SAFETY ...................................................................................................................................................... 00-2-3

GENERAL INFORMATION ......................................................................................................................... 00-2-5

LUBRICATION/MAINTENANCE CHART ................................................................................................... 00-2-6

SYSTEM CAPACITIES ............................................................................................................................... 00-2-7

ENGINE REMOVAL AND INSTALLATION ......................................................................SECTION 10, CHAPTER 1

ENGINE REMOVAL .................................................................................................................................... 10-1-3

ENGINE INSTALLATION .......................................................................................................................... 10-1-10

FUEL TANK / FUEL SENDER REMOVAL AND INSTALLATION....................................SECTION 10, CHAPTER 2

SPECIAL TORQUES .................................................................................................................................. 3001-3

FUEL TANK REMOVAL AND INSTALLATION .......................................................................................... 3001-3

FUEL LEVEL SENDER REMOVAL AND INSTALLATION........................................................................ 3001-10

HOOD REMOVAL ............................................................................................................SECTION 10, CHAPTER 3

HOOD REMOVAL ....................................................................................................................................... 10-3-3

HOOD INSTALLATION ............................................................................................................................... 10-3-5

COOLING SYSTEM MODULE REMOVAL AND INSTALLATION ...................................SECTION 10, CHAPTER 4

COOLING MODULE REMOVAL ................................................................................................................ 10-4-3

COOLING MODULE INSTALLATION ........................................................................................................ 10-4-7

VISCOUS FAN DRIVE TEST ...........................................................................................SECTION 10, CHAPTER 5

REQUIRED TOOLS .................................................................................................................................... 10-5-3

DIAGNOSTIC PROCEDURE ...................................................................................................................... 10-5-4

FAN SPEED TEST ..................................................................................................................................... 10-5-7

POWERSHIFT TRANSMISSION SYSTEM -

HOW IT WORKS AND TROUBLESHOOTING ................................................................SECTION 21, CHAPTER 1

TRANSMISSION SYSTEM INTRODUCTION ............................................................................................ 21-1-3

TRANSMISSION SYSTEM CONTROLS .................................................................................................... 21-1-5

TRANSMISSION SYSTEM COMPONENTS .............................................................................................. 21-1-6

TRANSMISSION LUBE AND DISTRIBUTION TUBES .............................................................................. 21-1-8

POWERSHIFT TRANSMISSION CLUTCH LAYOUT ............................................................................... 21-1-10

POWERSHIFT VALVE CLUTCH ENGAGEMENTS ................................................................................. 21-1-11

POWER FLOW (FORWARD SPEEDS) ................................................................................................... 21-1-12

POWER FLOW (REVERSE SPEEDS) ..................................................................................................... 21-1-30

POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) ..................................................................... 21-1-34

POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) ...................................................................... 21-1-40

INCHING VALVE OPERATION ................................................................................................................ 21-1-42

INSTRUMENTATION CLUSTER - TRANSMISSION LEAKAGE CHECK ................................................ 21-1-46

MASTER CLUTCH PRESSURE CHECK ................................................................................................. 21-1-49

FRONT FRAME TO SPEED TRANSMISSION SPLIT .....................................................SECTION 21, CHAPTER 2

SPECIAL TOOLS ........................................................................................................................................ 21-2-3

SPECIAL TORQUES .................................................................................................................................. 21-2-3

FRONT FRAME TO SPEED TRANSMISSION SPLIT ............................................................................... 21-2-4

