14 3930 DUMP SOLENOID
Y15 3950 LO -- PWM
Y16 3970 HI -- PWM
Y17 2930 DUAL COMMAND SOLENOID (8X2 MODEL ONLY)

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

NOTES PAGE

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP

line 10--360

(1)

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC

STARTING
G1 Battery
K1 Ignition Relay
K2 Start Relay
M1 Starter Motor and Solenoid
S1 Ignition Switch
S2 Start Inhibitor Switch
S53 Thermostatic Switch for Wax Motor
CHARGING
G2 Alternator
THERMOSTART AND FUEL SYSTEM
F8 Shut off Solenoid Fuse
F19 Fuse
KVII Thermostart relay
R1 Thermostart coil
R2 Fuel Injection Pump Wax Motor
Y1 Shut Off Solenoid
Y2 Electric Lift Pump
ENGINE SHUTDOWN
KF Engine Shutdown Relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 10--360

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10-- 1998

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

LESS CAB DUAL COMMAND
TS 90, 100, 110, With cab Electroshift with EDC
& 115 With cab Dual Command with EDC STARTING
With cab Dual Command Less EDC
G1 Battery
K1 Ignition Relay
K2 Start Relay
M1 Starter Motor and Solenoid
S1 Ignition Switch
S2 Start Inhibitor Switch
S53 Thermostatic Switch For Wax Motor

CHARGING
G2 Alternator

THERMOSTART AND FUEL SYSTEM

F8 Shut off Solenoid Fuse
F19 Fuse
KVII Thermostart relay
R1 Thermostart coil
R2 Fuel Injection Pump (FIP) Wax Motor
Y1 Shut Off Solenoid
Y2 Electric Lift Pump
STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP
line 10--360

(1)
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 10--360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10-- 1998

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. Less cab Electroshift
Less cab Dual Command STARTING

G1 Battery
K1 Ignition Relay
K2 Start Relay
M1 Starter Motor and Solenoid
S1 Ignition Switch
S2 Start Inhibitor Switch
S53 Thermostatic Switch For Wax Motor

CHARGING
G2 Alternator

THERMOSTART AND FUEL SYSTEM

F8 Shut off Solenoid Fuse
F19 Fuse
KVII Thermostart relay
R1 Thermostart coil
R2 Fuel Injection Pump (FIP) Wax Motor
STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP Y1 Shut Off Solenoid
Y2 Electric Lift Pump
line 10--360

(1A)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 10--360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10-- 1998

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Synchro--Command
STARTING

G1 Battery
K1 Ignition Relay
K2 Start Relay
M1 Starter Motor and Solenoid
S1 Ignition Switch
S2 Start Inhibitor Switch
S53 Thermostatic Switch For Wax Motor

CHARGING
G2 Alternator

THERMOSTART AND FUEL SYSTEM

(1B)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 10--360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10-- 1998

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less cab Synchro--Command
STARTING

G1 Battery
K1 Ignition Relay
K2 Start Relay
M1 Starter Motor and Solenoid
S1 Ignition Switch
S2 Start Inhibitor Switch

CHARGING
G2 Alternator

THERMOSTART AND FUEL SYSTEM

F8 Shut off Solenoid Fuse
F19 Fuse
KVII Thermostart relay
R1 Thermostart coil
Y1 Shut Off Solenoid

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP

line 10--360

(1C)
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 10--360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10-- 1998

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. Less cab Econoshift
NOTES PAGE

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP

line 10--360

(1D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

TRANSMISSION / EDC PROCESSOR

line 370--1800

(2--5D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC

Transmission Processor
A001 Processor
C125 Diagnostic plug

PIN Description PIN Description

1 Radar 8 12V power from fuse 9
2 Wheel speed 9 GROUND
3 Implement status 10 Serial IN
4 Data out 11 Serial OUT
5 Data in 12 Program in
6 Engine RPM 13 Not used
7 Service

C128 (Black processor connector)

PIN Description PIN Description
1 High Range Switch Input 14 Serial input from diagnostic plug
2 Low Range Switch Input 15 Radar input
3 1--4 Gear Switch Input 16 Maximum slip potentiometer input
4 5--8 Gear Switch Input 17 Not used
5 Shift Up Input 18 Transmission oil temp. output
6 Power Fuse 12 19 Clutch pedal potentiometer input
7 Left Hand Brake Switch Input 20 Right hand brake switch input
8 Rocker Shaft potentiometer input 21 Fender switch left hand RH raise position
input
9 Lift arms drop rate potentiometer input 22 Service input and output diagnostic plug
10 Draft Position mix control potentiometer 23 Shuttle dump switch input
input
11 Right hand draft pin input 24 Power shift down input
12 Programme enable 25 Differential lock switch on manual input
13 Serial output to diagnostic plug

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 370--720

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND WITH EDC
TS 90, 100, 110. With cab Electroshift with EDC
Transmission Processor
& 115
A001 Processor
C125 Diagnostic plug

PIN Description PIN Description

1 Radar 8 12V power from fuse 9
2 Wheel speed 9 GROUND
3 Implement status 10 Serial IN
4 Data out 11 Serial OUT
5 Data in 12 Program in
6 Engine RPM 13 Not used
7 Service
C128 (Black processor connector)
PIN Description PIN Description
1 not used 14 Serial input from diagnostic plug
2 1--2/3--4 switch 15 Radar input
TRANSMISSION PROCESSOR 3 Hi/Med/Neutral switch 16 Maximum slip potentiometer input

line 370--720 4 not used 17 2nd clutch pedal sensor (where fitted)
5 Shift Up Input 18 Transmission oil temp. output
6 Power Fuse 12 19 Clutch pedal potentiometer input
(2)
7 Left Hand Brake Switch Input 20 Right hand brake switch input
8 Rocker Shaft potentiometer input 21 Fender switch left hand RH raise posi-
tion input
9 Lift arms drop rate potentiometer in- 22 Service input and output diagnostic
put plug
10 Draft Position mix control potentiome- 23 Shuttle dump switch input
ter input
11 Right hand draft pin input 24 Power shift down input
12 Programme enable 25 Differential lock switch on manual in-
put
13 Serial output to diagnostic plug

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 370--720

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND LESS EDC
TS 90, 100, 110. With cab Dual Command with EDC
Transmission Processor
& 115
A001 Processor
C125 Diagnostic plug

PIN Description PIN Description

1 Radar 8 12V power from fuse 9
2 Wheel speed 9 GROUND
3 Implement status 10 Serial IN
4 Data out 11 Serial OUT
5 Data in 12 Program in
6 Engine RPM 13 Not used
7 Service

C128 (Black processor connector)

PIN Description PIN Description

TRANSMISSION PROCESSOR 1 not used 14 Serial input from diagnostic plug

2 1--2/3--4 switch 15 Radar input
line 370--720
3 Hi/Med/Neutral switch 16 Maximum slip potentiometer input
4 not used 17 not used
(2A) 5 Shift Up Input 18 Transmission oil temp. output
6 Power Fuse 12 19 Clutch pedal potentiometer input
7 Left Hand Brake Switch Input 20 Right hand brake switch input
8 Rocker Shaft potentiometer input (not 21 Fender switch left hand RH raise posi-
used) tion input (not used)
9 Lift arms drop rate potentiometer in- 22 Service input and output diagnostic
put plug
10 Draft Position mix control potentiome- 23 Shuttle dump switch input
ter input
11 Right hand draft pin input (not used) 24 Power shift down input
12 Programme enable 25 Differential lock switch on manual in-
put
13 Serial output to diagnostic plug
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 370--720

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Dual Command Less EDC
Transmission Processor
& 115
A001 Processor
C125 Diagnostic plug

PIN Description PIN Description

1 Radar 8 12V power from fuse 9
2 Wheel speed 9 GROUND
3 Implement status 10 Serial IN
4 Data out 11 Serial OUT
5 Data in 12 Program in
6 Engine RPM 13 Not used
7 Service

C128 (Black processor connector)

PIN Description PIN Description

TRANSMISSION PROCESSOR 1 not used 14 Serial input from diagnostic plug

2 1--2/3--4 switch 15 Radar input
line 370--720
3 Hi/Med/Neutral switch 16 Maximum slip potentiometer input
4 not used 17 not used
(2B) 5 Shift Up Input 18 Transmission oil temp. output
6 Power Fuse 12 19 Clutch pedal potentiometer input
7 Left Hand Brake Switch Input 20 Right hand brake switch input
8 Rocker Shaft potentiometer input (not 21 Fender switch left hand RH raise posi-
used) tion input (not used)
9 Lift arms drop rate potentiometer in- 22 Service input and output diagnostic
put plug
10 Draft Position mix control potentiome- 23 Shuttle dump switch input
ter input
11 Right hand draft pin input (not used) 24 Power shift down input
12 Programme enable 25 Differential lock switch on manual in-
put
13 Serial output to diagnostic plug
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 370--720

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB DUAL COMMAND

TS 90, 100, 110. Less cab Electroshift
Transmission Processor
A001 Processor
C125 Diagnostic plug

PIN Description PIN Description

1 Radar 8 12V power from fuse 9
2 Wheel speed 9 GROUND
3 Implement status 10 Serial IN
4 Data out 11 Serial OUT
5 Data in 12 Program in
6 Engine RPM 13 Not used
7 Service

C128 (Black processor connector)

PIN Description PIN Description

TRANSMISSION PROCESSOR 1 not used 14 Serial input from diagnostic plug

2 1--2/3--4 switch 15 Radar input
line 370--720
3 Hi/Med/Neutral switch 16 Maximum slip potentiometer input
4 not used 17 not used
(2C) 5 Shift Up Input 18 Transmission oil temp. output
6 Power Fuse 12 19 Clutch pedal potentiometer input
7 Left Hand Brake Switch Input 20 Right hand brake switch input
8 Rocker Shaft potentiometer input (not 21 Fender switch left hand RH raise posi-
used) tion input (not used)
9 Lift arms drop rate potentiometer in- 22 Service input and output diagnostic
put plug
10 Draft Position mix control potentiome- 23 Shuttle dump switch input
ter input
11 Right hand draft pin input (not used) 24 Power shift down input
12 Programme enable 25 Differential lock switch on manual in-
put
13 Serial output to diagnostic plug
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 370--720

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB ELECTROSHIFT WITH EDC

WITH CAB DUAL COMMAND WITH EDC
TS 90, 100, 110. Less cab Dual Command
Transmission & EDC Processor continued
A001 Processor

C128 (Black processor connector)

PIN Description
26 Raise/work/float switch, raise position input
27 Transmission neutral input
28 Fender hydraulic control switch RH/LH lower input
29 Raise/work/float switch work position input
30 Hydraulic lift and low potentiometer input
31 Hydraulic arms height limit potentiometer input
32 Hydraulic oil temperature switch input
TRANSMISSION PROCESSOR 33 Left hand draft pin input
34 Engine RPM input
line 370--720
35 Serial diagnostic output
36 Serial diagnostic input
(2D)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 730--1080

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND LESS EDC
TS 90, 100, 110. With cab Electroshift with EDC
Transmission & EDC Processor continued
& 115 With cab Dual command with EDC
A001 Processor

C128 (Black processor connector)

PIN Description
26 Raise/work/float switch, raise position input (not used)
27 Transmission neutral input
28 Fender hydraulic control switch RH/LH lower input (not used)
29 Raise/work/float switch work position input (not used)
30 Hydraulic lift and low potentiometer input (not used)
31 Hydraulic arms height limit potentiometer input (not used)
32 Hydraulic oil temperature switch input
33 Left hand draft pin input (not used)
TRANSMISSION & EDC PROCESSOR (continued) 34 Engine RPM input
line 730--1080 35 Serial diagnostic output
36 Serial diagnostic input

(3)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 730--1080

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

LESS CAB DUAL COMMAND
TS 90, 100, 110. With cab Dual Command Less EDC
& 115 Transmission & EDC Processor continued
A001 Processor

C128 (Black processor connector)

PIN Description
26 Raise/work/float switch, raise position input (not used)
27 Transmission neutral input
28 Fender hydraulic control switch RH/LH lower input (not used)
29 Raise/work/float switch work position input (not used)
30 Hydraulic lift and low potentiometer input (not used)
31 Hydraulic arms height limit potentiometer input (not used)
32 Hydraulic oil temperature switch input
TRANSMISSION & EDC PROCESSOR (continued) 33 Left hand draft pin input (not used)
34 Engine RPM input
line 730--1080
35 Serial diagnostic output
36 Serial diagnostic input
(3B)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 730--1080

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1450--1800

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Dual Command Less EDC
Transmission & EDC Processor continued
& 115
A001 Processor

C127 (Red processor connector)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1450--1800

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB DUAL COMMAND

TS 90, 100, 110. Less Cab Electroshift
Transmission & EDC Processor continued
A001 Processor

C127 (Red processor connector)

PIN Description
23 EDC Slip Lamp output (not used)
24 EDC status lamp output (not used)
25 +8.5V output to draft pins (not used)
26 Low input
27 EDC valve power solenoid return input (not used)
28 EDC valve raise solenoid return input (not used)
29 12V power input fuse 14
30 Clutch pedal switch input
TRANSMISSION & EDC PROCESSOR (continued) 31 12V power input fuse 20
line 1450--1800 32 GND output
33 GND output
(5C) 34 Power input fuse 13
35 Power input fuse 13
36 not used

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1450--1800

604.55.041.01 - 10 - 1998
SECTION55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. Less cab Dual Command
NOTES PAGE

TRANSMISSION & EDC PROCESSOR (continued)

line 1450--1800

(5D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

ELECTRONIC INSTRUMENT CLUSTER AND ASSOCIATED SENSORS

line 1810 -- 2890

(6--8)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC

EIC & Sensors

A EIC & AEIC

C079 Instrument cluster connector

PIN Description
1 Trailer #2 indicator light input
2 Eng. oil pressure light input
3 Trailer #1 indicator light input
4 Not used
5 left turn indicator light input
6 Power input fuse 9
7 GND output
8 Engine coolant temp. output
9 Alternator charging input
10 Main beam light input
11 Air filter restriction light input
12 Thermostart light input
13 Dual power Hi light input
14 LCD back light power input
15 Power input fuse F20
16 Fuel level input

B2 Engine coolant temperature sensor

B3 Fuel tank sender
F9 Fuse 9
S3 Engine oil pressure switch
S12 Air filter vacuum switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 1810--2170

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Electroshift with EDC
& 115 With cab Dual Command with EDC
With cab Dual Command Less EDC EIC & Sensors
A EIC & AEIC
C079 Instrument cluster connector
PIN Description
1 Trailer #2 indicator light input
2 Eng. oil pressure light input
3 Trailer #1 indicator light input
4 Not used
5 left turn indicator light input
6 Power input fuse 9
7 GND output
8 Engine coolant temp. output
9 Alternator charging input
10 Main beam light input
11 Air filter restriction light input
EIC / AEIC & SENSORS 12 Thermostart light input
line 1810--2170 13 Dual power Hi light input
14 LCD back light power input
(6) 15 Power input fuse F20
16 Fuel level input
B2 Engine coolant temperature sensor
B3 Fuel tank sender
F9 Fuse 9
S3 Engine oil pressure switch
S12 Air filter vacuum switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1810--2170

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

LESS CAB DUAL COMMAND
TS 90, 100, 110. With cab Synchro--Command
& 115

EIC & Sensors

A EIC & AEIC
C079 Instrument cluster connector
PIN Description
1 Trailer #2 indicator light input
2 Eng. oil pressure light input
3 Trailer #1 indicator light input
4 Not used
5 left turn indicator light input
6 Power input fuse 9
7 GND output
8 Engine coolant temp. output
9 Alternator charging input
10 Main beam light input
AEIC / AIC & SENSORS 11 Air filter restriction light input
line 1810--2170 12 Thermostart light input
13 Dual power Hi light input
(6A) 14 LCD back light power input
15 Power input fuse F20
16 Fuel level input
B2 Engine coolant temperature sensor
B3 Fuel tank sender
F9 Fuse 9
S3 Engine oil pressure switch
S12 Air filter vacuum switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1810--2170

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB SYNCHRO--COMMAND

TS 90, 100, 110. Less Cab Electroshift
Less Cab Dual Command
EIC & Sensors
A EIC & AEIC
C079 Instrument cluster connector
PIN Description
1 Trailer #2 indicator light input
2 Eng. oil pressure light input
3 Trailer #1 indicator light input
4 Not used
5 left turn indicator light input
6 Power input fuse 9
7 GND output
8 Engine coolant temp. output
9 Alternator charging input
10 Main beam light input
11 Air filter restriction light input
12 Thermostart light input
AEIC & SENSORS 13 Dual power Hi light input
line 1810--2170 14 LCD back light power input
15 Power input fuse F20
(6B) 16 Fuel level input
B2 Engine coolant temperature sensor
B3 Fuel tank sender
F9 Fuse 9
S3 Engine oil pressure switch
S12 Air filter vacuum switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1810--2170

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less cab Synchro--Command

EIC & Sensors

A EIC & AEIC
C079 Instrument cluster connector
PIN Description
1 Trailer #2 indicator light input
2 Eng. oil pressure light input
3 Trailer #1 indicator light input
4 Not used
5 left turn indicator light input
6 Power input fuse 9
7 GND output
8 Engine coolant temp. output
9 Alternator charging input
10 Main beam light input
11 Air filter restriction light input
AEIC / AIC & SENSORS 12 Thermostart light input
line 1810--2170 13 Dual power Hi light input
14 LCD back light power input
(6C) 15 Power input fuse F20
16 Fuel level input
B2 Engine coolant temperature sensor
B3 Fuel tank sender
F9 Fuse 9
S3 Engine oil pressure switch
S12 Air filter vacuum switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 1810--2170

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB ELECTROSHIFT WITH EDC

TS 90, 100, 110. Less Cab Econoshift
EIC & Sensors continued

C080

PIN Description
1 Transmission oil pressure light input
2 Differential lock light input
3 4WD engaged input
4 Hydraulic oil temp. light input
5 Not used
6 Transmission oil temp. light input
7 Dual command low light input
8 Brake fluid level & hand brake light input
9 Park brake light input
10 Engine RPM input
11 1000 rpm PTO light input
12 GND output
13 GND output
AIC & SENSORS
14 Right turn indicator light input
line 1810--2170
15 Low hydraulic charge pressure light input
16 GND output
(6D) 17 Alarm external trigger output
18 GND output
19 Serial Cluster input
20 Serial clutch output

S4 Low charge pressure switch (CCLS)

S5 Hydraulic oil temperature switch
S6 Hydraulic filter blocked switch
S7 Steering pressure switch
S8 Transmission pressure switch
S9 Transmission oil temperature switch
S10 Hand brake switch
S11 Brake fluid level switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2180--2530

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND WITH EDC
TS 90, 100, 110. With cab Electroshift with EDC EIC & Sensors continued

& 115 C080

PIN Description
1 Transmission oil pressure light input
2 Differential lock light input
3 4WD engaged input
4 Hydraulic oil temp. light input
5 Not used
6 Transmission oil temp. light input
7 Dual command low light input
8 Brake fluid level & hand brake light input
9 Park brake light input
10 Engine RPM input
11 1000 rpm PTO light input
12 GND output
13 GND output
EIC & SENSORS (continued)
14 Right turn indicator light input
line 2180--2530
15 Low hydraulic charge pressure light input (not used)
16 GND output
(7) 17 Alarm external trigger output
18 GND output (not used)
19 Serial Cluster input
20 Serial clutch output

S5 Hydraulic oil temperature switch

S7 Steering pressure switch
S8 Transmission pressure switch
S9 Transmission oil temperature switch
S10 Hand brake switch
S11 Brake fluid level switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2180--2530

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND LESS EDC
TS 90, 100, 110. With cab Dual Command with EDC
EIC & Sensors continued
& 115
C080

PIN Description
1 Transmission oil pressure light input
2 Differential lock light input
3 4WD engaged input
4 Hydraulic oil temp. light input
5 Case earth
6 Transmission oil temp. light input
7 Not used
8 Brake fluid level & hand brake light input
9 Park brake light input
10 Engine RPM input
11 1000 rpm PTO light input
12 GND output
EIC & SENSORS (continued)
13 not used
line 2180--2530
14 Right turn indicator light input
15 Low hydraulic charge pressure light input (not used)
(7A) 16 GND output (not used)
17 Alarm external trigger output
18 not used
19 Serial Cluster input
20 Serial clutch output

S5 Hydraulic oil temperature switch

S7 Steering pressure switch
S8 Transmission pressure switch
S9 Transmission oil temperature switch
S10 Hand brake switch
S11 Brake fluid level switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2180--2530

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Dual Command Less EDC EIC & Sensors continued

& 115
C080

line 2180--2530 14 Right turn indicator light input

15 Low hydraulic charge pressure light input (not used)
16 GND output (not used)
(7B)
17 Alarm external trigger output
18 not used
19 Serial Cluster input
20 Serial clutch output

S4 Low charge pressure switch (CCLS)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2180--2530

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. Less Cab Electroshift
EIC & Sensors continued

C080

EIC & SENSORS (continued) 11 1000 rpm PTO light input

12 GND output
line 2180--2530
13 not used
14 Right turn indicator light input
(7C) 15 Low hydraulic charge pressure light input (not used)
16 GND output (not used)
17 Alarm external trigger output
18 not used
19 Serial Cluster input
20 Serial clutch output

S5 Hydraulic oil temperature switch

S7 Steering pressure switch
S8 Transmission pressure switch
S9 Transmission oil temperature switch
S10 Hand brake switch
S11 Brake fluid level switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2180--2530

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB DUAL COMMAND

PIN Description
1 Wheel speed input
2 Implement status input
3 Radar input
4 Radar output
5 +5V output to oil pressure sensor
6 Engine oil pressure input
7 12V out to shut down relay
8 GND control for shut down relay
9 Fuel level sensor ground input
EIC & SENSORS (continued) 10 GND output
line 2180--2530 11 Oil pressure GND output

(7G)
B1 Engine oil pressure
B4 Radar

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 2540--2890

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. With cab Electroshift with EDC
& 115 With cab Dual Command with EDC NOTES PAGE
With cab Dual Command Less EDC

EIC & SENSOR (continued)

line 2540--2890

(8)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

FOUR WHEEL DRIVE AND DIFFERENTIAL LOCK

line 2900 -- 3260

(9)

604.55.041.01 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC
Four Wheel Drive
F15 Fuse 15
S13 FWD Switch
S16 Brake switch left hand
S17 Brake switch right hand
Y3 FWD Solenoid
Differential Lock
S14 Differential lock switch
S15 Diff lock engaged light switch
Y4 Differential lock solenoid

WIRE COLOUR CODES

(9D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

POWER TAKE OFF

line 3270 -- 3620

(10)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC

PTO
H1 PTO lamp
F21 Fuse 21
KV+VI PTO Relay
S18 PTO switch
S19 Seat switch
S20 540/1000 PTO speed switch
Y5 PTO solenoid

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 3270--3620

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Electroshift with EDC
& 115 With cab Dual Command with EDC PTO
With cab Dual Command Less EDC H1 PTO lamp
F21 Fuse 21
KV+VI PTO Relay
S18 PTO switch
S19 Seat switch
S20 540/1000 PTO speed switch
Y5 PTO solenoid

POWER TAKE OFF

line 3270--3620

(10) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 3270--3620

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

10A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Synchro--Command LESS CAB DUAL COMMAND

& 115
PTO
H1 PTO lamp
F21 Fuse 21
KV+VI PTO Relay
S18 PTO switch
S19 Seat switch
S20 540/1000 PTO speed switch
Y5 PTO solenoid

POWER TAKE OFF

line 3270--3620

(10A)
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 3270--3620

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

10B

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB SYNCHRO--COMMAND

TS 90, 100, 110. Less Cab Electroshift
Less Cab Dual Comand PTO
H1 PTO lamp
F21 Fuse 21
KV+VI PTO Relay
S18 PTO switch
S19 Seat switch
S20 540/1000 PTO speed switch
Y5 PTO solenoid

POWER TAKE OFF

line 3270--3620

(10B) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 3270--3620

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

10C

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less Cab Synchro--Command
PTO

KV Relay
S19 Seat switch
S56 PTO Inhibitor Switch

POWER TAKE OFF

line 3270--3620

(10C) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 3270--3620

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

10D

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. Less Cab Econoshift
NOTES PAGE

POWER TAKE OFF

line 3270--3620

(10D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

TRANSMISSION

line 3630 -- 3990

(11--11A)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
LESS CAB ELECTROSHIFT
16 X 16 Electroshift
A002 Gear display module
B18 Clutch pedal potentiometer
S22 Creeper switch
S50 Transmission oil pressure switch
S21 Clutch pedal switch
S23 Shuttle dump switch
S24 Up shift switch
S25 Down shift switch
S26 High range switch
S27 Low range switch
S28 1--4 range switch
S29 5--8 range switch
Y6 Creeper solenoid
Y7 PWM Valve 1
Y8 PWM Valve 2
Y9 PWM Valve 3
Y10 PWM Valve 4

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 3630--3990

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB DUAL COMMAND WITH EDC AND LESS EDC
TS 90, 100, 110. With Cab Electroshift with EDC LESS CAB DUAL COMMAND

& 115 Less Cab Electroshift

24x24 Dual Command
B18 Clutch pedal potentiometer
S50 Transmission oil pressure switch
S21 Clutch pedal switch
S23 Shuttle dump switch
S24 Up shift switch
S25 Down shift switch
S28 Hi--Med Switch
S51 1st--2nd switch
S52 3rd--4th switch
Y14 Dump solenoid
Y15 Lo -- PWM valve
Y16 Hi PWM Valve 2

16 X 16 ELECTROSHIFT
line 3630--3990

(11) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 3630--3990

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

11A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. With cab Dual Command with EDC and Less EDC
& 115 Less Cab Dual Command NOTES PAGE

24 x 24 Dual Command
line 3630--3990

(11A)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

ELECTRONIC DRAFT CONTROL

line 4000 -- 4730

(12--13B)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
Electronic draft control
F12 Fuse 12
S30 Raise/work switch
S31 Fender switch left hand
S32 Fender switch right hand
Y11 Raise solenoid (EDC valve)
Y12 Lower solenoid (EDC valve)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 4000--4360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. With cab Electroshift with EDC WITH CAB DUAL COMMAND LESS EDC
Electronic draft control
& 115 With cab Dual Command with EDC
F12 Fuse 12
S30 Raise/work switch (not used)
S31 Fender switch left hand (not used)
S32 Fender switch right hand (not used)

ELECTRONIC DRAFT CONTROL

line 4000--4360

(12) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 4000--4360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

12A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT LESS EDC

TS 90, 100, 110. With cab Dual Command Less EDC LESS CAB DUAL COMMAND LESS EDC
Electronic draft control continued
& 115
F12 Fuse 12

ELECTRONIC DRAFT CONTROL WIRE COLOUR CODES

line 4000--4360 B Black R Red LG Light Green K Pink

N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
(12A)
S Slate G Green P Purple
Line 4000--4360

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

line 4370--4730

(13A)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

INDICATORS AND HAZARDS

line 4740 -- 5100

(14)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC

Indicators and Hazards

F10 Fuse 10
F11 Fuse 11
F18 Fuse 18

H6 Front indicator lamp left hand

H7 Front indicator lamp right hand (ISO)
H8 Rear indicator lamp left hand
H9 Rear indicator lamp right hand

H10 Front indicator lamp left hand

H11 Front indicator lamp right hand (NASO)
H12 Rear indicator lamp left hand
H13 Rear indicator lamp right hand

K3 Flasher unit relay

KXI Flasher mode relay

KXII

MF3 Maxi Fuse 3

S33 Indicator switch

S34 Hazard switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 4740--5100

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Electroshift with EDC
Indicators and Hazards
& 115 With cab Dual Command with EDC
F10 Fuse 10
With cab Dual Command Less EDC F11 Fuse 11
F18 Fuse 18

H6 Front indicator lamp left hand

H7 Front indicator lamp right hand (ISO)
H8 Rear indicator lamp left hand
H9 Rear indicator lamp right hand

H10 Front indicator lamp left hand

H11 Front indicator lamp right hand (NASO)
H12 Rear indicator lamp left hand
H13 Rear indicator lamp right hand

K3 Flasher unit relay

KXI Flasher mode relay

KXII

INDICATORS AND HAZARDS MF3 Maxi Fuse 3

line 4740--5100 S33 Indicator switch

S34 Hazard switch
(14)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 4740--5100

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

14A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Synchro--Command LESS CAB DUAL COMMAND
LESS CAB SYNCHRO--COMMAND
& 115
Indicators and Hazards
F10 Fuse 10
F11 Fuse 11
F18 Fuse 18

H6 Front indicator lamp left hand

H7 Front indicator lamp right hand (ISO)
H8 Rear indicator lamp left hand
H9 Rear indicator lamp right hand

K3 Flasher unit relay

KXI Flasher mode relay

KXII

MF3 Maxi Fuse 3

S33 Indicator switch

S34 Hazard switch

INDICATORS AND HAZARDS

line 4740--5100

(14A) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 4740--5100

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

14B

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less cab Electroshift
Less cab Dual Command Indicators and Hazards
Less cab Synchro--Command F10 Fuse 10
F11 Fuse 11
F18 Fuse 18

H6 Front indicator lamp left hand

H7 Front indicator lamp right hand (ISO)
H8 Rear indicator lamp left hand
H9 Rear indicator lamp right hand

K3 Flasher unit relay

KXI Flasher mode relay

KXII

MF3 Maxi Fuse 3

INDICATORS AND HAZARDS S33 Indicator switch

S34 Hazard switch
line 4740--5100

(14B)
WIRE COLOUR CODES
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 4740--5100

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

14C

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. Less Cab Econoshift
NOTES PAGE

INDICATORS AND HAZARDS

line 4740--5100

(14C)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

MAIN LIGHTS

line 5110 -- 5470

(15)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC
Main Lights
F1 Fuse one
F2 Fuse two
F3 Fuse three
F4 Fuse four

H14 Head lamp left hand

H15 Head lamp right hand
H16 Front side lamp left hand
H17 Front side lamp right hand
H18 Rear brake/tail lamp left hand
H19 Rear brake/tail lamp right hand
H22 Licence plate lamp lower

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 5110--5470

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Electroshift with EDC
& 115 With cab Dual Command with EDC
Main Lights
With cab Dual Command Less EDC F1 Fuse one
F2 Fuse two
F3 Fuse three
F4 Fuse four

H14 Head lamp left hand

H15 Head lamp right hand
H16 Front side lamp left hand
H17 Front side lamp right hand
H18 Rear brake/tail lamp left hand
H19 Rear brake/tail lamp right hand
H22 Licence plate lamp lower

MAIN LIGHTS
line 5110--5470

(15) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 5110--5470

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

15A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

From Serial Number 086641B

TS 90, 100, 110. Less Cab Econoshift
NOTES PAGE

MAIN LIGHTS
line 5110--5470

(15D)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

WORK LAMPS

line 5480 -- 5840

(16)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
ALL WITH CAB MODELS

Work Lamps

F5 Fuse 5 front work lamps

F6 Fuse 6 rear work lamps
F7 Fuse 7 lower work lamps

H20 Licence plate lamp top right hand

H21 Licence plate lamp -- lower
H22 Licence plate lamp top left hand
H23 Upper front worklamp left hand
H24 Upper front worklamp right hand
H25 Lower front worklamp left hand
H26 Lower front worklamp right hand
H27 Upper rear work lamp left hand
H28 Upper rear work lamp right hand
H29 Lower rear work lamp left hand
H30 Lower rear work lamp right hand

KB Relay B front worklamps

KC Relay C rear worklamps
KD Relay D lower front work lamps
KE Relay E lower rear work lamps

S36 Front upper lamp switch

S37 Front lower lamp switch
S38 Rear lamp switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 5480--5840

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. All With Cab Models LESS CAB DUAL COMMAND
LESS CAB SYNCHRO--COMMAND
& 115
Work Lamps
F6 Fuse 6 rear work lamps

H27 Upper rear work lamp left hand

H28 Upper rear work lamp right hand

KC Relay C rear worklamps

MF4 Maxi Fuse 4

S38 Rear lamp switch

WORK LAMPS WIRE COLOUR CODES

line 5480--5840 B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
(16)
S Slate G Green P Purple
Line 5480--5840

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

16A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less Cab Electroshift
Less Cab Dual Command
Work Lamps
Less Cab Synchro--Command
F6 Fuse 6 rear work lamps

H27 Upper rear work lamp left hand

H28 Upper rear work lamp right hand

KC Relay C rear worklamps

MF4 Maxi Fuse 4

S38 Rear lamp switch

WORK LAMPS WIRE COLOUR CODES

line 5480--5840 B Black R Red LG Light Green K Pink

N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
(16A)
S Slate G Green P Purple

Line 5480--5840

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

16B

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. Less Cab Econoshift
NOTES PAGE

WORK LAMPS
line 5480--5840

(16B)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

WIPERS AND WASHERS

line 5850 -- 6210

(17)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
ALL WITH CAB MODELS

Wipers and Washers

F17 Fuse 17

KVIII Relay VIII intermittent module front

KIX Relay IX intermittent module rear

M2 Front wiper motor

M3 Rear wiper motor
M4 Washer motor
M5 Washer motor

S39 Front wiper and washer switch

S40 Rear wiper and washer switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 5850--6210

604.55.041.01 - 10 - 1998
SECTION 55 ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. All With Cab Models
& 115 NOTES PAGE

WIPERS AND WASHERS

line 5850--6210

(17)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

AIR--CONDITIONING AND CAB HEATING

line 6220 -- 6570

(18)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
ALL WITH CAB MODELS

Air conditioning/Cab heating

B14 Temperature control potentiometer
E1 Compressor clutch
F16 Fuse 16
M6 Blower motor
R3 Blower speed resistor
R5 Speed resistor
S41 High and low pressure switch
S42 Low pressure cut out switch
S43 Temperature exchange control switch
S44 Blower speed switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 6220--6570

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B

TS 90, 100, 110. All With Cab Models
& 115 NOTES PAGE

AIR--CONDITIONING & CAB HEATING

line 6220--6570

(18)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

CAB ACCESSORIES

line 6220 -- 7290

(19--21)

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
WITH CAB ELECTROSHIFT WITH EDC
WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC
Cab accessories
A004 Radio
B15 Speaker
B16 Speaker
B17 Horn
F22 Fuse 22
F23 Fuse 23
KII Accessory Socket Relay
MF5 Maxi Fuse 5
R4 Cigar Lighter
S48 Beacon Switch
X2 Accessory Socket
X6 Roof beacon socket left hand
X7 Roof beacon socket right hand

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple

Line 6220--6570

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB ELECTROSHIFT WITH EDC

TS 90, 100, 110. With cab Electroshift with EDC WITH CAB DUAL COMMAND WITH EDC
WITH CAB DUAL COMMAND LESS EDC
& 115 With cab Dual Command with EDC Cab accessories continued
With cab Dual Command Less EDC E2 Interior light
E3 Console light

K Implement socket relay

MF6 Maxi Fuse 6

M7 Air seat pump

P1 Clock/spare
P2 Clock B pillar

S45 Interior light door switches

S46 Interior light door switches
S47 40 amp. terminals and external 40 amp. 4 pin power switch

X1 40 amp. terminals
X3 Implement status socket
X4 Trailer socket
CAB ACCESSORIES X5 4 pin 40 amp. socket

line 6220--6570

(19)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6580--6930

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB ELECTROSHIFT WITH EDC

WITH CAB DUAL COMMAND WITH EDC
TS 90, 100, 110. With cab Electroshift with EDC
WITH CAB DUAL COMMAND LESS EDC
& 115 With cab Dual Command with EDC Cab accessories continued
With cab Dual Command Less EDC C225 Splice connector
F24 Fuse 24
KIV Remote valve relay
S49 Remote valve switch
Y13 Remote valve solenoid

CAB ACCESSORIES (cont)

line 6580--6930

WIRE COLOUR CODES

(20)
B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6940--7290

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Electroshift with EDC
& 115 With cab Dual Command with EDC
Cab accessories
With cab Dual Command Less EDC A004 Radio
B15 Speaker
B16 Speaker
B17 Horn
F22 Fuse 22
F23 Fuse 23
KII Accessory Socket Relay
MF5 Maxi Fuse 5
R4 Cigar Lighter
S48 Beacon Switch
X2 Accessory Socket
X6 Roof beacon socket left hand
X7 Roof beacon socket right hand

CAB ACCESSORIES (cont)

line 6940--7290

(21) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6220--6570

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

19A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With Cab Synchro--Command
& 115 Cab accessories continued
E2 Interior light
E3 Console light

K Implement socket relay

MF6 Maxi Fuse 6

M7 Air seat pump

P2 Clock B pillar

S45 Interior light door switches

S46 Interior light door switches
S47 40 amp. terminals and external 40 amp. 4 pin power switch

X1 40 amp. terminals
X4 Trailer socket
X5 4 pin 40 amp. socket
CAB ACCESSORIES
line 6220--6570

(19A)

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6580--6930

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

20A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B WITH CAB SYNCHRO--COMMAND

TS 90, 100, 110. With cab Synchro--Command
& 115 Cab accessories continued
C225 Splice connector
F24 Fuse 24
KIV Remote valve relay
S49 Remote valve switch
Y13 Remote valve solenoid

CAB ACCESSORIES (cont)

line 6580--6930

(20A) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6940--7290

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

21A

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ELECTROSHIFT

TS 90, 100, 110. With cab Synchro--Command LESS CAB DUAL COMMAND
LESS CAB SYNCHRO--COMMAND
& 115

Cab accessories

B17 Horn

X4 Trailer socket

KIV Remote valve relay

S49 Remote valve switch
Y13 Remote valve solenoid

CAB ACCESSORIES (cont)

line 6940--7290

(21A) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6220--7290

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

19B--21B

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B LESS CAB ECONOSHIFT

TS 90, 100, 110. Less Cab Electroshift
Less Cab Dual Command
Less Cab Synchro--Command Cab accessories

B17 Horn

X4 Trailer socket

KIV Remote valve relay

S49 Remote valve switch
Y13 Remote valve solenoid

CAB ACCESSORIES (cont)

line 6220--7290

(19B--21B) WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
Line 6220--7290

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

19C--21C

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

From Serial Number 086641B Line No Description

TS 90, 100, 110. Less Cab Econoshift 10 STOP LAMP SWITCH FEED
12 MAIN BEAM HEADLAMP FUSE SUPPLY
13 DIP BEAM HEADLAMP FUSE SUPPLY
28 WIPER MOTOR (PARK RETURN)
29 MAIN FUEL SENDER SIGNAL
31 ENGINE OIL PRESSURE SENDER SIGNAL
39 TEMPERATURE GAUGE SIGNAL
44 FLASHER UNIT (49A)
49 RIGHT HAND TURN SIGNAL
50 LEFT HAND TURN SIGNAL
56 WIPER MOTOR--HIGH
57 EARTH (ALL)
58 WIPER MOTOR--LOW
71 IGNITION SWITCHED FEEDS (UNFUSED)
97 WINDSHIELD WASHER FEED
137 RADIO FEED
138 RADIO KAM
150 BATTERY FEED (ALL)
181 BLOWER MOTOR FEED
CAB ACCESSORIES (cont) 376 HORN FEED
line 6220--7290 587 WINDSHIELD WIPER INTERMITTENT DELAY
810 STOP LAMP
979 BLOWER MOTOR HIGH SPEED
(19C--21C) 980 THERMOSTAT SWITCH SUPPLY
984 TEMPERATURE CONTROL POT. INPUT
986 TEMPERATURE CONTROL POT. OUTPUT
989 BLOWER MOTOR MEDIUM SPEED
997 WORK LAMP--REAR FEED (OUTER)
998 WORK LAMP--REAR FEED (INNER)
999 BLOWER MOTOR LOW SPEED
1000 SAFETY START SWITCH SUPPLY
1001 STARTER SOLENOID FEED
1002 IMPLEMENT LAMP SWITCH SUPPLY
1003 SUPPLY TO GAUGES
1004 SUPPLY TO HORN AND HEADLAMP FLASH
1005 AIR CLEANER WARNING LAMP
1006 ALTERNATOR WARNING LAMP
1010 IGNITION RELAY
1011 SUPPLY TO FUSES
1013 RIGHT HAND LAMPS
1014 LEFT HAND LAMPS
1015 DOME LAMP SWITCH FEED
1018 AIR CONDITIONING CLUTCH
1019 WINDSHIELD WIPER FEED
1020 HAZARD SWITCH SUPPLY
1021 HAZARD SWITCH SUPPLY (BATTERY)
1022 THERMOSTART
1023 LIGHT SWITCH FEED
1024 RIGHT & LEFT HAND SIDE LAMP FEED
1026 HIGH BEAM INDICATOR LAMP

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Line No Description

1027 HEADLAMP MAIN BEAM

1031 INSTRUMENT ILLUMINATION
1033 TURN SIGNAL WARNING LAMP (TERM C2)
1034 TURN SIGNAL WARNING LAMP (TERM C3)
1035 ENGINE OIL PRESSURE WARNING LAMP
1072 WORKLAMP FRONT RELAY SUPPLY
1090 REAR WORKLAMP RELAY SIGNAL
1092 FRONT WORKLAMP RELAY SIGNAL
1096 WORKLAMP FENDER MOUNTED
1097 FEED FRONT WORKLAMP OUTER
1099 FEED FRONT WORKLAMP INNER
1119 R, R, WINDSHIELD WIPER
1120 R, R, WINDSHIELD WIPER PARK RETURN
1121 R, R, WINDSHIELD WASH
1500
2012 TRANS. OIL PRESSURE WARNING LAMP
2014 ENGINE OIL PRESSURE SENDER
2015 TACHOMETER SENSOR--SIGNAL
2016 REAR AXLE SPEED SENSOR--SIGNAL
2025 AUDIO ALARM CONTROL
2026 IMPLEMENT SWITCH SIGNAL
2027 RADAR ASSEMBLY (GUN) POWER
2028 RADAR ASSEMBLY (GUN) SIGNAL
2029 INSTRUMENT MEMORY SUPPLY
2041 FUEL SHUT OFF
2042 PTO SOLENOID--REAR
2045 PTO SWITCH TO MODULE
2049 PTO SWITCH 1000RPM WARNING LAMP
2050 PTO SUPPLY
2060 PTO 540/1000 SWITCH
2065 PTO ENGAGED
2070 ENGINE SHUT OFF RELAY +12V
2080 ENGINE SHUT OFF RELAY
2095 INSTRUMENT SIGNAL GROUND
2200 SERVICE MODE INITIATE
3000 FLASHER UNIT SUPPLY
3001 LEFT HAND FLASHER CIRCUIT
3002 RIGHT HAND FLASHER CIRCUIT
3014 HAND BRAKE WARNING LAMP SIGNAL
3020 DUAL POWER SOLENOID SUPPLY
3025 FOUR WHEEL DRIVE SOLENOID
3030 ACCESSORY RELAY SIGNAL
3052 DOME LAMP TO DOOR SWITCH
3060 IMPLEMENT SOCKET RELAY
3070 ‘B’ PILLAR SKT SUPPLY
3090 SEAT PUMP SUPPLY
4001 TRANSMISSION OIL WARNING LAMP (TEMP.)
4011 ROTATING BEACON SWITCH SUPPLY
4012 ROTATING BEACON FEED
4101 TRANS. RANGE ENABLE

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Line No Description

5000 EDC MEMORY POWER

5010 EDC EARTH
5011 EDC EARTH CASE RFI
5020 EDC PROC +5V REF VOLTAGE DROP PSN/RATE
5021 EDC PROCESSOR REF VOLT (+5V) ROCKER SHAFT
5030 EDC RAISE SIGNAL
5035 EDC RETURN REF. VOLTAGE EARTH
5040 EDC DRAFT POSITION
5045 EDC DROP RATE
5050 EDC QUADRANT
5060 SERIAL DATA TO CLUSTER
5065 EDC RIGHT PIN
5070 EDC LEFT PIN
5075 EDC VOLTAGE TO PINS
5080 EDC ROCKER SHAFT
5085 EDC VALVE UP
5087 EDC VALVE UP RETURN
5090 EDC VALVE DOWN
5095 EDC EXTERNAL SWITCH DOWN
5097 EDC VALVE DOWN RETURN
5100 EDC EXTERNAL SWITCH UP
5110 EDC LAMP SIGNAL
5120 EDC HEIGHT LIMIT SIGNAL
5125 EDC RAISE SIGNAL--RAISE WORK SWITCH
5130 EDC WORK SIGNAL--RAISE WORK SWITCH
5145 EDC SLIP LIMIT POT
5150 EDC EXTERNAL SWITCH SUPPLY
5170 SERIAL DATA FORM CLUSTER
5180 EDC SLIP INDICATOR LAMP
5200 EDC VALVE SUPPLY
5300 ECU FLASH PROGRAM SIGNAL
7000 TRANS. CONTROL SUPPLY
7002 TRANS. MAIN CLUTCH SOL (C3/C4)
7004 TRANS. FRONT CLUTCH SOL (C1/C2)
7005 TRANS. CREEPER GR SOL
7010 TRANS. RANGE INDICATOR SWITCH (GR 1--4)
7020 TRANS. RANGE INDICATOR SWITCH (GR 5--8)
7070 TRANS. FEED
7080 DIFF--LOCK SOLENOID FEED
7120 DIFF--LOCK WNG LP
7130 HYD FILTER WNG LP
7160 HYD LOW CHARGE WARNING
7170 DIFF LOCK SWITCH OUTPUT
7195 TRANS. SOLENOID VALVE RETURN
7200 TRANSMISSION SHIFT DOWN
7210 TRANSMISSION SHIFT UP
7220 TRANSMISSION HIGH RANGE
7230 TRANSMISSION LOW RANGE
7430 CLUTCH POSITION SIGNAL
7500 TRANS. OIL TEMP. SENSOR

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Line No Description
7590 TRANS. CREEPER GEAR STATUS LAMP
7640 DIAGNOSTIC PLUG SERIAL232 IN
7650 DIAGNOSTIC PLUG SERIAL232 OUT
7660 TRANS. CLUTCH DISCONNECT
7700 TRANS. SHUTTLE DUMP SWITCH
7710 TRANS. OIL TEMPERATURE SWITCH
7810 TRANS. PWM SOLENOID C1
7815 TRANS. PWM SOLENOID C1 RETURN
7820 TRANS. PWM SOLENOID C2
7825 TRANS. PWM SOLENOID C2 RETURN
7830 TRANS. PWM SOLENOID C3
7835 TRANS. PWM SOLENOID C3 RETURN
7840 TRANS. PWM SOLENOID C4
7845 TRANS. PWM SOLENOID C4 RETURN
9020 HYDRAULIC REMOTE VALVE SOL

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
Fold out for Key to Electroshift Electrical System Diagram.

ELECTRICAL SYSTEM DIAGRAMS

ELECTROSHIFT AND DUAL COMMAND MODELS

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8
ELECTROSHIFT ELECTRICAL SYSTEM DIAGRAM PROCESSOR TERMINALS (C127=Red connector / C128=Black connector)
C127 -- 1. SENSOR EARTH / GROUND C128 -- 1. HIGH RANGE SWITCH
1. BATTERY 13. CLUTCH PEDAL SWITCH
2. MAXI FUSES 14. GEAR DISPLAY MODULE 2. DIFFERENTIAL LOCK -- AUTO 2. LOW RANGE SWITCH

3. IGNITION SWITCH 15. DIFFERENTIAL LOCK SWITCH 3. CREEPER SWITCH LAMP 3. 1 -- 4 GEAR RANGE SWITCH
4. IGNITION RELAY 16. BRAKE PEDAL SWITCHES 4. -- 4. 5 -- 8 GEAR RANGE SWITCH
5. CREEPER SWITCH 17. RAISE/WORK/LOWER SWITCH 5. +5 VOLT REFERENCE LINE 5. UPSHIFT SWITCH
6. SHUT DOWN RELAY 18. EDC FENDER SWITCHES
6. WHEEL SPEED SENSOR 6. FUSE 12 SENSE
7. FUEL SHUT OFF SOLENOID 19. EDC CONTROL PANEL
7. IMPLEMENT STATUS 7. BRAKE SWITCH -- LEFT
8. POWER TAKE OFF MODULE 20. SENSOR SIGNAL GROUND
8. WHEEL SPEED -- OUT 8. ROCK SHAFT POT.
9. SEAT SWITCH 21. CHASSIS GROUND
9. CASE EARTH / GROUND 9. DROP RATE CONTROL
10. STARTER SOLENOID 22. POWER GROUND
11. STARTER RELAY 23. SYSTEM DIAGNOSTICS CONNECTOR 10. 4WD SOLENOID 10. DRAFT / POSITION CONTROL

12. START INHIBITOR SWITCH 24. EDC/TRANS PROCESSOR 11. PWM 1 -- (C1) 11. RIGHT HAND DRAFT PIN
25. DIGITAL INSTRUMENT CLUSTER 12. PWM 4 -- RETURN 12. PROGRAMME ENABLE
INSTRUMENT CLUSTER - TERMINALS 13. PWM 2 -- RETURN 13. RS232 OUT
C079 -- 1. TRAILER 2 C080 -- 1. TRANSMISSION OIL PRESSURE AND 14. PWM 2 (C2) 14. SERIAL IN
STEERING PRESSURE
15. CREEPER SOLENOID 15. RADAR
2. ENGINE OIL PRESSURE 2. DIFFERENTIAL LOCK
16. DIFFERENTIAL LOCK SOLENOID 16. SLIP CONTROL
3. TRAILER 1 3. 4WD ’ON’
17. PWM 4 (C4) 17. NOT USED
4. NOT USED 4. HYDRAULIC OIL TEMPERATURE
18. PWM 3 (C3) 18. TRANSMISSION OIL TEMPERATURE
5. LEFT TURN 5. --
19. LOWER PWM 19. CLUTCH PEDAL POT.
6. BATTERY VOLTAGE INPUT SWITCHED -- FUSE 9 6. TRANSMISSION OIL TEMPERATURE
20. RAISE PWM 20. RIGHT BRAKE SWITCH
7. SIGNAL GROUND 7. NOT USED ON 16 X 16
8. ENGINE COOLANT TEMPERATURE 8. BRAKE FLUID LEVEL AND HANDBRAKE 21. GEAR DISPLAY -- 2 21. EXTERNAL UP
SWITCHES 22. GEAR DISPLAY -- 1 22. SERVICE
9. ALTERNATOR CHARGING 9. PARK BRAKE +12V. 23. SLIP LAMP 23. SHUTTLE DUMP SWITCH
10. MAIN BEAM 10. ENGINE RPM 24. STATUS LAMP 24. DOWN SHIFT SWITCH
11. AIR FILTER 11. PTO 1000 25. + 8.5 VOLTS FOR DRAFT PINS 25. DIFFERENTIAL LOCK MANUAL
12. THERMOSTART 12. EARTH / GROUND 26. PWM 3 -- RETURN 26. RAISE SWITCH
13. NOT USED ON 16 X 16 13. EARTH / GROUND 27. LOWER PWM RETURN 27. START SWITCH INPUT
14. BACKLIGHT POWER 14. RIGHT TURN 28. RAISE PWM RETURN 28. EXTERNAL DOWN
15. BATTERY VOLTAGE INPUT CONTINUOUS -- FUSE 20 15. LOW HYDRAULIC CHARGE PRESSURE 29. FUSE 14 -- INPUT 29. WORK SWITCH
16. FUEL LEVEL 16. EARTH / GROUND 30. FUSE 12 -- + 12V INPUT 30. QUADRANT LEVER POT.
17. ALARM -- EXTERNAL TRIGGER
31. FUSE 20 (CONTINUOUS + 12v SUPPLY) 31. HEIGHT LIMIT CONTROL
18. EARTH / GROUND
32. EARTH / GROUND 32. OIL TEMPERATURE SWITCH
19. SERIAL DATA IN
33. EARTH / GROUND 33. LEFT HAND DRAFT PIN
20. SERIAL DATA OUT
34. FUSE 13 -- +12v INPUT 34. ENGINE RPM
C081 -- 1, WHEEL SPEED
35. FUSE 13 -- +12V INPUT 35. SERIAL OUT
2. IMPLEMENT STATUS
36. PWM 1 -- RETURN 36. RS232 IN
3. RADAR SENSE
4. RADAR
5. +5V REF
6. ENGINE OIL PRESSURE
7. ENGINE SHUT DOWN (+V OUT)
8. ENGINE SHUT DOWN (RETURN)
9. FUEL LEVEL GROUND
10. EARTH / GROUND
11. ENGINE OIL PRESSURE GROUND
12. EARTH / GROUND

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

DUAL COMMAND ELECTRICAL SYSTEM DIAGRAM

PROCESSOR TERMINALS (C127=Red connector / C128=Black connector)
C127 -- 1. SENSOR EARTH / GROUND C128 -- 1. NOT USED
1. BATTERY 13. CLUTCH PEDAL SWITCH
2. DIFFERENTIAL LOCK -- AUTO 2. 1--2 / 3--4 SWITCHES
2. MAXI FUSES 14. BRAKE LAMPS
3. NOT USED 3. HI / MED / NEUTRAL SWITCH
3. IGNITION SWITCH 15. DIFFERENTIAL LOCK SWITCH
4. IGNITION RELAY 16. BRAKE PEDAL SWITCHES 4. -- 4. NOT USED

5. P.T.O. SWITCH 17. RAISE/WORK/LOWER SWITCH 5. +5 VOLT REFERENCE LINE 5. UPSHIFT SWITCH

6. SHUT DOWN RELAY 18. EDC FENDER SWITCHES 6. WHEEL SPEED SENSOR 6. FUSE 12 SENSE

7. FUEL SHUT OFF SOLENOID 19. EDC CONTROL PANEL 7. IMPLEMENT STATUS 7. BRAKE SWITCH -- LEFT
8. POWER TAKE OFF MODULE 20. SENSOR SIGNAL GROUND 8. WHEEL SPEED -- OUT 8. ROCK SHAFT POT.
9. SEAT SWITCH 21. CHASSIS GROUND 9. CASE EARTH / GROUND 9. DROP RATE CONTROL
10. STARTER SOLENOID 22. POWER GROUND 10. 4WD SOLENOID 10. DRAFT / POSITION CONTROL
11. STARTER RELAY 23. SYSTEM DIAGNOSTICS CONNECTOR 11. DUAL COMMAND LO LAMP 11. RIGHT HAND DRAFT PIN
12. START INHIBITOR SWITCH 24. EDC/TRANS PROCESSOR 12. HIGH PWM RETURN 12. PROGRAMME ENABLE
25. DIGITAL INSTRUMENT CLUSTER 13. DUMP SOLENOID RETURN 13. RS232 OUT
INSTRUMENT CLUSTER - TERMINALS 14. DUMP SOLENOID 14. SERIAL IN
C079 -- 1. TRAILER 2 C080 -- 1. TRANSMISSION OIL PRESSURE AND 15. DUAL COMMAND HI LAMP 15. RADAR
STEERING PRESSURE
2. ENGINE OIL PRESSURE 2. DIFFERENTIAL LOCK 16. DIFFERENTIAL LOCK SOLENOID 16. SLIP CONTROL
3. TRAILER 1 3. 4WD ’ON’ 17. HIGH PWM 17. 2ND CLUTCH PEDAL SENSOR (IF
FITTED)
4. NOT USED 4. HYDRAULIC OIL TEMPERATURE
5. LEFT TURN 5. -- 18. LOW PWM 18. TRANSMISSION OIL TEMPERATURE