T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for New Holland T8010

Page 1 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS NOTE: Engine repair information is not contained within this tractor Repair Manual. For engine repair, refer to publication number 87515682 for the 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System.
Page 2 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS SPEED TO RANGE TRANSMISSION SPLIT ..............SECTION 21, CHAPTER 3 SPECIAL TOOLS ............................21-3-3 SPECIAL TORQUES ..........................21-3-3 SPEED TO RANGE TRANSMISSION SPLIT ..................... 21-3-4 Removal ..............................21-3-4 Installation ..............................21-3-7 SPEED TRANSMISSION ....................SECTION 21, CHAPTER 4 SPECIFICATIONS ............................
Page 3 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS REAR FRAME ........................SECTION 21, CHAPTER 8 SPECIFICATIONS ............................21-8-3 SPECIAL TORQUES ..........................21-8-3 SPECIAL TOOLS ............................21-8-3 DIFFERENTIAL ............................21-8-4 Removal ..............................21-8-4 Disassembly ............................21-8-10 PINION SHAFT ............................21-8-14 Removal and Disassembly ........................21-8-14 Assembly and Installation ........................
Page 4 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS SUSPENSION FWD AXLE SYSTEM - HOW IT WORKS AND TROUBLESHOOTING ..SECTION 25, CHAPTER 5 SUSPENDED FWD AXLE OPERATION ....................25-5-3 SUSPENDED MFD AXLE- CALIBRATION MODE ..................25-5-9 ERROR TABLE ............................25-5-11 SUSPENDED FWD AXLE- MANUAL OPERATION MODE (TEST MODE) ..........25-5-13 SUSPENDED FWD AXLE- DEMONSTRATION MODE ................
Page 5 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS FWD PLANETARY HUB, STEERING KNUCKLE AND AXLE DRIVE SHAFT ....SECTION 25, CHAPTER 10 SPECIFICATIONS ............................ 25-10-3 SPECIAL TORQUES ..........................25-10-3 SPECIAL TOOLS ............................25-10-3 PLANETARY HUB DISASSEMBLY ......................25-10-4 STEERING KNUCKLE AND KINGPIN DISASSEMBLY ................25-10-9 AXLE DRIVE SHAFT DISASSEMBLY ....................
Page 6 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS PTO CLUTCH ASSEMBLY - SINGLE, REVERSIBLE AND DUAL SPEED.....SECTION 31, CHAPTER 2 SPECIAL TOOLS ............................31-2-3 SPECIAL TORQUES ..........................31-2-3 PTO CLUTCH ASSEMBLY ......................... 31-2-4 General ..............................31-2-4 PTO CLUTCH SERVICE ..........................31-2-4 Removal ..............................31-2-4 Disassembly ..............................
Page 7 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS HYDRAULIC SYSTEM - HOW IT WORKS WITH TROUBLESHOOTING .......SECTION 35, CHAPTER 2 GENERAL INTRODUCTION ........................35-2-3 REAR CHARGE/LUBE PUMP PRESSURE TEST ................... 35-2-19 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE ........35-2-21 FRONT/REGULATED SYSTEM PUMP FLOW TEST ................35-2-25 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE .........
Page 8 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS PFC PISTON PUMP AND HYDRAULIC FILTER.............SECTION 35, CHAPTER 8 SPECIAL TORQUES ..........................35-8-3 PFC PISTON PUMP ........................... 35-8-3 Removal ..............................35-8-3 Installation ..............................35-8-4 HITCH SYSTEM - HOW IT WORKS ................SECTION 35, CHAPTER 9 THREE POINT HITCH ..........................35-9-3 ELECTRONIC HITCH CONTROL ......................
Page 9 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS A/C TROUBLESHOOTING ....................SECTION 50, CHAPTER 1 SAFETY PROCEDURES ..........................50-1-5 SPECIAL TOOLS ............................50-1-6 A/C THERMAL OPERATION ........................50-1-7 A/C SYSTEM COMPONENTS ........................50-1-9 Cab HVAC Box Components - Automatic Temperature Control ............... 50-1-9 Chassis Components ..........................50-1-11 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION .............
Page 10 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS BLOWER AND BLOWER SPEED DRIVER ..................... 50-1-47 Background ............................. 50-1-47 Power, Signal and Ground Circuit ......................50-1-47 Possible Failure Modes ........................... 50-1-47 Blower Motor/Blower Driver Power, Signal and Ground Test ..............50-1-48 Cab And Evapator Temperature Sensors ....................50-1-49 Background .............................
Page 11 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS Evaporator Temperature Sensor ......................50-1-83 Background ............................. 50-1-83 Electrical Test – Sensor .......................... 50-1-83 Power Circuit ............................50-1-84 Service Note: Too Little Cooling/Too Much Heating without Symptoms ..........50-1-84 Evaporator Temperature Sensor and Circuit Test .................. 50-1-84 Controller Power, Ground And A/C Switch ....................
Page 12 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AIR CONDITIONER SYSTEM SERVICE.................SECTION 50, CHAPTER 2 SPECIFICATIONS ............................50-2-4 SPECIAL TORQUES ..........................50-2-4 SPECIAL TOOLS ............................50-2-4 SAFETY PROCEDURES ..........................50-2-9 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY ..............50-2-10 RECOVERING PURE 134A REFRIGERANT ................... 50-2-12 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 ............
Page 13 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS CAB RECIRCULATION AIR FILTER SERVICE ..................50-2-110 CAB PRESSURIZATION TEST ......................50-2-111 CAB PRESSURIZER MOTOR REPLACEMENT ..................50-2-113 VISCOUS FAN DRIVE ..........................50-2-116 ELECTRICAL SCHEMATIC POSTER - EUROPEAN ................. 87389711 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING .......SECTION 55, CHAPTER 1 SPECIAL TOOLS ............................
Page 14 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS POWER SEAT SYSTEM ........................55-1-184 Power Seat System Circuit Operation ....................55-1-184 Power Seat System Circuit Troubleshooting ..................55-1-184 Power Seat System Symptom Chart ..................... 55-1-185 Power Seat System Diagnostic Tests ....................55-1-186 STARTING SYSTEM ..........................55-1-190 Starting System Circuit Operation ......................
Page 15 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODES - TRACTOR MULTI-FUNCTION (TMF) CONTROLLER ............SECTION 55, CHAPTER 3 AUX/HITCH/PTO FAULT CODE 2 ......................55-3-7 AUX/HITCH/PTO FAULT CODE 4 ......................55-3-8 AUX/HITCH/PTO FAULT CODE 5 ......................55-3-9 AUX/HITCH/PTO FAULT CODE 7 ......................55-3-10 AUX/HITCH/PTO FAULT CODE 11 ......................
Page 16 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODE 87 ......................55-3-49 AUX/HITCH/PTO FAULT CODE 88 ......................55-3-50 AUX/HITCH/PTO FAULT CODE 89 ......................55-3-50 AUX/HITCH/PTO FAULT CODE 90 ......................55-3-51 AUX/HITCH/PTO FAULT CODE 92 ......................55-3-51 AUX/HITCH/PTO FAULT CODE 93 ......................55-3-52 AUX/HITCH/PTO FAULT CODE 94 ......................
Page 17 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODE 163 ....................... 55-3-93 AUX/HITCH/PTO FAULT CODE 164 ....................... 55-3-94 AUX/HITCH/PTO FAULT CODE 165 ....................... 55-3-95 AUX/HITCH/PTO FAULT CODE 166 ....................... 55-3-96 AUX/HITCH/PTO FAULT CODE 167 ...................... 55-3-97 AUX/HITCH/PTO FAULT CODE 168 ....................... 55-3-98 AUX/HITCH/PTO FAULT CODE 169 .......................
Page 18 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS TRANSMISSION CONTROLLER FAULT CODES ............SECTION 55, CHAPTER 4 FAULT CODE TRANS 11 ........................... 55-4-5 FAULT CODE TRANS 12 ........................... 55-4-6 FAULT CODE TRANS 24 ........................... 55-4-7 FAULT CODE TRANS 37 ........................... 55-4-8 FAULT CODE TRANS ..........................55-4-9 FAULT CODE TRANS 47 .........................
Page 19 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS FAULT CODE TRANS 129 ........................55-4-60 FAULT CODE TRANS 130 ........................55-4-60 FAULT CODE TRANS 131 ........................55-4-61 FAULT CODE TRANS 132 ........................55-4-61 FAULT CODE TRANS 133 ........................55-4-61 FAULT CODE TRANS 134 ........................55-4-62 FAULT CODE TRANS 135 ........................
Page 20 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS ARMREST CONTROLLER FAULT CODES ..............SECTION 55, CHAPTER 5 FAULT CODE ARM 19 ..........................55-5-4 FAULT CODE ARM 29 ..........................55-5-5 FAULT CODE ARM 39 ..........................55-5-6 FAULT CODE ARM 49 ..........................55-5-7 FAULT CODE ARM 59 ..........................55-5-8 FAULT CODE ARM 69 ..........................
Page 21 T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS CONTROLLER CONFIGURATION AND CALIBRATION ..........SECTION 55, CHAPTER 6 FAULT CODE RETRIEVAL ........................55-6-3 INSTRUMENTATION PROGRAMMING ....................55-6-5 Radar Calibration ............................55-6-9 Controller Configuration .......................... 55-6-12 INSTRUMENTATION DISPLAY SYMPTOM BASED FAULTS ..............55-6-17 ARMREST CONTROLLER CONFIGURATION AND CALIBRATION ............55-6-19 TRANSMISSION CONTROLLER CONFIGURATION AND CALIBRATION ..........
Page 22 Section 00 Chapter 1 STANDARD TORQUE SPECIFICATION January, 2006...
Page 23 Section 00 - General Information - Chapter 1 TABLE OF CONTENTS TORQUE SPECIFICATIONS - METRIC HARDWARE .................. 00-1-4 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ..............00-1-5 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ..............00-1-6 00-1-2...
Page 24 Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphites, Molydisulfide greases, or other extreme pressure lubricants are used.
Page 25 Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Page 26 Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton Hose ID Size Inches metres Hose ID Size Inches metres 37 Degree Flare Fitting Straight Threads with O-ring 1/4 inch 7/16-20 72 to 144...
Page 27 Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Nom. Dash Thread Pound- Newton Thread Pound- Newton Size Tube OD Size Inches metres Size Inches metres O-ring Boss End O-ring Face Seal End Fitting or Lock Nut 1/4 inch 9/16-18 120 to 144...
Page 28 Section 00 Chapter 2 SAFETY, GENERAL INFORMATION, MAINTENANCE SCHEDULE January, 2006...
Page 29 Section 00 - General Information - Chapter 2 TABLE OF CONTENTS SAFETY ................................00-2-3 GENERAL INFORMATION ..........................00-2-5 LUBRICATION/MAINTENANCE CHART ....................... 00-2-6 SYSTEM CAPACITIES ..........................00-2-7 00-2-2...
Page 30: Safety
Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 00 - General Information - Chapter 2 SAFETY THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
Page 31 Section 00 - General Information - Chapter 2 WARNING: Always wear heat protective WARNING: Use suitable floor (service) gloves to prevent burning your hands when jacks or chain hoist to raise wheels or tracks handling heated parts. off the floor. Always block machine in placed SM121A with suitable safety stands.
Page 32: General Information
When ordering refer to the Parts Catalog for the permit to air dry. DO NOT DRY BEARINGS WITH correct part number of the genuine New Holland COMPRESSED AIR. Check bearings for smooth replacement items. Failures due to the use of other easy action.
Page 33: Lubrication/Maintenance Chart
Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 00 - General Information - Chapter 2 LUBRICATION/MAINTENANCE CHART Service Interval Maintenance Requirement Check Grease Change Clean Drain When Warning Air Cleaner Element Message Displays Engine Oil Level Every 10 Hours Or Transmission Oil Level Daily Coolant Reservoir Level...
Page 34: System Capacities
148 Gal = Bolt quantity can be determined by observing the wheel ends. = 25 pints New Holland Ambra Hypoide 140 Gear Oil, SAE 85W140, plus 1 pint New Holland Limited Slip Additive (B96606) for 13 quarts total. = 27 pints New Holland Ambra Hypoide 140 Gear Oil, SAE 85W140, plus 1 pint New Holland Limited Slip Additive (B96606) for 14 quarts total.
Page 35 Section 00 - General Information - Chapter 2 This Page Left Blank. 00-2-8...
Page 36 Section 10 Chapter 1 ENGINE REMOVAL AND INSTALLATION January, 2006...
Page 37 Section 10 - Engine - Chapter 1 TABLE OF CONTENTS ENGINE REMOVAL ............................10-1-3 ENGINE INSTALLATION ..........................10-1-10 10-1-2...
Page 38 Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 10 - Engine - Chapter 1 ENGINE REMOVAL NOTE: Make note of where any wire harness and STEP 5 hose tie straps are removed during disassembly so Remove the cooling module. See Cooling Module they can be properly installed during assembly.
Page 39 Section 10 - Engine - Chapter 1 STEP 8 STEP 11 RD05N102 RD05N105 Properly support the muffler. Remove the mounting Tag and remove the heater supply hose (1) and hardware and remove the muffler / exhaust elbow return hose (2). assembly.
Page 40 Section 10 - Engine - Chapter 1 STEP 14 STEP 17 RD05N108 Remove the har nes s cla mp ( 1) . Remove th e compressor clutch harness (2) from the clamp. RD05N136 Disconnect the coolant fill tube (1) at the deaeration Reinstall the mounting bolt.
Page 41 Section 10 - Engine - Chapter 1 STEP 20 STEP 22 RD05N112 RD05N114 Remove the four air cleaner housing mounting nuts (1). Remove the air cleaner assembly. Remove the alternator wire harness (2) with the air cleaner assembly. STEP 21 RD05N115 Remove the charge-air cooler to intake manifold tube bushing bolt (1).
Page 42 Section 10 - Engine - Chapter 1 STEP 24 STEP 27 RD05N118 RD05N121 Remove the engine heater grid power cable. Pr oper l y supp or t the hood / de aeration tank mounting assembly. STEP 25 STEP 28 RD05N119 Remove the washer bottle from its mounting bracket.
Page 43 Section 10 - Engine - Chapter 1 STEP 30 STEP 33 RD05N124 RD05N127 Remove the fuel supply hose. Disconnect the high (1) and low (2) pressure A/C lines. STEP 31 STEP 34 RD05N125 Remove the two support mounting bolts. RD05N128 Remove the hydraulic oil cooling lines.
Page 44 Section 10 - Engine - Chapter 1 STEP 36 STEP 39 RD05N130 RD05N133 Remove the A / C tube exhaust shield. Properly support the hose / tube / air cleaner support bracket assembly and remove from the engine. STEP 37 STEP 40 RD05N131 Remove the right front mounting bolts.
Page 45 Section 10 - Engine - Chapter 1 ENGINE INSTALLATION STEP 41 STEP 42 RD05N135 RD05N133 Set the hose / tube / air cleaner support bracket assembly in place on top of the engine. STEP 43 RI02C011 RD05N132 Set the spacer (1) into place and install the mounting Apply a thin coat of anti seize lubricant to the bolts (2).
Page 46 Section 10 - Engine - Chapter 1 STEP 44 STEP 47 RD05N131 RD05N128 Install the right front mounting bolts. Install new O-rings on the fittings and tighten the hydraulic cooling lines. STEP 45 STEP 48 RD05N129 Install the right rear mounting bolts. Tighten ALL Rd05N127 bracket mounting bolts at this time.
Page 47 Section 10 - Engine - Chapter 1 STEP 50 STEP 53 RD05N126 RD05N123 Connect the engine wire harness connector. If removed, install the windshield step (1) and tighten the bolts (2). STEP 51 STEP 54 RD05N125 Install the support mounting bolts and tighten to a RD05N122 torque of 310 to 380 Nm (230 to 280 lb.
Page 48 Section 10 - Engine - Chapter 1 STEP 56 STEP 59 RD05N119 RD05N134 Install the front washer hose and electrical connector Install a new O-ring on the charge-air cooler to intake (1) and rear (2) if equipped. Install the bottle onto the manifold tube assembly.
Page 49 Section 10 - Engine - Chapter 1 STEP 61 STEP 64 RD05N113 RD05N110 Install the deaeration tank to coolant recovery bottle Install the air cleaner restriction switch connector. hose (1) and engine air bleed line (2). STEP 65 STEP 62 RD05N117 Connect the alternator harness.
Page 50 Section 10 - Engine - Chapter 1 STEP 67 STEP 70 RD05N108 RD05N105 Install the ground wire (1) and the clamp (2). Install the heater out (1) and in (2) hoses. STEP 68 STEP 71 RD05N107 RD05N104 Install the three alternator wires. Install the starter cables.
Page 51 Section 10 - Engine - Chapter 1 STEP 73 STEP 77 Recharge the A/C system. See A/C Service Section in this Repair Manual. STEP 78 Install the hood. See Hood Removal Section in this Repair Manual. STEP 79 RD05N102 Properly suppor t the muffler, lift into place and tighten the mounting bolts to a torque of 200 to 245 Nm (149 to 179 lb.ft.).
Page 52 Section 10 Chapter 2 FUEL TANK / FUEL SENDER REMOVAL AND INSTALLATION January 2006...
Page 53: Table Of Contents
Section 10 - Engine - Chapter 2 TABLE OF CONTENTS SPECIAL TORQUES ............................10-2-3 FUEL TANK ..............................10-2-3 General ............................... 10-2-3 Removal ..............................10-2-3 Installation ..............................10-2-7 FUEL LEVEL SENDER ..........................10-2-10 Removal ..............................10-2-10 Installation ..............................10-2-11 10-2-2...
Page 54: Special Torques
Section 10 - Engine - Chapter 2 SPECIAL TORQUES Bolts on cab steps ......................37 to 67 Nm (27 to 49 lb. ft.) FUEL TANK General Removal STEP 1 STEP 2 96R-28A 95-12 Before removing the fuel tank, do the following: Remove the six step mounting bolts (1).
Page 55 Section 10 - Engine - Chapter 2 STEP 4 STEP 7 50-23F RD05K005 Move the left rear wheel out on the axle as far as Loosen hose clamp (1) on fuel tank balance hose possible to provide clearance when removing the left located under the transmission speed housing.
Page 56 Section 10 - Engine - Chapter 2 STEP 10 STEP 13 101R-19A RD05K007 Remove the fuel supply fitting (1), the fuel return With prybars, lift up on the main tank and move it out fitting (2), vent fitting (3) and fuel sending unit cover a few inches.
Page 57 Section 10 - Engine - Chapter 2 STEP 16 STEP 19 RD02B106 101R-23A Remove the battery cables and move to the side. Lift the right tank free of the support bracket and Remove the batteries. remove the tank. STEP 17 IMPORTANT: Be prepared to collect some fuel when the tank is removed.
Page 58: Installation
Section 10 - Engine - Chapter 2 Installation STEP 24 STEP 21 101R-19A Install the fuel tank onto the support brackets with enough room to attach fittings. RD02B107 If the fuel tank suppor t bracket was removed, properly support the bracket and lift into position. STEP 25 Install and tighten all the retaining bolts (1).
Page 59 Section 10 - Engine - Chapter 2 STEP 27 STEP 30 95-15R 101R-23A Install and tighten two bolts through each of the two Move the right tank into position. Connect the lockdown plates. balance hose at the bottom of the tank (not shown) and tighten the clamp.
Page 60 Section 10 - Engine - Chapter 2 STEP 33 STEP 36 RD05K002 5-23 Install battery cover and toolbox. Position the wheels to the desired position on the rear axle. STEP 34 95-12 Move steps into position. Install six bolts and tighten to a torque of 37 to 67 Nm (27 to 49 lb.
Page 61: Fuel Level Sender
Section 10 - Engine - Chapter 2 FUEL LEVEL SENDER Removal STEP 40 STEP 37 RD05K003 Remove the sender. RD05J085 Disconnect the fuel sender wire harness. STEP 41 STEP 38 RD05K004 Remove the sender seal, inspect for damage and replace if necessary. RD05J087 Remove the fuel sender cover bolts.
Page 62: Installation
Section 10 - Engine - Chapter 2 Installation STEP 45 STEP 42 RD05J085 Connect the fuel sender wire harness. RD05K004 STEP 46 Lubricate the outside diameter of the seal with soap and install. Install fuel and check sender for proper operation. STEP 43 RD05K003 Lubricate the inside diameter of the seal (1) with...
Page 63 Section 10 - Engine - Chapter 2 10-2-12...
Page 64 Section 10 Chapter 3 HOOD REMOVAL / INSTALLATION January, 2006...
Page 65 Section 10 - Engine - Chapter 3 TABLE OF CONTENTS HOOD REMOVAL ............................10-3-3 HOOD INSTALLATION ..........................10-3-5 10-3-2...
Page 66 Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 10 - Engine - Chapter 3 HOOD REMOVAL STEP 1 STEP 4 RD02C070 RD05N003 Park the tractor on a hard, level surface. Put the Remove the windshield washer nozzle hose. transmission shift lever in PARK. Place blocks in front of and behind the rear wheels.
Page 67 Section 10 - Engine - Chapter 3 STEP 7 STEP 10 RD05N006 RD05N009 Remove the safety clip from each hood strut. Lower the hood and push rearward until the hood bracket (1) is free of the hood support rod (2). While balancing the hood, raise as necessary and remove STEP 8 from the chassis.
Page 68 Section 10 - Engine - Chapter 3 HOOD INSTALLATION STEP 11 STEP 14 RD05N005 RD05N008 Properly support the hood. While balancing the Install the locking bracket. hood, raise and set into place. STEP 15 STEP 12 RD05N007 Install the hood support struts. RD05N009 Align the hood bracket (1) with the hood support rod (2) and slide forward into place.
Page 69 Section 10 - Engine - Chapter 3 STEP 17 STEP 20 RD05N004 RD05N002 Remove the support from the hood. Connect the horn wire harness. STEP 18 STEP 21 RD05J074 RD05N001 Clip the hood lanyard to the support bracket. \Connect the hood lights wire harness. STEP 19 STEP 22 RD05N003...
Page 70 Section 10 Chapter 4 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION January, 2006...
Page 71 Section 10 - Engine - Chapter 4 TABLE OF CONTENTS COOLING MODULE REMOVAL ........................10-4-3 COOLING MODULE INSTALLATION ......................10-4-7 10-4-2...
Page 72 Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 10 - Engine - Chapter 4 COOLING MODULE REMOVAL STEP 1 NOTE: If A/C condenser DOES NOT have to be removed, DO NOT evacuate the system. STEP 4 RD02C070 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK.
Page 73 Section 10 - Engine - Chapter 4 STEP 5 Do the following steps if the A/C condenser does not have to be removed. STEP 6 RD05N015 Remove the air scoop upper (shown) (1) and lower plastic fasteners. Remove the air scoop. RD05N016 Remove the upper hydraulic cooling hose.
Page 74 Section 10 - Engine - Chapter 4 Cooling Module Removal with A / C STEP 12 Condenser STEP 9 RD05N022 Remove the radiator outlet (lower) pipe at the engine. Discard the gasket. RD05N019 STEP 13 Remove the fuel cooler inlet (1) and return (2) hoses. Remove the condenser outlet hose (3).
Page 75 Section 10 - Engine - Chapter 4 STEP 15 STEP 18 RD05N025 RD05N028 Remove the lower hydraulic oil cooler tube clamp (1) Slowly raise the cooling assembly and pull the lower and tube (2). Discard the O-ring. Have a container portion away from the cooling fan (1) to clear the fan ready to catch any hydraulic oil that may be in the shroud (2).
Page 76 Section 10 - Engine - Chapter 4 COOLING MODULE INSTALLATION STEP 20 STEP 23 RD05N026 RD05N027 Properly support the cooling assembly and move into Install the module mounting bolts (1) and tighten to a position on the front frame. torque of 90 to 107 Nm (66 to 79 lb. ft.) STEP 21 STEP 24 RD05N029...
Page 77 Section 10 - Engine - Chapter 4 STEP 26 Do the following step if the A/C condenser was not removed. STEP 28 RD05N022 Install a new gasket and bolt the radiator outlet / engine inlet pipe to the engine coolant inlet port. RD05N018 STEP 27 RD05N017...
Page 78 Section 10 - Engine - Chapter 4 STEP 30 STEP 33 RD05N019 RD05N015 Install a new O-ring on the condenser outlet hose Install the air cleaner scoop and install new plastic and tighten the fitting (1). Install the fuel cooler outlet fasteners (1).
Page 79 Section 10 - Engine - Chapter 4 STEP 36 STEP 38 RD05N013 RD02C070 Close the radiator drain. Refill the cooling system Remove wheel blocks. with the proper mix of ethylene glycol. See Operator Manual for coolant capacity. Install the pressure cap on the deaeration tank, start the engine and check for any leaks.
Page 80 Section 10 Chapter 5 VISCOUS FAN DRIVE TEST January, 2006...
Page 81 Section 10 - Engine - Chapter 5 TABLE OF CONTENTS REQUIRED TOOLS ............................10-5-3 DIAGNOSTIC PROCEDURE ......................... 10-5-4 FAN SPEED TEST ............................10-5-7 10-5-2...
Page 82 Section 10 - Engine - Chapter 5 REQUIRED TOOLS Digital Photo Tachometer OEM1057A or Equivalent OEM1057A Digital Thermometer with Probe (380001301) OR Digital Multimeter with Air Probe Equivalent 380001301 10-5-3...
Page 83 Section 10 - Engine - Chapter 5 DIAGNOSTIC PROCEDURE Physical Check STEP 1 Check the torque of the fan blade mounting bolts. 1. 690 Drive (40KPH Transmission): 10.3 - 14.8 lb. ft. (14 - 70 Nm). 2. 810 Drive (50 KPH Transmission): 12.1 - 14.8 lb.
Page 84 Section 10 - Engine - Chapter 5 STEP 4 Check the torque on the drive shaft hub – 66.7 - 82.6 lb. ft. (90 - 112 Nm). RD03C014 STEP 5 Check the fan drive, blade assembly, shroud and radiator for signs of interference with rotating parts. If damage is present, locate and repair the problem, replacing defective parts as needed.
Page 85 Section 10 - Engine - Chapter 5 STEP 8 Check for plugging in the fuel cooler, condenser, air cooler, oil cooler and radiator. Remove crop dust, dirt and debris in the air path to the engine. If necessary, use low pressure power wash or compressed air to clean.
Page 86 Section 10 - Engine - Chapter 5 FAN SPEED TEST STEP 10 IMPORTANT: This test is most effective at an ambient air temperature of 80° F (26.7° C) or higher. NOTE: Reading RPM with the tachometer in bright sunlight may be difficult; if possible, move the tractor to more suitable lighting conditions.
Page 87 Section 10 - Engine - Chapter 5 STEP 13 Loosen the shroud mounting screws on the left hand side of the fan, and route the temperature probe between the front of the viscous drive and the radiator. RD03C017 STEP 14 Secure the temperature probe to the rear of the radiator with wire ties so the sensing probe measures air temperature within 1 inch (25.4 mm) of the center...
Page 88 Section 10 - Engine - Chapter 5 STEP 17 As the engine warms up, A. The fan RPM should stabilize between 800- 1000 RPM. B. When engine coolant reaches 200-220° F (93.3-104.4° C), fan speed should increase to 1 8 7 0 R P M o n a l l m o d e l s w i t h 4 0 K P H transmission or 2125 on all models with 50 KPH transmission.
Page 89 Section 10 - Engine - Chapter 5 STEP 19 Remove the cover from the front of the radiator. Remove the air temperature probe and photo tachometer. Move the throttle to the low idle position and allow the engine to cool for two minutes before shutting down.
Page 90 Section 21 Chapter 1 POWERSHIFT TRANSMISSION SYSTEM How It Works and Troubleshooting January, 2006...
Page 91 Section 21 - Transmission, Drivelines - Chapter 1 TABLE OF CONTENTS TRANSMISSION SYSTEM INTRODUCTION ....................21-1-3 TRANSMISSION SYSTEM CONTROLS ....................... 21-1-5 TRANSMISSION SYSTEM COMPONENTS ....................21-1-6 TRANSMISSION LUBE AND DISTRIBUTION TUBES .................. 21-1-8 POWERSHIFT TRANSMISSION CLUTCH LAYOUT .................. 21-1-10 POWERSHIFT VALVE CLUTCH ENGAGEMENTS ..................21-1-11 POWER FLOW (FORWARD SPEEDS) .......................
Page 92: Transmission System Introduction
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION SYSTEM INTRODUCTION INSTRUMENTATION CLUSTER TRANSMISSION PROGRAMMABLE DISPLAY AND SPEED SENSOR CONTROLLER SEAT SWITCH ENGINE R.H. ARMREST CONTROLLER) CONTROLLER GEAR ENGINE SPEED SENSOR SELECTION SWITCH TRANSMISSION TRANSMISSION CONTROL LEVER CONTROLLER (FNRP) BOTTOM OF CLUTCH SWITCH S Y S T E M P R E S S U R E S I G N A L...
Page 93 Section 21 - Transmission, Drivelines - Chapter 1 All transmissions are full powershift transmission and controlled by the transmission controller. The standard transmission has 18 forward speeds and 4 reverse speeds. There is an optional transmission with 19 forward speeds and 4 reverse speeds. This transmission has 50Km/h roading capability. The optional creeper transmission has 23 forward speeds and 6 reverse speeds.
Page 94: Transmission System Controls
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION SYSTEM CONTROLS RH05J060 RD05J155 1. THROTTLE HAND LEVER 6. GEAR SHIFT UP BUTTON 2. TRANSMISSION CONTROL LEVER 7. GEAR SHIFT DOWN BUTTON 3. CREEPER CONTROL SWITCH (IF EQUIPPED) 8. PARK BUTTON (ACTIVATE IN NEUTRAL) 4.
Page 95: Transmission System Components
Template Name: SM_1_col Alt= to hide template information Template Date: 2001_03_06 Alt+ to display template information TRANSMISSION SYSTEM COMPONENTS RI02E087 and 088...
Page 96 Section 21 - Transmission, Drivelines - Chapter 1 RI02E086 1. POWERSHIFT VALVE ODD/EVEN 16. INCHING VALVE 2. EVEN CLUTCH SOLENOID 17. REGULATED PRESSURE INLET 3. ODD CLUTCH SOLENOID 18. MASTER CLUTCH LUBE INLET 4. CREEP CLUTCH SOLENOID 19. MASTER CLUTCH TEST PORT 5.