6. BATTERY VOLTAGE INPUT SWITCHED -- FUSE 9 6. TRANSMISSION OIL TEMPERATURE 19. LOWER PWM 19. CLUTCH PEDAL POT.
7. SIGNAL GROUND 7. DUAL COMMAND -- LO 20. RAISE PWM 20. RIGHT BRAKE SWITCH
8. ENGINE COOLANT TEMPERATURE 8. BRAKE FLUID LEVEL AND HANDBRAKE 21. NOT USED 21. EXTERNAL UP
SWITCHES
22. NOT USED 22. SERVICE
9. ALTERNATOR CHARGING 9. PARK BRAKE +12V.
23. SLIP LAMP 23. SHUTTLE DUMP SWITCH
10. MAIN BEAM 10. ENGINE RPM
24. STATUS LAMP 24. DOWN SHIFT SWITCH
11. AIR FILTER 11. PTO 1000
25. + 8.5 VOLTS FOR DRAFT PINS 25. DIFFERENTIAL LOCK MANUAL
12. THERMOSTART 12. EARTH / GROUND
13. DUAL COMMAND -- HI 13. EARTH / GROUND 26. LOW PWM RETURN 26. RAISE SWITCH

14. BACKLIGHT POWER 14. RIGHT TURN 27. LOWER PWM RETURN 27. START SWITCH INPUT

15. BATTERY VOLTAGE INPUT CONTINUOUS -- FUSE 20 15. LOW HYDRAULIC CHARGE PRESSURE 28. RAISE PWM RETURN 28. EXTERNAL DOWN

16. FUEL LEVEL 16. EARTH / GROUND 29. FUSE 14 -- INPUT 29. WORK SWITCH
17. ALARM -- EXTERNAL TRIGGER 30. FUSE 12 -- + 12V INPUT 30. QUADRANT LEVER POT.
18. EARTH / GROUND 31. FUSE 20 (CONTINUOUS + 12v SUPPLY) 31. HEIGHT LIMIT CONTROL
19. SERIAL DATA IN 32. EARTH / GROUND 32. OIL TEMPERATURE SWITCH
20. SERIAL DATA OUT 33. EARTH / GROUND 33. LEFT HAND DRAFT PIN
C081 -- 1, WHEEL SPEED 34. FUSE 13 -- +12v INPUT 34. ENGINE RPM
2. IMPLEMENT STATUS 35. FUSE 13 -- +12V INPUT 35. SERIAL OUT
3. RADAR SENSE
36. NOT USED 36. RS232 IN
4. RADAR
5. +5V REF
6. ENGINE OIL PRESSURE
7. ENGINE SHUT DOWN (+V OUT)
8. ENGINE SHUT DOWN (RETURN)
9. FUEL LEVEL GROUND
10. EARTH / GROUND
11. ENGINE OIL PRESSURE GROUND
12. EARTH / GROUND

604.55.041.01 - 10 - 1998
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 8

NOTES PAGE

ELECTRICAL SYSTEM DIAGRAM

DUAL COMMAND MODEL

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SECTION 55-- ELECTRICAL SYSTEMS -- CHAPTER 9 1

SECTION 55 -- ELECTRICAL SYSTEMS

Chapter 9 -- Harnesses and Connectors

Section Description Page

55 000 Harnesses -- general layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Harness to harness connector location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Earth location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lighting harness (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine harness (emmissionized engines, all models) . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission (Chassis) harness -- All 16x16 Electroshift models . . . . . . . . . . . . . . 12
Transmission (Chassis) harness -- All 24x24 Dual Command models . . . . . . . . . . 16
Cab (main rear) harness -- 16x16 Electroshift and 24x24 Dual Command . . . . . . 20

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2

There are Four Main Harnesses used on Cabbed

Tractors.

LT -- Lighting
FM -- Front Main (Engine Harness)

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RM -- Rear Main (Chassis Harness)
CM -- Cab Main
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Harness to Harness Connector location

Engine harness to Lighting

Harness Connector location.

Cab (rear) Main to Transmission

Cab (rear) Main to Engine Harness (chassis) Harness Connector
Connector location location.
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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3
4 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
Earth (Ground) Location Points

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LIGHTING HARNESS CONNECTORS

Connector No. Component Harness Connector No. Component Harness

C007 Brake Fluid Reservoir Level Switch LT
C056 Headlamp Harness LT
C057 Horn LT
C059 Right Hand Headlamp LT
C060 Left Hand Headlamp LT
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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5
6 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 7

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8
ENGINE HARNESS CONNECTORS

Connector No. Component Harness Connector No. Component Harness

C001 Front Main Bulkhead Connector M1 FM
C003 Oil Pressure Sender FM
C004 Oil Pressure Switch FM

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C005 Starter Relay FM
C006 Starter Solenoid FM
C009 Vacuum Switch FM
C010 Air-Con compressor FM
C011 Air--Con Hi--Lo Switch FM
C012 Temperature Sender FM
C013 Alternator FM
C015 Fuel Shut-Off Solenoid FM
C016 Fuel Pump FM
C018 Thermostart FM
C056 Lighting Harness Connector FM
C068 Radar Gun FM
C224 Air--Con Extension Harness FM
C229 Fuel Pump Cold Advance Unit FM
C230 Fuel Pump Cold Advance Temp Switch FM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 9

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10 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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11 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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12
CHASSIS HARNESS CONNECTORS (16x16 Electroshift models)

Connector No. Component Harness Connector No. Component Harness

C020 Rear Main Extension Connector RM C172 Oil temperature Switch RM
C021 Creeper Engaged Switch RM C173 Low Charge Pressure Switch RM

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C022 Fuel Tank Sender RM C174 Steering Pressure Switch RM
C023 Transmission Oil Temp Sender RM C176 Start inhibitor Switch RM
C025 Clutch 4 RM C217 EDC Raise Solenoid RM
C026 Clutch 3 RM C218 EDC Lower Solenoid RM
C027 Clutch 2 RM C222 Creeper Solenoid RM
C028 Clutch 1 RM
C034 Four Wheel Drive Solenoid RM
C036 Pressure Switch RM
C041 PTO Solenoid RM
C042 Diff Lock Solenoid RM
C043 Diff Lock Switch RM
C046 Axle Speed Sensor RM
C047 Left Hand Draft Pin RM
C048 Right Hand Draft Pin RM
C052 Rockshaft Potentiometer RM
C053 Hydraulic Remote Valve Solenoid RM
C154 HPL Filter Vacuum Switch RM
C164 Trans. Switch 1--4 range RM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

C165 Trans. Switch 5--8 range RM

C166 Low Range Switch RM
C167 High Range Switch RM
C171 Oil temperature Switch RM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 13

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14 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 15

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16
CHASSIS HARNESS CONNECTORS (24x24 Dual Command models)

Connector No. Component Harness Connector No. Component Harness

C020 Rear Main Extension Connector RM C154 HPL Filter Vacuum Switch RM
C022 Fuel Tank Sender RM C161 Clutch A RM

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C023 Transmission Oil Temp Sender RM C162 Clutch B RM
C034 Four Wheel Drive Solenoid RM C163 Dump Solenoid RM
C036 Pressure Switch RM C171 Oil temperature Switch RM
C041 PTO Solenoid RM C172 Oil temperature Switch RM
C042 Diff Lock Solenoid RM C176 Start inhibitor Switch RM
C043 Diff Lock Switch RM C177 Neutral Switch 3/4 Rail RM
C046 Axle Speed Sensor RM C178 Neutral Switch 1/2 Rail RM
C047 Left Hand Draft Pin RM C197 Hi/Medium range Switch RM
C048 Right Hand Draft Pin RM C217 EDC Raise Solenoid RM
C052 Rockshaft Potentiometer RM C218 EDC Lower Solenoid RM
C053 Hydraulic Remote Valve Solenoid RM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 17

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18 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 19

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20
CAB HARNESS CONNECTORS (16x16 Electroshift and 24x24 Dual Command models)

Connector No. Component Harness Connector No. Component Harness

C001 Cab Main Bulkhead Connector CM C091 Right hand Door Switch CM
C020 Cab Main Extension Connector CM C092 Console Lamp CM
C053 Remote Valve Solenoid CM C093 Left Hand NASO Rear Flasher CM

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C055 Trailer Socket CM C094 Right Hand NASO Rear Flasher CM
C062 Right Hand Stop Lamp Switch CM C095 Left Hand Rear Licence/Worklamp CM
C063 Left Hand Stop Lamp Switch CM C096 Right Hand Rear Licence/Worklamp CM
C064 Right Hand Lower Front Worklamp CM C097 Left Hand Beacon CM
C065 Left Hand Lower Front Worklamp CM C098 Right Hand Beacon CM
C066 Right Side Lamp CM C099 Interior Lamp CM
C067 Left Side Lamp CM C102 Fast Raise/Lower Switch CM
C068 Radar CM C103 Gear Shift Connector CM
C072 Starter Switch CM C104 Gear Shift Indicator CM
C073 Windshield Wiper Switch CM C106 Radio A CM
C074 Turn and Main Lights Switch CM C107 Radio B CM
C076 Clutch Switch CM C108 Clock CM
C077 Clutch Potentiometer CM
C078 Rear Wiper Switch CM
C079 Instrument Cluster ‘A’ CM
C080 Instrument Cluster ‘B’ CM
C081 Instrument Cluster ‘C’ CM
C082 Beacon Switch CM
C083 Hazard Switch CM
C084 Left Hand Upper Front Worklamp CM
C085 Right Hand Upper Front Worklamp CM
C086 Left Hand NASO Front Flasher CM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

C087 Right Hand NASO Front Flasher CM

C088 Front Wiper Motor CM
C090 Left hand Door Switch CM
CAB HARNESS CONNECTORS

Connector No. Component Harness Connector No. Component Harness

C109 Rear Wiper Motor CM C183 Differential Lock Switch CM
C110 Right hand Speaker CM C186 Hi--Lo Lamps wiring for 24x24 only CM
C111 Left hand Speaker CM C187 Implement Socket Switch CM
C116 Rear PTO Switch CM C188 Front Lower Worklamps Switch CM
C117 Rear PTO Engaged Lamp CM C189 Front Upper Worklamps Switch CM
C119 Heater Air-Con Connector CM C191 Rear Worklamps Switch CM
C120 EDC Control Panel 1 CM C192 Creeper Gear Switch CM
C121 EDC Control Panel 2 CM C193 Cigar Lighter CM
C122 EDC Control Panel 3 (solenoid lamps) CM C196 Shuttle Dump Switch CM
C125 Diagnostic Plug TCM CM C209 Battery CM
C127 EDC Module (CN2) CM C219 FWD and Diff Lock Switch Harness CM
C128 EDC Module (CN1) CM C220 Accessory Harness Connector CM
C129 Worklamp Right Hand Fender CM C221 Implement Status Socket CM
C130 Worklamp Left Hand Fender CM C223 ’B’ Pillar harness Connector CM
C131 Licence Plate Lamp CM C225 Cab Positive Splice Connector CM
C132 Rear Lamp Right Hand Fender CM C228 Clock 2 CM
C233 Flasher Relay CM
C133 Rear Lamp Left Hand Fender CM
C234 Implement Relay CM
C134 HPL Raise/Lower Right Hand Switch CM
C235 40 Amp pole terminal to Harness CM
C135 HPL Raise/Lower Left Hand Switch CM
C236 40 Amp Ring Terminals CM
C136 Handbrake CM
C137 PTO Alarm Seat Switch CM
C138 Seat Pump CM
C139 Front Washer Motor CM
C140 Rear Washer Motor CM
C143 External 40 Amp Implement Socket CM
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

C147 Remote Valve Switch CM

C149 Quadrant Potentiometer CM
C180 Accessory Socket CM
C181 540/100 PTO lever Switch CM
C182 Four Wheel Drive Switch CM

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21
22 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 23

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24 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 25

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26 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 27

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28 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 29

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30 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 31

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32 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 1
SECTION 55 -- ELECTRICS

CHAPTER 10 -- COMPONENT TESTING

CONTENTS
Section Description Page
55 000 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. Thermostart Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. Handbrake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11. Low Transmission Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12. Oil Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13. 40! C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
14. Low Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
15. Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
16. Load Sensing Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
17. Lift Lever Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
18. Lift Arm Cross Shaft Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
19. Electronic Draft Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
20. Electronic Draft Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Panel Connector Resistance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
21. PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
22. Transmission Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
23. Brake Pedal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
24. Forward/Reverse Dump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
25. 16x16 Transmission Gear Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
26. Clutch Pedal Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
27. Clutch Pedal Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
28. PWM Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
29. Upshift/Downshift Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
30. Differential Lock Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
31. Differential Lock, PTO, Creep, 4WD & Dump Solenoids . . . . . . . . . . . . . . . . . . . . . 42
32. Transmission Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
33. Transmission Status Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34. Multifunction Switch Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
35. Multifunction Switch Wiper/Wash Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

1. Thermostart Device 2. Coolant temperature

4. Engine Oil Pressure Sender 3. Engine Oil Pressure Switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 3

5. Alternator 6. Air Filter Restriction Switch

30. Differential Lock Micro Switch 31. Differential Lock, PTO, Creep,
4WD & Dump Solenoids

32. Transmission Oil

33. Transmission Status Switches Temperature Sensor

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10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

34. Multifunction Switch Lights 35. Multifunction Switch

Wiper/Wash Switch
5
4
2
7
1

3 6

TAG0
10

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 11

8x2 12x12 24x24 16x16

! ! ! !

1. THERMOSTART DEVICE

The thermostart which is efficient at ambient

temperatures of --18! C, comprises a heating
element fitted in the intake manifold. When the
thermostart is switched on it ignites fuel in the
manifold, thus heating the air before it enters the
combustion chamber.

The thermostart is activated when the key is turned

anti-clockwise. It is actioned for 15 seconds.

TEST PROCEDURE

Voltage

Turn the ignition key to the thermostart position. 12V

between the BROWN / RED wire and EARTH (for 15
seconds only).

OPERATIONAL LIGHT

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12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! ! !

2. COOLANT TEMPERATURE SENDER

The resistance of the temperature sender changes

proportionally to the temperature of the coolant,
which makes it possible to send a modulated voltage
signal to the instrument cluster to operate the bar
graph / temperature gauge.

TEST PROCEDURE

Voltage

5V between the GREEN / BLUE wire and EARTH.

Resistance

4500--6000 " Engine cold

Less than 650 " Engine hot

WARNING LAMP

ASSOCIATED ERROR CODES

EIC 7 Sender Short Circuit

EIC 12 Sender Open Circuit

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 13

8x2 12x12 24x24 16x16

! ! ! !

3. ENGINE OIL PRESSURE SWITCH

If the engine oil pressure drops below 0.68 bar, the

warning lamp is illuminated.

As the switch is a normally open type, the warning

lamp is illuminated when the ignition is switched on
and the engine is not running.

TEST PROCEDURE

Voltage

12V between the WHITE / BROWN wire and

EARTH.

WARNING LAMPS

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14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

EIC EIC

4. ENGINE OIL PRESSURE SENDER

The resistance of the oil pressure sender varies

proportionally with the engine oil pressure, which
makes it possible to send a modulated voltage signal
to the instrument cluster to operate the engine oil
pressure bar graph (EIC only).

TEST PROCEDURE

Voltage

5V between the GREEN / PINK wire and EARTH.

Resistance

-- Between pins A and B 26 k "

-- Between pins B and C 34 k "
-- Between pins A and C 26 k "

Sensor Calibration
Display Sensor Display Sensor Alarm function pressure will vary with
Segment Volts Segment Volts engine rpm
1 less than 1.47 7 2.93 -- 3.22 Sensor RPM Alarm
2 1.47 -- 1.76 8 3.22 -- 3.51
3 1.76 -- 2.06 9 3.51 -- 3.81 Volts Bar Less than 500 OFF
4 2.06 -- 2.35 10 3.81 -- 4.10 1.47 0.6 500 -- 1500 ON
5 2.35 -- 2.64 11 4.10 -- 4.39 1.76 1.1 1500 -- 2000 ON
6 2.64 -- 2.93 12 4.39 -- 4.83 2.06 1.7 2000 -- 3000 ON

ASSOCIATED ERROR CODES

EIC 1 Sender Short Circuit

EIC 2 Sender Open Circuit

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 15

8x2 12x12 24x24 16x16

! ! ! !

5. ALTERNATOR

This sends a square wave signal, the frequency of

which varies between 142.5 and 855 Hz (480--3060
rpm) to the microprocessor and to the instrument
panel.

TEST PROCEDURE

With the engine running, the warning light should go

out. If not, disconnect the wire connected to the
terminal D+. When D+ is not connected and the
warning light goes out, there is a fault with the
alternator. If it does not go out, then check the wiring
loom for a short to earth between D+ cable and the
warning light.

READING THE FREQUENCY (AT TERMINAL W, ENGINE SPEED FREQUENCY

WHITE / SLATE WIRE) (RPM) (Hz)

1000 300

1500 430

2000 560

2300 660

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16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! ! !

6. AIR FILTER RESTRICTION SWITCH

The warning lamp will illuminate when the switch has

been closed for 5 seconds.

When the vacuum pressure on the engine side of the

air intake filter exceeds 46.7 mm Hg, the warning
lamp is illuminated. This is a normally open switch.

TEST PROCEDURE

Voltage

12V between the BLACK / GREY and BLACK wires.

Checking the Switch

Removing the rubber plug and pressing against the

bottom of the switch with a suitable probe, should
cause the switch to close.

WARNING LAMPS

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 17

8x2 12x12 24x24 16x16

! ! !

7. BRAKE FLUID LEVEL SWITCH

When the fluid level drops below the minimum level,

a warning lamp is illuminated intermittently. This is a
normally open switch.

TEST PROCEDURE

Voltage

Handbrake Off. 12V between the RED / PINK and

the BLACK wires.

Resistance

If the level is correct, resistance is infinite.

If the level is too low, there is continuity.

WARNING LAMPS

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18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! !

8. FUEL INJECTION PUMP

The emissionised Fuel Injection Pump (FIP) has an

electric lift pump, a temperature related switch, a wax
motor and a shut-off solenoid.

TEST PROCEDURE

Fuel Pump

Fuel pump resistance 1.6" across the two wires,

BLACK and PURPLE / YELLOW.

12 V PURPLE / YELLOW to EARTH.

Temperature Switch

The temperature switch is normally open when cold

and closed when hot. Supply voltage of 12V at the
PURPLE / YELLOW.

Wax Motor

The wax motor has a typical resistance of 6" when

cold and 10" when hot.
Voltage of 12V when engine is hot and the
temperature switch closed.

Shut-off Solenoid

Receives 12 volts with ignition on

Resistance 9"

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 19

8x2 12x12 24x24 16x16

! ! !

9. HAND BRAKE SWITCH

When the handbrake has been applied, the switch

will be closed and the warning lamp is illuminated.

An alarm will be triggered if wheel movement of more

than 0.8 km/h is detected when the handbrake has
been applied and the ignition is switched on.

This alarm is also activated for 2 minutes when the

ignition has been switched off and the handbrake has
not been applied.

TEST PROCEDURE

Voltage

12V at RED / PINK to EARTH.

NOTE: The orange and white wire (or blue on the

side of the switch) is only connected where the
‘‘Italian’’ trailer braking system is fitted.

OPERATIONAL LIGHT

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20 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! ! !

10. FUEL GAUGE SENDER

The signal from the fuel sender potentiometer

determines the fuel level displayed on the instrument
cluster gauge.

TEST PROCEDURE

Voltage

5V at Green/Black wire to earth.

Resistance TRANSMITTER GAUGE

RESISTANCE INDICATION

31 5" FULL

25020" EMPTY

ASSOCIATED ERROR CODES

EIC 3 Short circuit

EIC 4 Open circuit

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 21

8x2 12x12 24x24 16x16

! ! !

11. LOW TRANSMISSION OIL

PRESSURE SWITCH

If the transmission oil pressure drops below 11 bars,

the warning lamp will be illuminated. This is a
normally closed pressure switch.

When there is no pressure in the system, contact is

made between the two terminals of the switch.

TEST PROCEDURE

Voltage

12V between the YELLOW / ORANGE and BLACK

wires.

WARNING LAMPS

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22 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! ! !

12. OIL FILTER RESTRICTION SWITCH

When the temperature is greater than 40! C and

when the suction pressure on the pump side of the
filter exceeds 406 mm Hg (5812 mm H2O), the
vacuum switch illuminates the warning lamp. This is
a normally open switch.

TEST PROCEDURE

Voltage

When the 40! C temperature switch is closed circuit,

i.e. greater than 40! C, or shorted out.

12V between the BLACK / BROWN wires and

EARTH.

WARNING LAMPS

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 23

8x2 12x12 24x24 16x16

! ! !

13. 40!C SWITCH (OIL TEMPERATURE)

When the transmission oil temperature exceeds

40! C, this switch (1) enables the oil filter restriction
switch. This is a normally open thermocontact.

TEST PROCEDURE

To check the switch, submerge it in oil. If the

temperature of the oil is in excess of 40! C, the switch
should close and there should be continuity between
the two terminals.

WARNING LAMPS

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24 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

14. LOW CHARGE PRESSURE SWITCH

If the charge pressure drops below 0.8 BAR, it will

cause the warning lamp to flash. The warning lamp
will flash when the switch has been closed for 5
SECONDS. This is a normally closed switch.

TEST PROCEDURE
R/N/B
Voltage

The voltage measured between RED / BROWN /

BLACK wires and EARTH should be 12V.

Pressure Switch

Contact must be established between the

connection socket (earth) and the pressure switch.

WARNING LAMPS

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 25

8x2 12x12 24x24 16x16

EIC EIC

15. RADAR

This detects the forward speed of the tractor and

sends a signal to the instrument cluster to display the
tractors speed, the percentage of wheel slip, the
distance and the cumulative total area worked.

TEST PROCEDURE

Voltage

Harness side
1 : Earth
2 : Frequency Signal
3 : Supply Voltage
4 : Radar Diagnostics

Relationship Between Frequency and Speed

Values must be read between the green wire and

earth.

FREQUENCY SPEED
ASSOCIATED ERROR CODES
Hz km/h m/h
EDC 2 Poor or no signal from tractor performance 0 0 0
monitor radar 550 15 9.3
EDC 3 Transmission output speed sensor or tractor 1100 30 18.7
performance monitor radar circuit
intermittent failure.

604.55.041.01 10-- 1998

26 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

EDC EDC

16. LOAD SENSING PINS

-- 50 kN pins

-- The fixing flange ensures correct pin orientation

TEST PROCEDURE

Resistance

1 to 2 177 k"
1 to 3 8.9 k"
2 to 3 177 k"

Voltage

8V at pin 1, PINK wire to EARTH.

ASSOCIATED ERROR CODES

EDC 14 Right hand load sensing pin failure/circuit

open or shorted to chassis.
EDC 15 Right hand load sensing pin failure/circuit
shorted to chassis.
EDC 16 Left hand load sensing pin failure/circuit
open or shorted to chassis.
EDC 17 Left hand load sensing pin failure/circuit
shorted to chassis.
EDC 18 Both load sensing pins disconnected or
open load sensing pin circuit.
EDC 19 Load sensing pin supply voltage shorted to
ground.
EDC 20 Load sensing pin supply voltage shorted to
battery.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 27

8x2 12x12 24x24 16x16

EDC EDC

17. LIFT LEVER POTENTIOMETER

-- The resistance of the potentiometer changes as

the lever is moved.

-- Its signal is continuously monitored by the

microprocessor.

TEST PROCEDURE

Voltage

B : Earth
K/Y : 5.3V (Ignition ON)
LN/B : Zero

LN/B
B
K/Y

Resistance

Lever Lever
Wire Forward Rearward
Black to Green 0.5 k" 3.6 k"
Black to Orange 4.0 k" 4.0 k"
Orange to Green 3.6 k" 0.3 k"

ASSOCIATED ERROR CODES

EDC 25 Lift control lever potentiometer

disconnected or circuit open or shorted to
chassis.
EDC 26 Lift control lever potentiometer failure or
circuit shorted to supply voltage.

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28 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

EDC EDC

18. LIFT ARM (CROSS SHAFT)

POTENTIOMETER

-- Mounted on the lift arm

-- Informs the microprocessor of the lift arm

position.

TEST PROCEDURE

Resistance

Arms Arms
Wire Lowered Raised
K/N
Black to Green 0.8 k" 3.58 k"
LN/G
Green to Orange 3.28 k" 0.49 k"
K/Y
Orange to Black 3.5 k" 3.5 k"

Voltage

PINK / YELLOW wire to earth 5V.

ASSOCIATED ERROR CODES

EDC 24 Perform hydraulic lift auto calibration.

EDC 27 Lift arm position sensing potentiometer
failure, disconnected, open circuit or circuit
shorted to chassis.
EDC 28 Lift arm position sensing potentiometer
failure, or circuit shorted to supply voltage.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 29

8x2 12x12 24x24 16x16

EDC EDC

19. ELECTRONIC DRAFT CONTROL

(EDC) SOLENOIDS

TEST PROCEDURE

Resistance

The resistance of each of the solenoids should be

between 6 and 8 ".

Frequency

The signal frequency should be 83 Hz. This is difficult

to measure with conventional test equipment.

Voltage/Intensity K/G/B
K/R
The average voltage, amperage and cyclic ratio
change in relation to the control instructions.

ASSOCIATED ERROR CODES

EDC 63 EDC hydraulic control valve lower

solenoid/circuit failed.
EDC 64 EDC hydraulic control valve raise
solenoid/circuit failed.
EDC 65 EDC hydraulic control valve lower
solenoid/circuit failed.
EDC 66 EDC hydraulic control valve raise
solenoid/circuit failed.
EDC 67 EDC hydraulic control valve supply voltage
too low.

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30 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

EDC EDC

20. ELECTRONIC DRAFT CONTROL

PANEL

Potentiometer Connector (C120)

Voltage Check
5V between LIGHT BROWN and EARTH
12V between RED/LIGHT GREEN/BLACK and
EARTH

Slip Connection (C121)

No voltage is present from loom.

Resistance
Panel connector -- see table for typical approximate
values. 1:TQ/R
4:TQ/G

Panel Light Connector (C122)

Voltage when EDC solenoids function.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 31
ASSOCIATED ERROR CODES

EDC 2 Poor or no signal from tractor performance

monitor radar.

EDC 6 Slip control potentiometer failure, open

circuit or shorted to chassis.
EDC 7 Slip control potentiometer failure or circuit
shorted to supply voltage.

EDC 10 Height limit control potentiometer/circuit --

open circuit or shorted to chassis.

EDC 11 Height limit control potentiometer/circuit

shorted to supply voltage.
EDC 12 Drop rate control potentiometer/circuit --
open circuit or shorted to chassis.

EDC 13 Drop rate control potentiometer/circuit

shorted to supply voltage.

EDC 21 Position/draft control sensitivity control

potentiometer/circuit -- open circuit or
shorted to chassis.

EDC 22 Position/draft control sensitivity control

potentiometer/circuit shorted to supply
voltage.

EDC 30 Circuit failure to EDC control panel.

EDC Panel Potentiometer and Printed Circuit Board Check, With and Less Slip
EDC Panel EDC Panel Potentiometer Typical Resistance "
Connecting, Connection, Potentiometer Setting
Pin No. Pin No. Anti-clockwise -- Clockwise
C120, 1 C121, 1 Slip (1) 33310 9510
C120,, 1 C120,, 2 Drop
p Rate (3)
( ) 33310 9510 W/Slip
41810 9510 L/Slip
C120,, 3 Draft Position 33310 9510 W/Slip
Mix (2) 41810 9510 L/Slip
C120,, 5 Height
g (4)
( ) 33310 9510 W/Slip
50515 18010 L/Slip
C120,, 1 C120,, 4 -- 341100 W/Slip
455100 L/Slip
C120, 5 C120, 8 Read Manual Light 135
C121,, 3 C120, 5 Slip Light 145
C120, 8 Slip and Read Manual Light 275
C122, 1 C122, 2 Up light 135
C122, 3 C122, 4 Down Light 135

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32 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! !

21. PTO SWITCH

The PTO switching system incorporates a safety

start function which takes a signal from the alternator
when the engine is running.

Voltage

Terminal Ignition On On PTO

Running
1: G 0 0
2: O/G 0 12V
3: G 12V 12V

Switch Continuity

PTO Switch Off No Continuity

Central button 1 to 3
depressed momentarily
PTO On 2 to 3

3:R
Operation Light 2:G
1:B

1000rpm.
Overspeed

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 33

8x2 12x12 24x24 16x16

Processor Processor

22. TRANSMISSION SPEED SENSOR

This sensor measures the output speed of the

transmission.

If the tractor is fitted with a radar, the signal from the

transmission speed sensor is used for the calculation
of the percentage wheel slip.

TEST PROCEDURE

Resistance

There should be a resistance of 2.5 k" across the

sensor wires.

ASSOCIATED ERROR CODES

EIC 5 Short Circuit

EIC 6 Open Circuit
E 49Wheel speed sensor open/short circuit
EDC 49Wheel speed sensor open/short circuit
EDC 4 Transmission output speed sensor circuit
intermittent failure
EDC 5 Transmission output speed sensor shorted
to chassis.

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34 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! !

23. BRAKE PEDAL SWITCHES

When either brake pedal is applied, the relevant

switch closes, causing the appropriate brake light to
illuminate. These switches, when closed, also send
a signal to the processor for the operation of the four
wheel drive and differential lock. This is a normally
open switch.

TEST PROCEDURE

Voltage

12V between both GREEN wires and EARTH.

Pedal up 1 and 4 have continuity

Pedal down 2 and 3 have continuity

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 35

8x2 12x12 24x24 16x16

! !

24. FORWARD/REVERSE DUMP

SWITCH

This is a sprung loaded to normally open switch,

when pressed and held it becomes closed circuit.

TEST PROCEDURE

Voltage

RED/LIGHT GREEN/BLACK wire 12V to EARTH.

Switch Test

Continuity between RED and GREEN when switch

depressed.

ASSOCIATED ERROR CODE

Transmission H
Clutchless shuttle operation attempted at too
high a speed and in too high a gear
LN/N/B

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36 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

25. 16x16 TRANSMISSION GEAR

DISPLAY

A set of lights numbered 1 to 8 indicate which gear

is selected.

TEST PROCEDURE

Voltage

12V at wires BLUE/YELLOW/BLACK and also at

RED/LIGHT GREEN/BLACK.

S/O/B

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 37

8x2 12x12 24x24 16x16

! !

26. CLUTCH PEDAL POTENTIOMETER

Informs the processor the relative position of the

clutch/inching pedal.

Resistance

Typical Pedal Up Pedal Down

Resistance
between wires
Orange to Green 0.3 k" 2.5 k"
Black to Green 3.6 k" 1.5 k"
Orange to Black 3.8 k" 3.8 k"

Y/R/B
B
LN

Voltage

5V LIGHT BROWN wire to EARTH.

ASSOCIATED ERROR CODES

E12 Clutch pedal potentiometer signal too high

E11 Clutch pedal potentiometer signal too low

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38 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! !

27. CLUTCH PEDAL DISCONNECT

SWITCH

TEST PROCEDURE

Switch

There should be continuity between the two central

pins (when the pedal is up).

Pedal down no continuity on central pins.

Voltage

12V BLUE/RED/BLACK to EARTH.

ASSOCIATED ERROR CODES

E37 Clutch disconnect switch open circuit

E47 Clutch disconnect switch misadjusted high
E48 Clutch disconnect switch short circuit
misadjusted, always closed.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 39

8x2 12x12 24x24 16x16

! !

28. PWM SOLENOID VALVES

There are two PWM units fitted to a 24x24

transmission and four fitted to a 16x16 transmission.

TEST PROCEDURE

Resistance

The resistance of the solenoid coil, measured at the

terminals, should be between 8 and 11 ".

Frequency

The supply signal has a high frequency which is

difficult to measure with conventional equipment.

Voltage

Average voltage 8.5V.

ASSOCIATED ERROR CODES

16x16
E39 C4 clutch solenoid open circuit
E38 C4 clutch solenoid short circuit
E41 C3 clutch solenoid open circuit
E40 C3 clutch solenoid short circuit
E43 C2 clutch solenoid open circuit
E42 C2 clutch solenoid short circuit
E45 C1 clutch solenoid open circuit
E44 C1 clutch solenoid short circuit
E24 All clutches not calibrated
24x24
E39 C2 (High) clutch solenoid open circuit
E38 C2 (High) clutch solenoid short circuit
E41 C1 (Low) clutch solenoid open circuit
E40 C1 (Low) clutch solenoid short circuit
E24 All clutches not calibrated

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40 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! !

29. UPSHIFT/DOWNSHIFT BUTTONS

These are sprung loaded -- normally open switches

TEST PROCEDURE

Voltage

Both R/LG/B to EARTH 12V.

Switch Test

1 Green to 4 Red continuity -- when pressing downshift

2 Black to 3 Red continuity -- when pressing upshift

ASSOCIATED ERROR CODES

E13 Up and down switches both on

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 41

8x2 12x12 24x24 16x16

! ! !

30. DIFFERENTIAL LOCK LIGHT

SWITCH

When the rear differential lock is hydraulically

engaged, a micro switch is actuated illuminating a
warning light.

The front differential lock is actuated from the same

hydraulic supply.

TEST PROCEDURE

Voltage

12V at YELLOW / BLACK wire to EARTH.

Switch Open Circuit when differential lock

disengaged.

WARNING LIGHT

ASSOCIATED ERROR CODES

To be determined.

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42 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10

8x2 12x12 24x24 16x16

! ! ! !

31. DIFFERENTIAL LOCK, PTO, 4WD,

CREEP AND DUMP SOLENOIDS

Resistance 7--11 ".

TEST PROCEDURE

Differential Lock
When the differential lock is engaged, the voltage at
the solenoid terminals should be 12V, and when it is
not engaged, it should be 0V.

Power Take Off

When the PTO is engaged, the voltage at the
solenoid terminals should be 12V and when it is not
engaged, it should be 0V.

Creep
When creep is engaged, voltage at solenoid
terminals should be 12V and when not engaged 0V.

Dump
When energised by 12V, low pressure oil is directed
to the PWM valves.

Four Wheel Drive

When the FOUR WHEEL DRIVE is engaged, the
voltage at the solenoid terminals should be 0V, and
when it is not engaged, it should be 12V.

ASSOCIATED ERROR CODES/WARNING LAMPS

16x16
C Wheel speed too high for creeper gear
HC Range shift too high with creeper engaged
E16 Creeper solenoid open/short circuit or attempt
was made to engage creeper after prior
creeper error
24x24
E36 12x12 dump solenoid open circuit
E35 12x12 dump solenoid closed circuit

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 43

8x2 12x12 24x24 16x16

! !

32. TRANSMISSION OIL

TEMPERATURE SENSOR

Situated in the transmission control valve packs for

both 24x24 and 16x16 transmissions.

TEST PROCEDURE

Voltage

LIGHTS/INDICATORS/HORN

Multifunction switch controls lights and indicators.

TEST PROCEDURE

Voltage

12V at BROWN, GREEN, LIGHT GREEN/BROWN

wires to EARTH.

Pin Loom Switch Function

No. Side Side
C074 C074
1 R R Side light
2 G/W LU Right hand Indicator
3 G/R LU/B Left hand Indicator
4 U/W B Main beam
5 N 12V S Supply -- side lights,
dip, main
6 LG/N 12V W/B Supply -- indicators
7 U/R S/B Dip beam
8 G 12V P/B Supply -- Horn,
Flash
9 P P Horn

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10 47

8x2 12x12 24x24 16x16

! ! !

35. MULTIFUNCTION WIPER/WASHER

SWITCH

Multifunctions switch controls wipers, washer and

horn

604.55.041.01 10-- 1998

48 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 10
TEST PROCEDURE

Voltage Test

Pin No. Wire Colour Wire Colour Function Voltage at C073

Connector Connector Multifunction Switch
C073 C073 With C088, With C088,
Loom Side Switch Side Wiper Motor Wiper Motor
Connected Disconnected
1 LG/O N Intermittent Wipe 1.5 1.5
2 R/LG S Slow Wipe 12 0
3 W/LG U Fast Wipe 12 0
4 G/O/B W Park Wipers 0 0
5 LG/U U/R Washer 12 12
6 B R Earth 0 0

Continuity Test

Pin No. Function Selected Continuity to Pin

6 Intermittent Wipe 1
6 Slow Wipe 2
6 Fast Wipe 3
6 Wash 5
5 Wash in Intermittent 1
5 Wash in Slow Wipe 2
5 Wash in Fast Wipe 3
2 Off 4
2 Intermittent 4

604.55.041.01 10-- 1998

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 1

SECTION 55 -- ELECTRICAL SYSTEMS

Chapter 11 -- Diagnostic ‘H’ Routines

Section Description Page

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16x16 Transmission ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12x12 Dual Command Transmission ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electronic Draft Control ‘H’ Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INTRODUCTION
The TS range of tractors has a built in diagnostic
system.
To gain access to the diagnostic ‘H’ menu mode
routine it is necessary to use the diagnostic test
switch, Tool No. 4FT 950, in the tractor diagnostic
connector (C125), located behind the right-hand
Instrument Control Panel.

1
The Instrument Cluster, either EIC (A) or AEIC (B),
is used to display the information. 1 A 2

Connect Tool No. 4FT 950 to the diagnostic

connector and turn the key start switch ON.

The display will show ‘HH’ to indicate that the ‘H’

menu has been activated.

1. Transmission display
2. Electronic Draft Control display

2
B
1 2

604.55.041.00 - 01 - 1998
2 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

16x16 Transmission ‘H’ Routine

The ‘H’ routine consists of the following H menu codes:

HH Service Menu Page

H1 Transmission clutch spring pressure calibration 3
H2 Transmission clutch spring pressure calibration review 6
H3 (EDC valve calibration values) 6
H4 Software revision level 7
H5 Switch test 7
H6 Select rear tyre rolling radius 8
H7 Auto radius calibration (400 Foot/122m Dash) 10
H8 Non volatile memory reset (Erase Calibrations) 11
H9 Vehicle sensor operation display 12
HA Clutch pedal position display and oil temperature 14
HB View stored error codes 14
HC Clear stored error codes 15
HD View live error codes 16
HE Clutch fill time adjustment 16

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 3

H1 Transmission Clutch Spring

Pressure Calibration
With the test switch connected, start the engine.
Switch off air conditioning.
Apply handbrake.
Select H1.

4
The word CAL should appear on the instrument
cluster display. This will be replaced after a few
seconds by the oil temperature, in degrees
Celsius.

Set the engine speed to 1200 +/-- 100 rpm.

5
C3 and C4 Calibration
Place all gear levers in the forward position.

6
C3 calibration :
Press and hold the Upshift button.
If the start up procedure was incorrect, a U code
will be displayed (see page 5).

604.55.041.00 - 01 - 1998
4 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

The display will change to show a number.

This number will flash and begin to scroll up, as
the clutch is calibrated.
When the processor detects a decrease in
engine rpm of 50, the calibration stops. This is
indicated by a fixed, non flashing number.
Release the Upshift button.

8
C4 calibration :
Use the downshift button to calibrate the C4
clutch in the same manor as the C3 clutch.

9
The display is similar to the C3 calibration.

10
C1 and C2 calibration :
Depress the clutch pedal.

Place the range lever in neutral, leaving the

shuttle lever and the main lever in the forward
position.

Release the clutch pedal.

Set the engine speed to 1200 +/-- 100 rpm.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 5

Press and hold the Upshift button to calibrate the

C1 clutch.
Press and hold the Downshift button to calibrate
the C2 clutch.
The procedure is the same as that for the C3 and
C4 clutches.

12
Clutch Spring Pressure Calibration Error Codes
U20 Correct start up sequence was not used -- Depress and release the clutch pedal, repeat
calibration procedure.
U21 Engine rev/min is too low (1200 rpm ¦ 100 rpm)
U22 Engine rev/min is too high (1200 rpm ¦ 100
rpm)
U23 Forward/Reverse shuttle lever is not in forward.
U24 Main lever is not in 5--8 range.
U25 Field/road lever is not in gear.
U26 Clutch pedal is not fully released.
U27 C3 calibration is too low -- The initial test pressure was sufficient to lug
the engine.
U28 C3 calibration is too high -- The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U29 C4 calibration is too low -- The initial test pressure was sufficient to lug
the engine.
U30 C4 calibration is too high -- The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U31 Wheel motion detected during calibration -- Handbrake was not applied or the calibration
threshold was too low such that initial test
pressure was enough to cause slight wheel
motion prior to lugging the engine.
U32 C1 calibration is too low -- The initial test pressure was sufficient to lug
the engine.
U33 C1 calibration is too high -- The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U34 C2 calibration is too low -- The initial test pressure was sufficient to lug
the engine.
U35 C2 calibration is too high -- The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.

604.55.041.00 - 01 - 1998
6 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

H2 Transmission Clutch Spring

Pressure Calibration Review
Select H2 with the test switch.

13
The display will automatically show the stored
calibration values for C1, C2, C3, C4 and then
return to the “HH” screen.

14
H3 See Electronic Draft Control ’H’ Menus

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 7

H4 Software Revision Level

Select H4 with the test switch.

16
The display will automatically show software
information:
AF 16x16 transmission
82 Software level
01 Prototype software (if any)
and then return to “HH” screen.

17
H5 Transmission/EDC Switch Test
Select H5 with the test switch.

18
The display will then show “d0”.
If a transmission or EDC switch is operated the
display will show a code number and an audible
tone will be heard to indicate correct operation.
If the code and tone do not operate, the switch or
wiring could be at fault.

604.55.041.00 - 01 - 1998
8 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

16x16 Switch Diagnostics

Code Switch Operated
d71 Inching Pedal Switch
d74 Downshift Switch
d75 Upshift Switch
d77 5--8 Range Switch
d78 Creeper Switch
d81 1--4 Range Switch
d82 Low Range Switch
d83 High Range Switch
d85 Neutral Switch
d91 Manual differential lock switch position
d92 40_C Oil Temperature Switch
d93 Fuse No. 12 Sense
d94 Shuttle Dump Switch
d95 Right Foot brake switch
d96 Left Foot brake switch
d99 Auto differential lock switch

H6 Select rear tyre rolling radius

Using a diagnostic lead, select H6 in the diagnostic

menu.
The current radius will be displayed (in millimetres).
On a new vehicle this will be the basic build tyre
radius and will not need changing unless different
size tyres are fitted.

20
By pressing the Transmission Upshift button a
larger radius may be selected and Downshift
button selects a smaller radius. Use the buttons to
select the value closest to the actual radius.

604.55.041.00 - 01 - 1998
SECTION 55-- ELECTRICAL SYSTEMS -- CHAPTER 11 9

TYRE RADIUS INDEX FOR ROAD SPEED CALCULATION

Tyre Size Radius Tyre Size Radius Tyre Size Radius
Designation Index Designation Index Designation Index
8.3 -- 24 470 18.4 -- 28 IND 685 360 / 70 R24 540
-- 32 570 -- 30 720 R28 590
-- 36 620 -- 30 IND 715 380 / 70 R20 510
-- 38 645 -- 34 770 R24 560
-- 44 720 -- 38 820 R28 610
9.5 -- 20 445 -- 42 870 400 / 70 R20 520
-- 24 495 19.5L -- 24 IND 610 R24 560
-- 28 545 20.8 -- 34 805 420 / 70 R24 590
-- 36 645 -- 38 855 R28 640
-- 38 670 -- 42 905 R30 665
-- 44 745 21L -- 24 IND 635 460 / 70 R24 590
-- 48 795 -- 30 720 480 / 70 R24 620
11.2 -- 20 465 23.1 -- 26 760 R26 645
-- 24 515 -- 26 IND 750 R28 670
-- 28 565 -- 30 810 R30 695
-- 36 665 -- 34 860 R34 745
-- 38 690 24.5 -- 32 855 R38 795
12.4 -- 20 490 28L -- 26 720 500 / 70 R34 745
-- 24 540 30.5L R32 860 520 / 70 R26 650
-- 28 590 1050 / 50 R32 855 R30 720
-- 32 640 800 / 60 R32 820 R34 770
-- 36 690 440 / 65 R24 560 R38 820
-- 38 720 R28 610 540 / 70 R34 770
-- 46 820 480 / 65 R24 590 580 / 70 R26 670
13.6 -- 24 560 R28 640 R38 855
-- 26 585 540 / 65 R24 620 R42 905
-- 28 610 R26 645 600 / 70 R30 745
-- 36 715 R28 670 620 / 70 R26 720
-- 38 740 R30 695 R38 855
14.9 -- 24 590 R34 745 R42 905
-- 24 IND 580 R38 795 650 / 70 R26 745
-- 26 615 600 / 65 R28 695 R30 795
-- 28 640 R32 745 680 / 70 R32 820
-- 28 IND 630 R34 770 R34 855
-- 30 665 R38 820 710 / 70 R38 905
-- 38 765 650 / 65 R38 855 340 / 75 R20 480
15.5 -- 38 745 R42 905 380 / 75 R20 500
16.9 -- 24 620 750 / 65 R26 770 620 / 75 R26 760
-- 24 IND 610 800 / 65 R32 870 R30 810
-- 26 645 260 / 70 R16 360 R34 860
-- 28 670 R18 390 650 / 75 R32 835
-- 28 IND 660 R20 415 R34 855
-- 30 695 280 / 70 R16 375 680 / 75 R32 870
-- 34 745 R18 400 710 / 75 R34 905
-- 34 IND 730 300 / 70 R16 375 210 / 80 R16 345
-- 38 795 R18 405 250 / 80 R16 385
-- 42 845 R20 445 R18 410
17.5L -- 24 IND 580 320 / 70 R20 465 260 / 80 R20 445
18.4 -- 24 IND 635 R24 515 320 / 80 R18 IND 475
-- 26 670 R28 565
-- 26 IND 665 360 / 70 R20 490

604.55.041.00 - 01 - 1998
10 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

Find the rolling radius of the rear tyres of the vehicle

using the table provided on the previous page or if
the tractor is fully built and tyres at the correct
pressure the radius can be measured (in
millimetres) from centre of rear axle to ground.

22
The Upshift and Downshift buttons pressed
together will toggle the groundspeed display
between Kph and Mph units. The default setting is
Mph.
Once you have the radius and display units
selected, key off and disconnect the diagnostic
lead. This will store the details in Non-Volatile
Memory (i.e. values will not be lost if battery is
disconnected).

23
H7 Auto Radius Calibration
(400 foot / 122m dash)
Mark out a 400 foot / 122 metre distance on level
ground.
Install the Test Switch and start the engine.
Select H7 with the test switch.

24
The display will change to show the current radius
(in millimetres). On a new vehicle this will be the
basic build tyre radius and will not need changing
unless different size tyres are fitted.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 11

With the transmission in high range (hare) and gear

lever in 1--4 group.
Drive the tractor towards Start Line, as the front
wheels cross the line press the Upshift button. The
display will now show “Run”. Continue to the End
line and as the front wheels cross, press the
Downshift button.
The radius of the rear wheels will now be displayed.

Further presses of the Downshift button will toggle

the groundspeed display between Kph and Mph
units. The default setting is Mph.
Once you have the radius and display units 26
selected, key off to store the settings.

H8 Non Volatile Memory Reset

Select H8 with the test switch.
WARNING!
H8 WILL CLEAR ALL CALIBRATION VALUES
AND STORED ERROR CODES

27
After selecting H8 the display will change to “EE”
(Erase EPROM) automatically.
The display will then return to the “HH” screen.

604.55.041.00 - 01 - 1998
12 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

H9 Vehicle Sensor Operation Display

Select H9 with the test switch.
H9 allows various signals to and from solenoids,
potentiometers etc. to be checked for both
transmission and EDC systems.

29
The required channel can be selected by using the
up/downshift switches.
NOTE: 4 seconds after selecting a channel, the
channel number will be replaced by a value for that
channel.

Channel
Number Description Typical Approximate Values

0 Clutch Pedal position 91 Released, 26 Depressed

1 Transmission Oil Temperature 75 at 40_C
2 Transmission 40_C 96 > 40_C, 2 < 40_C
3 Fuse 12 Sense 96
4 Not applicable to service 49
5 5 Volt Reference (Transmission Control) 49
6 12 Volt Vf Input (Fuse 13) 42
7 12 Volt Vd Input (Clutch Switch) 43
8 12 Volt Vh Input (Fuse 14) 43
9 8 Volt Reference (EDC Control) 79
10 Not used --
11 Not applicable to service --
12 Not applicable to service --
13 Not applicable to service --
14 C1 Valve Current Sense 92 Engaged, 0 Not Engaged
15 C2 Valve Current Sense 92 Engaged, 0 Not Engaged
16 C3 Valve Current Sense 92 Engaged, 0 Not Engaged
17 C4 Valve Current Sense 92 Engaged, 0 Not Engaged
18 EDC Valve Raise Solenoid Current 0--73

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 13

Channel
Number Description Typical Approximate Values

19 EDC Valve Lower Solenoid Current 0--73

20 Ground Speed Signal 64
21 Not used --
22 Not used --
23 Not used --
24 Not used --
25 Implement Status Lamp Sense 7 when illuminated
26 Wheel Slip Lamp Sense 7 when illuminated
27 Not used --
28 Lift Arm Position Sensing Potentiometer 33 Lift Lowered
83 Lift Raised
29 Lift Control Lever Potentiometer 27 Fully Lowered
83 Fully Raised
30 Drop Rate Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
31 Height Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
32 Position/Draft Sensitivity Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
33 Slip Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
34 Right Hand Load Sensing Pin 48 When Implement not being used
35 Left Hand Load Sensing Pin 48 When Implement not being used

NOTE: To observe the values for channels 14, 15, 16 and 17 the engine needs to be running and the appropriate
gear selected.

The values quoted are approximate typical values and these may vay slightly from tractor to tractor. Allow up
to 10% on the figures quoted.

Explanations:
Vf Input: This is the input voltage into the microprocessor to transmission components not directly affected
by the clutch pedal switch, i.e. PWM solenoids C1 and C2 and the Creeper solenoid.
Vd Input: This is the input voltage into the microprocessor to transmission components which are affected by
the clutch pedal switch, i.e. PWM solenoids C3 and C4.
Vh Input: This is the input voltage into the microprocessor for EDC components, i.e. Raise and Lower
solenoids.

604.55.041.00 - 01 - 1998
14 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

HA Clutch Pedal Position Display

and Oil Temperature
Select HA with the test switch.

31
The position of the clutch pedal can then be
monitored.
Use this mode to correctly set up the clutch pedal
switch. The switch should operate between 8
(down click) and 14 (upwards click).

32
HB View Stored Error Codes
Select HB with the test switch.

33
The most recent error code will be displayed.

Up to 30 error codes can be stored. This display

mode sorts the error codes so that the errors which
occurred most recently are displayed first.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 15

To view the hours of the last occurence depress

and hold the upshift button.
Continue to hold the upshift button and after 2
seconds of displaying the hours, the screen will go
blank then the number of occurences will be
displayed.

35
To select the next stored error code press the
downshift.
NOTE: Ongoing error conditions will be counted
each time the key switch is turned on. For
example, E51 (temperature sensor open circuit)
could show a large number of occurrences simply
because the circuit has been open for months, and
the error was detected each time the tractor was
started.

To return to the ’top’ of the list depress both up and

downshift buttons together.

36
When there are no more error codes to select the
display will show three dashes.

37
HC Clear Stored Error Codes
This mode functions like ’H8’ but only clears stored
error codes. Calibration values are not affected.

Select HC with the test switch.

The dispaly will go blank, show ’EE’ go blank again
and then return to ’HH’.

604.55.041.00 - 01 - 1998
16 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

HD View Live Error Codes

Select HD with the test switch.
After a few seconds the display will revert to normal
operating mode.
This mode allows normal tractor operation, but any
detected errors will cause an error code to be
displayed, whether they are disabling or not.
Key off, then on, to reset system to normal
operation, i.e. only disabling error codes
displaying.

39
HE Clutch Fill Time Adjustment
Set up procedure:
S Warm the oil to normal operating temperature,
at least 60!C.
S Park the tractor on a level surface. Allow some
space as the tractor will move when testing
clutches 3 and 4.
S with a diagnostic tool installed start the engine
and set engine speed to 1200 +/-- 100 rpm.

40
Entering the calibration mode :
Place the 4--5 (main) and range levers in neutral,
place the shuttle lever in forward and release the
clutch pedal.
Using diagnostic tool 4FT950 select mode HE.

If the oil temperature is less than 60!C ’F1’ will

be displayed, alternating with the display of oil
temperature. This will NOT stop until the oil
reaches 60!C.

41
CLUTCH SELECTION:
While the 4--5 lever is in neutral, the display will
indicate which clutch is selected.

To select C1 or C2 the range lever must be in

neutral.
To select C3 or C4 the range lever must be in the
high range

To switch between C1 and C2 or C3 and C4,

press the upshift or downshift switch while the
4--5 lever is in neutral.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 17

ADJUST AND TEST C1 OR C2

Shift the 4--5 lever into 5 (forward).
This display will show C1 or C2 and to the left of
this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on the C3 and
C4 clutches to prevent output rotation of the C1
and C2 clutches.

43
The display will then change to a single digit
number which is indicating the quickfill time in 10
millisecond units.
This can be adjusted using the upshift and
downshift switches.

44
To test the quickfill setting, press and release the
dump switch. The display will show ’Fill’ and then
return to the quickfill setting.
Listen to the clutch engagement ’Slap’.
Increase the value to a point where a ’slap’ is just
audible and then reduce the value by 2.

45
ADJUST AND TEST C3 OR C4

Ensure that the handbrake is OFF.

Shift the range lever into the high range.

Shift the 4--5 lever into 5 (forward) and release

the clutch pedal.