Page 97: Transmission Lube And Distribution Tubes
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION LUBE AND DISTRIBUTION TUBES 14 15 16 RH98C089 Rear View 1. SPEED POWERSHIFT VALVE MOUNTING PLATE 13. LOW CLUTCH DISTRIBUTION TUBE 2. SPEED C1 CLUTCH DISTRIBUTION TUBE 14. SPEED LUBE DISTRIBUTION TUBE 3.
Page 98 Section 21 - Transmission, Drivelines - Chapter 1 RH98C089 Top Rear View 21-1-9...
Page 99: Powershift Transmission Clutch Layout
Section 21 - Transmission, Drivelines - Chapter 1 POWERSHIFT TRANSMISSION CLUTCH LAYOUT Neutral DROP BOX MASTER CLUTCH RANGE INPUT SPEED SHAFT OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER COUNTER SHAFT SHAFT EVEN HYDRAULIC PUMP DRIVE GEAR FINAL DRIVE CREEPER...
Page 100: Powershift Valve Clutch Engagements
Section 21 - Transmission, Drivelines - Chapter 1 POWERSHIFT VALVE CLUTCH ENGAGEMENTS CLUTCHES GEAR MASTER EVEN HIGH REVERSE CREEP/ OVERDRIVE NEUTRAL PARK REV-1 REV-2 REV-3 REV-4 RCR-1 RCR-2 21-1-11...
Page 101: Power Flow (Forward Speeds)
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIRST GEAR - As the operator selects first speed, he simultaneously engages the odd speed clutch pack, the first speed clutch pack, and the low range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, through the engaged odd-speed clutch pack gear, to the countershaft gear.
Page 102 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 1 DROP BOX MASTER CLUTCH RANGE 1/2 3/4 INPUT SPEED SHAFT OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED...
Page 103 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) THIRD GEAR - As the operator selects third speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd speed clutch, the countershaft, the third speed clutch, across the output shaft, to the master clutch.
Page 104 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 3 DROP BOX MASTER CLUTCH RANGE INPUT SPEED SHAFT OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 105 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIFTH GEAR - As the operator selects fifth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the third-speed clutch is disengaged, and the fifth-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the fifth speed clutch, and across the output shaft to the master clutch.
Page 106 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 5 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 107 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) SEVENTH GEAR - As the operator selects seventh speed, the even-speed clutch is disengaged, and the odd- speed clutch is engaged. At the same time, the fifth-speed clutch and the low-range clutch are disengaged, the first speed clutch and medium range clutch are engaged.
Page 108 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 7 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 109 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) NINTH GEAR - As the operator selects ninth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the third speed clutch, and across the output shaft to the master clutch.
Page 110 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 9 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 111 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) ELEVENTH GEAR - As the operator selects eleventh speed, the even-speed clutch is disengaged, and the odd- speed clutch is engaged. At the same time, the third-speed clutch is disengaged, the fifth-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the fifth speed clutch, and across the output shaft to the master clutch.
Page 112 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 11 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 113 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) THIRTEENTH GEAR - As the operator selects thirteenth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the fifth-speed clutch and the medium-range clutch are disengaged, the first-speed clutch and the high-range clutch are engaged.
Page 114 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 13 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 115 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIFTEENTH GEAR - As the operator selects fifteenth speed, the even-speed clutch is disengaged, and the odd- speed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged.
Page 116 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 15 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 117 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) SEVENTEENTH GEAR - As the operator selects seventeenth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the third-speed clutch is disengaged, the fifth-speed clutch is engaged.
Page 118 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 17 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 119: Power Flow (Reverse Speeds)
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE SPEEDS) FIRST REVERSE GEAR - As the operator selects first reverse speed, he simultaneously engages the odd-speed clutch pack, the reverse-speed clutch pack and the low-range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, the engaged odd-speed clutch pack gear, to the countershaft gear.
Page 120 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Reverse No. 1 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 121 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE SPEEDS) THIRD REVERSE GEAR - As the operator selects third reverse speed, he simultaneously engages the odd-speed clutch, reverse-speed clutch pack and the medium-range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, the engaged odd-speed clutch pack, to the countershaft gear.
Page 122 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Reverse No. 3 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 123: Power Flow (Forward Creeper Drive Speeds)
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) FIRST CREEP GEAR - As the operator selects first creep speed, he simultaneously disengages and locks out the odd-speed clutch pack and the even-speed clutch pack. He also engages the creep speed clutch pack, the first speed clutch pack and the low range clutch pack.
Page 124 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 1 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 125 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) THIRD CREEP GEAR - As the operator selects third-creep speed, he simultaneously disengages the third-speed clutch and engages the fifth-speed clutch. Power then flows from the speed transmission input shaft through the creep-speed clutch on the countershaft, to the fifth-speed clutch, across the output shaft to the master clutch.
Page 126 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 3 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 127 Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) FIFTH CREEP GEAR - As the operator selects fifth creep speed, he simultaneously disengages the first-speed clutch and engages the third-speed clutch. Power then flows from the speed transmission input shaft, through the creep-speed clutch on the countershaft, to the third-speed clutch on the output shaft, across to the master clutch.
Page 128 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 5 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED COUNTER...
Page 129: Power Flow (Reverse Creeper Drive Speeds)
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) CREEPER REVERSE FIRST GEAR (CR1) - As the operator selects creeper first-reverse speed, he simultaneously disengages and locks out the odd-speed clutch pack and the even-speed clutch pack. He also engages the creep-speed clutch pack, the reverse-speed clutch pack, and the low-range clutch pack.
Page 130 Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Reverse Gear No. 1 DROP BOX MASTER CLUTCH RANGE SPEED INPUT OUTPUT SHAFT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT RANGE SPEED...
Page 131: Inching Valve Operation
Section 21 - Transmission, Drivelines - Chapter 1 INCHING VALVE OPERATION RH02F070 1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING 2. INCHING VALVE BODY 7. INNER MODULATOR SPRING 3. MODULATOR SPOOL 8. PISTON CENTER PIN 4. REGULATED PRESSURE SUPPLY 9. MODULATOR PISTON ASSEMBLY 5.
Page 132 Section 21 - Transmission, Drivelines - Chapter 1 RH02F071 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING 2. INCHING VALVE BODY 7. INNER MODULATOR SPRING 3. MODULATOR SPOOL 8. PISTON CENTER PIN 4. REGULATED PRESSURE SUPPLY 9.
Page 133 Section 21 - Transmission, Drivelines - Chapter 1 RH02F072 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING 2. INCHING VALVE BODY 7. INNER MODULATOR SPRING 3. MODULATOR SPOOL 8. PISTON CENTER PIN 4. REGULATED PRESSURE SUPPLY 9.
Page 134 Section 21 - Transmission, Drivelines - Chapter 1 RH02F073 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING 2. INCHING VALVE BODY 7. INNER MODULATOR SPRING 3. MODULATOR SPOOL 8. PISTON CENTER PIN 4. REGULATED PRESSURE SUPPLY 9.
Page 135: Instrumentation Cluster - Transmission Leakage Check
Section 21 - Transmission, Drivelines - Chapter 1 INSTRUMENTATION CLUSTER - TRANSMISSION LEAKAGE CHECK The regulated circuit pump is the front section of the tandem gear pump. The pump draws oil from the system reservoir through a 100 mesh suction screen. The pump flow passes through the regulated circuit filter housing and into the priority regulator valve.
Page 136 Section 21 - Transmission, Drivelines - Chapter 1 STEP 1 - Record Clutch Pressures in each Gear with Tractor Instrumentation NOTE: Clutch pack leaks can be identified through the tractor instrumentation pressure readings. IMPORTANT: The tractor must be driven to perform this test. Perform this test in an open outdoor location free of obstacles and people.
Page 137 Section 21 - Transmission, Drivelines - Chapter 1 Low pressure for Speeds 1, 2, 7, 8, 13 and 14 ---------------------- Indicates 1st Speed Clutch Leakage. Low pressure for Speeds 3, 4, 9, 10, 15 and 16-----------------Indicates 3rd Speed Clutch Leakage. Low pressure for Speeds 5, 6,11,12, 17 and 18 -------------------Indicates 5th Speed Clutch Leakage.
Page 138: Master Clutch Pressure Check
Section 21 - Transmission, Drivelines - Chapter 1 MASTER CLUTCH PRESSURE CHECK RH98F161 1. DIAGNOSTIC TEST PORT 2. PUMP DRIVE GEAR HOUSING The master clutch pressure diagnostic test port is - Place the transmission control lever in forward. located on the right hand side of the transmission below the pump drive gear housing.
Page 139 Section 21 - Transmission, Drivelines - Chapter 1 • Inspect the inching valve modulator spool and modulator piston. Both must move freely within the valve bore. See Inching Valve Operation in this section and the Transmission Control Valves and Inching Valve s e c t i o n t h i s m a n u a l...
Page 140 Section 21 Chapter 2 FRONT FRAME TO SPEED TRANSMISSION SPLIT January, 2006...
Page 141 Section 21 - Transmission, Drivelines - Chapter 2 TABLE OF CONTENTS SPECIAL TOOLS ............................21-2-3 SPECIAL TORQUES ............................21-2-3 FRONT FRAME TO SPEED TRANSMISSION SPLIT ................... 21-2-4 21-2-2...
Page 142 Section 21 - Transmission, Drivelines - Chapter 2 SPECIAL TOOLS 0507TLSR 1. SPLITTING STAND 17-526A 4. SUPPORT ASSEMBLY 17-526-4A 2. ADAPTER PLATES CAS-2604 5. REAR HOUSING HANDLER 17-527 3. SUPPORT BRACE 17-526-14 6. ADAPTER BRIGE 17-526-7 SPECIAL TORQUES Front Frame To Speed Transmission Front End Housing M16 Bolts........................
Page 143 Section 21 - Transmission, Drivelines - Chapter 2 FRONT FRAME TO SPEED TRANSMISSION SPLIT Disassembly STEP 2 STEP 1 RD02E069 Disconnect the negative (1) and positive (2) battery cables. 96RS28A Prepare for disassembly as follows: STEP 3 1. Park the tractor on a hard level surface. 2.
Page 144 Section 21 - Transmission, Drivelines - Chapter 2 STEP 5 STEP 8 RD05N119 RD05N128 If equipped, remove the rear windshield washer Disconnect the hydraulic cooling lines at the fittings hose. located at the rear of the engine. STEP 6 STEP 9 RD05N126 RD06A166 Disconnect the main electrical connector.
Page 145 Section 21 - Transmission, Drivelines - Chapter 2 STEP 11 STEP 13 RD06A168 RD05N124 Remove the fuel supply (1) and return (2) hoses. Remove the return hose at the fuel cooler. STEP 14 RD06A169 If equipped, tag and disconnect the four suspended front axle solenoid connectors (1) and remove the suspended axle valve hydraulic hoses (2).
Page 146 Section 21 - Transmission, Drivelines - Chapter 2 STEP 15 STEP 17 RD02C173 RD02C177 Push on the front wheels to move the front frame Remove bolt (1) on the left and right hand sides. forward a few inches. Check to be sure there are no Install an alignment dowel on each side.
Page 147 Section 21 - Transmission, Drivelines - Chapter 2 Assembly STEP 18 STEP 19 RD02C RD02C175 Install a bolt on both sides. Evenly tighten the bolts until the adapter plate and front frame flanges contact. Install and tighten all the side bolts except those blocked by the frame brackets.
Page 148 Section 21 - Transmission, Drivelines - Chapter 2 STEP 23 RD06A169 RI02D004 1......251 to 280 Nm (185 to 205 lb. ft.) 2......430 to 485 Nm (315 to 355 lb. ft.) Remove the frame suppor t brackets to make clearance for a torque wrench.
Page 149 Section 21 - Transmission, Drivelines - Chapter 2 STEP 25 STEP 28 RD06A166 RD05N126 Install the steering hoses (1) and brake switch Connect the main electrical connector. connectors (2). STEP 29 STEP 26 RD05N119 If equipped, install the rear windshield washer hose. RD05N128 Install new O-ring and install the hydraulic cooling hoses.
Page 150 Section 21 - Transmission, Drivelines - Chapter 2 STEP 31 STEP 33 RD05N104 RD02E069 Connect the battery cables at the starter. Connect the positive (1) negative (2) and battery cables. STEP 32 STEP 34 When tractor assembly is complete, run the tractor and check for hydraulic leaks.
Page 151 Section 21 - Transmission, Drivelines - Chapter 2 This Page Left Blank. 21-2-12...
Page 152 Section 21 Chapter 3 SPEED TO RANGE TRANSMISSION SPLIT January, 2006...
Page 153 Section 21 - Transmission, Drivelines - Chapter 3 TABLE OF CONTENTS SPECIAL TOOLS ............................21-3-3 SPECIAL TORQUES ............................21-3-3 SPEED TO RANGE TRANSMISSION SPLIT ....................21-3-4 Removal ..............................21-3-4 Installation ..............................21-3-7...
Page 154: Special Tools
Section 21 - Transmission, Drivelines - Chapter 3 SPECIAL TOOLS 0507TLSR 1. SPLITTING STAND 17-526A 5. REAR HOUSING HANDLER 17-527 2. ADAPTER PLATES CAS-2604 6. ADAPTER BRIDGE 17-526-7 3. SUPPORT BRACE 17-526-14 7. SUPPORT ASSEMBLY 17-526-5 4. SUPPORT ASSEMBLY 17-526-4A SPECIAL TORQUES Speed to Range Transmission Bolts 20 mm ......................
Page 155: Speed To Range Transmission Split
Section 21 - Transmission, Drivelines - Chapter 3 SPEED TO RANGE TRANSMISSION SPLIT Removal STEP 1 STEP 2 96RS28A 91S17 Prepare for removal as follows: Drain the transmission fluids from the range, speed, and rear frame. Drain fluid into clean drain pans. 1.
Page 156 Section 21 - Transmission, Drivelines - Chapter 3 STEP 3 STEP 4 RD02C163 RD02C165 Disconnec t the wir e har nes s fr om the speed powershift valve solenoids. STEP 5 RD02C164 Position the front splitting stand 17-526A (1) and attach the adapter plates (2) on both sides.
Page 157 Section 21 - Transmission, Drivelines - Chapter 3 STEP 7 STEP 9 RD02C167 RD02C170 1. STEERING SENSING 4. REGULATED PRESSURE R e m o v e t h e 1 0 b o l t s a t t a c h i n g t h e s p e e d AND SUPPLY LINES SUPPLY LINE transmission to the range transmission and install a...
Page 158: Installation
Section 21 - Transmission, Drivelines - Chapter 3 Installation STEP 11 STEP 12 RD02C171 Rd02C170 Install and partially tighten the 10 bolts. STEP 13 RD02C172 With the range transmission supported by the rear housing handler 17-527 and speed transmission supported by the splitting stand 17-526A, install guide studs (1).
Page 159 Section 21 - Transmission, Drivelines - Chapter 3 STEP 14 STEP 16 RD02C169 RD02C168 1. ODD EVEN VALVE 3. OIL COOLER SUPPLY If equipped, install the true ground speed radar on to RETURN LINE LINE the transmission housing and connect to the wire 2.
Page 160 Section 21 - Transmission, Drivelines - Chapter 3 STEP 19 STEP 21 RD02C164 96R28A Complete installation as follows: 1. Install the MFD driveshaft. See MFD Driveshaft information. 2. Install the fuel tanks. See Fuel Tank Removal and Installation information. 3. Install the cab. See Cab Raise/Removal and Installation information.
Page 161 Section 21 - Transmission, Drivelines - Chapter 3 This Page Left Blank.
Page 162 Section 21 Chapter 4 SPEED TRANSMISSION January, 2006...
Page 163 Section 21 - Transmission, Drivelines - Chapter 4 TABLE OF CONTENTS SPECIFICATIONS ............................21-4-4 SPECIAL TORQUES ............................21-4-4 TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR ............... 21-4-4 SPECIAL TOOLS ............................21-4-5 SPEED TRANSMISSION WITH CREEP OPTION ..................21-4-6 ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH ..........21-4-14 TRANSMISSION ASSEMBLY WITH CREEP OPTION ................
Page 164 Section 21 - Transmission, Drivelines - Chapter 4 PICTORIAL INDEX - SPEED TRANSMISSION 85L94A 1. 1ST SPEED CLUTCH 4. OUTPUT SHAFT 7. CREEPER SPEED 9. ODD SPEED CLUTCH 2. 5TH SPEED CLUTCH 5. INPUT SHAFT CLUTCH 10. 3RD SPEED CLUTCH 3.
Page 165: Specifications
Section 21 - Transmission, Drivelines - Chapter 4 SPECIFICATIONS End Play for Installed Speed Transmission Countershaft, Input Shaft and Output Shaft..............0.03 to 0.13 mm (0.0012 to 0.0051 inch) Clutch Pack Oil Leakage ..................0.5 L/min (0.13 gpm) Maximum SPECIAL TORQUES Mounting Bolts for Front Bearing Support Cover on Speed Transmission Housing ..................
Page 166: Special Tools
Section 21 - Transmission, Drivelines - Chapter 4 SPECIAL TOOLS T98826 T98826 Compression Sleeve with Notch CAS1903-3 1. Mounting Plate 17-52-14 (first used on Page 10). 2. Mounting Brackets 17-52-16 (set of two) 3. Engine Mounting Stand CAS10431 CAS1903-4 Centering Sleeve CAS1903-4 (first used on Page 52). CAS19031 Compression Plate with 6 Tangs and 2 Capscrews CAS1903-1 (first used on Page 12).
Page 167: Speed Transmission With Creep Option
Section 21 - Transmission, Drivelines - Chapter 4 SPEED TRANSMISSION WITH CREEP OPTION STEP 1 STEP 3 886L0 1. INPUT SHAFT 2. OUTPUT SHAFT 3. COUNTERSHAFT 886L0 Remove any remaining seal material from the bolt Remove the mounting bolts from the front bearing hole threads.
Page 168 Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, And Output Shaft Removal For Transmissions With Creep Option STEP 5 STEP 6 18-8 18-11 Remove housing as follows: 1. Connect a chain to the rear of the speed housing (shown with cab mounting bracket attached).
Page 169 Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, and Output Shaft Removal for Transmissions without Creep STEP 8 STEP 10 25-32 25-20 Remove transmission housing cover as follows: Remove output shaft. 1. With the transmission housing on the engine STEP 11 stand, turn the housing so the cover is in the upright position.
Page 170 Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Countershaft with Creeper Speed Clutch STEP 12 STEP 14 T95237 T95239 Remove the two seal rings from the shaft. Remove the caged needle bearing. STEP 13 STEP 15 T95238 A11511 Remove the rear needle thrust bearing and the two Use a hydraulic press to remove the front bearing bearing thrust washers.
Page 171 Section 21 - Transmission, Drivelines - Chapter 4 STEP 16 STEP 18 A11501 RD05M014 Remove snap ring as follows: Remove the lube management ring. 1. Install the compression sleeve CAS1903-3 with STEP 19 the notch over the piston retur n Belleville washers (see the Special Tools page in this section).
Page 172 Section 21 - Transmission, Drivelines - Chapter 4 STEP 21 STEP 24 A11515 T95251 Use a hydraulic press to move the shaft through the Remove the spacer. clutch plate carrier, spacer and the (2nd-4th-6th) speed driven gear. STEP 25 STEP 22 T95252 Remove the (2nd-4th-6th) speed driven gear and steel ball.
Page 173 Section 21 - Transmission, Drivelines - Chapter 4 STEP 27 STEP 28 PRESS T95267 Remove the snap ring. DBR01 1. COUNTERSHAFT 3. 1ST-3RD-5TH DRIVEN GEAR 2. 3RD-4TH DRIVER GEAR 4. SUPPORT Turn the shaft over and use a hydraulic press to remove the (3rd-4th) speed driver gear and the (1st- 3rd-5th) speed driven gear.
Page 174 Section 21 - Transmission, Drivelines - Chapter 4 Alternative Method for Snap Ring STEP 31 Removal NOTE: This method can be used on any clutch carrier. The large snap ring, backing plate, friction plates, separator plates and reaction plate must be removed first.
Page 175: Assembling The Countershaft With Creeper Speed Clutch
Section 21 - Transmission, Drivelines - Chapter 4 ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH RI05M091M 1. SHAFT 11. CAGE 21. PISTON 31. THRUST WASHER 2. PLUG 12. BOLT M10 X 25 22. SEPERATOR DISC 32. THRUST BEARING 3. STEEL BALL 13.
Page 176 Section 21 - Transmission, Drivelines - Chapter 4 STEP 33 STEP 34 A22751R DIMENSION 66L94 1. 1ST-2ND DRIVERGEAR 5. 3RD-4TH DRIVER GEAR 2. REAR BEARING CONE 6. 1ST STEEL BALL 3. 3RD STEEL BALL 7. 1ST-3RD-5TH DRIVEN 4. 2ND STEEL BALL GEAR Install steel balls as follows: 1.
Page 177 Section 21 - Transmission, Drivelines - Chapter 4 5. Heat the (3rd-4th) speed drive gear (5) in a STEP 36 bearing oven for 3 to 4 hours at a temperature of 350 to 370° F (177-187° C). NOTE: Do not heat the gear beyond a temperature of 375 °...
Page 178 Section 21 - Transmission, Drivelines - Chapter 4 STEP 38 STEP 40 T95276A Install the spacer. T95278 STEP 39 40-35 T95277 Remove and replace teflon ring and O-ring as Hit the clutch plate carrier against a wood block to follows: remove the clutch piston.
Page 179 Section 21 - Transmission, Drivelines - Chapter 4 STEP 41 STEP 43 T95280 A10875 Install the reaction plate (thicker than separator plate). NOTE: The reaction plate is similar to a separator plate except that it is thicker. STEP 44 41-3 Apply petroleum jelly to the teflon rings.
Page 180 Section 21 - Transmission, Drivelines - Chapter 4 STEP 45 STEP 48 A10877 AA11505 Install a separator plate. Install the remaining seven Put the carrier assembly in a press. Align the oil hole new fr ic tion pl ates and six se parator pla te s, in the carrier with the oil gallery hole in the shaft.
Page 181 Section 21 - Transmission, Drivelines - Chapter 4 STEP 50 STEP 53 RD05M013 A11501 1. Install the snap ring on the shaft. 2. Install the compression sleeve CAS1903-3 with Install the first piston-return Belleville washer. The the notch over the shaft. concave side of the washer must be facing down.
Page 182 Section 21 - Transmission, Drivelines - Chapter 4 STEP 56 STEP 59 T95296 A11514 Align the friction plate teeth. Install the creeper driven Install the bearing cone with the larger OD bearing gea r in to the c lu tch c ar r ie r as s embly. S l igh t end facing down.
Page 183 Section 21 - Transmission, Drivelines - Chapter 4 Countershaft with Creep 85L94A 1. 1ST SPEED CLUTCH 4. OUTPUT SHAFT 7. CREEPER SPEED 9. ODD SPEED CLUTCH 2. 5TH SPEED CLUTCH 5. INPUT SHAFT CLUTCH 10. 3RD SPEED CLUTCH 3. REVERSE SPEED CLUTCH 6.
Page 184 Section 21 - Transmission, Drivelines - Chapter 4 Disassembly and Assembly of Countershaft without Creep RD05N030M 1. SHAFT 5. STEEL BALL 9. PINION DRIVE GEAR 29T 13. CAGE 2. SNAP RING 6. PINION DRIVEN GR. 37T 10. SHIM 14. BOLT M10 X 25 3.
Page 185 Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Speed Input Shaft STEP 62 STEP 65 T95300a T95305a Remove the five seal rings from the speed input Remove the two snap rings. shaft. STEP 66 STEP 63 T95306a Remove the spacer. T95301a Use a bearing puller to remove the rear bearing cone.
Page 186 Section 21 - Transmission, Drivelines - Chapter 4 STEP 68 STEP 71 T95308a T95311a Remove the (1st-3rd-5th) speed drive gear. Remove the snap ring. STEP 69 STEP 72 T95309a T95312a Remove the caged needle bearing. Remove the backing plate. STEP 70 STEP 73 T95310a T95313a...
Page 187 Section 21 - Transmission, Drivelines - Chapter 4 STEP 74 STEP 77 T95315a T95317 Use a bearing puller to remove the front bearing Remove the snap ring. cone. STEP 78 STEP 75 A11538 Remove the two bearing thrust washers and the 890L0 Non Creep Transmission needle thrust bearing.
Page 188 Section 21 - Transmission, Drivelines - Chapter 4 STEP 80 STEP 83 T95320 A11532 Remove the caged needle bearing. Remove the snap ring. STEP 81 STEP 84 T95321 A11531 Remove the spacer. Remove the backing plate. STEP 82 STEP 85 T95322 T95325 Remove the second caged needle bearing.
Page 189 Section 21 - Transmission, Drivelines - Chapter 4 STEP 86 STEP 88 T95327 T95331 Remove the two bearing thrust washers and the Remove the piston return Belleville washers and lube needle thrust bearing. management ring from each side of the clutch plate carrier.
Page 190 Section 21 - Transmission, Drivelines - Chapter 4 STEP 90 STEP 91 T95333 Press the splined front end of the shaft so that the shaft moves through the clutch plate carrier. 468L72 1. MARK ON FACE OF 2. MARK ON FRONT END OF CARRIER SHAFT Make an appropriate mark with scratch awl, prick...
Page 191 Section 21 - Transmission, Drivelines - Chapter 4 Speed Input Shaft Assembly With Creep Speed Or 50 KPH Transmission 9 17 RI05M069M 21-4-30...
Page 192 Section 21 - Transmission, Drivelines - Chapter 4 1. COIL PIN 10. THRUST WASHER 19. LUBE RING 28. SEAL 37. SPACER 2. SHAFT 11. THRUST BEARING 20. SHAFT 29. O-RING 38. BEARING 3. BOLT M10 X 10 12. PINION GEAR 37T 21. PLUG 30.
Page 193 Section 21 - Transmission, Drivelines - Chapter 4 STEP 94 STEP 96 T95280 468L72 1. MARK ON FACE OF 2. MARK ON FRONT END CARRIER OF SHAFT Before pressing the shaft through the clutch plate carrier, find the mark on the end of the shaft (2) and on the face of the carrier (1).
Page 194 Section 21 - Transmission, Drivelines - Chapter 4 STEP 97 STEP 99 T95340a A11519 Install the shaft on the carrier as follows: Install a clutch piston into each side of the carrier. The flat side of the piston must be down. Push the 1.
Page 195 Section 21 - Transmission, Drivelines - Chapter 4 STEP 102 STEP 104 RD05M003 A11525 Install the remaining Belleville washers as follows: Install the snap ring as follows: 1. Install the second Belleville washer. 1. Install the snap ring over the centering sleeve. concave side of the washer must be facing up.
Page 196 Section 21 - Transmission, Drivelines - Chapter 4 STEP 106 STEP 109 A11528 A11531 Install the reaction plate (thicker separator plate). Install the backing plate. The flat side of the plate must face down. STEP 107 STEP 110 A11529 Install a new friction plate. A11532 Install the snap ring.
Page 197 Section 21 - Transmission, Drivelines - Chapter 4 STEP 112 STEP 114 A11533 A11535 1. SEAL Install a caged needle bearing into the gear hub. Install a new seal ring on the (2nd-4th-6th) speed STEP 115 drive gear at location shown by arrow. Align the friction plate teeth.
Page 198 Section 21 - Transmission, Drivelines - Chapter 4 STEP 117 STEP 120 A11538 T95363 Install the two bearing thrust washers and the needle 1. LONGER HUB thrust bearing. The needle thrust bearing must be Press the creeper speed gear into position. between the two bearing thrust washers.
Page 199 Section 21 - Transmission, Drivelines - Chapter 4 STEP 123 STEP 126 RD05M005 A11541a Install the lube management ring. Install the Belleville washer compression sleeve CAS1903-5 over the shaft and on top of the snap STEP 124 ring. The smaller OD side of the sleeve must be facing up.
Page 200 Section 21 - Transmission, Drivelines - Chapter 4 STEP 128 STEP 131 T95313a A11544 Install the reaction plate, fr iction plates, and Install the two bearing thrust washers and the needle separator plates as follows: thrust bearing. The needle thrust bearing must be between the two thrust washers.
Page 201 Section 21 - Transmission, Drivelines - Chapter 4 STEP 133 STEP 135 T95379 A11547a Slight oscillation of the gear will help with the Install the two bearing thrust washers and the needle installation. The splined hub of the gear must thrust bearing.
Page 202 Section 21 - Transmission, Drivelines - Chapter 4 STEP 138 STEP 140 A11551 T95300a Install the second spacer. Install five new seal rings on the end of the input shaft. STEP 139 A11517 Install the bearing cone on the shaft. The larger OD end of the bearing must be facing down.
Page 203 Section 21 - Transmission, Drivelines - Chapter 4 Speed Input Shaft 385L7 1. (1st-3rd-5th) SPEED DRIVE GEAR 4. CREEPER SPEED GEAR (IF EQUIPPED) 7. EVEN SPEED CLUTCH PACK 2. CLUTCH PLATE CARRIER 5. FRONT BEARING CONE 8. ODD SPEED CLUTCH PACK 3.
Page 204 Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Speed Output Shaft STEP 141 STEP 144 T95386 T95391 Remove the four seal rings. Remove the reverse driven gear. STEP 142 STEP 145 T95387 A11638 Use a bearing puller to remove the front bearing Remove the caged needle bearing and nylon spacer.
Page 205 Section 21 - Transmission, Drivelines - Chapter 4 STEP 147 STEP 150 A11556 RD05M010 Remove the snap ring from inside the clutch plate Remove one piston return Belleville washers. carrier. STEP 151 STEP 148 RD05M011 A11557 Remove the lube management ring. Remove the backing plate, friction plates, separator plates, and reaction plate (thicker separator plate).