604.55.041.00 - 01 - 1998
18 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

This display will show C3 or C4 and to the left of

this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on C1 clutch to
connect C3 and C4 to the engine.

47
The display will then change to a single digit
number which is indicating the quickfill time in 10
millisecond units.This can be adjusted using the
upshift and downshift switches.

48
To test the quickfill setting, press and release the
dump switch. The display will show ’Fill’ and then
briefly to the clutch selected then the quickfill
setting.
As the dump switch is released the tractor should
be felt to ’rock’ as the clutch fills.

49
Adjust the fill time until the rock is barely noticeable,
then reduce the value by 2.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 19

24x24 Dual Command Transmission ‘H’ Routine

The ‘H’ routine consists of the following H menu codes:

HH Service Menu Page

H1 Not used for 24x24 transmission 20
H2 Transmission clutch spring pressure calibration review 20
H3 (EDC valve calibration values) 21
H4 Software revision level 21
H5 Switch test 22
H6 Select rear tyre rolling radius 23
H7 Auto radius calibration (400 Foot / 122m Dash) 25
H8 Non volatile memory reset (Erase Calibrations) 26
H9 Vehicle sensor operation display 27
HA Clutch pedal position view and oil temperature 29
HB View stored error codes 29
HC Clear stored error codes 30
HD View live error codes 31
HE Clutch fill time adjustment 31
HF Transmission clutch spring pressure calibration 33

604.55.041.00 - 01 - 1998
20 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

H1 Not used

51
H2 Transmission Clutch Calibration
Value Review
Select H2 with the test switch.

52
The display will change to show first the Lo clutch
stored calibration value and then the Hi clutch
value.

NOTE: The appropriate light, hare or tortoise will

also illuminate.

53
The display automatically returns to HH.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 21

H3 See “Electronic Draft Control” ’H’ Menus

55
H4 Software Revision Level
Select H4 with the test switch.

56
The display will automatically display:
AE 24x24 dual command transmission
82 Software level
01 Prototype software (if any)
and then return to “HH” screen.

604.55.041.00 - 01 - 1998
22 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

H5 Transmission/EDC Switch Test

Select H5 with the test switch.

58
The display will then show “d0”.

59
If a transmission or EDC switch is operated a code
number will be displayed along with an audible tone
to indicate correct operation.
If the code number and tone do not operate, the
switch or wiring could be at fault.

Switch Code Switch Description

d71 Clutch Pedal Switch
d74 Dual Power Downshift Switch
d75 Dual Power Upshift Switch
d81 High/medium in Gear Switch
d82 Main in Gear Switch -- 1/2 and 3/4 Gear Switches
d85 Neutral Start Switch
d91 Shuttle Dump Switch
d92 Hydraulic Oil Temperature Switch
d93 Fuse No. 12 Sense
d94 Manual Differential Switch
d95 Right Foot Brake Switch
d96 Left Foot Brake Switch
d99 Auto differential Lock Switch

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 23

H6 Select Rear Tyre Rolling Radius

Using a diagnostic lead, select H6 in the diagnostic

menu.
The current radius will be displayed (in millimetres).
On a new vehicle this will be the basic build tyre
radius and will not need changing unless different
size tyres are fitted.

61
By pressing the Transmission Upshift button a
larger radius may be selected and Downshift
button selects a smaller radius. Use the buttons to
select the value closest to the actual radius.

62
Find the rolling radius of the rear tyres of the vehicle
using the table provided on the following page or if
the tractor is fully built and tyres at the correct
pressure the radius can be measured (in
millimetres) from centre of rear axle to ground.

604.55.041.00 - 01 - 1998
24 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

TYRE RADIUS INDEX FOR ROAD SPEED CALCULATION

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 25

The Upshift and Downshift buttons pressed

together will toggle the groundspeed display
between Kph and Mph units. The default setting is
Mph.
Once you have the radius and display units
selected, key off and disconnect the diagnostic
lead. This will store the details in Non-Volatile
Memory (i.e. values will not be lost if battery is
disconnected).

H7 Auto Radius Calibration

(400 foot / 122m dash)
Mark out a 400 foot / 122 metre distance on level
ground.
Install the Test Switch and start the engine.
Select H7 with the test switch.

65
The display will change to show the current radius
(in millimetres). On a new vehicle this will be the
basic build tyre radius and will not need changing
unless different size tyres are fitted.

604.55.041.00 - 01 - 1998
26 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

With the transmission in high range and main shift

lever in gear 2.
Drive the tractor towards Start Line, as the front
wheels cross the line press the Upshift button. The
display will now show “Run”. Continue to the End
line and as the front wheels cross, press the
Downshift button.
The radius of the rear wheels will now be displayed.

Further presses of the Downshift button will toggle

the groundspeed display between Kph and Mph
units. The default setting is Mph.
Once you have the radius and display units 67
selected, key off to store the settings.

H8 Non Volatile Memory Reset

Select H8 with the test switch.
WARNING!
H8 WILL CLEAR ALL CALIBRATION VALUES
AND STORED ERROR CODES

68
After selecting H8 the display will change to “EE”
(Erase EPROM) automatically.
The display will then return to the “HH” screen.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 27

H9 Vehicle Sensor Operation Display

Select H9 with the test switch.
H9 allows various signals to and from solenoids,
potentiometers etc. to be checked for both
transmission and EDC systems.

70
The required channel can be selected by using the
up/downshift switches.
NOTE: 4 seconds after selecting a channel, the
channel number will be replaced by a value for that
channel.

71
Channel
Number Description Typical Approximate Values

0 Clutch Pedal position 91 Released, 26 Depressed

1 Transmission Oil Temperature 75 at 40_C
2 40_C Hydraulic Oil Switch 96 > 40_C, 2 < 40_C
3 Fuse 12 Sense 96
4 Not applicable to service --
5 5 Volt Reference (Transmission Control) 49
6 12 Volt Vf Input (Fuse 13) 42
7 12 Volt Vd Input (Clutch Switch) 43
8 12 Volt Vh Input (Fuse 14) 43
9 8 Volt Reference (EDC Control) 79
10 Not used --
11 Not applicable to service --
12 Not applicable to service --
13 Not applicable to service --
14 Not used --
15 Dump Solenoid Current Sense 0 Clutch engaged, out of gear
97 Clutch engaged, in gear
16 C1 Clutch Solenoid Current Sense 0 Clutch engaged, out of gear
82 Clutch pedal released in underdrive

604.55.041.00 - 01 - 1998
28 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

Channel
Number Description Typical Approximate Values

17 C2 Clutch Solenoid Current Sense 0 Clutch engaged, out of gear

82 Clutch pedal released in direct drive
18 EDC Valve Raise Solenoid Current 0--66
19 EDC Valve Lower Solenoid Current 0--66
20 Ground Speed Signal 64
21 Not used --
22 Not used --
23 Not used --
24 Not used --
25 Implement Status Lamp Sense 7 when illuminated
26 Wheel Slip Lamp Sense 7 when illuminated
27 Not used --
28 Lift Arm Position Sensing Potentiometer 33 Lift Lowered
83 Lift Raised
29 Lift Control Lever Potentiometer 27 Fully Lowered
83 Fully Raised
30 Drop Rate Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
31 Height Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
32 Position/Draft Sensitivity Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
33 Slip Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
34 Right Hand Load Sensing Pin 48 When Implement not being used
35 Left Hand Load Sensing Pin 48 When Implement not being used

NOTE: To observe the values for channels 15, 16 and 17 the engine needs to be running and the appropriate
gear selected.

The values quoted are approximate typical values and these may vay slightly from tractor to tractor. Allow up
to 10% on the figures quoted.

Explanations:
Vf Input: This is the input voltage into the microprocessor to transmission components not directly affected
by the clutch pedal switch, i.e. Dump solenoid, Diff lock solenoid and four wheel drive solenoid
Vd Input: This is the input voltage into the microprocessor to transmission components which are affected by
the clutch pedal switch, i.e. PWM solenoids C1 and C2.
Vh Input: This is the input voltage into the microprocessor for EDC components, i.e. Raise and Lower
solenoids.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 29

HA Clutch Pedal Position Display

and Oil Temperature
Select HA with the test switch.

72
The position of the clutch pedal can then be
monitored.
Use this mode to correctly set up the clutch pedal
switch. The switch should operate between 8
(down click) and 14 (upwards click).

73
HB View Stored Error Codes
Select HB with the test switch.

The most recent error code will be displayed.

Up to 30 error codes can be stored. This display

mode sorts the error codes so that the errors which
occurred most recently are displayed first.

604.55.041.00 - 01 - 1998
30 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

To view the hours of the last occurence depress

and hold the upshift button.
Continue to hold the upshift button and after 2
seconds of displaying the hours, the screen will go
blank then the number of occurences will be
displayed.

76
To select the next stored error code press the
downshift.
NOTE: Ongoing error conditions will be counted
each time the key switch is turned on. For
example, E51 (temperature sensor open circuit)
could show a large number of occurrences simply
because the circuit has been open for months, and
the error was detected each time the tractor was
started.

To return to the ’top’ of the list depress both up and

downshift buttons together.

77
When there are no more error codes to select the
display will show three dashes.

78
HC Clear Stored Error Codes
This mode functions like ’H8’ but only clears stored
error codes. Calibration values are not affected.

Select HC with the test switch.

The dispaly will go blank, show ’EE’ go blank again
and then return to ’HH’.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 31

HD View Live Error Codes

80
HE Clutch Quick Fill Adjustment

Warm the oil to normal operating temperature, at

least 60 degrees Celsius.

Park the tractor on a level surface. Allow some

space, as the tractor will move during testing.

With the diagnostic switch installed, start the

engine and set the engine speed to 1200 rpm.
Select diagnostic mode HE.

604.55.041.00 - 01 - 1998
32 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

If the oil temperature is less than 60 degrees

Celsius, ”F1” will be displayed, Alternating with
display of oil temperature. This display WILL NOT
GO AWAY unless the oil temperature reaches 60
degrees.

82
CLUTCH SELECTION:
While the 1--4 lever is in neutral, press the
downshift switch to select the Lo clutch or press the
upshift switch to select the Hi clutch. The selected
clutch will be indicated at all times by an L or an H
in the left digit of the transmission LCD display. The
number to the right of the L or H indicates the
quickfill duration for the selected clutch.

83
ADJUST AND TEST CLUTCHES
Shift the main shift lever into gear (no need to use
the clutch pedal, the clutches are all dumped), then
use the shuttle dump button or the clutch pedal,
shift the shuttle lever into gear, Release the hand
brake and SLOWLY release the clutch pedal until
the tractor “moves” (approx 20 % of pedal travel).
Observe whether the tractor nudges at the
beginning of clutch engagement. If there is no
nudge, the quickfill duration should be increased
until there is a slight nudge.
If the nudge is more of a jerk, the quick fill duration
should be decreased.
The factory setting is 3. 84

To adjust the quickfill duration, depress the clutch

pedal or shift the shuttle lever to neutral (but leave
the main shift lever in gear), then use the upshift
and downshift switches to increase or decrease the
number on the display.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 33

HF Clutch Spring Pressure Calibration

Connect diagnostic test switch 4FT950.

86
Start the engine.
Select mode HF, using the test switch.

87
”CAL” will be displayed for a few seconds, then
the display will be controlled by clutch pedal
position as follows:
Pedal down (below 10%) -- Calibration value for
the selected clutch is displayed.
Pedal up (above 98%) -- Oil temperature is
displayed.
Pedal between 10% and 98% -- Pedal position is
displayed.

88
Set engine speed to 1200 +/-- 100 rpm.

604.55.041.00 - 01 - 1998
34 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

1. To select the clutch to be calibrated, shift the

90
2. Depress the clutch pedal, select a gear and
range, and slowly release the pedal to check
the engagement point.

Note 1: Releasing the pedal beyond 35% will not

further increase the clutch pressure.

Note 2: If the pedal is released above 90%, the

clutch pressure will dump after a few seconds.
Fully depress the pedal to restore operation.

Note 3: If the calibration value has previously been

set too high, the clutch may engage and move the
tractor, particularly if a low gear has been selected 91
and the brake is not firmly engaged. If calibration
is required because a PWM valve has been
replaced, the calibration number should be
reduced to 110 or less before releasing the clutch
pedal, as the old calibration value may be much too
high.

3. Use the upshift switch to increase the

calibration value or use the downshift switch to
decrease the calibration value as required to
move the clutch engagement point to 35%
pedal travel. The value can be adjusted even
when it is not being displayed.
4. After calibrating both clutches, turn off the key
switch for at least 1 second to store the
calibration values.

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 35

Electronic Draft Control (EDC) -- ‘H’ Routines

The EDC ‘H’ routine consists of the following H menu codes:

HH Service Menu Page

H1 EDC Calibration Procedure 35
H2 EDC Disable 36
H3 EDC Valve Calibration review 37
H4 Software review (as transmission) 38
H5 Switch Test 39
H8 Non volatile memory reset 40
H9 Voltmeter (as transmission) 40

H1 EDC Calibration Procedure

Disconnect the Automatic Pick Up Hitch (APUH)
rods.
Lower linkage using control lever & connect to
suitable weights (approx 200Kg) capable of
overcoming any binding within the system.
Install the diagnostic switch, Tool No.4FT.950 or
start the engine with the raise/work/lower switch
depressed to enter the calibration mode, H1.

The instrument cluster EDC display will show

’CAL’.
Set the engine speed to 1200 +/-- 100 rpm

604.55.041.00 - 01 - 1998
36 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

Set all EDC panel potentiometers fully clockwise

95
Move the lift lever to the fully lowered position.

Pull the lever to the top of its travel and allow arms
to fully raise. Check that the display increases to
99.
Reconnect and adjust the APUH rods. Adjust the
length of the rods so that when the lift is fully raised
using the external fender switches the lift rods are
slightly loose. Check that the APUH operates
correctly

96
Lower the control lever to 70% to 90% to start valve
calibration sequence. During calibration the
linkage is automatically raised & lowered a small
amount 3 times, which takes 2--3 minutes. Each
raise & lower is accompanied by a count on the
display 0--1--2. When display indicates ”end” the
calibration is complete.

Key off to store calibration values

97
H2 EDC Disable
To prevent false EDC error codes on tractors not
fitted with EDC it is possible to disable the test
which looks for sensors fitted. This can be used to
overcome concerns where water and corrosion
affects unused connectors.
Select H2 with the test switch

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 37

EDC Disable:
Wait until H2 is cleared from the display, as the
transmission clutch pressure values are being
displayed, press the main shift lever upshift and
downshift switches together. The EDC display
should now be disabled.
Key off and remove test switch.

99
EDC Re--enable:
WARNING!
H8 WILL CLEAR ALL CALIBRATION VALUES
AND STORED ERROR CODES

Enter H8 diagnostic mode using diagnostic lead.

Once EE has flashed twice to indicate clearing of
calibration values key off.
Re--calibrate transmission clutches and EDC as
previously described in this section.
The processor will now have EDC enabled.

100
H3 EDC Valve Calibration Review
Select H3 with the test switch.

101
The display will show the solenoid calibration
values (milliamps) for raise first and then lower.
NOTE: The default value is 50, other values
indicate that a calibration has been performed.

102

604.55.041.00 - 01 - 1998
38 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

After a few seconds the display will show an ’r’

followed by a number between 0 and 3.
This indicates the number of assist rams fitted.
This can be adjusted by toggling the raise/work
switch between the work and raise positions until
the correct figure for the tractor build is shown.
This is important to ensure correct operation of the
EDC system.

103
H4 Software Revision Level
Select H4 with the test switch.

104
The display will automatically display:
AE 24x24 dual command transmission
82 Software level
01 Prototype software (if any)
and then return to “HH” screen.

105

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 39

H5 Transmission/EDC Switch Test

Select H5 with the test switch.

106
The display will then show “d0”.

107
If a transmission or EDC switch is operated a code
number will be displayed along with an audible tone
to indicate correct operation.
If the code number and tone do not operate, the
switch or wiring could be at fault.

108
Switch Code Switch Description
d1 External Fender switch -- Lower
d2 External Fender switch -- Raise
d3 Raise/work/Lower internal switch -- Raise
d4 Raise/work/Lower internal switch -- Work
d5 Raise/work/Lower internal switch -- Lower

604.55.041.00 - 01 - 1998
40 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11

H8 Non Volatile Memory Reset

Select H8 with the test switch.
WARNING!
H8 WILL CLEAR ALL CALIBRATION VALUES
AND STORED ERROR CODES

109
After selecting H8 the display will change to “EE”
(Erase EPROM) automatically.
The display will then return to the “HH” screen.

110
H9 Vehicle Sensor Operation Display
Select H9 with the test switch.
H9 allows various signals to and from solenoids,
potentiometers etc. to be checked for both
transmission and EDC systems.

111
The required channel can be selected by using the
up/downshift switches.
NOTE: 4 seconds after selecting a channel, the
channel number will be replaced by a value for that
channel.

112

604.55.041.00 - 01 - 1998
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 11 41

Channel
Number Description Typical Approximate Values

2 40_C Hydraulic Oil Switch 96 > 40_C, 2 < 40_C

3 Fuse 12 Sense 96
4 Not applicable to service --
5 5 Volt Reference (Transmission Control) 49
8 12 Volt Vh Input (Fuse 14) 43
9 8 Volt Reference (EDC Control) 79
10 Not used --
11 Not applicable to service --
12 Not applicable to service --
13 Not applicable to service --
14 Not used --
18 EDC Valve Raise Solenoid Current 0--66
19 EDC Valve Lower Solenoid Current 0--66
20 Ground Speed Signal 64
21 Not used --
22 Not used --
23 Not used --
24 Not used --
25 Implement Status Lamp Sense 7 when illuminated
26 Wheel Slip Lamp Sense 7 when illuminated
27 Not used --
28 Lift Arm Position Sensing Potentiometer 33 Lift Lowered
83 Lift Raised
29 Lift Control Lever Potentiometer 27 Fully Lowered
83 Fully Raised
30 Drop Rate Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
31 Height Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
32 Position/Draft Sensitivity Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
33 Slip Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
34 Right Hand Load Sensing Pin 48 When Implement not being used
35 Left Hand Load Sensing Pin 48 When Implement not being used

The values quoted are approximate typical values and these may vay slightly from tractor to tractor. Allow up
to 10% on the figures quoted.
Explanations:
Vf Input: This is the input voltage into the microprocessor to transmission components not directly affected
by the clutch pedal switch.
Vd Input: This is the input voltage into the microprocessor to transmission components which are affected by
the clutch pedal switch.
Vh Input: This is the input voltage into the microprocessor for EDC components, i.e. Raise and Lower
solenoids.

604.55.041.00 - 01 - 1998
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 1
SECTION 55 – ELECTRICAL SYSTEM

Chapter 12 – Wiring Diagrams

(Power Shuttle and with cab models from Serial no. 139307B)

CONTENTS

Description Page

Wiring diagram circuit descriptions (All Models) 1

How to use the linear wiring diagrams 2

Symbols 4

Component identification and wiring diagram location key 5

Wiring Diagrams:

Electroshift Transmission, With Cab 11

Electroshift Transmission, Less Cab 51
Dual Command Transmission, With Cab 91
Synchro Command Transmission, With Cab 131

Wire identification key 171

System Diagrams 183

Wiring Diagrams Circuit Description – All Models Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0–390

Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400–1590

Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600–2790

Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800–3190

Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200–3590

Circuit 6 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600–4390

Circuit 7 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400–5190

Circuit 8 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5200–5990

Circuit 9 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000–6390

Circuit 10 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400–6790

Circuit 11 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800–7190

Circuit 12 Air–Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7200–7590

604.55.041.02 01 –2000
2 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12

HOW TO USE THE LINEAR WIRING DIAGRAMS

The wiring diagrams have been drawn in a linear
style. This means that the complete wiring diagram
has been drawn over a number of pages but if joined
together would make a complete diagram.

There are a number of guides to help assist in

reading and understanding the wiring diagrams.

1. The wiring diagrams (1) are located at the top of

each page. The title and key (2) are located
below the diagram and the wire colour code table
(3) is located below the key.

The title under the diagram details the models of

the range that are applicable, the model
configuration, ie, transmission type, with or less
cab and the serial number of the tractor to which
the diagrams apply. The key then details all the
components used within that particular page.

2. Every component and connector has its own

unique reference number.

3. Every wire has a code assigned to it (1) this code

refers to its function, the code is not marked on
the actual wire. A key of all wire codes can be
found at the rear of this section. Letters (2), (3)
and (4) indicate the wire colour. The first letter (2) 2
indicates the main wire colour. The second letter
(3) indicates tracer wire colour, the third letter (4)
indicates the band colour, for example wire
reference (5) and number 57 is an earth wire,
letter (6) B indicates its a solid black wire.

4. Each component and connector pin appears

only once in the electrical drawings and has its
own location point on the page.

5. The wiring diagrams are drawn in sections.

However where a single component is used in a
number of circuits such as a processor or multi
function switch, it is drawn either on its own or on
the circuit which it influences the most.

604.55.041.02 01 –2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 3
6. The wiring is drawn between four lines three
across the top of the page and one at the bottom
of the page.

The two upper most lines (1) marked +30A and

+30B are the constant live lines.
Below the +30 line is the +15 (2) which is the
ignition key on live line.
The lowest line (4) is the ground/earth line. 4
On the lower part of the page (3) a line is marked
with numbers increasing by ten (10–20–30,
etc.). This is the line used to reference wires and
components.
Example
3
Figures 4 and 5 show a basic circuit drawn over two
pages.

Power comes in from the ignition on live line +15

through fuse F3, which is located at point 230.
F3

Power comes to switch S10. If the switch is operated,

power continues up and stops with an arrow (1) and a
number. The arrow indicates the wire continuing to
another page. The Number 780 refers to the line
4
reference where it appears on a new page. Note the
line reference directly below the wire being traced ie.
260. Following the line reference until 780 is found.
Using either the index or following the page
reference line. When 780 is located on the reference
line the number 260 will be observed at the top of the
page. Note the arrow points back to the previous part Y3

of the circuit. From this point follow the wire down to

solenoid ’Y3’. The diagram now indicates that power
goes to ground.

Where a circuit originates or terminates at a

processor, ie, Transmission processor, EDC 5
processor, Electronic Management Unit or
Instrument cluster, the wire in the diagram is ended
with a small circle and a connector reference
number. A white circle (1) indicates a processor, a
black circle (2) indicates an instrument cluster.
The diagrams have been constructed to ensure the
minimum number of pin–outs, detailed above, are
used. Due to this, many diagrams have been spread
across 2 sheets and it will be necessary to follow from
one page across to the next to complete a circuit.

604.55.041.02 01 –2000
4 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
Symbols

Fuse

Horn

Relay

Diode

Motor

Switch

Earth/ground point

Resistor

Sensor

Electro–Valve/solenoid
Potentiometer

Temperature Switch
Lamp

Pressure Switch
Speaker

Processor
Connector pin

604.55.041.02 01 –2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 5
SYMBOL DRAWING DESCRIPTION
LOCATION
(A) PROCESSORS,
MODULES AND PANELS
A001 7140 Transmission And EDC Processor
A002 1080 Gear Shift Display Module
A003 1740 EDC Panel
A004 4320 Radio
A005 6810 Diagnostic Connector
A006 4540 External Buzzer Unit
A007 7020 Instrument Cluster A (C079)
A008 7020 Instrument Cluster B (C080)
A009 7000 Instrument Cluster C (C081)
(B) SENSORS, SENDERS
AND POTENTIOMETERS
B1 6280 Engine Oil Pressure Sensor
B2 6210 Engine Coolant Temperature Sensor
B3 6320 Fuel Tank Sender
B4 6370 Radar
B5 2160 Axle Speed Sensor
B6 1740 Height Limit Potentiometer
B7 1740 Slip Limit Potentiometer
B8 1740 Drop Rate Potentiometer
B9 1740 Draft/Position Potentiometer
B10 2310 Rocker Shaft Potentiometer
B11 1930 Quadrant Lever Potentiometer
B12 2160 Draft Pin Left
B13 2310 Draft Pin Right
B14 7520 Temperature Control Potentiometer
B15 4350 Speaker
B16 4290 Speaker
B17 3620 Horn
B18 1550 Clutch Pedal Potentiometer
B19 1480 Synchroniser Position Potentiometer
(C) SPECIAL CONNECTORS
C226 3100 Four Wheel Drive Braking Connector
(Synchro Command Only)
(E) MISCELLANEOUS
E1 7400 Air Conditioning Compressor Clutch
E2 4170 Interior Light
E3 3750 Console Light
(F) FUSES
F1 4590 Head Lamp Main 15A
F2 4600 Head Lamp Dip 15A
F3 5020 Side Lamp RH 15A
F4 5150 Side Lamp LH 15A
F5 5870 Work Lamp Front Low 10A
F6 5370 Work Lamp Rear Fender 15A

604.55.041.02 01 –2000
6 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
SYMBOL DRAWING DESCRIPTION
LOCATION
F7 5490 Work Lamp Front And Rear Cab Roof 20A
F8 240 Fuel Shut Off Solenoid 10A
F9 2570 Gauges And External Switches 10A
F10 4440 Hazard Lights 15A
F11 4570 Horn, Flashers, Cigar Lighter,
Roof Beacon. 30A
F12 2450 EDC 10A
F13 540 Transmission Solenoids 15A
F14 7130 EDC 10A
F15 3050 Stop Lamps, 4wd, Diff. Lock 15A
F16 7230 Air Conditioning Heater Fan 25A
F17 6510 Wiper Washer, Front Wiper,
Rear Wiper Console Lamp 20A
F18 4430 Turn Indicators 10A
F19 320 Thermostart 25A
F20 350 Processor ‘keep Alive Memory’ (KAM) 5A
F21 3220 PTO 5A
F22 4070 Radio, Implement Socket Switch And
Relay 5A
F23 4080 Accessories, Interior Lamp, Radio KAM,
EIC Buzzer. 20A
F24 4100 Interior Light 10A
FL1 20 Fuse Link
FL2 110 Fuse Link

(H) LAMP AND LIGHTS

H1 3520 PTO Lamp
H2 1740 EDC Status Lamp
H3 1740 Slip Lamp
H4 1740 Raise Lamp
H5 1740 Lower Lamp
H6 5130 Front Indicator Lamp LH ISO
H7 5170 Front Indicator Lamp RH ISO
H8 4820 Rear Indicator Lamp LH ISO
H9 4820 Rear Indicator Lamp RH ISO
H10 5090 Front Indicator Lamp LH NASO
H11 4740 Front Indicator Lamp RH NASO
H12 5100 Rear Indicator Lamp LH NASO
H13 4750 Rear Indicator Lamp RH NASO
H14 4890 Head Lamp LH
H15 4920 Head Lamp RH
H16 5130 Front Side Lamp LH
H17 5170 Front Side Lamp RH
H18 4820 Rear Brake/Tail Lamp LH
H19 4820 Rear Brake/Tail Lamp RH
H20 5420 Licence Plate Light Top RH
H21 5390 Licence Plate Light Top LH
H22 5010 Licence Plate Lamp Lower
H23 5750 Upper Front Work Lamp LH

604.55.041.02 01 –2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 7
SYMBOL DRAWING DESCRIPTION
LOCATION

H24 5810 Upper Front Work Lamp RH

H25 5730 Lower Front Work Lamp LH
H26 5790 Lower Front Work Lamp RH
H27 5380 Upper Rear Work Lamp LH
H28 5410 Upper Rear Work Lamp RH
H29 5490 Lower Rear Work Lamp LH
H30 5520 Lower Rear Work Lamp RH
H31 5300 Licence Plate Lamp L/Cab