Page 206 Section 21 - Transmission, Drivelines - Chapter 4 STEP 153 STEP 154 T95410 A11559 Remove the clutch plate carrier from the shaft. STEP 155 A11560 Remove the snap ring from the clutch plate carrier. 468L72 STEP 156 1. MARK ON FACE OF 2.
Page 207 Section 21 - Transmission, Drivelines - Chapter 4 STEP 157 STEP 160 A11562 RD05M012 Install the compression sleeve CAS1903-3 with the Remove eight Belleville washers. notch over the piston return Belleville washers. The opening in the sleeve must be over the ends of the STEP 161 snap ring.
Page 208 Section 21 - Transmission, Drivelines - Chapter 4 STEP 163 STEP 166 T95431 T95434 Remove the (5th-6th speed) driven gear. Remove the (3rd-4th speed) driven gear. STEP 164 STEP 167 T95432 T95435 Remove the caged needle bearing. Remove the thrust washer spacer. STEP 165 STEP 168 T95433a...
Page 209 Section 21 - Transmission, Drivelines - Chapter 4 STEP 169 STEP 172 T95437 A11564 Remove the two bearing thrust washers and the Remove Belleville washers as follows: needle thrust bearing. 1. Install the compression sleeve with the notch CAS1903-3 over the piston return Belleville STEP 170 washers.
Page 210 Section 21 - Transmission, Drivelines - Chapter 4 STEP 174 STEP 177 A11566 T95469 Remove the caged needle bearing and the two Install the compression sleeve CAS1903-3 with the bearing thrust washers and needle thrust bearing. notch over the piston return Belleville washers. The opening in the sleeve must be over the ends of the STEP 175 snap ring.
Page 211 Section 21 - Transmission, Drivelines - Chapter 4 STEP 179 T95474 468L72 1. MARK ON CARRIER FACE 2. MARK ON SHAFT FRONT Remove snap ring. Make a mark on carrier face that will align with mark on the end of shaft. This mark will help align carrier on the shaft during assembly.
Page 212 Section 21 - Transmission, Drivelines - Chapter 4 Speed Output Shaft Front Clutch Assembly RI05N028M NOTE: If any clutch pack is disassembled, new friction plates must be installed. 1. O-RING 9. THRUST WASHER 17. BELLEVILLE SPRING 25. PINION 39T 2. SHAFT 10.
Page 213 Section 21 - Transmission, Drivelines - Chapter 4 Speed Output Shaft Rear Clutch Assembly RI05N028M NOTE: If any clutch pack is disassembled, new friction plates must be installed. 1. O-RING 9. CLUTCH DISC 17. SEAL RING 25. BEARING CONE 2. SHAFT 10.
Page 214 Section 21 - Transmission, Drivelines - Chapter 4 STEP 181 STEP 183 T95337 DBR02 Replace the teflon ring and O-ring on the piston and 1. PLUG carrier as follows: 1. Install the plug (2) flush to the surface, as shown. 2.
Page 215 Section 21 - Transmission, Drivelines - Chapter 4 STEP 185 STEP 186 T95498 Assemble the clutch plate carrier as follows: 1. Install the front end of the rear clutch plate carrier over the rear end of the shaft. 2. Align the mark on the rear end of the shaft with the mark on the front face of the rear clutch plate carrier before pressing the carrier over the shaft, aligning the marks will align the oil holes in the...
Page 216 Section 21 - Transmission, Drivelines - Chapter 4 STEP 188 STEP 190 T95280 Rd05M007 Install the first piston return Belleville washer. The concave side of the washer must be facing down. STEP 191 41-3 Apply petroleum jelly to the teflon rings. STEP 189 Rd05M008 Install the lube management ring.
Page 217 Section 21 - Transmission, Drivelines - Chapter 4 STEP 193 STEP 195 A11571 A11574 Install the centering sleeve CAS1903-4 over the Install the sleeves and snap ring as follows: shaft. 1. Install the compression sleeve with the notch over the shaft. STEP 194 2.
Page 218 Section 21 - Transmission, Drivelines - Chapter 4 STEP 197 STEP 200 A11577 A11580 Install a new friction plate. Install the snap ring. NOTE: Dip all friction plates in clean transmission STEP 201 fluid. STEP 198 A11581 Install the needle thrust bearing and the two bearing thrust washers.
Page 219 Section 21 - Transmission, Drivelines - Chapter 4 STEP 202 STEP 204 A11582 A11584 1. SEAL Install the two bearing thrust washers and the needle thrust bearing. The needle thrust bearing must be Install 1st-2nd speed driven gear as follows: between the two bearing thrust washers.
Page 220 Section 21 - Transmission, Drivelines - Chapter 4 STEP 206 STEP 208 A11592 A11593 Turn the shaft over and install the first piston return Install the second Belleville washer. Belleville washer. NOTE: The concave side of the washer must be NOTE: The concave side of the washer must be facing up.
Page 221 Section 21 - Transmission, Drivelines - Chapter 4 STEP 210 STEP 212 A11596 A11599 1. Install the compression sleeve CAS1903-3 with Install a new friction plate. the notch over the shaft. NOTE: Dip all friction plates in clean transmission 2. Use a hydraulic press to press the sleeves down. fluid.
Page 222 Section 21 - Transmission, Drivelines - Chapter 4 STEP 215 STEP 217 A11591 A11602 Install the snap ring. 1. SEAL Install the 3rd-4th speed driven gear as follows: STEP 216 1. Install a new seal ring on the (3rd - 4th speed) driven gear.
Page 223 Section 21 - Transmission, Drivelines - Chapter 4 STEP 219 STEP 222 A11607 A11604 Install the spacer. Install a new seal ring on the (5th-6th speed) gear. Install the gear on the shaft. STEP 220 NOTE: The splined hub of the gear must be facing STEP 223 A11605 Install the fiber thrust washer on the spacer ring.
Page 224 Section 21 - Transmission, Drivelines - Chapter 4 STEP 224 STEP 227 T95429 RD05M010 Install the retaining ring for the piston return Belleville washers on the shaft. Install final washer with concave facing upward. STEP 225 STEP 228 RD05M012 T95424 1.
Page 225 Section 21 - Transmission, Drivelines - Chapter 4 STEP 230 STEP 232 A11608 T95416 Install the snap ring as follows: Install the backing plate over the gear. 1. Install the compression sleeve CAS1903-3 with NOTE: The flat side of the place must be facing up. the notch over the shaft.
Page 226 Section 21 - Transmission, Drivelines - Chapter 4 STEP 235 STEP 237 T95419 T95337 Install the remaining six new friction plates and five separator plates, alternating the plates. STEP 236 40-35 Install the teflon and O-rings as follows: 1. Hit the clutch carrier against a wood block to remove the clutch pistons.
Page 227 Section 21 - Transmission, Drivelines - Chapter 4 STEP 239 STEP 240 T95413 Install carrier as follows: 1. Install the rear face of the carrier over the front end of the shaft. 2. Align the marks on the carrier and the shaft before pushing the carrier down on the shaft.
Page 228 Section 21 - Transmission, Drivelines - Chapter 4 STEP 242 STEP 244 A11610 T95411 Install the compression sleeve CAS1903-5 over the Use a screwdriver to install the snap ring that was shaft. installed on top of the gear (Step 219), into the inside groove in the carrier.
Page 229 Section 21 - Transmission, Drivelines - Chapter 4 STEP 246 STEP 249 RD05M012 A11614 1. Install the first washer with the concave side Install snap ring and Belleville washer compression facing up. sleeve as follows: 2. Install the second washer with the concave side 1.
Page 230 Section 21 - Transmission, Drivelines - Chapter 4 STEP 251 STEP 254 T95398 T95395 Install the reaction plate (thicker separator plate). Install the backing plate. The flat side must be facing down. STEP 252 STEP 255 T95399 Install a new friction plate. T95393 Install the snap ring.
Page 231 Section 21 - Transmission, Drivelines - Chapter 4 STEP 257 STEP 259 A11616 T95389 1. SEAL Install the needle thrust bearing and the two bearing thrust washers. Install the reverse speed driven gear as follows: NOTE: The needle thrust bearing must be between 1.
Page 232 Section 21 - Transmission, Drivelines - Chapter 4 Cross-Section View of Output Shaft 73I94 1. 1ST SPEED CLUTCH PACK 8. FRONT CLUTCH PLATE CARRIER 2. 3RD SPEED CLUTCH PACK 9. (5TH-6TH) SPEED DRIVEN GEAR 3. 5TH SPEED CLUTCH PACK 10. (3RD-4TH) SPEED DRIVEN GEAR 4.
Page 233 Section 21 - Transmission, Drivelines - Chapter 4 Air Check for Speed Transmission Clutch Piston Operation STEP 262 STEP 264 T95508 T95510A 1. CREEPER CLUTCH PLATES 1. EVEN CLUTCH PLATES Use an air gun to check the movement of the creeper Check the even gear clutch piston operation as clutch piston, if equipped, as follows: follows:...
Page 234 Section 21 - Transmission, Drivelines - Chapter 4 STEP 266 STEP 268 T95512 T95514 1. 5TH CLUTCH PLATES 1. 3RD CLUTCH PLATES Check 5th gear clutch piston operation as follows: Check 3rd gear clutch piston operation as follows: 1. Install the tip of the air gun into the oil hole in the 1.
Page 235 Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, and Output Shaft Installation - Exploded View 73L94AR 1. OUTPUT SHAFT REAR BEARING CAGE 9. SHIM 2. SHIM 10. COUNTERSHAFT REAR BEARING CAGE 3. BEARING CUP 11. SHIM 4. OUTPUT SHAFT ASSEMBLY 12.
Page 236 Section 21 - Transmission, Drivelines - Chapter 4 Bearing Removal and Replacement STEP 269 STEP 271 A11623 A11621 If the MFD shaft bearing must be replaced, press the Press a new bearing cup into the cage until the cup is old bearing out of the housing.
Page 237 Section 21 - Transmission, Drivelines - Chapter 4 STEP 274 STEP 276 41-13 CVR901 Use a bearing puller to remove the bearing cup from 1. BEARING CUP the rear input shaft cage if the bearing cone on the Remove all foreign material from the rear surface of input shaft has been replaced.
Page 238 Section 21 - Transmission, Drivelines - Chapter 4 STEP 278 STEP 279 23-13 T95515 Install the rear bear ing shim packs that were Re m ove al l fo r ei g n m a te r i al f r o m th e s p e e d removed during disassembly, and the rear bearing transmission housing front flange.
Page 239: Transmission Assembly With Creep Option
Section 21 - Transmission, Drivelines - Chapter 4 TRANSMISSION ASSEMBLY WITH CREEP OPTION STEP 280 STEP 282 A11624 886L0 Put the bearing support cover on support blocks as Install and tighten a bolt in the bearing support cover shown in Step 4 in this section. Apply petroleum jelly at the 1 and 7 o’clock position.
Page 240 Section 21 - Transmission, Drivelines - Chapter 4 Shafts in Speed Transmission 85L94 1. OUTPUT SHAFT ASSEMBLY 2. INPUT SHAFT ASSEMBLY 3. COUNTERSHAFT ASSEMBLY 21-4-79...
Page 241: Transmission Assembly Without Creep Option
Section 21 - Transmission, Drivelines - Chapter 4 TRANSMISSION ASSEMBLY WITHOUT CREEP OPTION STEP 283 STEP 285 25-14 25-26 Install input shaft as follows: Install the countershaft as follows: 1. Mount the transmission housing in the engine 1. Raise the input shaft approximately 44 mm (1-3/ stand.
Page 242 Section 21 - Transmission, Drivelines - Chapter 4 Setting the End Play of the Speed Transmission Countershaft, Input Shaft, and Output Shaft STEP 287 4. Tighten two opposite bolts, alternately, in three increments until the bolts are tightened to a torque of 5.6 Nm (50 lb in).
Page 243 Section 21 - Transmission, Drivelines - Chapter 4 STEP 290 STEP 292 SCH309 SCH311 Remove the rear bearing cage. Take the average Do the following: measurement from Step 275. To this average 1. Rotate the shaft a minimum of 12 revolutions. measurement, add the following amount of shims thickness: 2.
Page 244 Section 21 Chapter 5 RANGE TRANSMISSION TO REAR FRAME SPLIT January, 2006...
Page 245 Section 21 - Transmission, Drivelines - Chapter 5 TABLE OF CONTENTS SPECIAL TOOLS ............................21-5-3 SPECIAL TORQUES ............................21-5-3 RANGE TRANSMISSION TO REAR FRAME SPLIT ..................21-5-4 Disassembly ..............................21-5-4 Assembly ..............................21-5-7 21-5-2...
Page 246: Special Tools
Section 21 - Transmission, Drivelines - Chapter 5 SPECIAL TOOLS 0507TLSR 1. SPLITTING STAND 17-526A 4. SUPPORT ASSEMBLY 17-526-4A 2. ADAPTER PLATES CAS-2604 5. REAR HOUSING HANDLER 17-527 3. SUPPORT BRACE 17-526-14 6. ADAPTER BRIGE 17-526-7 SPECIAL TORQUES Range Transmission to Rear Frame Bolts M16 x 60 mm......................
Page 247: Range Transmission To Rear Frame Split
Section 21 - Transmission, Drivelines - Chapter 5 RANGE TRANSMISSION TO REAR FRAME SPLIT Disassembly STEP 2 NOTE: Clean the entire transmission housing before beginning this procedure. STEP 1 RD02C181 96R-28A Before starting the procedure, do the following: 1. Park the tractor on a hard, level surface. 2.
Page 248 Section 21 - Transmission, Drivelines - Chapter 5 STEP 3 STEP 6 RD02C182 RD02C185 Remove the hitch position sensor cover. Disconnect the wire harness from the PTO (1) and MFD (2) solenoids. STEP 4 STEP 7 RD02C183 Disconnect the hitch position sensor connector. RD02C186 Remove the two lines (1) from the trailer brake valve (if equipped).
Page 249 Section 21 - Transmission, Drivelines - Chapter 5 STEP 8 STEP 11 RD02C197 RD02C193 Disconnect the remote auxiliary controller (1) from Remove the top bolts. the wire harness. Move the remaining controllers and STEP 12 wire harness (2) forward until the harness is on the front side of the rear housing/range housing seam.
Page 250: Assembly
Section 21 - Transmission, Drivelines - Chapter 5 Assembly STEP 16 STEP 14 RD02C194 Using a bolt on both sides, draw the rear frame and range transmission together evenly. Remove guide studs when two bolts are drawn tight and replace RD02C196 Clean off all old gasket material in the flange area.
Page 251 Section 21 - Transmission, Drivelines - Chapter 5 STEP 18 STEP 20 RD02C188 Install tube removed from the remote valve. STEP 21 BOLTSEQ5 Tighten the bolts to the following torques: M16 x 60mm..232 to 262 Nm (171 to 193 lb. ft.) M16 x 80mm..
Page 252 Section 21 - Transmission, Drivelines - Chapter 5 STEP 23 STEP 26 RD02C185 RD02C182 Install the hitch position sensor cover and tighten the Connect the wire harness to the MFD and PTO bolts. solenoids. STEP 27 STEP 24 91S17 RD02C184 If not already done, install all removed drain plugs in Connect the draft pin connector (1 - LH and RH side) the transmission.
Page 253 Section 21 - Transmission, Drivelines - Chapter 5 STEP 29 STEP 30 When tractor assembly is complete, run the tractor and check for hydraulic leaks. Check the fluid level in the transmission and add as required. 96R28A Complete the installation as follows: 1.
Page 254 Section 21 Chapter 6 RANGE TRANSMISSION January, 2006...
Page 255 Section 21 - Transmission, Drivelines - Chapter 6 TABLE OF CONTENTS SPECIFICATIONS ............................21-6-3 TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR .............. 21-6-3 SPECIAL TORQUES ............................21-6-3 SPECIAL TOOLS ............................21-6-4 RANGE TRANSMISSION ..........................21-6-5 Removing the Shaft Master Clutch ......................21-6-5 Removing the Input Shaft, Countershaft and Mechanical Front Drive (FWD) / Park Brake Assembly ...............
Page 256: Specifications
Section 21 - Transmission, Drivelines - Chapter 6 SPECIFICATIONS Range Input Shaft Master Clutch Spring: Free Length ........................... 35.82 mm (1.41 inches) Compress to 30.99 mm (1.220 inches) ..................... 42.26 N (9.5 lb.) FWD Clutch Pack Oil Leakage ................. 0.40 L/min max (0.10 gpm max) FWD Input Shaft Bearing End Play .............0.025 to 0.153 mm (0.001 to 0.006 inch) End Play for Installed Range Transmission Countershaft......0.013 to 0.100 mm (0.0005 to 0.004 inch) End Play for Installed Range Transmission Input Shaft ........0.03 to 0.13 mm (0.001 to 0.005 inch)
Page 257: Special Tools
Section 21 - Transmission, Drivelines - Chapter 6 SPECIAL TOOLS T95952 C1903H5 1. 17-52-14 MOUNTING 3. CAS 10431 ENGINE Compression Sleeve without notch CAS1903-5 PLATE MOUNTING STAND 2. 17-52-16 MOUNTING BRACKETS (SET OF 2) Engine Mounting Stand CAS10431, Mounting Brackets 17-52-16, and Mounting Plate 17-52-14 CAS 2358 Compression Sleeve with notch CAS2602 C1903H3...
Page 258: Range Transmission
Section 21 - Transmission, Drivelines - Chapter 6 RANGE TRANSMISSION Removing the Shaft Master Clutch STEP 1 STEP 4 15S1R 12S9CUR4 After completing the procedures outlined in the Remove valve body plate. Speed to Range Transmission Split Section and the Range Transmission to Differential Split Section of STEP 5 this Service Manual, the range transmission is ready...
Page 259 Section 21 - Transmission, Drivelines - Chapter 6 STEP 7 STEP 10 15S21 A22306 Remove the clutch backing plates. Enlarged View: STEP 8 A22306CU 1. ALIGNMENT MARK 15S24 Mark the master clutch for reassembly. Remove the Remove the clutch hub. snap ring that fastens the master clutch to the range input shaft.
Page 260: Removing The Input Shaft, Countershaft And Mechanical Front Drive (Fwd) / Park Brake Assembly
Section 21 - Transmission, Drivelines - Chapter 6 Removing the Input Shaft, Countershaft and Mechanical Front Drive (FWD) / Park Brake Assembly STEP 12 STEP 14 15S33 16S4 Remove the lubrication tube from the input shaft Remove the mounting bolts from the input shaft bearing cage.
Page 261 Section 21 - Transmission, Drivelines - Chapter 6 STEP 16 STEP 19 16S12 16S21 Remove the shims for the input shaft bearing cage. Remove the shims for the countershaft bearing cage. Keep the shims together with the bearing cage. The Keep the shims together with the bearing cage.
Page 262 Section 21 - Transmission, Drivelines - Chapter 6 STEP 22 STEP 23 A22319 A22321 Remove the input shaft. NOTE: If only the FWD/Emergency Brake Assembly needs to be removed, the range input and counter shafts DO NOT have to be removed. Remove the countershaft as follows: 1.
Page 263 Section 21 - Transmission, Drivelines - Chapter 6 FWD/Emergency Brake Removal STEP 24 STEP 27 RD05K011 A22326 Remove the FWD lube supply tube from the rear of Remove the emergency brake supply fitting. the FWD / emergency brake input shaft. STEP 25 STEP 28 RD05K012...
Page 264 Section 21 - Transmission, Drivelines - Chapter 6 STEP 29 STEP 30 RD05K017 RD05K018 Properly suppor t the FWD / emergency brake Carefully lift the assembly from the range housing. assembly. 21-6-11...
Page 265: Disassembly Of The Master Clutch
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Master Clutch STEP 31 STEP 33 A22350 A22347 Use a bridge and hydraulic press to compress the Remove the 16 springs from the clutch piston. spring retainer plate. Remove the snap ring from the clutch carrier.
Page 266 Section 21 - Transmission, Drivelines - Chapter 6 STEP 35 STEP 36 A22343 248L7 Check seals and replace if necessary as follows: Check the clutch springs with a spring compression tester. 1. Inspect the seals (see arrows) on the master clutch carrier.
Page 267: Exploded View Of The Master Clutch
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Master Clutch 31L94R 1. SEAL 9. SNAP RING 2. HUB 10. SPRING RETAINER 3. SEAL 11. SPRING 4. BACKING PLATE 12. PISTON 5. SNAP RING 13. CLUTCH CARRIER 6.
Page 268: Assembly Of The Master Clutch
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Master Clutch STEP 37 STEP 39 A22345 A22348 Install the clutch piston into the clutch carrier. Install the spring retainer plate. Be sure the spring Carefully push the clutch piston down over the locators in the plate engage each spring.
Page 269: Disassembly Of The Range Transmission Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Range Transmission Input Shaft STEP 41 STEP 43 A22361 T95702 Put the input shaft on a clean work bench. Remove Use a puller to remove the medium range clutch pack the four seal rings on the front of the shaft (1).
Page 270 Section 21 - Transmission, Drivelines - Chapter 6 STEP 46 STEP 49 A10882 RD05K110 Install the compression sleeve with the notch Remove one piston return Belleville spring. CAS1903-3 to remove the retaining ring for the piston return Belleville springs. STEP 50 STEP 47 RD05K109 Remove the lube management ring.
Page 271 Section 21 - Transmission, Drivelines - Chapter 6 STEP 52 STEP 55 A10909 T95719 Remove the snap ring for the Belleville springs. Remove the medium range drive gear. STEP 53 STEP 56 A10910 T95720 Remove the snap ring for the bearing thrust washers Remove the caged needle bearing.
Page 272 Section 21 - Transmission, Drivelines - Chapter 6 STEP 58 STEP 61 T85722 A10908 Remove the thrust washer spacer ring. Remove the two bearing thrust washers and the needle thrust bearing. STEP 59 STEP 62 T95723 Remove the high range drive gear. A10884 Remove the piston retur n Belleville springs as follows:...
Page 273 Section 21 - Transmission, Drivelines - Chapter 6 STEP 63 STEP 66 RD05K108 A10888 Remove 8 piston return Belleville springs. Use a puller to remove the rear bearing cone. STEP 64 STEP 67 RD05K109 A10889 Remove the snap ring and remove the high range Remove the lube management ring.
Page 274 Section 21 - Transmission, Drivelines - Chapter 6 STEP 69 40S33 Turn the assembly over and remove the friction and separator plates. STEP 70 A10891 Remove the snap ring. 21-6-21...
Page 275: Exploded View Of The Range Transmission Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Input Shaft RI05N027 Exploded View of the Range Transmission Input Shaft 1. SHAFT ASSEMBLY 10. THRUST BEARING 19. O-RING 28. BEARING 2. PLUG 11. SNAP RING 20.
Page 276: Assembly Of The Range Transmission Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Range Transmission Input Shaft STEP 71 STEP 73 T95747 T95277 Hit the high range clutch plate carrier against a wooden block to remove the clutch piston. STEP 74 27L94 1.
Page 277 Section 21 - Transmission, Drivelines - Chapter 6 STEP 75 STEP 78 T95280 A10875 Install a separator plate. STEP 79 41S3 Put petroleum jelly on the teflon rings. A10876 STEP 76 Install a new friction plate. NOTE: Dip all friction plates in clean transmission fluid.
Page 278 Section 21 - Transmission, Drivelines - Chapter 6 STEP 81 STEP 83 A10878 A10889 Install the backing plate. The flat side of the plate Install the high range clutch pack assembly as must be facing down. shown. NOTE: The oil gallery hole in the shaft must be STEP 82 aligned with the hole in the carrier.
Page 279 Section 21 - Transmission, Drivelines - Chapter 6 STEP 85 STEP 87 RD05K110 A10899 Install the first piston return Belleville spring. The 1. Install a snap ring (1) over the shaft. concave side of the spring must be facing down. 2.
Page 280 Section 21 - Transmission, Drivelines - Chapter 6 STEP 89 STEP 92 A10903 A10904 Remove the two compression sleeves. Install a new seal ring on the hub of the high range drive gear. STEP 90 STEP 93 A10908 A10906 Install the needle thrust bearing and two bearing Install the high range drive gear.
Page 281 Section 21 - Transmission, Drivelines - Chapter 6 STEP 95 STEP 98 T95722 T95719 Install the thrust washer spacer ring. Install a new seal ring on the medium range drive gear. Install the gear. The hub of the gear must be facing up.
Page 282 Section 21 - Transmission, Drivelines - Chapter 6 STEP 101 STEP 104 A10909 RD05K110 Install the snap ring for the piston return Belleville Install the final Belleville spring concave side down. washers. This ring goes into the second groove down on the shaft.
Page 283 Section 21 - Transmission, Drivelines - Chapter 6 STEP 107 STEP 110 A10913 T95707 Remove the compression sleeve. Check to make Install a friction plate. sure the snap ring is properly seated in the groove on the shaft. NOTE: Dip all friction plates in clean transmission fluid.
Page 284 Section 21 - Transmission, Drivelines - Chapter 6 STEP 112 STEP 114 A10915 T95699 Install the medium range clutch plate carrier onto the Install the low range drive gear. shaft, open end facing down. Align holes between shaft and carrier. Carefully press the carrier on over STEP 115 the friction and separator plates.
Page 285: Cross-Section Of Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 STEP 116 Install four new seal rings (1) on the front end of the shaft. A22361 Cross-Section of Input Shaft 11L94R2 1. REAR BEARING CONE 5. FRONT BEARING CONE 2. HIGH RANGE DRIVE GEAR 6.
Page 286: Disassembly Of The Range Transmission Countershaft
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Range Transmission Countershaft STEP 117 STEP 120 T95748 T95751 Put the countershaft on a clean work bench. Remove the high range driven gear. STEP 118 STEP 121 T95749 T95752 Use a puller to remove the constant mesh gear and Remove the medium range driven gear from the the rear bearing cone.
Page 287 Section 21 - Transmission, Drivelines - Chapter 6 STEP 123 STEP 126 A10923 A10926 Turn the shaft assembly over and use a hydraulic Remove the four seal rings from the hub on the gear press to push the shaft through the remaining parts. (two rings in each of two grooves).
Page 288 Section 21 - Transmission, Drivelines - Chapter 6 STEP 129 STEP 132 T95771 T95774 Remove the caged needle bearing. Remove the two bearing thrust washers and the needle thrust bearing. STEP 130 STEP 133 T95772 Remove the bearing spacer. A10939 Remove the snap ring as follows: 1.
Page 289 Section 21 - Transmission, Drivelines - Chapter 6 STEP 134 STEP 137 T95778 RD05M018 Remove the two bearing thrust washers and the Remove eight piston return Belleville washers. needle thrust bearing. NOTE: Mark the orientation of the Belleville springs and lube management ring for proper reinstallation. STEP 135 STEP 138 RD05M016...
Page 290: Exploded View Of The Range Transmission Countershaft
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Countershaft RI05M088 1. SHAFT 14. THRUST BEARING 27. SPACER 2. NEEDLE BEARING 15. CIRCLIP 28. O-RING 3. SNAP RING 16. SNAP RING 29. SEAL RING 4. RING 17.
Page 291: Assembly Of The Range Transmission Countershaft
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Range Transmission Countershaft STEP 139 STEP 140 T95782 A10937 20.64 mm (0.81 INCH) 498L7 Make sure that all the oil passages in the shaft are open. DEPTH1 Install bearing inside of shaft with the numbers on the bearing facing outward.
Page 292 Section 21 - Transmission, Drivelines - Chapter 6 STEP 142 STEP 145 RD05M017 T95777 Install the lube management ring. Install the snap ring onto the shaft. STEP 143 STEP 146 RD05M016 A10939 Install the final three piston return Belleville washers Install the snap ring and Belleville washers as as shown.
Page 293 Section 21 - Transmission, Drivelines - Chapter 6 STEP 147 STEP 150 SNAP07 T95750 Install the snap ring for the medium range driven Install the gear spacer. gear. STEP 151 STEP 148 A10949 Install the constant mesh gear (1). Install the bearing T95752 Install a new seal ring (1) on the medium range cone.
Page 294 Section 21 - Transmission, Drivelines - Chapter 6 STEP 152 STEP 154 T95774CR 40S24 Turn shaft over. Install the needle thrust bearing and the two bearing thrust washers. The needle thrust bearing must be between the two bearing thrust washers. STEP 153 40S21 Remove the teflon ring (1) and O-ring (2) from the...
Page 295 Section 21 - Transmission, Drivelines - Chapter 6 STEP 156 STEP 158 40S27 A10932 Install the clutch piston into the carrier. The flat side Install the reaction plate (thicker separator plate). of the piston must be down. Push the piston into the carrier by hand.
Page 296 Section 21 - Transmission, Drivelines - Chapter 6 STEP 160 STEP 163 A10934 T95785R2 Install separator plates as follows: Install the low range driven gear and clutch pack assembly onto the shaft. The gear end of the carrier 1. Install a separator plate. must be facing up.
Page 297 Section 21 - Transmission, Drivelines - Chapter 6 STEP 165 STEP 167 A10942 A10945 Install the needle thrust bearing and the two bearing Install the front bearing cone so that the larger OD thrust washers. The needle bearing must be between side of the bearing cone is facing down.
Page 298: Front Wheel Drive (Fwd) - Emergency Brake Disassembly
Section 21 - Transmission, Drivelines - Chapter 6 Front Wheel Drive (FWD) - Emergency Brake Disassembly STEP 168 STEP 171 RD05K020 RD05K040 Remove the two Allen head mounting screws. C o m p r e s s t h e B e l l ev i l l e s p r i n g s u s i n g To o l Repeat for the opposite side.
Page 299 Section 21 - Transmission, Drivelines - Chapter 6 STEP 174 STEP 177 RD05K053 RD05K070 Remove the piston sealing ring and discard. Remove the friction plate. Continue until all friction and separator plates are removed. STEP 175 NOTE: When replacing separator and friction plates, they have to be replaced as complete assemblies.
Page 300 Section 21 - Transmission, Drivelines - Chapter 6 STEP 180 STEP 183 Rd05K034 RD05K030 Remove the retaining ring for the emergency brake Remove the hub seal backing O-ring and discard. clutch assembly. IMPORTANT: Mark the shaft and hub (1) for proper STEP 181 reassembly.
Page 301 Section 21 - Transmission, Drivelines - Chapter 6 STEP 186 STEP 189 RD05K075 RD05K038 Note the orientation of the Belleville springs and Remove the friction plate. Continue to remove all remove. friction and separator plates. There is a total of six separator and six friction plates.
Page 302 Section 21 - Transmission, Drivelines - Chapter 6 STEP 192 STEP 195 RD05K054 RD05K077 Remove the seal backing O-ring and discard. Remove bearing retainer ring (1) from the shaft. STEP 193 STEP 196 RD05K051 RD05K079 Remove the seal from the emergency hub. Remove the spacer and shim pack.
Page 303 Section 21 - Transmission, Drivelines - Chapter 6 STEP 197 STEP 199 RD05K043 RD05K045 Support the gear/can weldment (1) as shown and Using a soft drift (1), remove the bearing cup (2). press the FWD/park brake shaft (2) free from the weldment.
Page 304: Exploded View Of Fwd And Emergency Brake
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of FWD and Emergency Brake 20 21 1. SHAFT ASSY., FWD/PARK BRAKE 12. RING, RETAINER 23. SEAL, EMERGENCY BRAKE HUB 2. TUBE, JUMPER W/ O-RINGS & FITTING 13. WELDMENT, FWD GEAR/CAN 24.
Page 305: Assembly Of The Fwd / Emergency Brake
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the FWD / Emergency Brake NOTE: Be sure parts are free of all contaminants STEP 204 before reassembly. STEP 202 RD05K049 Press cup into place. RD05K047 IMPORTANT: DO NOT overpress cup against the Install snap rings.
Page 306 Section 21 - Transmission, Drivelines - Chapter 6 STEP 206 STEP 208 RD05K080 RD05K082 Using an appropriate tool, press bearing onto the Set Bearing Preload As Follows: shaft. 1. Attach a spring scale to one of the holes in the gear/can weldment (1).
Page 307 Section 21 - Transmission, Drivelines - Chapter 6 STEP 211 STEP 213 RD05K083 RD05K062 Support the gear (1) as shown. Backseat the bearing Install the retainer ring. against the retainer ring. DO NOT over press. IMPORTANT: Over pressing the bearing may distort STEP 214 the retainer ring which may cause improper shaft end play.
Page 308 Section 21 - Transmission, Drivelines - Chapter 6 STEP 216 STEP 218 Rd05K059 Measure the distance between the top of the hub (1) Rd04K066 and the top of the piston (2). Install a separator plate. Continue until the six friction and six separator plates are installed.
Page 309 Section 21 - Transmission, Drivelines - Chapter 6 STEP 220 STEP 223 RD05K087 RD05K029 Place the 5 inch long piece of PVC pipe (1) over the Lubricate a new seal with petroleum jelly and install. shaft (2). Make sure the pipe is centered at the Use care not to overstretch the seal.
Page 310 Section 21 - Transmission, Drivelines - Chapter 6 STEP 226 STEP 229 RD05K088 RD05K025 Place the FWD hub (1) over the shaft (2) and set on Install a separator plate. Alternate separator and the PVC pipe (3). friction plates until there are six separator and six friction plates for the ten-bolt FWD axle and seven NOTE: Do not install shaft seals at this time.
Page 311 Section 21 - Transmission, Drivelines - Chapter 6 STEP 231 STEP 233 RD05K060 RD05K022 Measure the distance between the top of the hub Place the spring spacer(s) (if required), locking ring flange (1) and the top of the piston (2). (1) and retaining ring (2) over the shaft.
Page 312 Section 21 - Transmission, Drivelines - Chapter 6 STEP 235 STEP 237 RD05K093 Place the 2 inch long piece of PVC pipe (1) over the RD05K021 shaft (2). Make sure the pipe is centered at the R e m ove t h e F W D c l u t c h a s s e m bl y f r o m t h e bottom of the gear/can weldment (3).
Page 313 Section 21 - Transmission, Drivelines - Chapter 6 STEP 240 STEP 243 RD05M020 RD05K096 Install a friction plate. Hand press the piston onto the hub to “size” the seal rings. Remove the piston and set aside. STEP 244 STEP 241 RD05K097 Install a separator plate.
Page 314 Section 21 - Transmission, Drivelines - Chapter 6 STEP 245 STEP 247 RD05K098 RD05K0101 Install the piston. Place the spacer(s) (if required) and retainer ring on top of the Belleville springs. IMPORTANT: Use care when installing the piston to prevent damage to the piston and hub seals. IMPORTANT: Belleville springs must be aligned and centered so that they do not catch on the shaft when STEP 246...
Page 315 Section 21 - Transmission, Drivelines - Chapter 6 STEP 249 STEP 251 RD05K103 RD05K104 Turn the weldment (1) over. Lift the weldment and Properly support the park brake hub assembly as remove the park brake hub assembly (2) and PVC shown and lower into the weldment.
Page 316 Section 21 - Transmission, Drivelines - Chapter 6 STEP 254 STEP 257 RD05K020 RD05K033 Make sure that the jumper tube supply hole (1) is not Lubricate with petroleum jelly and install three new covered by the shield. Install the allen head bolts (2). shaft seals.
Page 317 Section 21 - Transmission, Drivelines - Chapter 6 STEP 259 STEP 261 RD05K017 A22327 Continue to lower the assembly into the housing until Install the FWD lube tube at the shaft end and to it is seated in the bore. fitting in top of range casting.
Page 318 Section 21 - Transmission, Drivelines - Chapter 6 STEP 263 STEP 264 RD05K011 RD05K012 1. Install the emergency brake release supply 1. Install the FWD fitting (1). DO NOT install the fittings (1). FWD supply tube (2) at this time. 2.
Page 319: Exploded View Of The Range Transmission Countershaft, Input Shaft, And Fwd Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Countershaft, Input Shaft, and FWD Input Shaft 29L94R 1. SHIMS 7. FRONT BEARING CUP 13. PLUG 2. FRONT BEARING CUP 8. SHIM 14. HEATER 3. INPUT SHAFT BEARING CAGE 9.
Page 320: Installing The Range Transmission Countershaft, Input Shaft, And Fwd Input Shaft Into The Range Transmission Housing
Section 21 - Transmission, Drivelines - Chapter 6 Installing the Range Transmission Countershaft, Input Shaft, and FWD Input Shaft into the Range Transmission Housing STEP 265 STEP 267 T95671 T95673 Drive the bearing cage for the bevel pinion shaft out Drive new bearing cups into the bores until the cups of the range transmission housing, if required.
Page 321 Section 21 - Transmission, Drivelines - Chapter 6 STEP 269 STEP 271 41S19 T95883R Press a new cup into the bore of the input shaft Install a snap ring pliers through the opening in the bearing cage until the cup seats against the cage hydraulic pump drive gear which is installed on top of shoulder.
Page 322 Section 21 - Transmission, Drivelines - Chapter 6 STEP 274 STEP 277 T95886R T95889 Press a new bearing cup into the bearing cage until Install a new seal ring inside the gear. the bearing seats against the cage shoulder. STEP 278 STEP 275 T95890 Install the gear retaining snap ring inside the gear...
Page 323 Section 21 - Transmission, Drivelines - Chapter 6 STEP 280 STEP 282 T95883R Reach through the opening in the gear and install the T95887 snap ring into the groove in the bearing cage. Install the bearing snap ring. NOTE: Make sure that the alignment pin located at the STEP 281 end of the output shaft mounting flange is aligned with the alignment hole as shown in the following step.
Page 324 Section 21 - Transmission, Drivelines - Chapter 6 STEP 283 STEP 286 A22319 16S21 Tilt the range input shaft over to the side and install Place the original shims over the end of the range the range transmission countershaft. transmission countershaft. STEP 284 STEP 287 16S27...
Page 325 Section 21 - Transmission, Drivelines - Chapter 6 STEP 289 16S9 Install the range input shaft front bearing cage. Install the mounting bolts to a torque of 54 to 61 Nm (40 to 45 lb. ft.). 21-6-72...
Page 326: Setting The End Play Of The Range Transmission Countershaft And Input Shaft
Section 21 - Transmission, Drivelines - Chapter 6 SETTING THE END PLAY OF THE RANGE TRANSMISSION COUNTERSHAFT AND INPUT SHAFT STEP 290 STEP 291 The end play of each shaft must be checked if any of the following parts were replaced: shaft, front bearing cage, bearing cones and cups, or front bearing support cover.
Page 327 Section 21 - Transmission, Drivelines - Chapter 6 STEP 293 STEP 294 14S25 15S30 Install a new O-ring onto the transmission speed Apply petroleum jelly to the seal ring on the input sensor and install the sensor into the top of the range shaft front bearing cage.
Page 328: Installing The Range Input Master Clutch
Section 21 - Transmission, Drivelines - Chapter 6 Installing the Range Input Master Clutch STEP 295 STEP 297 A22306 15S24 Install the snap ring that fastens the master clutch Install new seal on the outside of the hub. Lubricate assembly to the input shaft. Align the clutch to the the seal ring with petroleum jelly.
Page 329 Section 21 - Transmission, Drivelines - Chapter 6 STEP 299 STEP 302 A22305CR 12S15 Install a new friction plate into the master clutch. Install new O-ring on the feeder tubes and lubricate Install the remaining eight separator plates and eight with petroleum jelly.
Page 330 Section 21 Chapter 7 TRANSMISSION CONTROL VALVES AND INCHING VALVE January, 2006...
Page 331 Section 21 - Transmission, Drivelines - Chapter 7 TABLE OF CONTENTS SPECIAL TORQUES ............................21-7-3 POWERSHIFT TRANSMISSION CONTROL VALVES .................. 21-7-3 TRANSMISSION CONTROL VALVE CONFIGURATION ................21-7-4 INCHING VALVE ............................21-7-15 21-7-2...
Page 332: Special Torques
Section 21 - Transmission, Drivelines - Chapter 7 SPECIAL TORQUES Transmission Control Valves Plug, M18 ........................19 to 25 Nm (14 to 18 lb. ft.) Plug, M27 ........................34 to 54 Nm (25 to 40 lb. ft.) Pressure Sensor ......................19 to 25 Nm (14 to 18 lb. ft.) Solenoid Cartridge .....................
Page 333: Transmission Control Valve Configuration
Section 21 - Transmission, Drivelines - Chapter 7 TRANSMISSION CONTROL VALVE CONFIGURATION This chart matches transmission valve configuration with tractor options controlled by those valves (Figures 1 through 6). SPEED ODD-EVEN RANGE TRANSMISSION TRANSMISSION TRANSMISSION TRANSMISSION OPTIONS CONTROL VALVE CONTROL VALVE CONTROL VALVE NAO WITHOUT FWD/WITHOUT CREEP FIGURE 1...
Page 334 Section 21 - Transmission, Drivelines - Chapter 7 Figure 1 - Transmission Control Valve with Four Solenoids This type of control valve is used with thes e Speed control valve for all tractor configurations. transmission configurations: RI02E100 1. VALVE BODY 5.
Page 335 Section 21 - Transmission, Drivelines - Chapter 7 Figure 2 - Transmission Control Valve with Four Solenoids This type of control valve is us ed with thes e Range control valve with FWD. transmission configurations: Odd - Even control valve with NA park and creep. RI02E099 1.
Page 336 Section 21 - Transmission, Drivelines - Chapter 7 Figure 3 - Transmission Control Valve with Three Solenoids and Plug This type of control valve is used with thes e Range control valve without FWD. transmission configurations: RI02E096 1. VALVE BODY 5.
Page 337 Section 21 - Transmission, Drivelines - Chapter 7 Figure 4 - Transmission Control Valve with Three Solenoids and Plug This type of control valve is us ed with thes e Odd-even control valve with NA park without transmission configurations: creep. RI02E097 1.
Page 338 Section 21 - Transmission, Drivelines - Chapter 7 Figure 5 - Transmission Control Valve with Two Solenoids, Check Valve and Plug T h i s t y p e o f c o n t r o l va l ve i s u s e d w i t h t h i s Odd-even control valve with Euro park without transmission configuration: creep.
Page 339 Section 21 - Transmission, Drivelines - Chapter 7 Figure 6 - Transmission Control Valve with Three Solenoids and Check Valve T h i s t y p e o f c o n t r o l va l ve i s u s e d w i t h t h i s Odd-even control valve with Euro park with creep.
Page 340 Section 21 - Transmission, Drivelines - Chapter 7 Valve Removal NOTE: Before removing components, 3. Remove the valve retaining bolts, valve body, thoroughly clean the valve body and the area on the and gasket. Discard the gasket. transmission housing adjacent to the valve body to eliminate any contamination.
Page 341 Section 21 - Transmission, Drivelines - Chapter 7 Disassembly STEP 7 NOTE: Disassembly of range valve shown. Other valves are similar. NOTE: Only the speed control valve is equipped with a pressure sensor. See Figure 1 - Transmission Control Valve with Four Solenoids for pressure sensor location.
Page 342 Section 21 - Transmission, Drivelines - Chapter 7 Assembly STEP 10 NOTE: Disassembly of range valve shown. Other valves are similar. NOTE: Only the speed control valve is equipped with a pressure sensor. See Figure 1 - Transmission Control Valve with Four Solenoids for pressure sensor location.
Page 343 Section 21 - Transmission, Drivelines - Chapter 7 Valve Installation STEP 11 STEP 13 RD02E274 RD02E276 Install the range transmission control valve as Install the speed transmission valve as follows: follows: 1. Install a new gasket and the valve. 1. Install a new gasket and the valve. 2.
Page 344: Inching Valve
Section 21 - Transmission, Drivelines - Chapter 7 INCHING VALVE Removal STEP 14 STEP 15 RI02E086 RD02E274 The inching valve (1) is located under the range Remove the inching valve as follows: transmission valve (2). Raise or remove the cab for 1.
Page 345 Section 21 - Transmission, Drivelines - Chapter 7 Disassembly STEP 16 STEP 18 56-34 57-10 Place the inching valve on a clean work surface. Remove solenoid cartridge. Remove plug. NOTE: The solenoid cartridge is not designed to be disassembled. STEP 17 STEP 19 57-6 Remove nut, two O-rings and coil from the solenoid...
Page 346 Section 21 - Transmission, Drivelines - Chapter 7 STEP 20 STEP 21 57-19 54-33 Remove the plug. Remove the plug, spring and modulator spool assembly. NOTE: Parts of the modulator spool assembly are not serviced separately. 21-7-17...
Page 347 Section 21 - Transmission, Drivelines - Chapter 7 Assembly RT98C002 1. VALVE BODY 9. O-RING 24. SLEEVE 2. M18 PLUG 11. O-RING 25. BALL 3. O-RING 12. O-RING 26. SPRING 4. M27 PLUG 13. O-RING 27. SPRING 5. O-RING 20. M14 PLUG 28.
Page 348 Section 21 - Transmission, Drivelines - Chapter 7 STEP 22 STEP 25 54-33 57-19 Install the inching modulator spool assembly and Install a new O-ring on plug. Install plug in valve body spring. and tighten to a torque of 34 to 54 Nm (25 to 40 lb. ft.). STEP 23 STEP 26 57-25...
Page 349 Section 21 - Transmission, Drivelines - Chapter 7 STEP 28 Installation STEP 31 57-10 Install the solenoid cartridge and tighten to a torque to 12 to 18 Nm (9 to 13 lb. ft.). RD02E274 Install the inching valve and range transmission STEP 29 control valve as follows: 1.
Page 350 Section 21 - Transmission, Drivelines - Chapter 7 Inching Valve Cross Section 302171AA.WMF 1. VALVE BODY 7. SPRING 2. PLUG 8. SPRING 3. SOLENOID 9. PLUG 4. INCHING SPOOL 10. INCHING MODULATOR SPOOL ASSEMBLY 5. BALL 11. MODULATOR ASSEMBLY PISTON 6.
Page 351 Section 21 - Transmission, Drivelines - Chapter 7 This Page Left Blank. 21-7-22...
Page 352 Section 21 Chapter 8 REAR FRAME January, 2006...
Page 353 Section 21 - Transmission, Drivelines - Chapter 8 TABLE OF CONTENTS SPECIFICATIONS ............................21-8-3 SPECIAL TORQUES ............................21-8-3 SPECIAL TOOLS ............................21-8-3 DIFFERENTIAL .............................. 21-8-4 Removal ..............................21-8-4 Disassembly .............................. 21-8-10 PINION SHAFT ............................21-8-14 Removal and Disassembly ........................21-8-14 Assembly and Installation .........................
Page 354: Specifications
Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 21 - Transmission, Drivelines - Chapter 8 SPECIFICATIONS Differential Bearing Retainer Seal Recess ..................0.8 mm (0.031 inch) Differential Bearing Rolling Torque (New)..............4.5 to 7.9 Nm (40 to 70 lb. inch) Differential Bearing Rolling Torque (Used) ............2.25 to 3.95 Nm (20 to 35 lb. inch) Ring and Pinion Backlash................0.179 to 0.279 mm (0.007 to 0.011 inch) Pinion Shaft End Play ................0.013 to 0.102 mm (0.0005 to 0.004 inch) Ring and Pinion Nominal Setting Distance................33.92 mm (1.335 inch)
Page 355: Differential
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL Removal 5. Remote valve return line. 6. Regulated supply to PTO valve. STEP 1 7. Difflock supply tube. Prepare to remove the differential as follows: STEP 6 1. Start the tractor and lower the hitch. Disconnect the hydraulic lines to the hitch lift 2.
Page 356 Section 21 - Transmission, Drivelines - Chapter 8 STEP 9 STEP 11 26s27b 76-6a While supporting the vertical lifting link, drive out the Remove the bolt and locking flag plate in the upper hitch swivel pin with a suitable tool. Repeat Steps 9 end of the hitch lift cylinder (both sides).
Page 357 Section 21 - Transmission, Drivelines - Chapter 8 STEP 13 STEP 15 36s21b 36s34b Remove the two bolts that attach the rockshaft Remove pin and free the upper end of the hitch lift sensor shield to the hitch support C-bracket. cylinder.
Page 358 Section 21 - Transmission, Drivelines - Chapter 8 STEP 18 STEP 21 36s4 35-21 Remove the position sensor bracket. Use a long piece of wood to reach through the rockshaft and contact the rocker pin. Tap the piece of wood to dislodge the rockshaft pin. Use care not to STEP 19 damage the seal or bushing.
Page 359 Section 21 - Transmission, Drivelines - Chapter 8 STEP 23 STEP 26 35-14 T98138 When both rockshaft pins are removed, lift and set Remove the differential lock supply line from the aside the rockshaft casting. differential. NOTE: Keep bearings and seals free of foreign STEP 27 material.
Page 360 Section 21 - Transmission, Drivelines - Chapter 8 STEP 29 STEP 32 T98214A T98187 Install the differential lifting tool, CAS-1952, on the Remove the RH bearing retainer from the housing. differential. Connect a hoist to the differential lifting STEP 33 tool and put tension on the hoist chain or strap.
Page 361: Disassembly
Section 21 - Transmission, Drivelines - Chapter 8 Disassembly STEP 38 STEP 35 T98151 Remove the differential lock separator and friction plates from the housing. t98146 Remove and discard the 12 ring gear mounting bolts. Remove the ring gear. Remove the differential STEP 39 housing seal rings.
Page 362 Section 21 - Transmission, Drivelines - Chapter 8 STEP 41 STEP 44 RD98C189 T98160 Remove the piston from the housing. Remove each short pinion shaft from the housing. STEP 42 STEP 45 T98155 T98161 Remove the short pinion shaft retaining bolts from Remove the short spacers from the housing.
Page 363 Section 21 - Transmission, Drivelines - Chapter 8 STEP 47 STEP 50 T98163 T98166 Remove the thrust washers from the housing. Remove the long pinion shaft gears from the housing. Remove the thrust ring and needle bearings from both long shaft pinion gears. STEP 48 STEP 51 T98164...
Page 364 Section 21 - Transmission, Drivelines - Chapter 8 STEP 53 STEP 56 88-19A T98205 Remove the thrust washer from the housing. Remove the oil seal from each bearing retainer. STEP 54 STEP 57 RD98C192 T98183 Remove the seal ring and the bearing cone from the Remove the bearing cup from the housing.
Page 365: Pinion Shaft
Section 21 - Transmission, Drivelines - Chapter 8 PINION SHAFT Removal and Disassembly STEP 62 STEP 59 If required, split the rear frame and range transmission (refer to Range Transmission to Differential Split in this manual) before servicing the pinion shaft. STEP 60 T95913 Remove the shims from the bearing cage.
Page 366 Section 21 - Transmission, Drivelines - Chapter 8 STEP 65 STEP 68 T95935 T95925 Press the pinion shaft and bearings out of the Remove the inner snap ring from the bearing cage. bearing cage. STEP 69 NOTE: Make sure that the rear bearing (against the gear) will clear the press.
Page 367: Assembly And Installation
Section 21 - Transmission, Drivelines - Chapter 8 Assembly and Installation 238I7 1. RING GEAR 8. BEARING CAGE 2. PINION SHAFT 9. SNAP RING* 3. CUP PLUG WITH HOLE 10. SPACER* 4. BEARING CONE 11. CONSTANT MESH GEAR* 5. BEARING CUP 12.
Page 368 Section 21 - Transmission, Drivelines - Chapter 8 STEP 71 STEP 74 t95924 88-33A Press the rear bearing cup into the bearing cage until Press the bearing cone on the pinion shaft until seated. seated against the gear. STEP 72 STEP 75 T95925 T95928...
Page 369 Section 21 - Transmission, Drivelines - Chapter 8 STEP 77 STEP 79 T95923 T95935 Measure the distance from the bearing cone to the Backseat the front bearing on the snap ring with front of the snap ring groove using feeler gauges. 10,000 to 15,000 lb.
Page 370 Section 21 - Transmission, Drivelines - Chapter 8 How To Determine Ram Pressure STEP 80 Do the following to determine what the pressure gauge must show for your ram: 1. Determine the effective area of your ram. 2. Determine the minimum and maximum pressure gauge readings desired.
Page 371 Section 21 - Transmission, Drivelines - Chapter 8 STEP 81 STEP 82 T95912 T98212 Install the pinion shaft assembly without any shims. Install the pinion shaft depth setting tool CAS1902-1 Install and tighten retaining bolts to a torque of 102 to into the differential bearing retainer bores so the bar 113 Nm (75 to 83 lb.
Page 372 Section 21 - Transmission, Drivelines - Chapter 8 Differential Assembly 1. SHIM 11. THRUST WASHER 21. NEEDLE BEARING 32. CONE BEARING 43. PIN 55. PLATE 2. HOUSING 12. WASHER 22. RING 33. CUP BEARING 44. SEAL 56. PLATE 3. PIN 13.
Page 373 Section 21 - Transmission, Drivelines - Chapter 8 STEP 83 STEP 85 T98202 T95913 Determine dimension as follows: Select the correct shim pack, determined in Step 83, within 0.03 mm (0.001 inch). Install the shims over 1. Apply 50 to 100 lbs forward loading on the pinion the alignment dowels.
Page 374 Section 21 - Transmission, Drivelines - Chapter 8 STEP 87 STEP 88 T95912 T95911 Place the pinion shaft assembly on the housing. Install the pinion shaft assembly mounting bolts. Apply a torque of 101.7 to 112.5 Nm (75 to 83 lb ft) to each bolt.
Page 375: Differential Assembly
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL ASSEMBLY STEP 89 STEP 91 rd98c191 T98206 Install the bearing cones on both the right-hand (RH) and left-hand (LH) bearing retainer until seated against the shoulder of the retainer. STEP 90 397L7 Install the oil seals into the bearing retainers.
Page 376 Section 21 - Transmission, Drivelines - Chapter 8 STEP 93 STEP 96 T98209 T98168 Install a new O-ring lubricated with petroleum jelly on Install the standard side gear in the housing so the the differential lock supply tube. gear teeth face away from the thrust washer. STEP 94 STEP 97 88-22A...
Page 377 Section 21 - Transmission, Drivelines - Chapter 8 STEP 99 STEP 102 T98207 T98164 Install the needle bearing spacers in the gears on top Install the long pinion shaft into the housing bore of the needle bearings. without locking bolts holes and through the long spacer.
Page 378 Section 21 - Transmission, Drivelines - Chapter 8 STEP 105 STEP 108 T98161 RD98C189 Install the short spacers into the housing so the Install the differential lock piston in the housing. smaller diameter ends face the long shaft. STEP 109 STEP 106 T98154 Install the six dowel pins into the housing.
Page 379 Section 21 - Transmission, Drivelines - Chapter 8 STEP 111 STEP 114 T98151 T98172 Install one separator plate in the housing so it locks Install the bearing cup into the differential cover until on the dowel pins. seated against the cover. STEP 112 STEP 115 T98152...
Page 380: Differential Installation
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL INSTALLATION STEP 116 STEP 118 T98149 T98146 Place the ring gear on the differential housing. Install 12 new ring gear bolts and torque to 310 Nm (230 lb. ft.). STEP 119 T98182 Install the differential cover on the housing.
Page 381 Section 21 - Transmission, Drivelines - Chapter 8 STEP 121 STEP 123 T98192 T98193 Install two aligning dowels in each bearing retainer Install bearing retainers as follows: mounting surface of the rear frame. 1. Align the lube passage on the rear frame housing with the lube passage in the bearing retainer (shown).
Page 382 Section 21 - Transmission, Drivelines - Chapter 8 STEP 126 STEP 128 35-18 36s1 The rockshaft pins must be clean and free of oil, Install the tie rod as follows: grease, antiseize compound, etc. Orient pin with 1. Place one washer and retainer in place on the bearing surface outboard.
Page 383 Section 21 - Transmission, Drivelines - Chapter 8 STEP 130 STEP 132 36s8 36s17 Install the nut that attaches the position locator Install the nut for the rockshaft sensor link assembly. bracket to the end of the tie rod. Tighten to a torque Torque to 18 to 23 Nm (14 to 17 lb ft).
Page 384 Section 21 - Transmission, Drivelines - Chapter 8 STEP 134 STEP 136 36s34b 27s12b Insert the top cylinder pin as follows: Connect the hydraulic lines to the top and bottom of the hitch cylinder. Repeat for the other hitch lift 1.
Page 385 Section 21 - Transmission, Drivelines - Chapter 8 STEP 138 STEP 141 26s24b 91s16 Insert the slotted end of a locking flag plate into the Install and tighten the rear frame drain plug in the groove on the inside of the hitch swivel pin. housing.
Page 386: Adjusting The Differential Preload
Section 21 - Transmission, Drivelines - Chapter 8 ADJUSTING THE DIFFERENTIAL PRELOAD NOTE: When the differential bearings or housing are STEP 151 replaced, the bearing preload must be adjusted. STEP 149 T98143 Tighten the three retainer mounting bolts to a torque of 235 to 260 Nm (173 to 192 lb ft).
Page 387 Section 21 - Transmission, Drivelines - Chapter 8 STEP 153 STEP 155 T98144 T98198 Tighten the three bearing retainer bolts while rotating Use a depth micrometer to measure from the RH the differential to seat the bearings. Torque the bolts bearing retainer face to the rear frame through the equally and evenly in steps of 2.8 Nm (25 lb inch) three equally spaced holes.
Page 388: Adjusting The Ring And Pinion Backlash
Section 21 - Transmission, Drivelines - Chapter 8 ADJUSTING THE RING AND PINION BACKLASH STEP 156 3. The rolling torque of the differential must be 4.5 to 8.0 Nm (40 to 70 lb inch) for new bearings and 2 to 4 Nm (20 to 35 lb inch) for old bearings (used for more than 200 hours).
Page 389: Bevel Pinion And Gear Tooth Contact Check
Section 21 - Transmission, Drivelines - Chapter 8 BEVEL PINION AND GEAR TOOTH CONTACT CHECK STEP 161 STEP 160 Put Prussian Blue or red lead onto the convex side of the gear teeth. Turn the pinion several revolutions in the forward (clockwise) direction, while applying a braking force on the gear, to determine the contact pattern.
Page 390 Section 21 - Transmission, Drivelines - Chapter 8 247L0 Pattern B The pinion is in too far. Add approximately 0.10 mm (0.005 inch) of shim material under the pinion bearing cage. Adjust the backlash to specifications. See Step 159 before checking contact pattern again. 244L0 1.
Page 391 Section 21 - Transmission, Drivelines - Chapter 8 RH98C093 1. DIFFERENTIAL LOCK ASSEMBLY 3. DRIVE PINION SHAFT 2. RING GEAR 4. DIFFERENTIAL ASSEMBLY 21-8-40...
Page 392 Section 21 Chapter 9 HYDRAULIC PUMP DRIVE January, 2006...
Page 393 Section 21 - Transmission, Drivelines - Chapter 9 TABLE OF CONTENTS SPECIAL TORQUES ............................21-9-3 SPECIFICATIONS ............................21-9-3 PUMP DRIVE ..............................21-9-3 Removal ..............................21-9-3 Disassembly ..............................21-9-4 Assembly ..............................21-9-7 Installation ..............................21-9-12 21-9-2...
Page 394: Special Torques
Section 21 - Transmission, Drivelines - Chapter 9 SPECIAL TORQUES Bearing Cage Bolt ......................55 to 60 Nm (41 to 44 lb. ft.) Hydraulic Drive Pump Assembly Mounting Bolts............52 to 61 Nm (38 to 45 lb. ft.) SPECIFICATIONS Driven Gear Shaft End Play................0.026 to 0.1 mm (0.001 to 0.004 inch) PUMP DRIVE Removal STEP 1...
Page 395: Disassembly
Section 21 - Transmission, Drivelines - Chapter 9 Disassembly STEP 5 STEP 8 RP98B083 RP98B049 Remove the bearing cage from the pump drive Mark the gear positions and remove the drive gear housing. assembly from the pump drive housing. STEP 6 STEP 9 RP98B053 T94753...
Page 396 Section 21 - Transmission, Drivelines - Chapter 9 STEP 11 STEP 14 T94752 T94749 Remove the idler gear shaft from the pump drive Remove the spacer from the idler gear. housing. STEP 15 STEP 12 T94748 Press the other bearing from the idler gear. Discard T94751 Remove the idler gear assembly from the pump drive the bearing.
Page 397 Section 21 - Transmission, Drivelines - Chapter 9 STEP 17 RP98B051 Remove the front and rear bearing cone from the driven gear shaft using a bearing puller or a press and collet. 21-9-6...
Page 398: Assembly
Section 21 - Transmission, Drivelines - Chapter 9 Assembly SCRH98A5 1. PUMP DRIVE HOUSING 7. BEARING CUP 2. IDLER SHAFT 8. BEARING CONE 3. BEARING 9. DRIVEN GEAR 4. SPACER 10. SHIM 5. RETAINING RING 11. O-RING 6. IDLER GEAR 12.
Page 399 Section 21 - Transmission, Drivelines - Chapter 9 STEP 18 STEP 21 RP98B051 T94749 Press the front and rear bearing cones on the drive Install the spacer on top of the bearing in the idler gear shaft until the bearing cones are flush with the gear.
Page 400 Section 21 - Transmission, Drivelines - Chapter 9 STEP 24 STEP 27 T94752 RR98C026 Install the idler gear shaft through the pump drive Install the bearing cage as follows: housing and the idler gear. 1. Install the bearing cage on the pump drive housing without shims or O-rings.
Page 401 Section 21 - Transmission, Drivelines - Chapter 9 STEP 29 STEP 32 RP98B083 RP98B083 Remove the bearing cage from the pump drive Install the bearing cage on the pump drive housing. housing. STEP 33 STEP 30 RR98B005 Tighten the bearing cage bolts to a torque of 55 to 60 RP08B052 Lubricate a new O-ring with petroleum jelly.
Page 402 Section 21 - Transmission, Drivelines - Chapter 9 STEP 34 RR98B004 If necessary, adjust shim pack to obtain correct end play as follows: 1. Rotate and push down the drive gear shaft. 2. Install a dial indicator on the bearing cage and indicate to the end of the drive gear shaft.
Page 403: Installation
Section 21 - Transmission, Drivelines - Chapter 9 Installation STEP 35 STEP 38 RD02D029 RD02D002 Apply a continuous bead of Loctite® 515 Sealant, With the hydraulic pump drive (1) installed on the 4.76 mm (3/16 inch) wide to the mounting surface of transmission, install the hydraulic PFC pump (2) and the pump drive housing and around the bolt holes.