(G) CHARGING

G1 10 Battery
G2 70 Alternator

(K) RELAYS

K 3870 Implement Socket Relay

K1 80 Ignition Relay
K2 140 Starter Relay
K3 4460 Flasher Unit Relay
KXI+XII 4690 Flasher Mode Relay
KA 2930 Diff Lock Relay (12x12 Only)
KB 5880 Front Work Lamp Relay
KC 5380 Rear Work Lamp Relay
KD 5710 Lower Front Work Lamp Relay
KE 5500 Lower Rear Work Lamp Relay
KF 230 Engine Shut Down Relay
KG 2930 Diff Lock Relay (12x12 Only)
KV+VI 3400 PTO Relay
KII 470 Accessory Socket Relay
KIV 3780 Remote Valve Relay
KVII 310 Thermostart Relay
KVIII 8540 Intermittent Front Wiper Relay
KIX 8700 Intermittent Rear Wiper Relay
KX 4650 Multi–function Switch Unload Relay

(M) MOTORS

M1 40 Starter Motor
M2 6540 Front Wiper Motor
M3 6760 Rear Wiper Motor
M4 6560 Washer Motor
M5 6640 Washer Motor
M6 7340 Blower Motor
M7 5960 Air Seat

604.55.041.02 01 –2000
8 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
SYMBOL DRAWING DESCRIPTION
LOCATION
(MF) MAXI FUSE
MF1 50 To Ignition Relay And Supply To
Fuse 9/14/15/16/17/18/21.
MF2 260 To Ignition Switch And Supplying
Fuses 8/10/11/12/13/20/22. And
Thermostart Module Fuse 19
MF3 4590 Turn Switch And Supplying Fuses 1/2/3/4.
MF4 5870 Work Lamps Fuses 5/6/7.
MF5 4080 Accessories Fuses 23/24.
MF6 3910 40 Amp. Implement Socket.
(P) CLOCKS
P2 4260 Clock
(R) RESISTORS
R1 320 Thermostart Coil
R2 250 Fuel Injection Pump Wax Motor
R3 7290 Blower Speed Resistor
R4 4030 Cigar Lighter
R5 7340 Blower Speed Resistor
(S) SWITCHES
S1 300 Ignition Switch
S2 170 Start Inhibitor Switch
S3 6240 Engine Oil Pressure Switch
S4 6130 Low Charge Pressure Switch (CCLS)
S5 6090 Hydraulic Oil Temp. Switch
S6 6070 Hydraulic Filter Blocked Switch
S7 6170 Steering Pressure Switch
S8 6190 Transmission Pressure Switch
S9 6070 Transmission Oil Temperature Switch
S10 6040 Hand Brake Switch
S11 6010 Brake Fluid Level Switch
S12 6150 Air Filter Vacuum Switch
S13 2850 FWD Switch
S14 2930 Differential Lock Switch
S15 2990 Differential Lock Engagement
Light Switch
S16 3120 Brake Switch Right Hand
S17 3120 Brake Switch Left Hand
S18 3310 PTO Switch
S19 3460 Seat Switch
S20 3260 540/1000 PTO Speed Switch
S21 670 Clutch Pedal Switch
S22 460 Creeper Switch
S23 910 Shuttle Dump Switch
S24 870 Up Shift Switch
S25 890 Down Shift Switch
S26 930 High Range Switch

604.55.041.02 01 –2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 9
SYMBOL DRAWING DESCRIPTION
LOCATION
S27 950 Low Range Switch
S28 970 1–4 Range Switch(16x16) / Hi–med Sw. (24x24)
S29 990 5–8 Range Switch
S30 2530 Raise Work Switch
S31 2610 Fender Switch Left
S32 2650 Fender Switch Right
S33 4600 Indicator Switch
S34 4460 Hazard Switch
S36 5860 Front Upper Lamp Switch
S37 5650 Front Lower Lamp Switch
S38 5380 Rear Lamp Switch
S39 6460 Front Wiper And Washer Switch
S40 6700 Rear Wiper And Washer Switch
S41 7400 Air Con High Low Pressure Switch
S42 7400 Air Con Low Pressure Cut Out Switch
S43 7530 Air Con Temp. Exchange Control Switch
S44 7270 Blower Speed Switch
S45 4150 Interior Light Door Switch
S46 4200 Interior Light Door Switch
S47 3870 40 Amp. Terminal And External
40 Amp. 4 Pin Power Switch
S48 3670 Beacon Switch
S49 3780 Remote Valve Switch
S50 760 Transmission Oil Pressure Switch
S51 950 1st / 2nd Switch
S52 990 3rd / 4th Switch
S53 250 Thermo Switch For Wax Motor
S57 610 Forward/Reverse Shuttle Lever
(X) POWER SOCKETS
Xi 3850 40 Amp. Screw Terminal
X2 4120 Accessory Socket
X3 3960 Implement Status Socket
X4 4970 Trailer Socket
X5 3890 Four Pin 40 Amp. Socket
X6 3670 Roof Beacon Socket LH
X7 3710 Roof Beacon Socket RH
(Y) SOLENOID VALVES
Y1 210 Fuel Shut Off Solenoid
Y2 280 Electric Fuel Pump
Y3 2880 Fwd Solenoid
Y4 2970 Differential Lock Solenoid
Y5 3500 PTO Solenoid
Y6 1370 Creeper Solenoid
Y7 1220 PWM Valve 1
Y8 1250 PWM Valve 2
Y9 1280 PWM Valve 3
Y10 1310 PWM Valve 4
Y11 1940 Raise Solenoid EDC Valve

604.55.041.02 01 –2000
10 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
SYMBOL DRAWING DESCRIPTION
LOCATION
Y12 1940 Lower Solenoid EDC Valve
Y13 3790 Remote Valve Solenoid
Y14 1250 Dump Solenoid
Y15 1280 Lo – PWM
Y16 1310 Hi – PWM
Y18 1410 Forward PWM
Y19 1440 Reverse PWM

604.55.041.02 01 –2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 11
WIRING DIAGRAMS:

TS SERIES:Electroshift Transmission, (16x16 with Power Shuttle) W/Cab,

Wiring Diagrams Circuit Description Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0–390

Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400–1590

Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600–2790

Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800–3190

Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200–3590

Circuit 6 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600–4390

Circuit 7 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400–5190

Circuit 8 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5200–5990

Circuit 9 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000–6390

Circuit 10 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400–6790

Circuit 11 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800–7190

Circuit 12 Air–Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7200–7590

604.55.041.02 – 01–2000
12 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP
line 0–390
STARTING KVII Thermostart relay
KF Fuel Shut Off Relay
FL1 Fuse Link
R1 Thermostart coil
FL2 Fuse Link
R2 Fuel Injection Pump Wax Motor
G1 Battery
S53 Thermostatic Switch
K1 Ignition Relay
Y1 Shut Off Solenoid
K2 Start Relay
Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch
MF1 Maxi Fuse 1 50A
CHARGING MF2 Maxi Fuse 2 60A
G2 Alternator F20 5A, Processor ’Keep alive memory’ Fuse
THERMOSTART AND FUEL SYSTEM
F8 10A, Shut off Solenoid Fuse
F19 25A Fuse

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

13
14 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

E2 Interior light R4 Cigar lighter

F22 5A, radio and accessory socket fuse S45 Interior light door switch
F23 20A, Accessories, radio S46 Interior light door switch
F24 10A, interior lamp
X2 Accessory socket
KII Accessory socket relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

33
34 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

A006

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

INDICATOR AND HAZARD LIGHTS
Line 4400–4790
A006 External Buzzer Unit
K3 Flasher unit relay
F1 15A Headlamp dip fuse KX Multi–function switch unload relay
F2 15A Headlamp main fuse KXI + Flasher mode relay
F10 15A Hazards fuse KXII
F11 30A Horn, flashers, cigar lighter, beacon fuse
F18 10A Indicators fuse MF3 Maxi fuse 3, 40A

WORKLAMPS
Line 5600–5990

F5 10A Low front worklamp KD Front lower worklamp relay

H23 Left hand upper front worklamp M7 Air seat pump

H24 Right hand upper front worklamp
H25 Left hand lower front worklamp MF4 Maxi fuse 4, 60A
H26 Right hand lower front worklamp
S36 Front upper worklamp switch
KB Front worklamp relay S37 Front lower worklamp switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

41
42 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

49
50 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12

NOTES PAGE

604.55.041.02–01–2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 51
WIRING DIAGRAMS:

TS SERIES:Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

Wiring Diagrams Circuit Description Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0–390

Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400–1590

Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600–2790

Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800–3190

Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200–3590

Circuit 6 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600–4390

Circuit 7 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400–5190

Circuit 8 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5200–5990

Circuit 9 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000–6390

Circuit 10 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400–6790

Circuit 11 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800–7190

Circuit 12 Air–Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7200–7590

604.55.041.02 – 01–2000
52 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP
line 0–390
STARTING KVII Thermostart relay
FL1 Fuse Link
R1 Thermostart coil
FL2 Fuse Link
R2 Fuel Injection Pump Wax Motor
G1 Battery
S53 Thermostatic Switch
K1 Ignition Relay
Y1 Shut Off Solenoid
K2 Start Relay
Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch
MF1 Maxi Fuse 1 50A
CHARGING MF2 Maxi Fuse 2 60A
G2 Alternator F20 5A, Processor ’Keep alive memory’ Fuse
THERMOSTART AND FUEL SYSTEM
F8 10A, Shut off Solenoid Fuse
F19 25A Fuse

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

53
54 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

WIRE COLOUR CODES

Not Applicable to this model

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

CAB ACCESSORIES
Line 4000–4390

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

73
74 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

INDICATOR AND HAZARD LIGHTS
Line 4400–4790
F1 15A Headlamp dip fuse KXI + Flasher mode relay
F2 15A Headlamp main fuse KXII
F10 15A Hazards fuse
F11 30A Horn, flashers, cigar lighter, beacon fuse MF3 Maxi fuse 3, 40A
F18 10A Indicators fuse
S33 Indicator switch
K3 Flasher unit relay S34 Hazard light switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

75
76 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

MAIN LIGHTS
Line 4800–5190
F3 15A Right hand side lamp fuse H15 Right hand headlamp
F4 15A Left hand side lamp fuse H18 Left hand rear brake lamp
H19 Right hand rear brake lamp
H8 Left hand rear indicator lamp, ISO
H9 Right hand rear indicator lamp, ISO X4 Trailer socket
H14 Left hand headlamp

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

77
78 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

WORKLAMPS
Line 5200–5590
F6 15A Rear fender worklamps fuse KC Rear worklamp relay

MF4 Maxi fuse 4, 40A

H31 Licence plate lamp S38 Rear worklamp switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

79
80 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

Not applicable to this model

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

WORKLAMPS
Line 5600–5990

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

81
82 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Electroshift Transmission, (16x16 with Power Shuttle) Less Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

SENSORS
Line 6000–6390

B2 Engine coolant temperature sender S8 Transmission pressure switch

B3 Fuel tank sender S9 Transmission oil temperature switch
S10 Handbrake switch
S3 Engine oil pressure switch S11 Brake fluid level switch
S4 Low charge pressure switch (CCLS) S12 Air filter vacuum switch
S6 Hydraulic filter blocked switch
S7 Steering pressure switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

83
84 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

Not applicable to this model

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

89
90 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12

NOTES PAGE

604.55.041.02–01–2000
SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 91
WIRING DIAGRAMS:

TS SERIES:Dual Command Transmission, (24x24) W/Cab,

Wiring Diagrams Circuit Description Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0–390

Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400–1590

Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600–2790

Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800–3190

Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200–3590

Circuit 6 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600–4390

Circuit 7 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400–5190

Circuit 8 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5200–5990

Circuit 9 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000–6390

Circuit 10 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400–6790

Circuit 11 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800–7190

Circuit 12 Air–Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7200–7590

604.55.041.02 – 01–2000
92 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

STARTING, CHARGING, THERMOSTART, FUEL INJECTION PUMP
line 0–390
STARTING KVII Thermostart relay
KF Fuel Shut Off Relay
FL1 Fuse Link
R1 Thermostart coil
FL2 Fuse Link
R2 Fuel Injection Pump Wax Motor
G1 Battery
S53 Thermostatic Switch
K1 Ignition Relay
Y1 Shut Off Solenoid
K2 Start Relay
Y2 Electric Lift Pump
M1 Starter Motor and Solenoid
S1 Ignition Switch
MF1 Maxi Fuse 1 50A
S2 Start inhibitor switch
MF2 Maxi Fuse 2 60A
CHARGING F20 5A, Processor ’Keep alive memory’ Fuse
G2 Alternator
THERMOSTART AND FUEL SYSTEM
F8 10A, Shut off Solenoid Fuse
F19 25A Thermostart Fuse

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

93
94 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

TRANSMISSION SYSTEM
Line 400–790
F13 15A, Transmission Fuse

S21 Clutch Pedal Switch

S22 Creeper Switch
S50 Transmision Oil Temperature Switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

95
96 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

TRANSMISSION SYSTEM
Line 800–1190
A002 Gear Display Module (Not fitted to Dual Command Models) S25 Downshift switch
S28 High/medium range switch
S23 Shuttle dump switch S51 1st/2nd switch
S24 Upshift switch S52 3rd/4th switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

97
98 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

Y16
Y15
Y14

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

TRANSMISSION SYSTEM
Line 1200–1590
B18 Clutch pedal potentiometer

Y14 Dump solenoid

Y15 Lo PWM valve
Y16 Hi PWM valve

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

99
100 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

107
108 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

POWER TAKE OFF
Line 3200–3590
F21 5A, PTO fuse S18 PTO switch
S19 Seat switch
H1 PTO engaged lamp S20 540/1000 PTO speed switch

KV+V1 PTO Relay Y5 PTO Solenoid

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

109
110 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

S47 40Amp Accessory terminals switch Y13 Remote valve solenoid

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

111
112 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

CAB ACCESSORIES
Line 4000–4390
A004 Radio
MF5 Maxi fuse 5 30A
B15 Speaker
B16 Speaker P2 Clock

E2 Interior light R4 Cigar lighter

F22 5A, radio and accessory socket fuse S45 Interior light door switch
F23 20A, Accessories, radio S46 Interior light door switch
F24 10A, interior lamp
X2 Accessory socket
KII Accessory socket relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

113
114 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

A006

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

H11 Right hand front indicator lamp – NASO S33 Indicator switch
H13 Right hand rear indicator lamp – NASO S34 Hazard light switch

WORKLAMPS
Line 5600–5990

F5 10A Low front worklamp KD Front lower worklamp relay

H23 Left hand upper front worklamp M7 Air seat pump

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

121
122 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

SENSORS
Line 6000–6390

B1 Engine oil pressure sender S6 Hydraulic filter blocked switch

B2 Engine coolant temperature sender S7 Steering pressure switch
B3 Fuel tank sender S9 Transmission oil temperature switch
B4 Radar S10 Handbrake switch
S11 Brake fluid level switch
S3 Engine oil pressure switch S12 Air filter vacuum switch
S4 Low charge pressure switch (CCLS)
S5 Hydraulic oil temperature switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

123
124 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Dual Command Transmission, (24x24) W/Cab,

Wiring Diagrams Circuit Description Line Reference Range

Circuit 1 Starting, Charging, Thermostart, Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 0–390

Circuit 2 Transmission Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400–1590

Circuit 3 Electronic Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1600–2790

Circuit 4 Four Wheel Drive and Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800–3190

Circuit 5 Power Take Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200–3590

Circuit 6 Cab Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600–4390

Circuit 7 Main Lamps, Indicators & Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4400–5190

Circuit 8 Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5200–5990

Circuit 9 Sensors / Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000–6390

Circuit 10 Wipers & Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6400–6790

Circuit 11 Processor Feed and Ground connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800–7190

Circuit 12 Air–Conditioning & Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7200–7590

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

ELECTRONIC DRAFT CONTROL
Line 2400–2790
F9 10A, Gauges and external switches fuse

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

145
146 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

7
5
2

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

FOUR WHEEL DRIVE AND DIFFERENTIAL LOCK
Line 2800–3190
F15 15A, Stop lamps fuse S17 Brake Switch – Left Hand

KA Differential lock relay (normally open) Y3 Four Wheel Drive Solenoid

KG Differential lock relay (normally closed) Y4 Differential Lock Solenoid

S13 FWD, cab switch C266 Four wheel drive braking disable connector
S14 Differential, cab switch (Join to disable FWD braking)
S15 Differential Lock Engaged Switch
S16 Brake Switch – Right Hand

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

147
148 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

POWER TAKE OFF
Line 3200–3590
F21 5A, PTO fuse S18 PTO switch
S19 Seat switch
H1 PTO engaged lamp S20 540/1000 PTO speed switch

KV+V1 PTO Relay Y5 PTO Solenoid

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

149
150 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

CAB ACCESSORIES
Line 3600–3990
B17 Horn S48 Beacon switch
S49 Remote valve switch
E3 Console Light
X1 40 Amp screw terminal
K Implement socket relay X5 4 Pin 40 amp socket
KIV Remote valve relay X6 Roof beacon left hand
X7 Roof beacon right hand
MF6 Maxi Fuse 6, 40A
Y13 Remote valve solenoid
S47 40Amp Accessory terminals switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

151
152 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

CAB ACCESSORIES
Line 4000–4390
A004 Radio
MF5 Maxi fuse 5 30A
B15 Speaker
B16 Speaker P2 Clock

E2 Interior light R4 Cigar lighter

F22 5A, radio and accessory socket fuse S45 Interior light door switch
F23 20A, Accessories, radio S46 Interior light door switch
F24 10A, interior lamp
X2 Accessory socket
KII Accessory socket relay

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

153
154 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

INDICATOR AND HAZARD LIGHTS
Line 4400–4790
F1 15A Headlamp dip fuse K3 Flasher unit relay
F2 15A Headlamp main fuse KX Multi–function switch unload relay
F10 15A Hazards fuse KXI + Flasher mode relay
F11 30A Horn, flashers, cigar lighter, beacon fuse KXII
F18 10A Indicators fuse
MF3 Maxi fuse 3, 40A
H11 Right hand front indicator lamp – NASO
H13 Right hand rear indicator lamp – NASO S33 Indicator switch
S34 Hazard light switch

WORKLAMPS
Line 5600–5990

F5 10A Low front worklamp KD Front lower worklamp relay

H23 Left hand upper front worklamp M7 Air seat pump

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

161
162 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

SENSORS
Line 6000–6390

B2 Engine coolant temperature sender S9 Transmission oil temperature switch

B3 Fuel tank sender S10 Handbrake switch
S11 Brake fluid level switch
S3 Engine oil pressure switch S12 Air filter vacuum switch
S6 Hydraulic filter blocked switch
S7 Steering pressure switch

WIRE COLOUR CODES

B Black R Red LG Light Green K Pink
N Brown O Orange U Blue W White
LN Light Brown Y Yellow TQ Turquoise
S Slate G Green P Purple
604.55.041.02–01–2000

163
164 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 12

604.55.041.02–01–2000
TS SERIES Synchro Command Transmission, (12x12) W/Cab,

12 U/W MAIN BEAM HEADLAMP FUSE SUPPLY

13 U/R DIP BEAM HEADLAMP FUSE SUPPLY

15 U LIGHTING SWITCH SUPPLY

28 Y/LG WIPER MOTOR (PARK RETURN)

29 G/B MAIN FUEL SENDER SIGNAL

31 Y/S ENGINE OIL PRESSURE SENDER SIGNAL

39 G/U TEMPERATURE GAUGE SIGNAL

44 LG/N FLASHER UNIT (49A)

49 G/W RIGHT HAND TURN SIGNAL

50 G/R LEFT HAND TURN SIGNAL

56 W/LG WIPER MOTOR–HIGH

57 B EARTH (ALL)

58 R/LG WIPER MOTOR–LOW

63 U/LG WIPER MOTOR–PARK FEED

65 W DUAL POWER/4 WHEEL DRIVE SWITCH FEED

71 W IGNITION SWITCHED FEEDS (UNFUSED)

84 G WINDSHIELD WASHER SWITCH FEED

90 G DUAL POWER / FOUR WHEEL DRIVE SWITCH

97 LG/B WINDSHIELD WASHER FEED

137 W/K RADIO FEED

138 P RADIO KAM

150 N BATTERY FEED (ALL)

181 G BLOWER MOTOR FEED

182 P/LG THERMOSTATIC SWITCH FEED

252 N/G ALTERNATOR FIELD

365 G/O LOW FUEL WARNING LAMP (DELAY ON)

366 O/U LOW FUEL WARNING LAMP (DELAY SWITCH)

376 P/N HORN FEED

587 LG/O W1NDSHIELD WIPER INTERMITTENT DELAY

649 B/O COOLANT TEMPERATURE SWITCH

666 P/W DOMELAMP SWITCH FEED

787 G AUXILIARY FUEL PUMP SUPPLY

810 G/P STOPLAMPS

820 B/R/S STOPLAMP SWITCH LH

830 B/U/S STOPLAMP SWITCH RH

840 G/O R & L STOPLAMP SIGNAL

979 G/S BLOWER MOTOR HIGH SPEED

980 N/U THERMOSTAT SWITCH SUPPLY

981 G/P/B A/C CLUTCH RELAY FEED

604.55.041.02 –01 –2000

172 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
982 G/S/B BLOWER MOTOR FEED

984 P/G TEMPERATURE CONTROL POT. INPUT

986 P/K TEMPERATURE CONTROL POT. OUTPUT

989 P/G BLOWER MOTOR MEDIUM SPEED

997 G/N WORK LAMP–REAR FEED (OUTER)

998 G/LN WORK LAMP–REAR FEED (INNER)

999 G/Y BLOWER MOTOR LOW SPEED

1000 W/Y SAFETY START SWITCH SUPPLY

1001 W/R STARTER SOLENOID FEED

1002 P IMPLEMENT LAMP SWITCH SUPPLY

1003 G SUPPLY TO GAUGES

1004 G SUPPLY TO HORN AND HEADLAMP FLASH

1005 B/S AIR CLEANER WARNING LAMP

1006 N/Y ALTERNATOR WARNING LAMP

1007 W ETHER START BUTTON SUPPLY

1008 N/K ETHER START SOLENOID SUPPLY

1009 N/P ALTERNATOR FIELD

1010 G IGNITION RELAY (COIL)

1011 Y/W SUPPLY TO FUSES

1013 R RIGHT HAND LAMPS

1014 R/B LEFT HAND LAMPS

1015 P DOME LAMP SWITCH FEED

1016 P/N HORN FEED

1017 LG/G AIR CON. THERMOSTATIC SWITCH FEED

1018 LG/W AIR CONDITIONER CLUTCH

1019 G WINDSHIELD WIPER FEED

1020 G HAZARD SWITCH SUPPLY

1021 P HAZARD SWITCH SUPPLY (BATTERY)

1022 N/R THERMOSTART

1023 N LIGHT SWITCH FEED

1024 R RIGHT & LEFT HAND SIDELAMP FEED

1025 G HZD SWITCH IGN FEED

1026 U/W HIGH BEAM INDICATOR LAMP

1027 U/W HEADLAMP MAIN BEAM

1028 U/W HEADLAMP MAIN BEAM FUSE

1029 U/R HEADLAMP DIP BEAM FUSE

1030 U/R HEADLAMP DIP BEAM

1031 R/W INSTRUMENT ILLUMINATION

1032 LG/P TURN SIGNAL WARNING LAMP (TERM C)

1033 LG/Y TURN SIGNAL WARNING LAMP (TERM C2)

1034 LG/R TURN SIGNAL WARNING LAMP (TERM C3)

604.55.041.00 –02 –2000

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 173
1035 W/N ENGINE OIL PRESSURE WARNING LAMP

1036 N IGNITION SWITCH (BATTERY)

1037 LG/N FLASHER UNIT (TERM 49A)

1040 LG/K FLASHER SWITCH TO RELAY–RHS CUT OUT

1041 LG/U FLASHER SWITCH TO RELAY–LHS CUT OUT

1050 G ACCESSORY FEED

1070 R FRONT WORKLAMP SWITCH FEED

1071 P WORKLAMP FRONT FEED

1072 P/U WORKLAMP FRONT RELAY SUPPLY

1073 P WORKLAMP FRONT FEED

1090 R REAR WORKLAMP RELAY SIGNAL

1091 R FRONT WORKLAMP LOWER RELAY SIGNAL

1092 R FRONT WORKLAMP RELAY SIGNAL

1093 R FENDER WORKLAMP RELAY SIGNAL

1096 R/Y WORKLAMP FENDER MOUNTED

1097 R/S FEED FRONT WORKLAMP OUTER

1098 W/B FRONT WORKLAMP RELAY GROUND

1099 R/O FEED FRONT WORKLAMP INNER

1119 G/R/B RR WINDSHIELD WIPER

1120 G/O/B RR WINDSHIELD WIPER PARK RETURN

1121 G/Y/B RR WINDSHIELD WASH

1130 N/S ENGINE HEATER CONTROL TO IGN SWITCH

1135 G/K/B THERMOSTART WARNING LAMP

1140 K/W/S THERMOSTART INITIATE SIGNAL TO RELAY

2001 N/G BATTERY TEMPERATURE SENSOR

2002 N/P BATTERY TEMP SENSOR (ALT OUTPUT)

2003 W/R STARTER SOLENOID FEED

2006 U/O DE–ICING SWITCH – AIR CONDITIONER

2009 G FUEL PUMP SUPPLY

2010 LG/W AIRCON PLUG TO DE–ICING SWITCH

2011 P/B HORN RETURN

2012 Y/O TRANS OIL PRESSURE WARNING LAMP

2013 Y/R PTO OVERSPEED WARNING LAMP

2014 G/K ENGINE OIL PRESSURE SENDER (+5 VOLT)

2015 W/S TACHOMETER SENSOR–SIGNAL

2016 Y/G REAR AXLE SPEED SENSOR–SIGNAL

2017 B/P BULB TEST (EIC)

2018 B/R RADAR PRESENT

2019 B/K ENGINE RPM (TACHO MODULE TO TPM)

2020 Y/K ENGINE SHUT DOWN (TACHO MODULE TO TPM)

2021 Y/P AXLE GROUND SPEED (TACHO MODULE TO TPM)

604.55.041.02 –01 –2000

174 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
2022 B/Y PTO 540/1000 RPM (TACHO MODULE TO TPM)