Page 404 Section 25 Chapter 1 FRONT WHEEL DRIVE FWD CONTROL SYSTEM How It Works January, 2006...
Page 405 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TABLE OF CONTENTS FRONT WHEEL DRIVE (FWD) ........................25-1-3 ELECTRONIC FRONT WHEEL DRIVE (FWD) CONTROL ................25-1-5 FRONT WHEEL DRIVE (FWD) CONTROL MODES ..................25-1-7 FRONT WHEEL DRIVE (FWD) FUNCTIONAL TESTS ................. 25-1-8 TROUBLESHOOTING ..........................
Page 406: Front Wheel Drive (Fwd)
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) General Description The Front Wheel Drive (FWD) consists of the FWD The PTO controller supplies current to the FWD axle, a drive shaft, FWD clutch, FWD control valve, va l v e t o o p e r a t e t h e F W D c l u t c h b a s e d o n FWD control switch, brake pedal switches, true commands from the operator (FWD switch).
Page 407 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 RI02E086 1. FWD SOLENOID 2. POWERSHIFT VALVE RANGE 25-1-4...
Page 408: Electronic Front Wheel Drive (Fwd) Control
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 ELECTRONIC FRONT WHEEL DRIVE (FWD) CONTROL General Description The FWD consists of the FWD axle, a drive shaft, All FWD operator commands are sent to the Arm FWD clutch, FWD control valve, FWD control switch, Rest Control Module (hard wired to the Arm Rest brake pedal switches, true ground speed circuit, hitch Control Module), then relayed to the PTO controller...
Page 409 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 RH05J060 1. FRONT WHEEL DRIVE (FWD) SWITCH 25-1-6...
Page 410: Front Wheel Drive (Fwd) Control Modes
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) CONTROL MODES OFF – When the FWD switch is placed in the OFF position, the FWD clutch will be deactivated (coil-energized) unless both brakes are applied. The FWD clutch is applied as both brake pedals are applied to allow four wheel braking.
Page 411: Front Wheel Drive (Fwd) Functional Tests
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) FUNCTIONAL TESTS Switch Position F W D E n g a g e d / FWD Operation Description Disengaged Disengaged Except: When both brake pedals are pressed. RD05J067 Engaged Operator will feel engagement as switch is cycled.
Page 412 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 RI02E086 1. FWD SOLENOID 3. MID CLUTCH SOLENOID 2. LOW CLUTCH SOLENOID 4. HIGH CLUTCH SOLENOID FWD Valve The FWD valve is a closed center valve and is contained as a part of the range transmission powershift valve manifold.
Page 413: Troubleshooting
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TROUBLESHOOTING Problem – FWD clutch will not disengage 1. Check for PTO fault codes. (FWD fault codes are monitored by PTO controller.) A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section.
Page 414 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TROUBLESHOOTING Problem – FWD will not engage 1. Check for PTO fault codes. (FWD fault codes are monitored by PTO controller.) A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section.
Page 415 Section 25 - Four-Wheel Drive Front Axle - Chapter 1 WARNING These tractors are equipped with a spring-applied mechanical front wheel drive (FWD) clutch and a limited slip differential. Even with the engaging switch in the OFF position, the FWD clutch can propel both front wheels if any of the following conditions exist.
Page 416 Section 25 Chapter 2 DIFFERENTIAL LOCK CONTROL SYSTEM How It Works January, 2006...
Page 417 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TABLE OF CONTENTS DIFFERENTIAL LOCK ........................... 25-2-3 ELECTRONIC DIFFERENTIAL LOCK CONTROL ..................25-2-5 DIFFERENTIAL LOCK CONTROL MODES ....................25-2-7 DIFFERENTIAL LOCK CONTROL ......................... 25-2-8 DIFFERENTIAL LOCK FUNCTIONAL TESTS ....................25-2-9 TROUBLESHOOTING ..........................
Page 418: Differential Lock
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK General Description – The Differential Lock consists of the differential lock piston, differential lock control valve, differential lock control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission speed circuit, and electronic control modules (through the Data Bus).
Page 419 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 RI02E086 1. PTO/DIFF LOCK VALVE 2. DIFF LOCK CLUTCH SOLENOID 25-2-4...
Page 420: Electronic Differential Lock Control
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 ELECTRONIC DIFFERENTIAL LOCK CONTROL General Description – The Differential Lock consists of the differential lock clutch, differential lock control valve, differential lock control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission speed circuit, and electronic control modules (through the Data Bus).
Page 421 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 RD05J060 1. DIFFERENTIAL LOCK SWITCH 25-2-6...
Page 422: Differential Lock Control Modes
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK CONTROL MODES ON (Differential Symbol) – When the differential lock switch is placed in the ON position the differential lock will be activated. A differential symbol will be illuminated on the tractor monitor.The differential lock will disengage when either brake pedal is pushed.
Page 423: Differential Lock Control
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK CONTROL TRUE GROUND ENGINE SPEED SENSOR TRANSMISSION INST. CONTROL MODULE TRANSMISSION SPEED SENSOR AUX/HITCH/PTO CONTROL MODULE (TMF) SWITCH DIFF. L SWITCH SWITCH SWITCH OFF/ON OFF/ CONTROL ARMREST CONTROL MODULE MICRO TRANSCEIVER...
Page 424: Differential Lock Functional Tests
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK FUNCTIONAL TESTS IMPORTANT: Hitch position and wheel slip will influence differential lock operation when tractor is in motion. Switch Position E n g a g e d / Operational Comments Disengaged Engaged...
Page 425 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 RI02E087 1. PTO/DIFF LOCK VALVE 2. DIFF LOCK SOLENOID Differential Lock Valve The differential lock valve is a closed center valve and is contained as a part of the PTO valve. Oil is supplied to the differential lock cartridge valve from the regulated pressure circuit.
Page 426 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 Differential Lock Clutch Disengaged When the switch is in the disengaged position (middle) and a brake pedal is pushed, the solenoid will be de- energized. Regulated pressure will be at the valve cartridge. The piston of the differential lock clutch is mechanically returned to the neutral position.
Page 427: Troubleshooting
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TROUBLESHOOTING Problem – Differential lock will not engage 1. Check for PTO System fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section.
Page 428 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 Differential Lock Engaged When the switch is in the engaged position (differential symbol) the solenoid will be activated. Oil pressure, available to the valve cartridge, will be ported (internally) to the rear frame transmission housing of the tractor. The clutch will be engaged, as the piston extends, locking the friction and separator plates together.
Page 429 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TROUBLESHOOTING Problem – Differential lock will not disengage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section.
Page 430: Pto/Differential Lock Valve Circuit
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 PTO/DIFFERENTIAL LOCK VALVE CIRCUIT P TO C L U T C H PISTON D I F F E R E N T I A L LOCK PISTON P TO C L U T C H LUBE P TO SOLENOID...
Page 431 Section 25 - Four-Wheel Drive Front Axle - Chapter 2 This Page Left Blank. 25-2-16...
Page 432 Section 25 Chapter 3 FWD OUTPUT SHAFT January, 2006...
Page 433 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 TABLE OF CONTENTS SPECIAL TORQUES ............................25-3-3 FWD OUTPUT SHAFT ........................... 25-3-4 FWD Output Shaft Removal ........................25-3-4 FWD Output Shaft Disassembly ......................... 25-3-5 FWD Output Shaft Assembly ........................25-3-9 25-3-2...
Page 434: Special Torques
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 SPECIAL TORQUES FWD Output Shaft Yoke Retaining Bolt ..............252 to 280 Nm (186 to 206 lb. ft.) FWD Output Shaft Bearing Cage Bolt ..............375 to 485 Nm (276 to 358 lb. ft.) FWD Drive Shaft Retaining Bolts ...................
Page 435: Fwd Output Shaft
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 FWD OUTPUT SHAFT FWD Output Shaft Removal STEP 1 STEP 3 96RS28A RD02H172 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn off the engine and remove the key.
Page 436: Fwd Output Shaft Disassembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 4 FWD Output Shaft Disassembly STEP 6 11S19 Remove four bolts and four washers on the output shaft bearing cage. 108RS4 Place the FWD output shaft in a vise and remove the STEP 5 yoke retaining bolt.
Page 437 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 8 STEP 11 108RS10 108RS28 Remove and discard the O-ring. Remove the internal retaining ring. STEP 9 STEP 12 108RS16 108RS23 Remove the yoke from the output shaft spline. Remove the bearing spacer.
Page 438 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 13 STEP 15 108RS29 Remove the shim(s). The bearing spacer is shown with two shims. 2940CUP1 Remove the rear bearing cup from the bearing cage, NOTE: Keep the shim(s) with the bearing cage. as shown in drawing above.
Page 439 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 18 STEP 19 109RS28 109RS11 Press the rear bearing cone from output shaft. Remove and discard the O-ring from bearing cage. 25-3-8...
Page 440: Fwd Output Shaft Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 FWD Output Shaft Assembly 2940FUL2 1. SEAL 8. BEARING SPACER 2. YOKE 9. O-RING 3. WASHER 10. SHIMS 4. BOLT 11. EXTERNAL RETAINING RING 5. SHIMS 12. BEARING CONE 6. O-RING 13.
Page 441 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 20 STEP 23 109RS16 109RS31 Lubricate a new O-ring with clean hydraulic oil and Install a new front bearing cone on the output shaft. install into the groove on the bearing cage. Press the front bearing cone against the external retaining ring.
Page 442 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 25 STEP 26 109RS7 Install the bearings and shims as follows: 1. Install the output shaft into the bearing cage. 2. Install a new front bearing cup. 3. Use a press to seat the front bearing cup into the bearing cage while rotating and moving the shaft back and forth.
Page 443 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 27 STEP 29 108RS16 Install the yoke on the output shaft spline. STEP 30 2940DIAL Use a dial indicator to measure the bearing end play while slightly moving the shaft up and down. If the end play does not fall within 0.025 to 0.150 MM.
Page 444 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 31 STEP 33 108RS4 Place the FWD output shaft in a vise and install the yoke retaining bolt. Apply a torque of 252 to 280 Nm (186 to 206 lb. ft.) to the bolt. NOTE: Do not install the output shaft if the FWD clutch is to be serviced.
Page 445 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 35 STEP 36 11S19 RD02H173 Install the FWD output shaft into the needle bearing in the rear wall of the speed housing. Engage the FWD output shaft with the FWD hub spline. Install the four bolts through the output shaft bearing cage and the drop box.
Page 446 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 37 STEP 38 91S17 96RS28A Replace the transmission drain plug and fill the Check for oil leaks. Make sure the transmission shift transmission with hydraulic oil. lever is in Park. Remove the blocks in front of and behind the rear wheels.
Page 447 Section 25 - Four-Wheel Drive Front Axle - Chapter 3 This Page Left Blank. 25-3-16...
Page 448 Section 25 Chapter 4 FWD DRIVE SHAFT January, 2006...
Page 449 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 TABLE OF CONTENTS SPECIAL TORQUES ............................25-4-3 FWD DRIVE SHAFT ............................25-4-4 25-4-2...
Page 450 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 SPECIAL TORQUES Drive Shaft Retaining Bolts..................... 58 to 64 Nm (43 to 47 lb. ft.) 25-4-3...
Page 451 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 FWD DRIVE SHAFT Removal STEP 3 NOTE: Tractor with suspended axle shown. All drive shafts are similar. STEP 1 RD06A007 Remove the suspended front axle hoses (1), if equipped. Remove the steering hoses (2) (right side shown) from the drive shaft cover.
Page 452 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 STEP 6 STEP 7 RD02H168 Mark the drive shaft to FWD output shaft yolks. Remove the four drive shaft to transmission yoke retaining bolts. Remove the drive shaft. RD02H191 Place the drive shaft (1) on V blocks (2). Position a dial indicator (3) over the drive shaft.
Page 453 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 Installation STEP 10 STEP 8 RD02H169 Support the FWD drive shaft. Align the marks on the yokes (2). Install and tighten the four drive shaft to pinion yoke bolts (2) to a torque of 58 to 64 Nm (43 to RD02H168 47 lb.
Page 454 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 STEP 12 STEP 13 RD06A007 96RS28A A tt ac h th e s te er i ng ho s e s ( 1) . T i e s t ra p t h e Check for oil leaks.
Page 455 Section 25 - Four-Wheel Drive Front Axle - Chapter 4 25-4-8...
Page 456 Section 25 Chapter 5 SUSPENDED FWD AXLE SYSTEM How It Works and Troubleshooting January, 2006...
Page 457 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 TABLE OF CONTENTS SUSPENDED FWD AXLE OPERATION ....................25-5-3 SUSPENDED MFD AXLE- CALIBRATION MODE ..................25-5-9 ERROR TABLE ............................25-5-11 SUSPENDED FWD AXLE- MANUAL OPERATION MODE (TEST MODE) ........... 25-5-13 SUSPENDED FWD AXLE- DEMONSTRATION MODE ................
Page 458: Suspended Fwd Axle Operation
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE OPERATION The front axle suspension system: A. allows increased operating speeds with greater tractor stability in the field and on the road. B. improves ride quality and operator comfort when working on rough terrain and for high speed shuttling. C.
Page 459 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 RI03A003 1. RAISE SOLENOID 6. RELIEF VALVE 11. CHECK VALVE 16. TANK 2. LOWER SOLENOID 7. RELIEF VALVE 12. ORIFICE 17. SUPPLY 3. LOCKOUT SOLENOID 8. CHECK VALVE 13. ORIFICE 18.
Page 460 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 When the axle hits a medium-sized bump, oil will be forced from the piston side through the lockout valve (4) and check (11) to the rod side of the cylinder and through lock out valve (3) to orifice (9) and relief valve (10). Since orifice (9) will not handle this much flow relief valve (10) will open allowing the oil to pass to the accumulator.
Page 461 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 RD03A035 FRONT SUSPENDED AXLE CONTROL VALVE 1. RAISE SOLENOID - COLOR CODE RED 6. PUMP SUPPLY 2. LOWER SOLENOID - COLOR CODE GREEN 7. LOAD SENSE SIGNAL 3. PISTON SIDE LOCKOUT SOLENOID - COLOR CODE YELLOW 8.
Page 462 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 TOP VIEW-REAR TOP VIEW-FRONT RH03A106 AND 108 1. RAISE SOLENOID - COLOR CODE RED 8. ROD END SUPPLY TO SUSPENSION CYLINDER 2. LOWER SOLENOID - COLOR CODE GREEN 9. PISTON END SUPPLY TO SUSPENSION CYLINDER 3.
Page 463 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SIDE VIEW-REAR SIDE VIEW-FRONT RH03A107 AND 109 1. RAISE SOLENOID - COLOR CODE RED 8. ROD END SUPPLY TO SUSPENSION CYLINDER 2. LOWER SOLENOID - COLOR CODE GREEN 9. PISTON END SUPPLY TO SUSPENSION CYLINDER 3.
Page 464: Suspended Mfd Axle- Calibration Mode
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED MFD AXLE- CALIBRATION MODE STEP 1 STEP 3 RD06A021 Push and hold the PROG key for two seconds within RD06A023 The display will read TRANS VIEW. the first ten seconds after starting the tractor. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU.
Page 465 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 6 STEP 8 RD06A026 RD06A028 Press the PROG key. The calibration process is now Seconds later the display will read FSUS Cal Done activated. The lamp will flash at 2.5 Her tz. The and the lamp will stop flashing.
Page 466: Error Table
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 ERROR TABLE ERROR MESSAGE ERROR DESCRIPTION AND TROUBLESHOOTING Pot Open Ckt Front axle potentiometer open circuit. Automatic Calibration Procedure will not work. Check wire harness. Check position sensor signal circuit. Check continuity from connector 192 pin 3 to connector 185 pin C, next from connector 185 pin C to connector 353 pin 2.
Page 467 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 Slow to max Suspension unable to reach maximum height within 20 seconds. Check the raise valve installation. Check unload solenoid “GREEN” installation. Check suspension mechanics. Check hydraulic pressure. Disconnect Implement. Slow Dn Mvmnt Suspension is stationary during lowering command in the Automatic Calibration Procedure.
Page 468: Suspended Fwd Axle- Manual Operation Mode (Test Mode)
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE- MANUAL OPERATION MODE (TEST MODE) The Manual Operation Mode is used to test the front STEP 2 suspension system. It permits bypass of the front suspension controller and gives the operator the ability to directly command the valves.
Page 469 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 5 STEP 7 RD06A030 RD06A031 Push the DECR key until the display reads Fsus Next use the DECR key until the display reads Raise Manual. Press the PROG key. nnnnn mV.
Page 470 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 9 STEP 11 RD06A033 RD06A030 The display will read Lock nnnnn mV. The nnnnn The display will read Fus Manual. Press the DECR reading is the millivolt reading for the position sensor key.
Page 471: Suspended Fwd Axle- Demonstration Mode
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE - DEMONSTRATION MODE IMPORTANT: The Electronic Service Tool (EST) STEP 3 must be connected to the diagnostic port to get into the Demonstration mode. STEP 1 RD06A023 The display will read TRANS VIEW.
Page 472 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 6 STEP 9 RD06A036 RD06A039 Press the DECR key and the display will read Fsus Press the PROG key and the display now reads Demo. Demo Working. The front suspension can now be turned ON and OFF at speeds above 12 km/h (7.5 STEP 7 mph) by pressing the front suspension rocker switch.
Page 473 Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 11 RD06A036 Press the PROG key. The display will read Fsus Demo. STEP 12 RD06A035 Press the DECR key and select Exit Fsus. STEP 13 RD06A024 Press the PROG key and the display will read TRANS FSUS.
Page 474 Section 25 Chapter 6 SUSPENDED FWD AXLE REMOVAL January, 2006...
Page 475 Section 25 - Four-Wheel Drive Front Axle - Chapter 6 TABLE OF CONTENTS SUSPENDED FWD AXLE ..........................25-6-3 Removal ..............................25-6-3 Installation ..............................25-6-5 25-6-2...
Page 476 Section 25 - Four-Wheel Drive Front Axle - Chapter 6 SUSPENDED FWD AXLE Removal STEP 1 STEP 3 Before removing the axle, do the following: 1. Park the tractor on a hard, level surface and place the transmission in PARK. Remove the keys and block the front and rear of the rear wheels.
Page 477 Section 25 - Four-Wheel Drive Front Axle - Chapter 6 STEP 5 STEP 7 RD02K102 RD02K101 Tag and remove the axle hydraulic supply (1) and Remove the jack. Lower the axle and remove from return (2) lines. Remove the axle pivot pin retaining the tractor.
Page 478 Section 25 - Four-Wheel Drive Front Axle - Chapter 6 Installation STEP 8 STEP 10 RD02K192 RD02K114 Install the thrust washers as shown. STEP 9 RI02K095 Making sure the axle pivot pin bore and thrust washers are aligned with the frame bore, install the pivot pin (1).Be sure not to damage the pivot pin bore seals (2).
Page 479 Section 25 - Four-Wheel Drive Front Axle - Chapter 6 STEP 12 STEP 14 RD02K101 RD02K103 Install the axle hydraulic supply (1) and return (2) Connect the right and left steering lines (1). If lines. equipped, connect the hydraulic differential lock supply and return lines (not shown).
Page 480 Section 25 Chapter 7 SUPERSTEER AXLE REMOVAL AND INSTALLATION January, 2006...
Page 481 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 TABLE OF CONTENTS SPECIAL TORQUES ............................25-7-3 SPECIAL TOOLS ............................25-7-3 FRONT AXLE REMOVAL ..........................25-7-4 FRONT AXLE INSTALLATION ........................25-7-7 25-7-2...
Page 482: Special Torques
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 SPECIAL TORQUES Axle Side Plate Bolt ....................735 to 945 Nm (542 to 627 lb. ft.) Front Pivot Pin Bolt ....................111 to 198 Nm (82 to 146 lb. ft.) Tie Rod Support Plate Retaining Bolt..............
Page 483: Front Axle Removal
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 FRONT AXLE REMOVAL STEP 1 STEP 3 Park the tractor on hard, level ground, with the wheels straight ahead. Place the transmission in park. Stop the engine and remove the key. Put blocks in front of and behind the rear wheels.
Page 484 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 5 STEP 8 RD02B155 RD02B159 Properly suppor t and remove the tractor front Use proper lifting equipment to support the front weights. Wedge the axle (arrows) to keep the axle weight bracket.
Page 485 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 11 STEP 13 RD02C017 RD02C011 Remove the three axle side plate retaining bolts from Remove the pivot pin and the front and rear pivot arm both sides of the axle. shims.
Page 486: Front Axle Installation
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 FRONT AXLE INSTALLATION STEP 15 STEP 17 RD02C026 RD02C017 Properly support the front axle and carefully move Properly support the rear pivot bushing bracket to under the tractor. Raise the front axle into position. align the holes in the side plates.
Page 487 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 19 STEP 21 RD02C024 RD02B158 Install the two tie rod support plate retaining bolts (1) Using the identification tags from the disassembly on both sides of the axle. Tighten the bolts to a procedure, install and tighten the cylinder supply torque of 300 to 550 Nm (225 to 405 lb.
Page 488 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 23 STEP 25 RD02B155 RD02B151 Remove the axle supports and lower the front axle. Remove the wedges (arrows). STEP 24 RD02B150 Install the axle shield (1). Install and tighten the two shield retaining bolts (2).
Page 489 Section 25 - Four-Wheel Drive Front Axle - Chapter 7 25-7-10...
Page 490 Section 25 Chapter 8 LIMITED SLIP FWD DIFFERENTIAL January, 2006...
Page 491 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 TABLE OF CONTENTS SPECIFICATIONS ............................25-8-2 SPECIAL TORQUES ............................25-8-2 SPECIAL TOOLS ............................25-8-2 DIFFERENTIAL CARRIER ASSEMBLY REMOVAL ..................25-8-3 DIFFERENTIAL DISASSEMBLY ........................25-8-4 Pinion Disassembly ............................. 25-8-8 DIFFERENTIAL ASSEMBLY ........................25-8-11 DIFFERENTIAL CARRIER ASSEMBLY ......................
Page 492 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL CARRIER ASSEMBLY REMOVAL STEP 1 STEP 3 Remove the front axle from the tractor. Remove the axle shafts (both sides) from the axle (refer to axle disassembly information). NOTE: Do not alter the tie rod adjustment. STEP 2 RR98K029 Support the differential carrier with a chain or lift...
Page 493 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL DISASSEMBLY STEP 5 STEP 8 RR98K038 RR98K015 Mark the bearing cap and differential housing for reassembly. STEP 6 RR98K016 Remove the bearing caps and adjusting rings. STEP 9 RR98K046 Remove the bolts, washers and ring clips from the bearing caps.
Page 494 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 10 STEP 12 RR98K049 RR98K228 To remove the ring gear from the differential gear Mark the housing halves for reassembly. Also, mark housing half, place shop towels over vise jaws and the end of the cross shaft that is nearest the housing secure the assembly in the vise.
Page 495 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 14 STEP 17 RR99K229 RR99K231 Remove the differential housing bolts. (9/16 inch Remove the friction discs and the separator plates. socket). NOTE: If reused, make sure the discs and plates are kept in the same order for reassembly.
Page 496 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 20 STEP 23 RR98K025 RR99K238 Remove the pinion mate cross shaft, pinion mates Remove the dished disc, the separator plated and (pinion gears), and thrust washers. friction discs. NOTE: If reused, make sure the discs and plates are STEP 21 kept in the same order for reassembly.
Page 497 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Pinion Disassembly STEP 25 STEP 27 RR98K021 RR98K012 Hold end yoke or flange with tool similar to the one If a new yoke dust shield is required, use CAS-2596 shown, and remove nut and washer. Discard nut as or 3800011108 Yoke Dust Shield Installer with FNH new one must be used at reassembly.
Page 498 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 31 WARNING: Gear teeth may have sharp edges. When handling gear, use care to avoid personal injury. M687 NOTE: On the spline end of the pinion, there are bearing preload shims These shims may stick to the bearing, pinion or even fall out.
Page 499 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 33 STEP 35 T98491 RR98K036 Remove inner bearing adjustment shims. Install a split collet and press the bearing cone off of the pinion shaft. STEP 34 WARNING: Do not allow the shaft to fall. It can strike legs or feet and may cause serious injury.
Page 500 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL ASSEMBLY RI03B004 1. BEARING CUP 8. SEPARATOR PLATES 2. BEARING CONE 9. SIDE GEAR 3. RING GEAR BOLT 10. PINION GEAR (4)(PINION MATES) 4. HOUSING HALF 11. CROSS SHAFT (1) 5.
Page 501 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 38 STEP 40 RR99K237 RI03B005 Apply grease to the shoulder of the side gear, then Be sure the plates are arranged for installation as install the side gear in dished disc in the flanged follows: housing half.
Page 502 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 43 STEP 45 RR99K233 RI03B005 Install a dished disc. Position the disc so the convex Be sure the plates are arranged for installation as ID touched the side gear shoulder. follows: 3 Plates (in board side) STEP 44...
Page 503 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 46 STEP 47 RR99K229 RR98K035 Install the plate/disc stack into the differential Install the differential ring gear to the housing half. housing. The end of the stack with 3 plates goes to Install new ring gear bolts.
Page 504 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL CARRIER ASSEMBLY RH98K105 1. DIFFERENTIAL CARRIER 4. INPUT YOKE 7. PINION SHAFT 10. PINION SHAFT POSITION SHIMS 2. SPACER 5. WASHER 8. BEARING CONE 11. OIL BAFFLE 3. PINION BEARING ADJUSTMENT SHIMS 6.
Page 505 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Shim Pack Thickness Chart New Pinion Marking Pinion Marking +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.008 +0.007 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 -0.001 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 -0.001 -0.002...
Page 506 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Setting The Pinion Depth STEP 49 STEP 52 RR98K042 T98517 Install the outer bearing cup. Install Aligning Disc FNH 00405 or 380001136 and the Gauge Disc FNH 00403 or 380001134. STEP 50 STEP 53 RB99C113...
Page 507 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 55 STEP 57 If the pinion shaft has a “+” marking, subtract the amount shown from the measurement taken in Step 65. The remainder is your shim pack thickness. If the pinion shaft has a “-’...
Page 508 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 60 STEP 62 T98491 RR98K037 Install the proper amount of shims. Assemble inner bearing cone on pinion. Drive bearing onto pinion using suitable press. STEP 61 T98513 Install the inner bearing cup. 25-8-19...
Page 509 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Adjusting Bearing Preload STEP 63 STEP 66 T98610 T98531 Install the pinion into the carrier. Install a shim pack Using an inch pound torque wrench, measure the of 0.070 inch on the pinion shaft. rolling torque needed to turn the pinion shaft.
Page 510 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 67 STEP 69 RR98K043 T98534 Remove nut and end yoke. Apply Loctite 515 to the Use tool CAS-2596 or 380001108 and install a new housing face and to the outer diameter of oil seal. dust shield (slinger) on the input yoke.