2023 S TPM TO EIC (AXLE SPEED DRIVE)

2024 S/N RADAR SIGNAL DRIVE

2025 S/U AUDIO ALARM CONTROL

2026 S/R IMPLEMENT SWITCH SIGNAL

2027 R RADAR ASSEMBLY (GUN) POWER

2028 G RADAR ASSEMBLY (GUN) SIGNAL

2029 P INSTRUMENT MEMORY SUPPLY

2030 N/O ELECTRONIC DRAFT CONTROL

2040 LG/G/S WATER IN FUEL SENSOR

2041 P/Y FUEL SHUT OFF

2042 O/S PTO SOLENOID–REAR

2043 O/K PTO SOLENOID–FRONT

2045 O/G PTO SWITCH TO MODULE

2046 O/LG PTO SWITCH (VCC)

2047 O/W PTO SWITCH (VCCO)

2048 O/Y PTO SWITCH (VCCS)

2049 O/P PTO SWITCH 1000RPM WARNING LAMP

2050 G PTO SUPPLY

2052 W/R/B PTO LUBE SOL

2053 P/W/B PTO LUBE SOL RETURN

2055 B/W/S PTO SYNCHRO GROUND SPEED ENGAGED

2060 O/LG PTO 540/1000 SWITCH

2065 N/G/B PTO ENGAGED

2070 O/U/B ENGINE SHUT OFF RELAY +12V

2080 O/R ENGINE SHUT OFF RELAY

2090 W/U STARTER RELAY TO START INHIBIT SWITCH

2095 G/W/B INSTRUMENT SIGNAL GROUND

2100 G/U/B A/C CONDENSER MOTOR FEED

2120 B/LN/S PTO BRAKE SIGNAL

2130 B/N/S PTO BRAKE SOLENOID

2140 B/O/S PTO SPEED SENSOR

2150 B/P/S PTO EXT. SWITCH OFF

2200 G/N/B SERVICE MODE INITIATE

2245 K/LN/S PTO FRONT – SWITCH TO MODULE (MOM)

2248 K/N/S PTO FRONT – SWITCH (VCCS)

225O K/O/S PTO FRONT – SUPPLY

2500 N/B/S FRONT HITCH SOLENOID

2510 N/G/S FRONT HITCH POSITION SIGNAL

2520 N/K/S FRONT HITCH SET POSITION SIGNAL

2530 N/LG/S FRONT HITCH V REF

2540 N/O/S FRONT HITCH +12v IGN

604.55.041.00 –02 –2000

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 175
2550 N/P/S FRONT HITCH OVERIDE SWITCH

2560 N/R/S FRONT HITCH 0v REF

2600 Y/G/S REAR AXEL SPEED MONITOR

3000 G/LG FLASHER UNIT SUPPLY (TERMINAL 49)

3001 G/R LEFT HAND FLASHER CIRCUIT

3002 G/W RIGHT HAND FLASHER CIRCUIT

3003 W/K RADIO FEED

3004 G/W RIGHT HAND TURN SIGNAL WARNING LAMP

3005 G/R LEFT HAND TURN SIGNAL WARNING LAMP

3006 G/S AUXILIARY FUEL TANK SENDER

3007 G/B FUEL GAUGE FEED

3008 U/B WORKLAMP WARNING LIGHT

3010 R/Y FOGLAMP FEED

3011 R/Y FOGLAMP FEED

3012 G HANDBRAKE WARNING FEED

3013 LG/S AUXILIARY FUEL TANK SIGNAL

3014 R/K HANDBRAKE WARNING LAMP SIGNAL

3015 P/K ACCESSORY SOCKET (POWER)

3020 Y DUAL POWER SOLENOID SUPPLY

3022 Y/N DUAL POWER (HIGH) WARNING LAMP

3025 Y/U FOUR WHEEL DRIVE SOLENOID

3030 W/K ACCESSORY RELAY SIGNAL

3045 Y/U/S FOUR WHEEL DRIVE WARNING LAMP

3050 P AUXILIARY FEED CONNECTOR SUPPLY

3051 P CIGAR LIGHTER SUPPLY

3052 P/W DOME LAMP TO DOOR SWITCH

3053 S/O SPEAKER RIGHT HAND

3054 S/Y SPEAKER NEGATIVE RH

3055 S/K SPEAKER LEFT HAND

3056 N/B SPEAKER NEGATIVE LH

3060 P IMPLEMENT SOCKET RELAY

3061 P/S IMPLEMENT SOCKET

3062 P/O IMPLEMENT SOCKET SWITCH

3070 P ’B’ PILLAR SKT SUPPLY

3075 O TRAILER SOCKET (ACCESSORY FEED)

3076 O/N ACCESSORY SWITCH FEED

3080 P/LN CONSOLE LAMP

3090 Y/LN SEAT PUMP SUPPLY

3100 B/G/S STEERING SENSOR +5v

3120 B/K/S STEERING SENSOR SIGNAL

3140 B/LG/S STEERING SENSOR GROUND

604.55.041.02 –01 –2000

176 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
3150 W/O HANDBRAKE SWITCH (N.C CONTACT) OFF SIG

3155 W/G HANDBRAKE TRANS INTERLOCK

4001 R/U TRANSMISSION OIL WARNING LAMP (TEMP)

4002 R/U TRANSMISSION OIL WARNING LAMP SWITCH

4010 N/W RETURN TO DIG

4011 P/G ROTATING BEACON SWITCH SUPPLY

4012 P/R ROTATING BEACON FEED

4013 U/N TRANS CONTROL FEED

4014 U/G FORWARD CLUTCH SOLENOID FEED

4015 U/Y REVERSE CLUTCH SOLENOID FEED

4016 U/K TORQUE CONVERTOR LOCK–UP RELAY FEED

4017 U/S TORQUE CONVERTOR LOCK–UP LAMP

4018 S/P TORQUE CONVERTOR LOCK–UP SOLENOID FEED

4019 S/G HYDRAULIC FILTER BY–PASS SWITCH FEED

4020 S/LG HYDRAULIC FILTER BY–PASS LAMP

4021 S/W BACK–UP ALARM RELAY FEED

4022 S/B BACK–UP ALARM FEED

4025 Y/LN 4 IN 1 BUCKET FEED

4040 G LINK LEVEL SWITCH SUPPLY

4050 W/P LINK LEVEL RAISE

4051 W/G LINK LEVEL LOWER

4100 TQ/Y TRANS RANGE ENABLE SWITCH SUPPLY

4101 TQ/B TRANS RANGE ENABLE

5000 P EDC MEMORY POWER

5005 N/O EDC KEY SWITCH FEED

5010 B EDC EARTH

5011 B EDC EARTH CASE RFI

5015 R EDC CONTROLS BACKLIGHTING

5020 LN EDC PROC +5V REF VOLTAGE DROP POSN/RATE

5021 K/Y EDC PROCESSOR REF VOLT (+5V) ROCKSHAFT

5022 K/B EDC PROCESSOR REF VOLT +5V QUADRANT

5023 K/S EDC PROCESSOR REF VOLT +5V HEIGHT LIMIT

5025 LN/U EDC LOWER SIGNAL

5030 LN/R EDC RAISE SIGNAL

5035 LN/G EDC RETURN REF. VOLTAGE EARTH

5040 LN/W EDC DRAFT POSITION

5045 LN/Y EDC DROP RATE

5050 LN/B EDC QUADRANT

5055 LN/S EDC CLOCK LINE TO DISPLAY

5060 LN/O SERIAL DATA TO CLUSTER

604.55.041.00 –02 –2000

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 177
5065 LN/P EDC RIGHT PIN

5070 LN/LG EDC LEFT PIN

5075 K EDC VOLTAGE TO PINS

5080 K/N EDC ROCKSHAFT

5085 K/U EDC VALVE UP

5087 K/U/B EDC VALVE UP RETURN

5090 K/R EDC VALVE DOWN

5095 K/G EDC EXTERNAL SWITCH DOWN

5097 K/G/B EDC VALVE DOWN RETURN

5100 K/W EDC EXTERNAL SWITCH UP

5105 S/R EDC IMPLEMENT STATUS SWITCH

5110 K/LG EDC LAMP SIGNAL

5115 K/P EDC SLIP SIGNAL

5120 K/O EDC HEIGHT LIMIT SIGNAL

5125 TQ/W EDC RAISE SIGNAL–RAISE WORK SWITCH

5130 TQ/P EDC WORK SIGNAL–RAISE WORK SWITCH

5135 TQ EDC +WHEEL SPEED SIGNAL

5140 TQ/N EDC –WHEEL SPEED SIGNAL

5145 TQ/R EDC SLIP LIMIT POT

5150 G EDC EXTERNAL SWITCH SUPPLY

5155 B/U EDC LOWER LIMIT POT

5160 TQ/O EDC HEIGHT LIMIT POT FEED

5170 LN/TQ SERIAL DATA FROM CLUSTER

5180 TQ/G EDC SLIP INDICATOR LAMP

5190 R/W/B HPL INTERLOCK

5200 N/R/B EDC VALVE SUPPLY

5210 N/S/B EDC VALVE ENABLE

5300 K/W/B ECU FLASH PROGRAM SIGNAL

5820 B EDC ROCKSHAFT POT

6000 K/LG/S ENGINE SPEED SIGNAL

6010 B/TQ/S THROTTLE POSITION SWITCH

6100 U ENGINE COLD ADVANCE CONTROL

7000 U/R/B TRANS CONTROL SUPPLY

7001 U/0/B TRANS DISPLAY ILLUMINATION

7002 U/Y/B TRANS MAIN CLUTCH SOL (C3/C4)

7003 U/G/B TRANS DUMP SOL

7004 U/B TRANS FRONT CLUTCH SOL (C1/C2)

7005 U/P/B TRANS CREEPER GR SOL

7007 R/P/B TRANS DUAL POWER PRESSURE SWITCH HIGH

7008 R/S/B TRANS DUAL POWER PRESSURE SWITCH LOW

604.55.041.02 –01 –2000

178 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
7010 U/N/B TRANS RANGE INDICATOR SWITCH (GR 1–4)

7020 U/W/B TRANS RANGE INDICATOR SWITCH (GR 5–8)

7030 U/LG/B TRANS RANGE INDICATOR SWITCH COMMON

7035 N/LG/B TRANS DUMP SOLEN0ID FEED

7040 U/LN/B TRANS CREEPER SWITCH

7050 R/G/B TRANS RELAY SUPPLY – RUN

7060 R/K/B TRANS RELAY SUPPLY – START

7070 R/LG/B TRANS FEED

7071 N/K/B FEED HYD FILTER RESTRICTION IND LAMP

7080 B/LG DIFF–LOCK SOLENOID FEED

7090 LG DIFF–LOCK SWITCH TO BRAKE SWITCH

7100 N/LG DIFF–LOCK RELAY TO BRAKE SWITCH

7110 R/Y/B PTO INHIBITOR SWITCH TO TRANS

7120 Y/B DIFF–LOCK WNG LP

7130 B/N HYD FILTER WNG LP

7140 O/B DIFF–LOCK OFF SOLENOID

7150 S/G/B LOW OIL PRESSURE WRN FEED

7160 R/N/B HYD LOW CHARGE WARNING

7170 B/W DIFF LOCK SWITCH OUTPUT

7180 U/TQ CREEPER SWITCH MOM SIGNAL

7190 K/G/S TRANS SOLENOID VALVE SUPPLY

7195 K/U/S TRANS SOLENOID VALVE RETURN

7200 S/K/B TRANSMISSION SHIFT DOWN

7210 S/LG/B TRANSMISSION SHIFT UP

7220 S/N/B TRANSMISSION HIGH RANGE

7225 W/LG/B TRANS HI RANGE SOL – RET

7230 S/O/B TRANSMISSION LOW RANGE

7235 Y/LN/B TRANS LOW RANGE SOL – RET

7240 S/P/B TRANSMISSION DISPLAY SWITCH

7250 S/R/B TRANSMISSION FORWARD SIGNAL

7260 S/U/B TRANSMISSION REVERSE SIGNAL

7265 K/Y/S TRANS NEUTRAL SWITCH TO PROCESSOR (GR.SW 1)

7267 LG/N/S TRANS NEUTRAL SWITCH 2 TO PROCESSOR

7270 R/G TCM SERIAL DATA IN–DISPLY DATA OUT

7275 W/U/B TCM SERIAL DATA OUT–DISPLY DATA IN

7280 W/G/B LIMP HOME SWITCH 18x18 TRANS.

7290 W/K/B DIRECTIONAL INTERRUPT RELAY TO SOLENOID

7300 W/LG/B SOLENOID 1 18x9 TRANSMISSION

7301 Y/LN/B SOLENOID 1 18x9 RETURN

7320 W/N/B SOLENOID 2 18x9 TRANSMISSION

7321 P/Y/B SOLENOID 2 18x9 RETURN

7330 W/P/B SOLENOID 3 18x9 TRANSMISSION

604.55.041.00 –02 –2000

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 179
7331 Y/S/B SOLENOID 3 18x9 RETURN

7340 W/R/B SOLENOID F1 18x9 TRANSMISSION

7341 Y/W/B SOLENOID F1 18x9 RETURN

7350 W/S/B SOLENOID F2 18x9 TRANSMISSION

7351 S/W/B SOLENOID F2 18x9 RETURN

7355 S/Y/B SOLENOID R 18x9 TRANSMISSION

7356 U/S/B SOLENOID R 18x9 RETURN

7360 W/Y/B SOLENOID A 18x9 TRANSMISSION

7361 P/LG/B SOLENOID A 18x9 RETURN

7370 Y/G/B SOLENOID B 18x9 TRANSMISSION

7371 P/N/B SOLENOID B 18x9 RETURN

7380 Y/K/B SOLENOID C 18x9 TRANSMISSION

7381 P/O/B SOLENOID C 18x9 RETURN

7390 Y/LG/B SOLENOID PMW (F1) 18x9 TRANSMISSION

7391 P/R/B SOLENIOD PWM (F1) 18x9 RETURN

7392 O/G/B SOLENOID PWM (F2) 18x9 TRANSMISSION

7393 O/N/B SOLENOID PWM (F2) 18x9 RETURN

7395 P/S/B SOLENOID CREEP 18x9 TRANSMISSION

7396 P/W/B SOLENOID CREEP 18x9 RETURN

7400 Y/N/B TRANS RPM SPEED SENSOR TO TCM INPUT

7401 P/B/G TRANS RPM SPEED SENSOR

7410 Y/O/B TRANS RPM SPEED SENSOR TO TCM OUTPUT

7420 Y/P/B TCM TO CLUTCH POSITION SWITCH

7430 Y/R/B CLUTCH POSITION SIGNAL

7431 TQ/W/B CLUTCH ’A’ SUPPY

7440 Y/U/B TCM TO TRACTOR EIC–AXLE OUTPUT

7450 W/LN/B TRANS CREEPER INTERLOCK SUPPLY

7460 W/O/B TRANS CREEPER CLUTCH ENGAGED

7470 S/LN/B TRANS CREEPER CLUTCH DISENGAGED

7480 G/K/S TRANS AUTO FUNCTION 1

7485 K/P/S TRANS AUTO FUNCTION LAMP 1

7490 G/LG/S TRANS AUTO FUNCTION 2

7495 K/R/S TRANS AUTO FUNCTION LAMP 2

7500 B/G TRANS OIL TEMP. SENSOR

7520 G/N/S TRANS SENSOR SUPPLY 8v

7525 G/B/S TRANS SENSOR SUPPLY 5v

7560 G/LN/S TRANS WARNING LAMP

7570 B SIGNAL GROUND

7580 U/K/B CREEPER SOLENOID MONITOR

7590 O/W/B TRANS CREEPER GEAR STATUS LAMP

7600 N/W/B TRANS FEATHERING SOLENOID

7620 N/Y/B TRANS FEATHERING SOL. MONITOR

604.55.041.02 –01 –2000

180 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12
7630 N/U/B TRANS MAIN CLUTCH PRESSURE SWITCH

7640 B/LN DIAGNOSTIC PLUG RS232 IN

7650 W/LN DIAGNOSTIC PLUG RS232 OUT

7660 R/U/B TRANS CLUTCH DISCONNECT

7700 LN/N/B TRANS SHUTTLE DUMP SWITCH

7710 LN/O/B TRANS OIL TEMPERATURE SWITCH

7735 LN/P/B TRANS MID SPEED SIGNAL +

7740 LN/R/B TRANS MID SPEED SIGNAL –

7750 R/B/S TCM TO DOG 30/40 KPH SELECT

7760 W/N/B TORQUE SENSOR

7810 K/N/B TRANS PWM SOLENOID C1

7815 K/O/B TRANS PWM SOLENOID C1 RETURN

7820 K/P/B TRANS PWM SOLENOID C2

7825 K/R/B TRANS PWM SOLENOID C2 RETURN

7830 K/S/B TRANS PWM SOLENOID C3

7835 K/U/B TRANS PWM SOLENOID C3 RETURN

7840 K/W/B TRANS PWM SOLENOID C4

7845 K/Y/B TRANS PWM SOLENOID C4 RETURN

7850 G/P/S TRANS DIAGNOSTIC PROGRAM VOLTAGE

7855 G/R/S TRANS DIAGNOSTIC EA

7860 G/U/S TRANS DIAGNOSTIC RCV

7865 G/W/S TRANS DIAGNOSTIC XMT

7870 G/Y/S TRANS DIAGNOSTIC RTS

7875 K/B/S TRANS DIAGNOSTIC CTS

7880 B T C M SIGNAL GROUND

7900 TQ/K/B CLUTCH ’A’ SIGNAL

7910 TQ/N/B CLUTCH ’B’ SIGNAL

7915 P/O/S TCM CLUTCH B RETURN

7920 TQ/O/B CLUTCH ’C’ SIGNAL

7925 P/R/S TCM CLUTCH C RETURN

7930 TQ/R/B CLUTCH ’D’ SIGNAL

7935 P/N/S TCM CLUTCH D RETURN

7940 TQ/S/B CLUTCH ’E’ SIGNAL

7945 P/TQ/S TCM CLUTCH E RETURN

7950 TQ/Y/B CLUTCH SUPPLY

7960 P/K/B TRANS SLOW/FAST

7965 P/K/S HI/LO SYNCHRO SIGNAL

7970 P/TQ/B TRANS MED/REV

7980 K/LG/B TRANS MED RANGE

7982 W/P/B TRANS MED RANGE RET

7985 G/O/S TRANS REVERSE RANGE

7990 K/R/B TRANS BRAKE

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SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12 181

8000 N/TQ/B TRAILER BRAKE SOLENOID

8010 LN/W/B TRAILER BRAKE PRESSURE

8020 LN/K/B TRAILER BRAKE PRESSURE

8030 LG/O/S TRANS FWD SOLENIOD

8035 P/LG/S TRANS FWD SOL RET

8040 LG/P/S TRANS REV SOLENIOD

8045 P/LN/S TRANS REV SOL RET

9000 LN/S/B DIVERTER VALVE

9010 LN/U/B DIVERTER VALVE SUPPLY

9020 LN/Y/B HYDRAULIC REMOTE VALVE SOL

9025 LN/G/B HYDRAULIC REMOTE VALVE SWITCH

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182 SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 12

NOTES PAGE

604.55.041.00 –02 –2000

SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12 183
Fold out for Key to Electroshift Electrical System Diagram.

ELECTRICAL SYSTEM DIAGRAMS

POWER SHUTTLE ELECTROSHIFT AND

DUAL COMMAND MODELS

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184 SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12
ELECTROSHIFT ELECTRICAL SYSTEM DIAGRAM PROCESSOR TERMINALS (C127=Red connector / C128=Black connector / C242=Red Connector, rear)
C127 – 1. SENSOR EARTH / GROUND C128 – 1. HIGH RANGE SWITCH
1. BATTERY 13. CLUTCH PEDAL SWITCH
2. DIFFERENTIAL LOCK – AUTO 2. LOW RANGE SWITCH
2. MAXI FUSES 14. GEAR DISPLAY MODULE
3. IGNITION SWITCH 15. DIFFERENTIAL LOCK SWITCH 3. CREEPER SWITCH LAMP 3. 1 – 4 GEAR RANGE SWITCH
4. IGNITION RELAY 16. BRAKE PEDAL SWITCHES 4. – 4. 5 – 8 GEAR RANGE SWITCH
5. CREEPER SWITCH 17. RAISE/WORK/LOWER SWITCH 5. +5 VOLT REFERENCE LINE 5. UPSHIFT SWITCH
6. SHUT DOWN RELAY 18. EDC FENDER SWITCHES 6. WHEEL SPEED SENSOR 6. FUSE 12 SENSE
7. FUEL SHUT OFF SOLENOID 19. EDC CONTROL PANEL 7. IMPLEMENT STATUS 7. BRAKE SWITCH – LEFT
8. POWER TAKE OFF MODULE 20. SENSOR SIGNAL GROUND 8. WHEEL SPEED – OUT 8. ROCK SHAFT POT.
9. PTO SWITCH 21. CHASSIS GROUND
9. CASE EARTH / GROUND 9. DROP RATE CONTROL
10. SEAT SWITCH 22. POWER GROUND
10. 4WD SOLENOID 10. DRAFT / POSITION CONTROL
11. STARTER RELAY 23. SYSTEM DIAGNOSTICS CONNECTOR
11. PWM 1 – (C1) 11. RIGHT HAND DRAFT PIN
12. SHUTTLE NEUTRAL SWITCH 24. EDC/TRANS PROCESSOR
12. PWM 4 – RETURN 12. PROGRAMME ENABLE
25. DIGITAL INSTRUMENT CLUSTER
13. PWM 2 – RETURN 13. RS232 OUT
INSTRUMENT CLUSTER – TERMINALS
14. PWM 2 (C2) 14. SERIAL IN
C079 – 1. TRAILER 2 C080 – 1. TRANSMISSION OIL PRESSURE AND
STEERING PRESSURE 15. CREEPER SOLENOID 15. RADAR
2. ENGINE OIL PRESSURE 2. DIFFERENTIAL LOCK 16. DIFFERENTIAL LOCK SOLENOID 16. SLIP CONTROL
3. TRAILER 1 3. 4WD ’ON’ 17. PWM 4 (C4) 17. SYNCHRO POSITION POTENTIOMETER
4. NOT USED 4. HYDRAULIC OIL TEMPERATURE 18. PWM 3 (C3) 18. TRANSMISSION OIL TEMPERATURE
5. LEFT TURN 5. – 19. LOWER PWM 19. CLUTCH PEDAL POT.
6. BATTERY VOLTAGE INPUT SWITCHED – FUSE 9 6. TRANSMISSION OIL TEMPERATURE 20. RAISE PWM 20. RIGHT BRAKE SWITCH
7. SIGNAL GROUND 7. NOT USED ON 16 X 16 21. GEAR DISPLAY – 2 21. EXTERNAL UP
8. ENGINE COOLANT TEMPERATURE 8. BRAKE FLUID LEVEL AND HANDBRAKE 22. GEAR DISPLAY – 1 22. SERVICE
SWITCHES 23. SLIP LAMP 23. SHUTTLE DUMP SWITCH
9. ALTERNATOR CHARGING 9. PARK BRAKE +12V. 24. STATUS LAMP 24. DOWN SHIFT SWITCH
10. MAIN BEAM 10. ENGINE RPM 25. + 8.5 VOLTS FOR DRAFT PINS 25. DIFFERENTIAL LOCK MANUAL
11. AIR FILTER 11. PTO 1000 26. PWM 3 – RETURN 26. RAISE SWITCH
12. THERMOSTART 12. EARTH / GROUND 27. – 27. NEUTRAL SWITCH INPUT
13. NOT USED ON 16 X 16 13. EARTH / GROUND 28. – 28. EXTERNAL DOWN
14. BACKLIGHT POWER 14. RIGHT TURN 29. FUSE 14 – INPUT 29. WORK SWITCH
15. BATTERY VOLTAGE INPUT CONTINUOUS – FUSE 20 15. LOW HYDRAULIC CHARGE PRESSURE 30. FUSE 12 – + 12V INPUT 30. QUADRANT LEVER POT.
16. FUEL LEVEL 16. EARTH / GROUND 31. FUSE 20 (CONTINUOUS + 12v SUPPLY) 31. HEIGHT LIMIT CONTROL
17. ALARM – EXTERNAL TRIGGER 32. EARTH / GROUND 32. OIL TEMPERATURE SWITCH
18. EARTH / GROUND 33. EARTH / GROUND 33. LEFT HAND DRAFT PIN
19. SERIAL DATA IN 34. FUSE 13 – +12v INPUT 34. ENGINE RPM
20. SERIAL DATA OUT 35. FUSE 13 – +12V INPUT 35. SERIAL OUT
36. PWM 1 – RETURN 36. RS232 IN
C081 – 1, WHEEL SPEED
2. IMPLEMENT STATUS C242 – 1. EDC RAISE PWM RETURN
3. RADAR SENSE 4. HANDBRAKE SWITCH
4. RADAR 13. SEAT SWITCH
5. +5V REF 18. LOUD WARNING BUZZER
6. ENGINE OIL PRESSURE 22. FORWARD PWM RETURN
7. ENGINE SHUT DOWN (+V OUT) 23. REVERSE PWM RETURN
8. ENGINE SHUT DOWN (RETURN) 24. EDC LOWER PWM RETURN
9. FUEL LEVEL GROUND 27. REVERSE PWM VALVE
10. EARTH / GROUND 28. FORWARD PWM VALVE
11. ENGINE OIL PRESSURE GROUND 32. FORWARD SHUTTLE SWITCH
12. EARTH / GROUND 33. REVERSE SHUTTLE SWITCH

604.55.041.02 –01 –2000

SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12 185

C128–27

C242–32

C242–33

FORWARD

C242–1

C242–24

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186 SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12

DUAL COMMAND ELECTRICAL SYSTEM DIAGRAM

PROCESSOR TERMINALS (C127=Red connector / C128=Black connector)
C127 – 1. SENSOR EARTH / GROUND C128 – 1. NOT USED
1. BATTERY 13. CLUTCH PEDAL SWITCH
2. DIFFERENTIAL LOCK – AUTO 2. 1–2 / 3–4 SWITCHES
2. MAXI FUSES 14. BRAKE LAMPS
3. NOT USED 3. HI / MED / NEUTRAL SWITCH
3. IGNITION SWITCH 15. DIFFERENTIAL LOCK SWITCH
4. IGNITION RELAY 16. BRAKE PEDAL SWITCHES 4. – 4. NOT USED

5. P.T.O. SWITCH 17. RAISE/WORK/LOWER SWITCH 5. +5 VOLT REFERENCE LINE 5. UPSHIFT SWITCH

6. SHUT DOWN RELAY 18. EDC FENDER SWITCHES 6. WHEEL SPEED SENSOR 6. FUSE 12 SENSE

7. FUEL SHUT OFF SOLENOID 19. EDC CONTROL PANEL 7. IMPLEMENT STATUS 7. BRAKE SWITCH – LEFT
8. POWER TAKE OFF MODULE 20. SENSOR SIGNAL GROUND 8. WHEEL SPEED – OUT 8. ROCK SHAFT POT.
9. SEAT SWITCH 21. CHASSIS GROUND 9. CASE EARTH / GROUND 9. DROP RATE CONTROL
10. STARTER SOLENOID 22. POWER GROUND 10. 4WD SOLENOID 10. DRAFT / POSITION CONTROL
11. STARTER RELAY 23. SYSTEM DIAGNOSTICS CONNECTOR 11. DUAL COMMAND LO LAMP 11. RIGHT HAND DRAFT PIN
12. START INHIBITOR SWITCH 24. EDC/TRANS PROCESSOR 12. HIGH PWM RETURN 12. PROGRAMME ENABLE
25. DIGITAL INSTRUMENT CLUSTER 13. DUMP SOLENOID RETURN 13. RS232 OUT
INSTRUMENT CLUSTER – TERMINALS 14. DUMP SOLENOID 14. SERIAL IN
C079 – 1. TRAILER 2 C080 – 1. TRANSMISSION OIL PRESSURE AND 15. DUAL COMMAND HI LAMP 15. RADAR
STEERING PRESSURE
2. ENGINE OIL PRESSURE 2. DIFFERENTIAL LOCK 16. DIFFERENTIAL LOCK SOLENOID 16. SLIP CONTROL
3. TRAILER 1 3. 4WD ’ON’ 17. HIGH PWM 17. 2ND CLUTCH PEDAL SENSOR (IF
FITTED)
4. NOT USED 4. HYDRAULIC OIL TEMPERATURE
5. LEFT TURN 5. – 18. LOW PWM 18. TRANSMISSION OIL TEMPERATURE

6. BATTERY VOLTAGE INPUT SWITCHED – FUSE 9 6. TRANSMISSION OIL TEMPERATURE 19. LOWER PWM 19. CLUTCH PEDAL POT.
7. SIGNAL GROUND 7. DUAL COMMAND – LO 20. RAISE PWM 20. RIGHT BRAKE SWITCH
8. ENGINE COOLANT TEMPERATURE 8. BRAKE FLUID LEVEL AND HANDBRAKE 21. NOT USED 21. EXTERNAL UP
SWITCHES
22. NOT USED 22. SERVICE
9. ALTERNATOR CHARGING 9. PARK BRAKE +12V.
23. SLIP LAMP 23. SHUTTLE DUMP SWITCH
10. MAIN BEAM 10. ENGINE RPM
24. STATUS LAMP 24. DOWN SHIFT SWITCH
11. AIR FILTER 11. PTO 1000
25. + 8.5 VOLTS FOR DRAFT PINS 25. DIFFERENTIAL LOCK MANUAL
12. THERMOSTART 12. EARTH / GROUND
13. DUAL COMMAND – HI 13. EARTH / GROUND 26. LOW PWM RETURN 26. RAISE SWITCH

14. BACKLIGHT POWER 14. RIGHT TURN 27. LOWER PWM RETURN 27. START SWITCH INPUT

15. BATTERY VOLTAGE INPUT CONTINUOUS – FUSE 20 15. LOW HYDRAULIC CHARGE PRESSURE 28. RAISE PWM RETURN 28. EXTERNAL DOWN

16. FUEL LEVEL 16. EARTH / GROUND 29. FUSE 14 – INPUT 29. WORK SWITCH
17. ALARM – EXTERNAL TRIGGER 30. FUSE 12 – + 12V INPUT 30. QUADRANT LEVER POT.
18. EARTH / GROUND 31. FUSE 20 (CONTINUOUS + 12v SUPPLY) 31. HEIGHT LIMIT CONTROL
19. SERIAL DATA IN 32. EARTH / GROUND 32. OIL TEMPERATURE SWITCH
20. SERIAL DATA OUT 33. EARTH / GROUND 33. LEFT HAND DRAFT PIN
C081 – 1, WHEEL SPEED 34. FUSE 13 – +12v INPUT 34. ENGINE RPM
2. IMPLEMENT STATUS 35. FUSE 13 – +12V INPUT 35. SERIAL OUT
3. RADAR SENSE
36. NOT USED 36. RS232 IN
4. RADAR
5. +5V REF
6. ENGINE OIL PRESSURE
7. ENGINE SHUT DOWN (+V OUT)
8. ENGINE SHUT DOWN (RETURN)
9. FUEL LEVEL GROUND
10. EARTH / GROUND
11. ENGINE OIL PRESSURE GROUND
12. EARTH / GROUND

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SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12 187

604.55.041.02 –01 –2000

188 SECTION 55 – ELECTRICAL CIRCUITS – CHAPTER 12

NOTES PAGE

ELECTRICAL SYSTEM DIAGRAM

DUAL COMMAND MODEL

604.55.041.02 –01 –2000

SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 1

SECTION 55 – ELECTRICAL SYSTEMS

Chapter 13 – Diagnostic ‘H’ Routines

Electroshift Transmission (16x16 Power Shuttle) From Serial No.139307B

Section Description Page

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electroshift (16x16 Power Shuttle) Transmission ‘H’ Routines . . . . . . . . . . . . . . . . . 2

1
The Instrument Cluster, either EIC (A) or AEIC (B),
is used to display the information. 1 A 2

Connect Tool No. 4FT 950 to the diagnostic

connector and turn the key start switch ON.