Page 511 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL INSTALLATION STEP 71 STEP 73 RR98K047 RR98K015 Install ring gear and differential assembly with Be sure bearing cups are seated on bearing cones, bearing cups into carrier housing. then install differential bearing caps. Install bearing cap bolts (finger tight only) so adjusting nut can still IMPORTANT: Care should be used when installing be turned.
Page 512 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 75 Checking Backlash STEP 76 T98549 Next, tighten the adjustment ring on the tooth side (bottom side) of the ring gear in until the bearing cup is seated. T98550 Position dial indicator on lip of differential housing Use the Side Bearing Adjusting Wrench FNH 00409 and indicate to side of one tooth on ring gear.
Page 513 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 77 STEP 79 T98562 T98561 When backlash is adjusted properly, rotating torque Tighten all of the bearing cap bolts to a torque of 240 at the pinion shaft should be 5 to 10 lb. inch higher to 270 Nm (180 to 200 lb.
Page 514 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Ring Gear and Pinion Tooth Pattern Interpretation When setting the pinion position, many of the service 1. Paint the ring gear teeth with a marking manuals required a final pinion position check by compound to both the forward and reverse side.
Page 515 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Pattern Movements Summarized RR98K054 3. A thicker pinion position shim with the backlash RR98K050 constant moves the pinion closer to the ring gear. EXAMPLE OF CORRECT PATTERN Forward Pattern moves deeper on the tooth (flank contact) and slightly toward the toe.
Page 516 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Installation of Carrier Assembly to Axle Housing STEP 80 STEP 82 Thoroughly clean the inside of the axle housing. Remove any burrs and nicks from the carrier housing and axle housing mounting surface. STEP 81 RR99K241 T98567...
Page 517 Section 25 - Four-Wheel Drive Front Axle - Chapter 8 25-8-28...
Page 518 Section 25 Chapter 9 LOCKING FWD DIFFERENTIAL January, 2006...
Page 519 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 TABLE OF CONTENTS SPECIFICATIONS ............................25-9-3 SPECIAL TORQUES ............................25-9-3 SPECIAL TOOLS ............................25-9-3 REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY ............25-9-4 REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING ......... 25-9-5 DISASSEMBLY OF THE DIFFERENTIAL .....................
Page 520: Specifications
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 SPECIFICATIONS Pinion Shaft Rolling Torque (Preload)............2.26 to 4.52 Nm (20 to 40 lb. inch) Differential Assembly Rolling Torque (without input seal)......2.83 to 5.65 Nm (25 to 50 lb. inch) Differential Ring Gear Backlash 10 Stud Wheel End Axle ..............0.127 to 0.254 mm (0.005 to 0.010 inch) 12 Stud Wheel End Axle ..............0.127 to 0.203 mm (0.005 to 0.008 inch)
Page 521 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY NOTE: Before starting service work, park the tractor STEP 4 on level ground, stop the engine and remove the key. Put blocks in front and behind the rear wheels. STEP 1 Remove the left hand and right hand axle shafts.
Page 522 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING STEP 6 STEP 9 RD06A137 RD06A140 Place the carrier housing on a clean work surface. Remove the seal retainer. STEP 10 STEP 7 RD06A141 RD06A138...
Page 523 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 12 STEP 15 RD06A143 RD06A146 Remove the adjusting ring. Remove the differential from the carrier. STEP 13 STEP 16 RD06A144 RD06A147 Mark the opposite bearing cap (1). Remove the bolt Remove the bearing cup.
Page 524 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DISASSEMBLY OF THE DIFFERENTIAL STEP 18 STEP 21 RD06A149 RD06A153 Mark the housing halves (two places) for reassembly Remove the seal rings from the shaft. and remove the bolts. STEP 22 STEP 19 RD06A154 Remove the thrust washer.
Page 525 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 24 STEP 27 RD06A156 RR99K236 Remove the differential gear. Separate the pinion mate cross shaft, pinion mate gears and thrust washers. STEP 25 STEP 28 RD06A157 Remove the clutch housing. RD02H199 STEP 26 RD02H232...
Page 526: Pinion Disassembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 PINION DISASSEMBLY STEP 29 STEP 32 RR98K021 RR98K019 Hold end yoke or flange with tool similar to the one Remove the pinion by tapping with a rawhide shown, and remove nut and washer. Discard nut as hammer.
Page 527 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 34 STEP 36 T98492 RR98K039 Remove the spacer (ten bolt only) from the pinion Remove the inner bearing cup. shaft as shown. NOTE: Shims are located between the bearing cup and carrier bore.
Page 528 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 38 STEP 39 RR98K040 RR98K036 Turn nose of carrier down. Remove outer pinion Install a split collet and press the bearing cone off of bearing cup as shown. Locate driver on back edge the pinion shaft.
Page 529 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 ASSEMBLY OF THE DIFFERENTIAL R106A036 1. BOLT 10. SEAL 19. DIFF. CROSS SHAFT 2. WASHER 11. ADJUSTING NUT 20. DIFFERENTIAL PINION 3. CASE, CAP HALF 12. SEAL RETAINER 21. DIFF. THRUSTWASHER 4.
Page 530 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 36 STEP 39 RD02J004 Lubricate the pinion mate gear ID’s. Install the pinion RD02H200 mate gears, thrust washers and cross shaft into the Press bearing cone on each trunnion of each flange half case.
Page 531 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 42 STEP 43 RD06A163 RD05A154 Install the thrust washer. STEP 44 RD06A164 Starting with a separator plate (1), alternate with a friction plate (2) until all plates are installed. There RD06A153 are ten separator plates and nine friction plates.
Page 532 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 46 STEP 48 RD06A151 RD06H149 Install the piston (1) into the cap half of the case (2). Align the assembly marks (1), place the flange half on the clutch carrier, install the mounting bolts and NOTE: Use care when installing the piston to avoid torque to 60 to 65 Nm (44 to 48 lb.
Page 533: Differential Carrier Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DIFFERENTIAL CARRIER ASSEMBLY RH02J027 1. DIFFERENTIAL CARRIER 4. INPUT YOKE 7. PINION SHAFT 10. PINION SHAFT POSITION SHIMS 2. SPACER (10 BOLT ONLY) 5. WASHER 8. BEARING CONE 11. OIL BAFFLE 3.
Page 534: Shim Pack Thickness Chart
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Shim Pack Thickness Chart New Pinion Marking Pinion Marking +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 -0.001 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 -0.001 -0.002...
Page 535: Setting The Pinion Depth
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 SETTING THE PINION DEPTH STEP 48 STEP 51 RR98K042 T98517 Install the outer bearing cup. Install Aligning Disc CAS-1898-5 and the Gauge Disc CAS-1898-3. STEP 49 STEP 52 RB99C113 The pinion depth setting tool, CAS-1898, must be assembled into the differential as shown above.
Page 536 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 54 STEP 57 Remove the depth setting tool CAS-1898 from the carrier housing. STEP 58 T98522 Install the bearing caps and cap bolts. Tighten the bolts to a torque of 244 to 271 Nm (180 to 200 lb. ft.) (Use a 24 mm socket).
Page 537 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 60 STEP 61 T98513 RR98K037 Install the inner bearing cup. Assemble inner bearing cone on pinion. Drive bearing onto pinion using suitable press. 25-9-20...
Page 538: Adjusting Bearing Preload
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 ADJUSTING BEARING PRELOAD STEP 62 STEP 64 T98610 T98530 Install the pinion into the carrier. Install a shim pack Torque the pinion nut to 326 to 406 Nm (240 to 300 of 0.070 inch on the pinion shaft.
Page 539 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 65 STEP 67 T98531 RR98K044 Using an inch pound torque wrench, measure the Use the Pinion Seal Installer CAS-1899 to install a rolling torque needed to turn the pinion shaft. The new pinion shaft oil seal.
Page 540: Differential Installation
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DIFFERENTIAL INSTALLATION STEP 68 STEP 70 RD06A146 RD02J019 Install ring gear and differential assembly with Be sure bearing cups are seated on bearing cones, bearing cups into carrier housing. then install differential bearing caps. Install bearing cap bolts (finger tight only) so adjusting nut can still IMPORTANT: Care should be used when installing be turned.
Page 541 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 72 RD02J023 RD02J024 RD02J116 RD02J028 Position dial indicator (1) on lip of differential housing and indicate to side of one tooth on ring gear. L o o s e n a d j u s t i n g n u t ( B ) u n t i l b a c k l a s h i s approximately 0.127 mm (0.005 inch).
Page 542: Checking Backlash
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 73 Install the seal retainer and retain with the three socket head screws. Torque the screws to 4.0 to 4.5 Nm (36 to 4 0 lb. inch). RD02H185 Checking Backlash STEP 74 STEP 75 T98562...
Page 543: Ring Gear And Pinion Tooth Pattern Interpretation
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Ring Gear and Pinion Tooth Pattern Interpretation When setting the pinion position, many of the service 1. Paint the ring gear teeth with a marking manuals required a final pinion position check by compound to both the forward and reverse side.
Page 544 Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Pattern Movements Summarized RR98K050 EXAMPLE OF CORRECT PATTERN RR98K054 3. A thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear. Forward Pattern moves deeper on the tooth (flank contact) and slightly toward the toe.
Page 545: Installation Of Carrier Assembly To Axle Housing
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Installation of Carrier Assembly to Axle Housing STEP 76 STEP 78 Thoroughly clean the inside of the axle housing. Remove any burrs and nicks from the carrier housing and axle housing mounting surface. STEP 77 RD02K001 RD02J029...
Page 546 Section 25 Chapter 10 FWD PLANETARY HUB, STEERING KNUCKLE AND AXLE DRIVE SHAFT January, 2006...
Page 547 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 TABLE OF CONTENTS SPECIFICATIONS ............................25-10-3 SPECIAL TORQUES ............................ 25-10-3 SPECIAL TOOLS ............................25-10-3 PLANETARY HUB DISASSEMBLY ......................25-10-4 STEERING KNUCKLE AND KINGPIN DISASSEMBLY ................25-10-9 AXLE DRIVE SHAFT DISASSEMBLY ....................... 25-10-13 AXLE SHAFT ASSEMBLY .........................
Page 548: Specifications
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 SPECIFICATIONS FWD Differential Oil Capacity (10 Bolt) ................12.3 Liters (13 U.S. Quarts) FWD Differential Oil Capacity (12 Bolt) ................ 11.6 Liters (12.3 U.S. Quarts) Differential Oil Type......Case 135 H EP Gear Lubricant, SAE 85W-140 w/ Limited Slip Additive B91246 Planetary Hub Oil Capacity (10 Bolt)...................
Page 549: Planetary Hub Disassembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 PLANETARY HUB DISASSEMBLY STEP 1 STEP 3 96RS34A RR98K131 Park the tractor on a hard, level surface. Put the Allow the axle to cool before servicing. Slowly open transmission shift lever in PARK. Turn the engine off the axle fill plug to release any internal axle pressure.
Page 550 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 5 STEP 8 RR98K089 RR98K084 Remove the thrust washers from the top of the Properly support the planetary hub cover. Remove planetary gear. the three (3) Allen head bolts. Separate and remove the hub cover from the planetary hub.
Page 551 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 11 STEP 13 RD02J001 RR98K093 Remove the eight retaining plate bolts. Discard the bolts. NOTE: NEW BOLTS need to be installed during reassembly. STEP 14 RD02J002 Swivel the steering knuckle to gain access to the planetary input sun gear shaft.
Page 552 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 15 STEP 18 RR98K095 RD05J177 Remove the planetary hub. Ten bolt. Remove the bearing. NOTE: The hub seal may separate into two pieces during removal. STEP 19 STEP 16 RD05J1172 Ten bolt hub.
Page 553 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 21 STEP 23 RR98K098 RR98K101 Use a driver to remove the inner planetary hub Remove the wire retaining ring (3) and remove the bearing cup. gear hub. STEP 22 STEP 24 RR98K100 RR98K103...
Page 554: Steering Knuckle And Kingpin Disassembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEERING KNUCKLE AND KINGPIN DISASSEMBLY STEP 25 STEP 28 RR98K105 RR98K108 Place an identifying mark on the wheel stop before Remove the cotter pin from the lower end of the removing the clevis locking pin.
Page 555 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 30 STEP 33 RR98K110 Remove the cotter pin from the tie rod socket end RR98K112 Remove the upper king pin bearing cap (1) and the slotted nut. Loosen the slotted nut. Unseat the tie rod shims (2).
Page 556 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 36 STEP 39 RD02J013 RR99K247 Remove the axle drive shaft. STEP 37 RR99K249 Use a suitable puller (1), or a blind hole puller, to remove the upper king pin bearing outer ring (2) from the axle housing.
Page 557 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 40 STEP 41 RR98K061 RR98K062 Remove the outer and the inner axle shaft seals with Inspect the axle shaft bushing in the differential a slide hammer and a suitable puller. housing.
Page 558: Axle Drive Shaft Disassembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 AXLE DRIVE SHAFT DISASSEMBLY STEP 43 STEP 46 RD02J015 RD02J030 Place the axle shaft in a press. Press the other Remove the universal joint retaining rings from the universal cap from the yoke and remove the outer centering yoke on front axle drive shaft.
Page 559: Axle Shaft Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 AXLE SHAFT ASSEMBLY RI02H044 1. AXLE SHAFT 5. YOKE INNER SEAL 2. UNIVERSAL JOINT 6. RETAINING RING 3. RETAINING RING 7. YOKE 4. YOKE 8. YOKE OUTER VSEAL 25-10-14...
Page 560 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 48 STEP 50 RR98K078 RD02J014 Install a new retaining ring into the drive shaft yoke. In s ta ll new u n ive r s al jo i nt s by r ever s i ng th e disassembly procedure.
Page 561: Kingpin Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 KINGPIN ASSEMBLY RI99M007 1. UPPER KINGPIN GREASE SEAL 5. AXLE SHAFT BUSHING 2. KINGPIN BEARING INNER RING 6. AXLE SHAFT INNER OIL SEAL 3. KINGPIN BEARING OUTER RING 7. AXLE SHAFT OUTER OIL SEAL 4.
Page 562 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 55 STEP 56 RR98K118 RI06A23 NOTE: Lubricate the inner diameter of the seals with SAE 85W-140 gear lubricant. Install the axle shaft seals (1)(2) with the lips facing toward the differential. The inner seal (1) should be pressed flush with the bushing (4).
Page 563 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 58 STEP 61 RR99K254 RR99K253 Place the kingpin bearing cap in a press and install a Make sure the outer ring is fully seated in the new inner ring. Use a flat plate to evenly start the housing.
Page 564 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 64 RD02J013 Install the FWD axle drive shaft into the axle housing. Make sure the axle shaft splines engage the differential side gears. Use care so as not to damage the axle shaft seals.
Page 565: Steering Knuckle Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEERING KNUCKLE ASSEMBLY RI99M006 1. PLANETARY GEAR SHAFT SEAL 6. WHEEL STOP 11. UPPER KINGPIN BEARING CAP 2. PLANETARY GEAR SHAFT BUSHING 7. CLEVIS PIN 12. SHIMS 3. NUT 8. STEERING CYLINDER SOCKET END 13.
Page 566 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 67 STEP 69 RR98K114 RR99K244 Install lifting eyes and properly support the steering Remove the king pin bearing caps after verifying that knuckle. Guide the axle shaft outer yoke into the the bearings are fully seated and install the king pin steering knuckle.
Page 567 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 71 STEP 72 RR99K247 RR98K130 Place a inclinometer on the top machined surface of Clean the tie rod end stud and the tapered bore in the knuckle and level the assembly to within ± 2 the steering knuckle.
Page 568 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 74 STEP 75 RR98K071 RR98K105 Lubricate the two steering cylinder clevis pin bushing Use the identifying mark made during disassembly to O-rings with grease. Make sure an O-ring is installed position the wheel stop.
Page 569: Planetary Hub Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 PLANETARY HUB ASSEMBLY RI05M071 1. RETAINING RING 10. WIRE RETAINING RING 19. PLANETARY HUB COVER 2. WASHER 11. PLANETARY GEAR HUB 20. THRUST WASHER 3. PLANETARY HUB SEAL 12. PLANETARY RING GEAR 21.
Page 570 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 76 STEP 78 RR98K104 RD02J038 Lubricate the inner diameter of the outer planetary Clean and inspect the planetary hub. Lubricate the hub bearing cone with Case 135 H EP SAE 85W-140 outer bearing cup with Case 135 H EP SAE 85W-140 Gear Lubricant.
Page 571 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 80 STEP 83 RR98K081 RD05J176 Install new wheel studs, if necessary. Place a shop towel in the center of the steering knuckle (1) and clean the bolt holes with compressed air.
Page 572 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 86 STEP 88 RD05J178 RD05J180 LIGHTLY coat the outer hub bearing with a light Install the planetary gear hub. multipurpose oil. NOTE: If any of the hub components have been replaced (other than the hub oil seal), the procedure STEP 87 for shimming the planetary hub and adjusting the...
Page 573 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 90 STEP 93 RD05J182 RD05J184 Install the retaining plate with four bolts. Torque bolts The rolling torque reading should be 11.4 to 16 Nm to 110 to 125 Nm (82 to 92 lb. ft.) (100 to 140 lb.
Page 574: Ten Bolt Axle Only
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 96 Ten Bolt Axle Only STEP 98 RD05M041 Remove the planetary gear hub. RD04D227 STEP 97 RD04D228 RR98K095 Clean the spindle in the area of seal and bearing mounting so they are free of oil, grease and dirt. Remove the planetary hub.
Page 575 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 100 STEP 102 RD04D230 RD04D233 Install the seal driver tool over the pilot tool so that it is resting on the seal. STEP 103 RD04D231 With the rubber facing away from the spindle, install the seal over the pilot tool.
Page 576 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 105 STEP 107 RD04D236 RD04D238 While tightening the nut, make sure the seal is Remove all the installation tools except the for the squarely aligned on the spindle. Continue advancing flanged tool (1).
Page 577 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 110 STEP 113 RD05D241 RD04D245 Place the large aluminum pilot tool onto the bearing Push the hub (by hand) onto the spindle until contact cup with the small pilot diameter facing up. with the seal is made.
Page 578: Twelve Bolt Axle Only
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 116 Twelve Bolt Axle Only STEP 117 RD04D248 There should be a small gap (approximately 1 MM.) between the spindle and the hub. Make sure that the RD05J177 hub can be rotated by hand. Remove the inner bearing.
Page 579 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 120 STEP 122 RD05J191 RD05J195 When installing the dust seal make sure the larger lip Place the hub in a suitable vise. (1) is facing outboard. STEP 123 RD05J188 RD05J194 Hand press the dust seal into place.
Page 580 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 125 STEP 128 RD05J192 RD05J198 While holding the bearing (1) set the oil seal (2) into Place the centering cup into the opposite side of the place. hub. STEP 129 STEP 126 RD05J199 RD05J193...
Page 581 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 131 STEP 134 RD05M026 RD05M030 Slowly draw seal into the hub. Bolt the seal installation adapter over the end of the steering knuckle. STEP 132 STEP 135 RD05M027 RD05M031 If seal is not being drawn into the bore straight, tap on the installation tool to “square”...
Page 582 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 137 STEP 139 RD05M033 RD05M035 Apply a light coating of multipurpose grease to the Install a wheel nut (1) on one of the hub wheel studs dust sealing area on the wheel hub (2) and place a lifting device (3) on the stud.
Page 583: All Axles
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 141 All Axles STEP 142 RD05M040 Press the seal in until the shoulder (1) of the seal installation tool is bottomed against the hub (2). RD05M041 Remove the seal installation tool. Install the planetary gear hub and bearing.
Page 584 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 144 STEP 146 RD02J002 RD05M043 When installing the sun gear shaft (1) into the axle Tighten the bolts to a torque of 110 to 125 Nm (82 to drive shaft yoke (2), the drive shaft will have to be 92 lb.
Page 585 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 148 STEP 151 RD05M037 RR98K076 Apply petroleum jelly to the inner diameter of the Place the wire retaining ring (1) over the hub (2). planetary gear. Install the needle bearings in one side of the gear.
Page 586 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 153 STEP 156 RR98K084 RR98K089 Properly support the planetary hub cover and install Install the upper thrust washers on the planetary on the hub. Install the three Allen head bolts. Tighten gear.
Page 587 Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 159 STEP 161 RR98K083 96RS34A Move the planetary hub cover so that the fill plug is in Install the front fenders, if equipped. Remove the the horizontal position. Fill the planetary hub with wheel blocks in front of and behind the rear wheels.
Page 588 Section 25 Chapter 11 SUSPENSION FWD AXLE January, 2006...
Page 589 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 TABLE OF CONTENTS SPECIAL TORQUES ............................ 25-11-2 SUSPENSION FWD AXLE ........................... 25-11-3 Disassembly .............................. 25-11-3 Assembly ..............................25-11-13 Position Sensor Adjustment ........................25-11-25 SPECIAL TORQUES Shoulder bolt for cylinder mounting pin ................27 to 30 Nm (20 to 22 lb. ft.) Shoulder bolt for upper cradle swing arm pin ..............
Page 590 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 SUSPENSION FWD AXLE Disassembly STEP 3 ATTENTION: Take time to familiarize yourself with potential pinch and crush points on this axle before service work is started. IMPORTANT: Before beginning disassembly, the axle housing must be secured to prevent rollover and falls that could cause damage or injury.
Page 591 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 6 STEP 9 RD02M007 RD02M104 Remove the two sensor mounting screws and Disassembly of the following parts is from location remove the sensor from the bracket. “O”. STEP 7 STEP 10 RD02M009 RD02M013...
Page 592 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 12 STEP 14 RD02M015 RD02M105 Remove the swing arm cradle pin. The following parts are removed from locations “D” and “E”. STEP 13 STEP 15 RD02M105 RD02M018 Remove the snap ring from the cylinder pins. STEP 16 RD02M017 Remove the two shoulder bolts from location “C”.
Page 593 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 17 STEP 19 RD02M020 RD02M104 Slide the pin partially out. Do not let the spacer fall out. STEP 18 RD02M105 The following parts are removed from location “G” and “H”. STEP 20 RD02M021 Remove the pin and spacer.
Page 594 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 21 STEP 24 RD02M023 RD02M027 Remove both retaining plates. Install a slide hammer into the upper swing arm pin. STEP 22 STEP 25 RD02M024 RD02M028 Remove and discard the O-rings. Remove the pin.
Page 595 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 26 STEP 28 RD02M104 RD02M030 Remove the snap ring from the lower suspension swing arm. STEP 29 RD02M105 The following parts are removed from locations “A”, “K”, and “J”. STEP 27 RD02M031 Use a magnet and remove the lower swing arm...
Page 596 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 31 STEP 34 RD02M033 RD02M036 Remove the snap ring from the upper suspension Remove the upper pin. swing arm. STEP 35 STEP 32 RD02M037 Remove the snap ring from the suspension cradle. RD02M034 Use a magnet and remove the upper swing arm thrust washer.
Page 597 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 37 STEP 40 RD02M039 RD02M104 Inspect the bushing for wear or damage. Remove The following parts are removed from locations “E” and replace if necessary. and “L”. STEP 38 STEP 41 RD02M040 RD02 M042...
Page 598 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 43 STEP 46 RD02M044 RD02M047 Remove the snap rings that retain the spherical Remove the seals from the housing. Inspect the bearings and remove the bearings. Inspect the bores for damage. bearings for wear or damage.
Page 599 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 49 STEP 50 RD02M050 RD02M051 Remove the seals from the upper swing arm. Use a driver to remove the bushings from the swing arm bores. 25-11-12...
Page 600 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 Assembly NOTE: For ease of assembly, it is recommended that the axle be assembled with the housing upside down. RI02M063 1. CRADLE 8. AXLE PIN 15. PLATE 2. BEARING 9. SHOULDER BOLT 16.
Page 601 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 51 STEP 54 RD02M104 RD02M055 The following parts are assembled in location “L” and Apply grease to the counter bore. Install the thrust “E”. washer. STEP 52 STEP 55 RD02M052 RD02M056 Apply Loctite 609 to the new bushing.
Page 602 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 57 STEP 60 RD02M058 RD02M104 Apply grease to the housing bore. The following parts are assembled in locations “A” and “O”. STEP 58 STEP 61 RD02M059 Install the cylinder mounting pin into the bore. RD02M062 Apply Loctite 609 to the OD of the new bushing.
Page 603 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 63 STEP 66 RD02M064 RD02M068 Install the snap ring. Apply grease to the pin. STEP 64 STEP 67 RD02M065 RD02M069 Apply Loctite 609 to a new seal case. Install the pin into the housing. Align the bolt hole in the pin with the shoulder bolt bore in the housing.
Page 604 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 69 STEP 72 RD02M071 RD02M074 Tighten the shoulder bolt to a torque of 27 to 30 Nm Install the snap rings. (20 to 22 lb. ft.). STEP 73 STEP 70 RD02M105 The following parts are assembled at locations “A”...
Page 605 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 75 STEP 78 RD02M076 RD02M078 Apply grease to the cylinder pins. Use a suitable Install the bushing into the bore. lifting device and position the cradle so that the cylinders can be installed onto the pins.
Page 606 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 81 STEP 84 RD02M081 RD02M084 Apply grease to the swing arm pins. Install the dowel pin. STEP 82 STEP 85 RD02M082 RD02M085 Align the cradle and upper swing arm and install the Continue to drive the pin until seated.
Page 607 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 87 STEP 90 RD02M087 RD02M025 Install the snap ring. Tighten the shoulder bolt to a torque of 41 to 45 Nm (30 to 33 lb. ft.). STEP 88 STEP 91 RD02M088 Install the upper cradle swing arm pin.
Page 608 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 93 STEP 96 RD02M089 RD02M091 Tighten the plate bolts to a torque of 58 to 64 Nm (43 Install the lower swing arm pins. to 47 lb. ft.). STEP 97 STEP 94 RD02M093 Install the dowel pin.
Page 609 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 99 STEP 102 RD02M0495 RD02M098 Install the snap ring. Install the pin. STEP 100 STEP 103 RD02M096 RD02M099 Apply grease to the ID of the bearing. Align the dowel pin slot. STEP 101 STEP 104 RD02M097...
Page 610 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 105 STEP 108 RD02M012 RD02M009 Install the thrust washer. Install the sensor shaft. STEP 106 STEP 109 RD02M100 RD02M008 Install the snap ring. Align the set screw with the flat on the shaft. Tighten the screw.
Page 611 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 111 STEP 114 RD02M006 RD02M002 Tighten the mounting screws to a torque of 4 to 4.5 Apply Loctite 243 to the male threads of the ball joint. Nm (36 to 40 lb. in.). Install the ball joint onto the axle and tighten to a torque of 19 to 20 Nm (165 to 180 lb.
Page 612 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 Position Sensor Adjustment STEP 116 RD02M101 The angle position sensor must be checked at the fully collapsed and fully extended positions. Adjust the sensor as follows: 1. Apply 10 to 30 volts DC to pin 2. 2.
Page 613 Section 25 - Four-Wheel Drive Front Axle - Chapter 11 25-11-26...
Page 614 Section 25 Chapter 12 SUPERSTEER AXLE VERTICAL CONTROL LINKAGE January, 2006...