The display will show ‘HH’ to indicate that the ‘H’

menu has been activated.

1. Transmission display
2. Electronic Draft Control display

2
B
1 2

604.55.041.02 – 01 – 2000
2 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

Electroshift (16x16 Power Shuttle)

Transmission ‘H’ Routines
The ‘H’ routine consists of the following H menu codes:

HH Service Menu Page

H1 Transmission clutch spring pressure and synchroniser calibration 3
H2 Transmission clutch spring pressure and synchroniser calibration review 7
and C3/C4 clutches manual calibration adjustment
H3 (EDC valve calibration values) 8
H4 Software revision level 8
H5 Switch test 9
H6 Select rear tyre rolling radius 10
H7 Auto radius calibration (400 Foot/122m Dash) 12
H8 Non volatile memory reset (Erase Calibrations) 13
H9 Vehicle sensor operation display 14
HA Clutch pedal position display and oil temperature 17
HB View stored error codes 17
HC Clear stored error codes 20
HD View live error codes 20
HE Clutch Quick fill time adjustment 21
HF 4WD Braking – Engagement speed adjustment 23
HJ Hand brake loud buzzer control 24

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 3

H1 MENU MODE–
Spring Pressure And Synchroniser
Calibration
Entering the calibration mode :
Install diagnostic tool 4FT950 into the Black
diagnostic connector, located by the fuse box.

Start the tractor.

Enter mode H1.

4
The word CAL should appear on the instrument
cluster display. This will be replaced after a few
seconds by the oil temperature, in degrees
Celsius.

Set the engine speed to 1200 +/– 100 rpm.

NOTE: The engine RPM must be stable with no
noticeable surging. If necessary, adjust the
throttle position to achieve this, still remaining
within the 1200 +/– 100 rpm range.

5
C3 and C4 Calibration
Place the two gear levers in the forward position.
NOTE: No need to use the clutch pedal.

6
Move the shuttle lever into the forward drive posi-
tion.

604.55.041.02 – 01 – 2000
4 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

IMPORTANT: The shuttle synchroniser must be

calibrated before further calibration of the trans-
mission is attempted. Failure to observe this proce-
dure will result in error code U36 showing in the
gearshift display.
Press and hold the upshift and downshift switches,
the display will show ’Soc’. Continue to hold the up-
shift and downshift buttons.

8
The gearshift display will now sequence through
figures ’1’, ’2’, ’3’ and ’4’. When the display reads
’End’, calibration of the transmission synchronisers
has been completed, release the upshift and down-
shift buttons.
The display then returns to CAL then temperature
display.

9
C3 calibration :
Press and hold the Upshift button.
If the start up procedure was incorrect, a U code
will be displayed (see page 6).

10
The display will change to show a number.
This number will flash and begin to scroll up, as
the clutch is calibrated.
When the processor detects a decrease in
engine rpm of 30, the calibration stops. This is
indicated by a fixed, non flashing number.
Release the Upshift button.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 5

C4 calibration :
Use the downshift button to calibrate the C4
clutch in the same manor as the C3 clutch.

12
The display is similar to the C3 calibration.

13
C1 and C2 calibration :
Place the range lever in neutral, leaving the main
lever in the forward position. Leave the shuttle
lever in the forward drive position.

Set the engine speed to 1200 +/– 100 rpm.

14
Press and hold the Upshift button to calibrate the
C1 clutch.
Press and hold the Downshift button to calibrate
the C2 clutch.
The procedure is the same as that for the C3 and
C4 clutches.

604.55.041.02 – 01 – 2000
6 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

Clutch Spring Pressure Calibration Error Codes

U20 Handbrake not applied
U21 Engine rev/min is too low (1200 rpm 100 rpm)
U22 Engine rev/min is too high (1200 rpm 100
rpm)
U23 Forward/Reverse shuttle lever is not in forward.
U24 Main lever is not in 5–8 range.
U25 Range lever in low range
U26 Clutch pedal is not fully released.
U27 C3 calibration is too low – The initial test pressure was sufficient to lug
the engine.
U28 C3 calibration is too high – The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U29 C4 calibration is too low – The initial test pressure was sufficient to lug
the engine.
U30 C4 calibration is too high – The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U31 Wheel motion detected during calibration – Handbrake was not fully applied or the
calibration threshold was too low such that
initial test pressure was enough to cause
slight wheel motion prior to lugging the
engine.
U32 C1 calibration is too low – The initial test pressure was sufficient to lug
the engine.
U33 C1 calibration is too high – The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U34 C2 calibration is too low – The initial test pressure was sufficient to lug
the engine.
U35 C2 calibration is too high – The maximum test pressure was reached
without causing the engine speed to decrease
50 rpm.
U36 Synchroniser not calibrated Must calibrate synchroniser first
U37 Synchroniser reverse position outside limits
U38 Synchroniser forward position outside limits
U39 Reverse synchroniser, no movement at Full hydraulic pressure reached with no
maximum pressure synchroniser movement detected
U40 Forward synchroniser, no movement at Full hydraulic pressure reached with no
maximum pressure synchroniser movement detected

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 7

H2 MENU MODE –
Display of Clutch/synchroniser calibration
values and C3/C4 manual adjustment
NOTE: The tractor is driveable in this mode.

Install the diagnostic switch, Tool No. 4FT 950,

and start the engine.

Select mode H2 using the diagnostic switch.

16
The calibration values are displayed in the
following sequence:

Range of Values
Clutch 1 101–240
Clutch 2 101–240
Clutch 3 101–240
Clutch 4 101–240
Synchro position signal reverse 655–963
Synchro position signal forward 61–376
Display then returns to Oil temperature.

17
After the values have been displayed it is
possible to adjust the C3 and C4 clutches.

The transmission oil temperature should be at

least 40°C.
Depress the clutch, select either gear 7L (C4 is
used) or 8L (C3 is used), with the shuttle lever in
forward, release the clutch and perform shuttle
shifts driving the tractor at between 1500–1800
rpm.
NOTE: The tractor can be driven in all gears but
Powershifts are not possible. The tests are
performed in the low range because this is more
sensitive to calibration changes. 18

If the shuttle shifts require fine tuning:–

While driving the tractor, with the clutch pedal
fully released, the clutch value is displayed and
may be adjusted using the up and down
powershift switches. Make only small
adjustments and shuttle to test the performance.
WARNING
Take care to remain observant to the ouside
surroundings during these adjustments.

NOTE: If the shuttle lever is moved to neutral the

display will show either C3 or C4 depending on
the gear selected. 19

604.55.041.02 – 01 – 2000
8 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

H3 See Electronic Draft Control ’H’ Menus

H4 MENU MODE –
Software Revision Level
Select H4 with the test switch.

21
The display will automatically show software
information:
CC 16x16 Power Shuttle transmission
03 Software level

and then return to “HH” screen.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 9

H5 MENU MODE –
Transmission/EDC Switch Test
Select H5 with the test switch.

23
The display will then show “d0”.
If a transmission or EDC switch is operated the
display will show a code number and an audible
tone will be heard to indicate correct operation.
If the code and tone do not operate, the switch or
wiring could be at fault.

24
16x16 Switch Diagnostics
Code Switch Operated Notes:
d22 Forward Switch
d23 Reverse Switch
d71 Clutch Pedal Switch d71 Select Forward or Reverse then operate
d72 Seat Switch clutch.
d73 Handbrake Switch
d74 Downshift Switch
d75 Upshift Switch
d77 5–8 Range Switch
d81 1–4 Range Switch
d82 Low Range Switch
d83 High Range Switch d85 Clutch pedal needs to be depressed and the
d85 Neutral Switch (FNR Switch) shuttle lever cycled.
d92 40_C Oil Temperature Switch d92 Remove switch connector and bridge to cause
d93 Fuse No. 12 Sense transition
d94 Manual differential lock switch position d93 Cause a transition by removing and replacing
d95 Left Foot brake switch the fuse.
d96 Right Foot brake switch
d99 Auto differential lock switch

604.55.041.02 – 01 – 2000
10 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

H6 MENU MODE –
Select rear tyre rolling radius

Using a diagnostic lead, select H6 in the diagnostic

menu.
The current radius will be displayed (in millimetres).
On a new vehicle this will be the basic build tyre
radius and will not need changing unless different
size tyres are fitted.

25
By pressing the Transmission Upshift button a
larger radius may be selected and Downshift
button selects a smaller radius. Use the buttons to
select the value closest to the actual radius.

604.55.041.02 – 01 – 2000
SECTION 55– ELECTRICAL SYSTEMS – CHAPTER 13 11

TYRE RADIUS INDEX FOR ROAD SPEED CALCULATION

Tyre Size Radius Tyre Size Radius Tyre Size Radius
Designation Index Designation Index Designation Index
8.3 – 24 470 18.4 – 28 IND 685 360 / 70 R24 540
– 32 570 – 30 720 R28 590
– 36 620 – 30 IND 715 380 / 70 R20 510
– 38 645 – 34 770 R24 560
– 44 720 – 38 820 R28 610
9.5 – 20 445 – 42 870 400 / 70 R20 520
– 24 495 19.5L – 24 IND 610 R24 560
– 28 545 20.8 – 34 805 420 / 70 R24 590
– 36 645 – 38 855 R28 640
– 38 670 – 42 905 R30 665
– 44 745 21L – 24 IND 635 460 / 70 R24 590
– 48 795 – 30 720 480 / 70 R24 620
11.2 – 20 465 23.1 – 26 760 R26 645
– 24 515 – 26 IND 750 R28 670
– 28 565 – 30 810 R30 695
– 36 665 – 34 860 R34 745
– 38 690 24.5 – 32 855 R38 795
12.4 – 20 490 28L – 26 720 500 / 70 R34 745
– 24 540 30.5L R32 860 520 / 70 R26 650
– 28 590 1050 / 50 R32 855 R30 720
– 32 640 800 / 60 R32 820 R34 770
– 36 690 440 / 65 R24 560 R38 820
– 38 720 R28 610 540 / 70 R34 770
– 46 820 480 / 65 R24 590 580 / 70 R26 670
13.6 – 24 560 R28 640 R38 855
– 26 585 540 / 65 R24 620 R42 905
– 28 610 R26 645 600 / 70 R30 745
– 36 715 R28 670 620 / 70 R26 720
– 38 740 R30 695 R38 855
14.9 – 24 590 R34 745 R42 905
– 24 IND 580 R38 795 650 / 70 R26 745
– 26 615 600 / 65 R28 695 R30 795
– 28 640 R32 745 680 / 70 R32 820
– 28 IND 630 R34 770 R34 855
– 30 665 R38 820 710 / 70 R38 905
– 38 765 650 / 65 R38 855 340 / 75 R20 480
15.5 – 38 745 R42 905 380 / 75 R20 500
16.9 – 24 620 750 / 65 R26 770 620 / 75 R26 760
– 24 IND 610 800 / 65 R32 870 R30 810
– 26 645 260 / 70 R16 360 R34 860
– 28 670 R18 390 650 / 75 R32 835
– 28 IND 660 R20 415 R34 855
– 30 695 280 / 70 R16 375 680 / 75 R32 870
– 34 745 R18 400 710 / 75 R34 905
– 34 IND 730 300 / 70 R16 375 210 / 80 R16 345
– 38 795 R18 405 250 / 80 R16 385
– 42 845 R20 445 R18 410
17.5L – 24 IND 580 320 / 70 R20 465 260 / 80 R20 445
18.4 – 24 IND 635 R24 515 320 / 80 R18 IND 475
– 26 670 R28 565
– 26 IND 665 360 / 70 R20 490

604.55.041.02 – 01 – 2000
12 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

Find the rolling radius of the rear tyres of the vehicle

using the table provided on the previous page or if
the tractor is fully built and tyres at the correct
pressure the radius can be measured (in
millimetres) from centre of rear axle to ground.

27
On AEIC panels only the Upshift and Downshift
buttons pressed together will toggle the
groundspeed display between Kph and Mph units.
The default setting is Mph.
Once you have the radius and display units
selected, key off and disconnect the diagnostic
lead. This will store the details in Non-Volatile
Memory (i.e. values will not be lost if battery is
disconnected).

28
H7 MENU MODE –
Auto Radius Calibration
(400 foot / 122m dash)
Mark out a 400 foot / 122 metre distance on level
ground.
Install the Test Switch and start the engine.
Select H7 with the test switch.
NOTE: This mode can also be entered by starting
the engine with either the upshift or downshift
button depressed.

29
The display will change to show the current radius
(in millimetres). On a new vehicle this will be the
basic build tyre radius and will not need changing
unless different size tyres are fitted.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 13

With the transmission in high range (hare) and gear

lever in 1–4 group.
Drive the tractor towards Start Line, as the front
wheels cross the line press the Upshift button. The
display will now show “Run”. Continue to the End
line and as the front wheels cross, press the
Downshift button.
The radius of the rear wheels will now be displayed.

On AEIC panels only further presses of the

Downshift button will toggle the groundspeed
display between Kph and Mph units. The default
setting is Mph. 31
Once you have the radius and display units
selected, key off to store the settings.

H8 MENU MODE –
Non Volatile Memory Reset

Select H8 with the test switch.

WARNING!
H8 WILL CLEAR ALL CALIBRATION VALUES
AND STORED ERROR CODES

32
After selecting H8 the display will change to “EE”
(Erase EPROM) automatically.
The display will then return to the “HH” screen.

604.55.041.02 – 01 – 2000
14 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

H9 Vehicle Sensor Operation Display

Select H9 with the test switch.
H9 allows various signals to and from solenoids,
potentiometers etc. to be checked for both
transmission and EDC systems.

34
The required channel can be selected by using the
up/downshift switches.
NOTE: 4 seconds after selecting a channel, the
channel number will be replaced by a value for that
channel.

Channel
Number Description Typical Approximate Values
0 Clutch Pedal position 91 Released, 26 Depressed
1 Transmission Oil Temperature 71@0_C, 46@30_C, 26@60_C,
14@90_C
2 Not Used –
3 Fuse 12 Sense 99, (zero if blown)
4 Not used –
5 5 Volt Reference (sensor supply) 50
6 12 Volt Vf Input (Fuse 13) 48
7 12 Volt Vd Input (Clutch Switch) 47 Clutch pedal up and FNR in F or R
0 clutch pedal down or FNR in Neutral
8 12 Volt Vh Input (Fuse 14) 48
9 8 Volt Reference (EDC Control) 80
10 Not applicable to service –
11 Not applicable to service –
12 Not applicable to service –
13 Not applicable to service –
14 C1 Valve Current Sense 85+ Engaged, 0 Not Engaged
15 C2 Valve Current Sense 85+ Engaged, 0 Not Engaged
16 C3 Valve Current Sense 85+ Engaged, 0 Not Engaged
17 C4 Valve Current Sense 85+ Engaged, 0 Not Engaged

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 15

Channel
Number Description Typical Approximate Values
18 EDC Valve Raise Solenoid Current 0–73
19 EDC Valve Lower Solenoid Current 0–73
20 Ground Speed Signal 60 when tractor stopped
21 Not used –
22 Not applicable to service
23 Not applicable to service
24 Forward synchroniser solenoid current 0 except when shifting (45 approx. when
shifting)
25 Reverse synchroniser solenoid curent 0 except when shifting (45 approx. when
shifting)
26 Not used
27 Synchroniser Potentiometer 20 in forward, 80 in reverse
28 Lift Arm Position Sensing Potentiometer 33 Lift Lowered
83 Lift Raised
29 Lift Control Lever Potentiometer 27 Fully Lowered
83 Fully Raised
30 Drop Rate Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
31 Height Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
32 Position/Draft Sensitivity Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
33 Slip Limit Control Potentiometer 84 Turned Fully Clockwise
14 Turned Fully Counter Clockwise
34 Right Hand Load Sensing Pin 48 When Implement not being used
35 Left Hand Load Sensing Pin 48 When Implement not being used
36 Left Brake Pedal Switch 0 with brakes on, 99 with brakes off
37 Right Brake Pedal Switch 0 with brakes on, 99 with brakes off
38 Not used
39 Forward Switch (shuttle lever) 30 in neutral, 67 in forward
40 Reverse Switch (shuttle lever) 30in neutral, 67 in reverse
41 not used
42 not used
43 Wheel Speed Frequency 99 = approximately 50Kph
50 = approximately 25 Kph
44 Not used
45 Engine rev/min. Alternator Signal 99 = approximately 3000 rev/min.
50 = approximately 1500 rev/min.
46 RADAR Speed 99 = approximately 50Kph
50 = approximately 25 Kph

604.55.041.02 – 01 – 2000
16 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

NOTE: To observe the values for channels 14, 15, 16 17 and 24 and 25 the engine needs to be running and the
appropriate gear selected. For channels 14 and 16 select 1–4 range, for channels 15 and 17 select 5–8 range).

The values quoted are approximate typical values and these may vary slightly from tractor to tractor. Allow up
to 10% on the figures quoted.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 17

HA MENU MODE –
Clutch Pedal Position Display
and Oil Temperature
Select HA with the test switch.
This selection allows the tractor to be driven while
displaying the clutch pedal position.
The value is displayed as a percentage, 99 clutch
released and 0 clutch fully depressed.

36
The position of the clutch pedal can then be
monitored.
Use this mode to correctly set up the clutch pedal
switch. The switch should operate between 8
(down click) and 14 (upwards click).
When the clutch switch is closed, ’C’ is displayed
and when the clutch switch is open ’O’ is displayed
on the left hand display digit, when forward or
reverse is selected.

37
The OIl temperature is displayed when the clutch
pedal is released for more than 5 seconds.

38
HB View Stored Error Codes
Select HB with the test switch.
This mode displays the error codes stored in the
memory of the transmission processor.
Up to 10 transmission error codes and 10 EDC
error codes can be stored. The display mode sorts
the error codes so that the error codes which
occurred most recently are displayed first.

604.55.041.02 – 01 – 2000
18 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

Whilst in this mode the transmission upshift and

downshift switches and the EDC raise/lower switch
is used to control the display.

40
EDC error codes are displayed first, if there are
any. The transmission LCD is blank.
Momentarily press the EDC raise/lower switch to
view the next EDC error code.

41
To view transmission errors, momentarily push the
up or down shift buttons. The EDC display will go
blank.

To select the next stored error code, press either

the up or down shift switch.
To return to EDC error codes, momentarily depress
the raise/lower switch.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 19

Transmission – hours / occurences

To view the hours since the error last occurred,
press and hold the upshift switch. The hours will be
displayed for up to two seconds.
NOTE: Hours are counted whenever the engine is
running.
To view the number of times the error has occurred
(i.e. how many times the fault has been detected,
ongoing errors will be stored everytime the
keyswitch is turned on), continue to hold the upshift
switch after the hours have been displayed.

44
To return to the top of the list, at any time, press
both the upshift and downshift buttons together.

When there are no errors to display or the end of

the last has been reached, the display will show “
_ _ “.

45
EDC – hours / occurences
To view the hours since the error last occurred,
press and hold the raise/lower switch in the
lowering position.
Due to the EDC display only capable of displaying
2 digits, the display will show the hours in 2 stages
and the occurences in 2 stages.
The display will show a digit for approximately 0.8
of a second followed by 2 more digits for a further
2 seconds, this is the hours since the error last
occured.
NOTE: Hours are counted whenever the engine is
running.
46
Continuing to hold the lowering button will then
show the number of occurences, again a digit is
displayed for approximately 0.8 of a second
followed by 2 more digits.

604.55.041.02 – 01 – 2000
20 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

HC MENU MODE –
Clear Stored Error Codes
This mode functions like ’H8’ but only clears stored
error codes. Calibration values are not affected.

Select HC with the test switch.

The dispaly will go blank, show ’EE’ go blank again
and then return to ’HH’.

48
HD MENU MODE –
View Live Error Codes
Select HD with the test switch.
After a few seconds the display will revert to normal
operating mode.
This mode allows normal tractor operation, but any
detected errors will cause an error code to be
displayed, whether they are disabling or not.
Key off, then on, to reset system to normal
operation, i.e. only disabling error codes
displaying.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 21

HE MENU MODE –
CLUTCH FILL TIME CALIBRATION
Set up procedure:
S Warm the oil to normal operating temperature,
at least 60°C.
S Park the tractor on a level surface.
S with a diagnostic tool installed, depress the
clutch, start the engine and set engine speed
to 1200 +/– 100 rpm.

50
Entering the calibration mode :
Using diagnostic tool 4FT950 select mode HE.

Place the 4–5 (main) and range levers in neutral,

place the shuttle lever in forward and release the
clutch pedal.

If the oil temperature is less than 60°C ’F1’ will

be displayed, alternating with the display of oil
temperature. This will NOT stop until the oil
reaches 60°C.

51
CLUTCH SELECTION:
While the 4–5 lever is in neutral, the display will C1/C2 C3/C4
indicate which clutch is selected.

To select C1 or C2 the range lever must be in

neutral.
To select C3 or C4 the range lever must be in the
high range

To switch between C1 and C2 or C3 and C4,

press the upshift or downshift switch while the
4–5 lever is in neutral.

52
ADJUST AND TEST C1 OR C2
Shift the 4–5 lever into 5 (forward).
This display will show C1 or C2 and to the left of
this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on the C3 and
C4 clutches to prevent output rotation of the C1
and C2 clutches.

604.55.041.02 – 01 – 2000
22 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

The display will then change to a single digit

number which is indicating the quickfill time in 10
millisecond units.
This can be adjusted using the upshift and
downshift switches.
The factory default setting is 3.

54
To test the quickfill setting, press and hold both the
upshift and downshift buttons. The display will
show ’FILL’ The transmission will automatically
engage and release appropriate clutches.

NOTE: If nothing appears to happen depress the

clutch, cycle the shuttle lever and release the
clutch to re–enable the transmission.
To adjust, reduce the value until no ’clunk’ is
evident, then increase the value until there is a
distinct ’clunk’ evident.
Then reduce the value by 2.

55
ADJUST AND TEST C3 OR C4

Ensure that the handbrake is OFF.

If coming from C1/C2 testing, shift both the 4–5

and range levers to neutral.

Shift the range lever into the high range.

Shift the 1–4/5–8 lever into 5–8 range.

56
This display will show C3 or C4 and to the left of
this a sequence of horizontal lines will appear to
indicate a ramping up of pressure on C1 clutch to
connect C3 and C4 to the engine.

604.55.041.02 – 01 – 2000
SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13 23

The display will then change to a single digit

number which is indicating the quickfill time in 10
millisecond units.This can be adjusted using the
upshift and downshift switches.
The factory default setting is 4.

58
To test the quickfill setting, press and hold both the
upshift and downshift buttons.
The display will show ’FILL’ while C3 or C4 is
engaged briefly. The display will then show the
clutch selected followed by the quickfill value.
NOTE: If nothing appears to happen depress the
clutch, cycle the shuttle lever and release the
clutch to re–enable the transmission.
To adjust, decrease the value until the tractor does
not move, then increase the quickfill just enough to
cause the tractor to move.
Then reduce the value by 2.

59
HF MENU MODE –
4WD Braking, engagement speed adjustment
Select HF with the test switch.

60
The display will change to show a value between
0 to 4.
The value corresponds to the approximate ground
speed, in mph, below which the 4WD will not
engage.

604.55.041.02 – 01 – 2000
24 SECTION 55 – ELECTRICAL SYSTEMS – CHAPTER 13

The value is adjusted by depressing the upshift to

raise the value and the downshift to lower the
value.
The factory default setting is 4.

62
HJ MENU MODE –
Handbrake Loud Buzzer Control
This mode is used to switch ON/OFF the external
loud buzzer.
Useful for where a DIC panel is installed which has
its own internal buzzer.
Select HJ with the test switch.

63
0 = Buzzer off
1 = Buzzer on
Use the up/downshift buttons to change the
selection.

604.55.041.02 – 01 – 2000

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