Page 615 Section 25 - Four-Wheel Drive Front Axle - Chapter 12 TABLE OF CONTENTS SPECIAL TORQUES ............................ 25-12-3 VERTICAL LINK DISASSEMBLY AND REPAIR ..................25-12-3 Vertical Link Removal ..........................25-12-3 Roller Replacement ..........................25-12-4 Articulation Bearing Removal and Installation ..................25-12-5 Vertical Link Assembly ..........................
Page 616: Special Torques
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 SPECIAL TORQUES M20 x 70 mm Socket Head Screws................ 295 to 530 Nm (215 to 315 lb. ft.) Special Hex Head Bolts ..................220 to 280 Nm (160 to 205 lb. ft.) M24 x 355 mm Mounting Bolts ................
Page 617: Roller Replacement
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 STEP 5 Roller Replacement STEP 7 RD02K007 If the bushings need replaced in the axle links and the vertical link, remove the bushing seals. RD02K009 STEP 6 RD02K008 Use a press to remove the bushings from the axle RH02K003 links and vertical link if required.
Page 618: Articulation Bearing Removal And Installation
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 Articulation Bearing Removal and Installation STEP 8 STEP 10 RD02K011 RH02K005 Remove the safety guard to gain access for removal of the air to air aftercooler pipe. STEP 9 RD02K010 Support the bottom of the front axle rear support (1) to keep it from falling when the retaining ring (4) is removed.
Page 619: Vertical Link Assembly
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 Vertical Link Assembly STEP 11 STEP 13 RD02K008 RD02K003 Press the bushings into the axle links and vertical link (if required). Install the bushing seals into the vertical link and axle links. STEP 12 RH02K002 RH02K002...
Page 620 Section 27 Chapter 1 REAR AXLE AND PLANETARIES January, 2006...
Page 621 Section 27 - Rear Axle - Chapter 1 TABLE OF CONTENTS SPECIAL TOOLS ............................27-1-3 SPECIAL TORQUES ............................27-1-5 SPECIFICATIONS ............................27-1-5 GENERAL INFORMATION ..........................27-1-5 REAR AXLE ..............................27-1-6 AXLE HOUSING DISASSEMBLY ........................27-1-9 PLANETARY DISASSEMBLY ........................27-1-11 DIFFERENTIAL CARRIER SEAL REPLACEMENT ..................27-1-13 PLANETARY ASSEMBLY - THREE PIN .....................
Page 622: Special Tools
Section 27 - Rear Axle - Chapter 1 SPECIAL TOOLS RH02D122 RH02D124 Rear Housing Handler 17-527 Brake Disc Alignment Tool 89-581-5 RH02D123 CAS2601 Pushing Bridge 89-525-18 Alignment Guide Pins (studs) CAS2601 RD02E109 Cab Raising Bracket Kit CAS2577 27-1-3...
Page 623 Section 27 - Rear Axle - Chapter 1 400I7 Puller Set with 30-Ton Ram CAS10030 T82109 T82107 Bushing Bearing And Seal Driver Set CAS 10387 Universal Driver Set (3-1/16 Inch To 4-1/2 Inch Diameter) CAS10389 Tool Organizer Board CAS10390 T82108 Universal Driver Set (1/2 Inch To 4-1/2 Inch Diameter) CAS10388 27-1-4...
Page 624: Special Torques
Section 27 - Rear Axle - Chapter 1 SPECIAL TORQUES Axle Mounting Bolts....................220 to 250 Nm (171 to 193 lb. ft.) SPECIFICATIONS Axle Rolling Torque Without Outer Seal Set Torque 4 inch Axle ................. 250 to 300 lb. in. (28.0 to 34.0 Nm) 4.5 inch Axle ................
Page 625 Section 27 - Rear Axle - Chapter 1 REAR AXLE REMOVAL STEP 1 STEP 2 91S16 13S23 Move the rear housing handler CAS17-527 into position under the tractor. STEP 3 91S10 Drain the rear axle as follows: 1. Put a container under the transmission housing. 2.
Page 626 Section 27 - Rear Axle - Chapter 1 STEP 4 STEP 7 86S1 RD02F104 Remove the wheel and tire assemblies from both Remove the cab mounting bolt (1) from the cab axles. mount. Lifting bracket (2) can be left in place. STEP 5 STEP 8 Raise the rear of the cab.
Page 627 Section 27 - Rear Axle - Chapter 1 STEP 10 STEP 12 RD06A004 T97974 Install a lifting strap at the axle balance point. Install a Remove the retaining ring from the axle shaft. bolt (1) on each side of the axle, this will prevent the lifting strap from possibly sliding off.
Page 628: Axle Housing Disassembly
Section 27 - Rear Axle - Chapter 1 AXLE HOUSING DISASSEMBLY STEP 15 STEP 17 512L0 T97981 Remove the nylon wear insert from the axle shaft Remove the shims from the axle shaft. end. Remove the retaining ring from the axle shaft. Press on the thrust ring to relieve pressure on the STEP 18 retaining ring before removing retaining ring from...
Page 629 Section 27 - Rear Axle - Chapter 1 STEP 20 STEP 23 T97986 T97994 Use a puller to remove the bearing from the axle Use a puller to remove the inner bearing cup from the shaft. axle housing. STEP 21 STEP 24 T97988 T97997...
Page 630: Planetary Disassembly
Section 27 - Rear Axle - Chapter 1 PLANETARY DISASSEMBLY STEP 25 STEP 27 T98000 T98002 If the planetary gears are to be used again, make Remove the planet gear shaft from the planetary marks so that the gears are assembled in their gear carrier.
Page 631 Section 27 - Rear Axle - Chapter 1 STEP 29 STEP 30 RD98C193 RD98C194 Remove the thrust washer and needle bearings from Remove the thrust ring. Turn the planet gear over one side of the planet gear. and remove the other thrust washer and needle bearings.
Page 632: Differential Carrier Seal Replacement
Section 27 - Rear Axle - Chapter 1 DIFFERENTIAL CARRIER SEAL REPLACEMENT STEP 32 STEP 33 T98027 T98028 Remove the seal from the differential carrier. Use a driver to install a new seal until the seal is flush with the surface of the differential carrier. 27-1-13...
Page 633: Planetary Assembly - Three Pin
Section 27 - Rear Axle - Chapter 1 PLANETARY ASSEMBLY - THREE PIN 107l94A 1. THRUST WASHER 4. THRUST RING 7. ROLL PIN 2. NEEDLE BEARING 5. NEEDLE BEARING 8. PLANET GEAR CARRIER 3. PLANET GEAR 6. THRUST WASHER 9. BEARING SHAFT 27-1-14...
Page 634: Planetary Assembly - Four Pin
Section 27 - Rear Axle - Chapter 1 PLANETARY ASSEMBLY - FOUR PIN RI06A014 1. RING GEAR 6. GEAR SHAFT 11. NEEDLE BEARING 2. GEARS CARRIER 7. HUB 12. NYLON SPACER 3. SHAFT 8. WASHER 13. PLANETARY GEAR 4. PIN 9.
Page 635 Section 27 - Rear Axle - Chapter 1 STEP 34 STEP 36 RD98C0194 T98003 Lubricate the needle bearings with petroleum jelly to Put the planet gear assembly into position in the gear keep them in place and install the bearings on one carrier.
Page 636 Section 27 - Rear Axle - Chapter 1 STEP 38 STEP 39 T98001 T97999 Slide the bearing shaft through the planet gear Install the roll pin in the bearing shaft until the end of bearings until the roll pin hole can be seen in the the pin is flush with planet gear carrier housing.
Page 637: Axle Housing Assembly
Section 27 - Rear Axle - Chapter 1 AXLE HOUSING ASSEMBLY RI06A013 1. RETAINING RING 7. AXLE HOUSING 13. AXLE BUSHING 2. THRUST RING 8. WASHER 14. AXLE WEAR INSERT 3. SHIMS 9. BOLT 15. AXLE SHAFT 4. BEARING CONE 10.
Page 638 Section 27 - Rear Axle - Chapter 1 STEP 41 STEP 43 T97967 T97988 Install the retaining ring in the groove of the sun gear shaft. 4-Inch Axle STEP 42 115RING Lubricate a new O-ring (1) with transmission fluid or petroleum jelly and install in the groove of the axle bushing (2).
Page 639 Section 27 - Rear Axle - Chapter 1 4.5-Inch Axle STEP 48 STEP 45 T97995 Put antiseize compound on the OD of the inner 115BSHG Lubricate a new O-ring (1) with transmission fluid or bearing cup. Use a driver to install the bearing cup petroleum jelly and install into the groove in the axle into the axle housing until the cup is seated.
Page 640 Section 27 - Rear Axle - Chapter 1 4-Inch Standard Axle 4-Inch Heavy Duty Axle STEP 50 STEP 51 T98042 T98042 Press the inner bearing onto the axle shaft with about Press the inner bearing onto the axle shaft with about 93 450 N (21 000 lb.) force while oscillating and 93 450 N (21 000 lb.) force while oscillating and rotating the axle until a rolling torque of 28 to 34 Nm...
Page 641 Section 27 - Rear Axle - Chapter 1 For All Axles STEP 54 STEP 53 375L0 T97976 Determine shim pack requirements as follows: 1. Remove threaded rod, ram, and spacer. 2. Do not rotate the axle. 3. Measure the distance from the bearing to the far side of the bearing snap ring groove.
Page 642: How To Determine Ram Pressure
Section 27 - Rear Axle - Chapter 1 HOW TO DETERMINE RAM PRESSURE STEP 55 STEP 56 Do the following to determine what the pressure gauge must show for your ram: 1. Determine the effective area of your ram. 2. Determine the minimum and maximum pressure gauge readings desired.
Page 643 Section 27 - Rear Axle - Chapter 1 STEP 57 STEP 60 T97975 T98015 Put the planetary in place on the inner axle shaft (three planetary gears shown). STEP 58 280L7 4 Inch Axle T97974 Install the planetary assembly retaining ring in the groove on the axle shaft.
Page 644 Section 27 - Rear Axle - Chapter 1 STEP 61 STEP 63 95S3 T97973 Apply Loctite 515 gasket eliminator on the OD of the Install the ring gear on the axle housing assembly. seal. Install the seal over the axle shaft and into the axle housing.
Page 645: Axle Installation
Section 27 - Rear Axle - Chapter 1 AXLE INSTALLATION STEP 65 STEP 67 87S13 87S19 Use a brake aligning tool to align the teeth of the Remove the brake aligning tool from the brake discs. brake discs. STEP 68 STEP 66 92S5 If removed, install the guide pins in the rear frame.
Page 646 Section 27 - Rear Axle - Chapter 1 STEP 70 STEP 73 RD06A005 86S24CU Use a suitable tool and rotate the axle until the sun Tighten the axle housing mounting bolts to a torque and planet gears engage. of 232 to 262 Nm (171 to 193 lb. ft.). STEP 71 STEP 74 RD06A003...
Page 647 Section 27 - Rear Axle - Chapter 1 STEP 78 STEP 76 Remove the rear housing handler from the tractor. STEP 79 Fill the transmission with fluid. See the Operator’s Manual for the correct fluid type. Run the tractor and check the fluid level.
Page 648 Section 27 - Rear Axle - Chapter 1 RH98C007 1. AXLE SHAFT 7. BEARING CONE 13. LOCATOR BUTTON (RIGHT HAND ONLY) 19. RETAINING RING 2. BUSHING 8. PLANET GEAR CARRIER 14. SEAL 20. THRUST WASHER 3. SEAL 9. RING GEAR 15.
Page 649: Axle Seal Wear Sleeve Installation (4-Inch Axle Only)
Section 27 - Rear Axle - Chapter 1 AXLE SEAL WEAR SLEEVE INSTALLATION (4-Inch Axle Only) STEP 80 STEP 82 93S28 94S6 Remove the old seal from the axle housing. Clean the axle bushing of any foreign material and remove any scratches. Make sure that the axle bearing is not contaminated.
Page 650 Section 27 - Rear Axle - Chapter 1 STEP 84 STEP 86 94S10 94S26 Apply Loctite 290 to seal the area between the axle Install the wear sleeve as follows: bushing and axle. 1. Heat the new wear sleeve in a bearing oven to 191°...
Page 651 Section 27 - Rear Axle - Chapter 1 STEP 87 STEP 88 T98015 94S34 Apply Loctite 515 gasket eliminator to the OD of the axle shaft. STEP 89 280L7 Fill the inner two grooves of the axle seal approximately half full with 251H EP Lithium grease (1). 95S3 Start the axle seal over the axle and into the axle housing.
Page 652 Section 31 Chapter 1 POWER TAKE OFF CONTROL SYSTEM How it Works January, 2006...
Page 653 Section 31 - PTO - Chapter 1 TABLE OF CONTENTS POWER TAKE OFF ............................31-1-3 ELECTRONIC PTO CONTROL ........................31-1-4 PTO SYSTEM CONTROL ..........................31-1-7 PTO CONTROL MODES ..........................31-1-8 PTO VALVE OIL SUPPLY ..........................31-1-10 PTO DIFFERENTIAL LOCK VALVE ......................31-1-11 TROUBLESHOOTING ..........................
Page 654: Power Take Off
Section 31 - PTO - Chapter 1 POWER TAKE OFF General Description - The PTO system consists of the of the PTO control switch, engine RPM speed circuit, PTO shaft speed circuit, dual speed sensor, PTO control valve, PTO clutch, PTO control module, arm rest control module, and Instrument cluster unit, (through the Data Bus).
Page 655: Electronic Pto Control
Section 31 - PTO - Chapter 1 ELECTRONIC PTO CONTROL General Description - The PTO system consists of the PTO control switch, engine RPM speed circuit, PTO shaft speed circuit, dual speed sensor, PTO control valve, PTO clutch, PTO control module, arm rest control module, and instrument control unit, (through the Data Bus).
Page 656 Section 31 - PTO - Chapter 1 RD05J060 1. PTO CONTROL SWITCH 31-1-5...
Page 657 Section 31 - PTO - Chapter 1 PTO Control Module - The PTO control module is located under the SMV cover at the back of the cab. The PTO control module provides the electrical current to apply the PTO clutch when instructed by the operator. All PTO operator commands are sent to the Arm Rest Control Module (PTO switch is hard wired to the Arm Rest Control Module), then relayed to the PTO controller via the Data Bus.
Page 658: Pto System Control
Section 31 - PTO - Chapter 1 PTO SYSTEM CONTROL ENGINE SPEED ENGINE AUX/PTO/HITCH CONTROL SWITCH MODULE (TMF) ALTERNATOR ENGINE SPEED DIFF. L SWITCH SWITCH SWITCH OFF/ON OFF/ CONTROL TRANSMISSION ARMREST CONTROL MODULE CLUTCH CLUTCH VALVE PTO SHAFT SPEED SENSOR INST.
Page 659: Pto Control Modes
Section 31 - PTO - Chapter 1 PTO CONTROL MODES OFF - When the PTO switch is placed in the OFF position, the PTO clutch will be deactivated. The PTO switch OFF signal is directed to the armrest controller and communicated to the PTO control module through the Data Bus. NOTE: PTO switch ON signal is directed to the PTO control module directly (hard wired to PTO controller).
Page 660 Section 31 - PTO - Chapter 1 Excessive PTO Slip Detection - Excessive slip is defined as one of the following: 1. Slip is greater than 15% for 100 milliseconds continuously. 2. Slip of 3-15% for a period of 2 seconds continuously. 3.
Page 661: Pto Valve Oil Supply
Section 31 - PTO - Chapter 1 PTO VALVE OIL SUPPLY PTO Differential Lock Valve The PTO differential lock valve is a closed center valve supplying regulated circuit pressure to the PTO and differential lock control circuits. Regulated circuit oil is supplied to the PTO valve through the priority/regulator valve.
Page 662: Pto Differential Lock Valve
Section 31 - PTO - Chapter 1 PTO DIFFERENTIAL LOCK VALVE RT98A023 RI02B035 AND B036 PORT IDENTIFICATION 1. VALVE INLET PORT 8. REMOTE VALVE PILOT SUPPLY 2. PLUGGED PORT 9. DIF LOCK SUPPLY 3. LUBE INLET PORT 10. TANK 4. PTO LUBE 11.
Page 663: Troubleshooting
Section 31 - PTO - Chapter 1 TROUBLESHOOTING Problem - PTO clutch will not disengage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Place the PTO switch in the OFF position. Check tractor monitor for PTO icon in the instrumentation display. A.
Page 664 Section 31 - PTO - Chapter 1 PTO Clutch Engaged When the PTO switch is actuated, the PTO controller sends a fixed current signal to the PTO solenoid. The solenoid spool shifts, metering oil to the top of the modulator piston (2). As pressure builds the piston moves down against the force of both the inner and outer modulator springs (3 and 4).
Page 665 Section 31 - PTO - Chapter 1 TROUBLESHOOTING Problem - PTO will not engage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. 2. Place the PTO switch in the ON position. Check tractor monitor for PTO icon in the instrumentation display. A.
Page 666 Section 31 - PTO - Chapter 1 P TO C L U T C H PISTON D I F F E R E N T I A L LOCK PISTON P TO C L U T C H LUBE P TO SOLENOID D I F F L O C K SOLENOID...
Page 667 Section 31 - PTO - Chapter 1 Problem PTO engages too rapidly 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. B. If no fault codes are found, go to step 2. 2.
Page 668 Section 31 - PTO - Chapter 1 Problem PTO engages then stops 1. Check for PTO faults codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. B. If no fault codes are found, go to step 3. 2.
Page 669 Section 31 - PTO - Chapter 1 P TO C L U T C H PISTON D I F F E R E N T I A L LOCK PISTON P TO C L U T C H LUBE P TO SOLENOID D I F F L O C K SOLENOID...
Page 670 Section 31 Chapter 2 PTO CLUTCH ASSEMBLY Single, Reversible and Dual Speed January, 2006...
Page 671 Section 31 - PTO - Chapter 2 TABLE OF CONTENTS SPECIAL TOOLS ............................31-2-3 SPECIAL TORQUES ............................31-2-3 PTO CLUTCH ASSEMBLY ..........................31-2-4 General ............................... 31-2-4 PTO CLUTCH SERVICE ..........................31-2-4 Removal ..............................31-2-4 Disassembly ..............................31-2-6 Assembly ..............................31-2-16 Exploded View of PTO Clutch .........................
Page 672: Special Tools
Section 31 - PTO - Chapter 2 SPECIAL TOOLS RI05F022 CAS19956 380002454 PTO Clutch Brake Spring Compressor CAS-1995-6 Guide Pins SPECIAL TORQUES Reversible PTO Output Shaft Rolling Torque ..................2 to 18 in. lbs. Cover for PTO Clutch Assembly Bolts ..............490 to 550 Nm (361 to 406 lb. ft.) Output Shaft Housing Bolts ..................
Page 673: Pto Clutch Assembly
Section 31 - PTO - Chapter 2 PTO CLUTCH ASSEMBLY General Thoroughly clean the top, sides and rear of the PTO components to prevent any dirt or debris from entering the final drive. If the PTO clutch and or brake is to be serviced, the complete PTO clutch assembly must be removed from the final drive housing.
Page 674 Section 31 - PTO - Chapter 2 STEP 3 Remove the third link support/PTO clutch cover plate and gasket. Discard gasket. RD05A014 STEP 4 The PTO manifold plate (1) and speed sensor (2) are located on the rear frame cover plate between the r e m o t e v a l v e s a n d r e m o t e v a l v e c o u p l e r s .
Page 675: Disassembly
Section 31 - PTO - Chapter 2 STEP 7 Install two CAS-1995-6 guide pins (1) then remove the two lower mounting bolts (2). RD05A047 STEP 8 Remove the PTO assembly. RD05A048 Disassembly STEP 9 Place the PTO assembly in a press. Press down on the carrier just enough to free the snap ring.
Page 676 Section 31 - PTO - Chapter 2 STEP 10 Place a puller (1) on the clutch carrier with the jaws under the tabs of a separator plate (2). Once the carrier is free from the shaft, place on a clean work surface.
Page 677 Section 31 - PTO - Chapter 2 STEP 14 Turn the carrier over as shown and tap the carrier on a hard surface to dislodge the piston. RD05A027 STEP 15 Remove the piston. RD05A028 STEP 16 Remove the seal ring and discard. RD05A029 STEP 17 Remove the O-ring and discard.
Page 678 Section 31 - PTO - Chapter 2 STEP 18 Remove the seal and O-ring from the clutch carrier and discard. RD05A031 STEP 19 Remove the brake pusher disc. RD05N141 STEP 20 Remove the Belleville washer retaining ring. RD05N144 STEP 21 Remove the seven Belleville washers.
Page 679 Section 31 - PTO - Chapter 2 STEP 22 Once all Belleville washers are removed, remove the third retaining ring. RD05N142 STEP 23 Remove the thrust washers (1) and thrust bearing (2). RD05N145 STEP 24 Lift the hub off the shaft, taking care not to damage the bearings.
Page 680 Section 31 - PTO - Chapter 2 STEP 26 Remove the snap ring. RD05N146 STEP 27 Remove the top brake holder plate (1). Note the tabs (2) on the holder plate are facing towards the friction plate. RD05N147 STEP 28 Remove the brake friction plate.
Page 681 Section 31 - PTO - Chapter 2 STEP 30 Remove the second brake holder plate. Note the tabs (1) on the holder plate are facing towards the friction plate. RD05N150 STEP 31 Remove the first brake apply disc spring. RD05N151 STEP 32 Remove the second brake apply disc spring.
Page 682 Section 31 - PTO - Chapter 2 STEP 34 Remove the two needle bearing thrust washers (1) and the needle bearing (2). RD05B034 STEP 35 Place the drive shaft assembly in a press as shown and press down on the inner race of the bearing. Press only far enough to remove tension on the snap ring.
Page 683 Section 31 - PTO - Chapter 2 STEP 38 Remove shim pack. RD05B039 STEP 39 Place the bearing cage (1) between two support blocks (2) and press the drive shaft assembly (3) free of the bearing cage. IMPORTANT: Do not allow the shaft to fall to the floor.
Page 684 Section 31 - PTO - Chapter 2 STEP 42 Remove bearing cones from each side of the bearing cage. RD05D008 RD05D010 31-2-15...
Page 685: Assembly
Section 31 - PTO - Chapter 2 Assembly Exploded View of PTO Clutch RI05D013 1. COUNTERSHAFT 15. BEARING CUP 29. CLUTCH BACKING DISC 2. PTO DRIVE SHAFT 16. BEARING CAGE 30. PTO CLUTCH SEPARATOR DISC 3. RETAINING RING 17. SEAL RING 31.
Page 686 Section 31 - PTO - Chapter 2 STEP 43 Press bearing cup into bearing carrier. RD05D011 STEP 44 Press second cup into bearing carrier. RD05D012 STEP 45 Press bearing onto the PTO drive shaft. Make sure the bearing is seated against the bearing spacer. NOTE: DO NOT press on the bearing cage.
Page 687 Section 31 - PTO - Chapter 2 STEP 47 Apply petroleum jelly or Lubriplate® to the seal ring bore and chamfer of the bearing cage. Place the bearing cage over the shaft and press the bearing until a slight drag is felt on the cage as it is turned. RD05B041 STEP 48 Install the shim pack.
Page 688 Section 31 - PTO - Chapter 2 STEP 51 Install the retaining ring. RD05B037 STEP 52 Back press the bearing cone against the shims, s p a c e r a n d r e t a i n i n g r i n g . B a ck p r e s s i n g i s accomplished by supporting the bearing cage (1) on the rear flange face (2) and pressing down against the front of the shaft (3) where the internal spline is.
Page 689 Section 31 - PTO - Chapter 2 STEP 55 Install the second brake apply disc spring. Make sure spring fingers (1) are pointed away from the hub gear (2). RD05N151 STEP 56 Discs should be installed as shown. RD05N158 STEP 57 Install the first brake holder plate.
Page 690 Section 31 - PTO - Chapter 2 STEP 59 Install the three adjusting pins. RD05N149 STEP 60 Install the brake friction plate. RD05N148 STEP 61 Install the second brake holder plate with the tabs (1) facing down. Align the holes in the plate with the brake adjuster pins.
Page 691 Section 31 - PTO - Chapter 2 STEP 62 Place the retaining ring (1) over the clutch pack hub. Using Special Tool 380002454, compress the brake holder plates until the retaining ring is fully seated into the groove. NOTE: Make sure the cutouts (2) of the tool are NOT over the brake adjuster pins (3).
Page 692 Section 31 - PTO - Chapter 2 STEP 65 Install thrust washer (1), bearing (2) and thrust washer (1). RD05B034 STEP 66 Install needle bearing (1), bearing spacer (2) and needle bearing (3). RD05B033 STEP 67 Place the gear /hub assembly over the shaft. RD05B032 STEP 68 Install a thrust washer (1), bearing (2) and thrust...
Page 693 Section 31 - PTO - Chapter 2 STEP 69 Install the first retaining ring. NOTE: There should be three retaining ring grooves left after installing this retaining ring. RD05N142 STEP 70 Install the second retaining ring. Install the seven Belleville washers. NOTE: When installing the Belleville washers, make sure they are orientated as shown below.
Page 694 Section 31 - PTO - Chapter 2 STEP 72 Install the brake pusher plate. RD05N141 STEP 73 Apply petroleum jelly to the carrier seal groove. Apply petroleum jelly to a new O-ring and install. NOTE: Make sure the O-ring is not twisted when installed.
Page 695 Section 31 - PTO - Chapter 2 STEP 76 Apply petroleum jelly to a new seal and install. IMPORTANT: DO NOT stretch new seal any more than required. RD05A033 STEP 77 Making sure all sealing surfaces are well-lubed, install the piston into the clutch carrier. RD05A028 STEP 78 Install the first separator plate.
Page 696 Section 31 - PTO - Chapter 2 STEP 80 Install the clutch backing disc. RD05A024 STEP 81 Install the snap ring. RD05A023 STEP 82 With a depth micrometer, measure the distance from the top of the hub (1) to the top of the pusher plate (2) at each pin (3).
Page 697 Section 31 - PTO - Chapter 2 STEP 83 Align the teeth of the friction plates as shown. RD05B027 STEP 84 Place the clutch pack assembly over the hub, making sure all friction plate teeth are engaged in the splines. NOTE: It may be necessary to rotate and LIGHTLY tap the end of the clutch carrier to align the friction brake teeth with the splines.
Page 698 Section 31 - PTO - Chapter 2 STEP 87 Place the clutch assembly on the CAS-1995-6 guide pins (1) and slide into place. Install the two lower mounting bolts (2). NOTE: Clutch assembly may have to be rotated slightly to align the splines of the clutch drive shaft with the countershaft.
Page 699 Section 31 - PTO - Chapter 2 STEP 91 Install the third link support/PTO clutch cover plate with a new gasket. RD05A014 STEP 92 If equipped, install the quick coupler. RD05A013 STEP 93 If equipped with a hydraulic cylinder-assisted third link, note the position of the hoses and install into the quick couplers.
Page 700: Cross Section Of Pto Clutch And Output Shaft Assembly
Section 31 - PTO - Chapter 2 Cross Section of PTO Clutch and Output Shaft Assembly 24 25 16 17 RI05C001 1. SPEED SENSOR 11. NEEDLE BRG THRUST WASHER 21. CLUTCH CARRIER 2. PTO MANIFOLD PLATE 12. NEEDLE THRUST BEARING 22.
Page 701: Single Speed Reversible Shaft Pto
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO Disassembly STEP 94 Remove cotter pin and washer (1). Remove pivot rod, washers and spring (2). Remove the PTO top shield (3). RD05A014 STEP 95 Push quick disconnect coupler (1) to expose the locking ring (2) and remove the ring.
Page 702 Section 31 - PTO - Chapter 2 STEP 97 Remove the four coupler retaining balls. RD05B014 STEP 98 Remove the shaft seal and discard. RD05B018 STEP 99 Remove the eight mounting bolts. RD05B011 STEP 100 Remove the housing cover. Clean both mounting surfaces.
Page 703 Section 31 - PTO - Chapter 2 STEP 101 Remove the output sleeve shaft. NOTE: If bearing and cup on the PTO driven gear (1) needs service, see Single Speed Reversible Shaft Driven Gear Section. RD05A059 STEP 102 Remove the bearing cone from the housing. 83LS9 STEP 103 Press the bearing from the output sleeve shaft.
Page 704: Assembly
Section 31 - PTO - Chapter 2 Assembly Exploded View of PTO Output Shaft and Driven Gear Assembly RI05D011 1. OIL SHIELD COVER 7. SHIMS 13. BEARING CONE 2. RETAINING CLIP 8. BEARING CAGE 14. COVER 3. PTO DRIVEN GEAR 9.
Page 705 Section 31 - PTO - Chapter 2 STEP 104 Press bearing onto the output sleeve shaft. Be sure the bearing is fully seated. IMPORTANT: Do not press on the bearing cage as permanent damage to the bearing will occur. RD05B022 STEP 105 Press bearing cone into housing.
Page 706 Section 31 - PTO - Chapter 2 STEP 108 Install the eight mounting bolts and torque to 95 Nm (70 lb. ft.). IMPORTANT: Before installing the seal, check the rolling torque of the output shaft. See Reversible PTO Output Shaft Bearing Adjustment Section. RD05B011 STEP 109 Apply Loctite®...
Page 707 Section 31 - PTO - Chapter 2 STEP 112 Install a ball in each of the four holes. RD05B014 STEP 113 Slide the coupler over the shaft. RD05B015 STEP 114 Push the coupler inward to expose the ring grove and install the locking ring.
Page 708: Single Speed Reversible Shaft Pto Driven Gear
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR Removal Before servicing the PTO Driven Gear, the following will be necessary: Remove the cab (See Cab Removal Section). Remove the rockshaft (See Hitch Removal Section). Remove the final drive top cover (See Final Drive Section).
Page 709 Section 31 - PTO - Chapter 2 STEP 119 Remove the front half of the oil shield. RD05A054 STEP 120 Remove bearing cage and shim pack from the housing. RD05A053 STEP 121 Remove the shim pack from the bearing cage. Measure the thickness of the shim pack and note for reinstallation.
Page 710: Assembly
Section 31 - PTO - Chapter 2 STEP 123 Remove the bearing from the gear. RD05A056 Assembly NOTE: Thoroughly clean and inspect all components and replace as necessary. STEP 124 Press the bearing onto the gear, making sure it is properly seated.
Page 711 Section 31 - PTO - Chapter 2 STEP 126 Install the original shim pack on the bearing cage. NOTE: If starting with all new parts, start with a shim pack of 0.025”. RD05A052 STEP 127 Install the bearing cage with shim pack. RD05A053 STEP 128 Install the front portion of the PTO oil shield.
Page 712: Reversible Pto Output Shaft Bearing Adjustment
Section 31 - PTO - Chapter 2 STEP 130 Place the rear half of the PTO oil shield (1) over the gear (2) and lower them into place. RD05A058 STEP 131 Install the four shield retaining clips. RD05B019 Reversible PTO Output Shaft Bearing Adjustment STEP 132 Install the output shaft sleeve.
Page 713 Section 31 - PTO - Chapter 2 STEP 133 Install the output shaft cover. DO NOT apply Loctite® 515 at this time. RD05A060 STEP 134 Install the mounting bolts and torque to 95 Nm (70 lb. ft.). DO NOT install the seal at this time, the following rolling torque measurements are taken without the seal.
Page 714: Single Speed Reversible Shaft Pto
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO Cross Section of PTO Output Shaft Assembly RI05C002 1. PTO OUTPUT SHAFT, REVERSIBLE 7. BEARING CUP 13. BOLT, M12 X 45 CL. 10.9 2. BOLT, M10 X 30 CL. 10.9 8.
Page 715 Section 31 - PTO - Chapter 2 This Page Left Blank. 31-2-46...
Page 716 Section 33 Chapter 1 BRAKE VALVE January, 2006...
Page 717 Section 33 - Brakes - Chapter 1 TABLE OF CONTENTS SPECIAL TORQUES ............................33-2-2 BRAKE VALVE ............................... 33-2-3 Removal ..............................33-2-3 Disassembly ..............................33-2-4 Assembly ..............................33-2-6 Installation ..............................33-2-8 SPECIAL TORQUES Allen head plate to valve body retaining screw............... 35 to 40 Nm (26 to 30 lb. ft.) 33-1-2...
Page 718: Brake Valve
Section 33 - Brakes - Chapter 1 BRAKE VALVE Removal STEP 3 NOTE: Park the tractor on a hard, level surface and place the transmission in PARK. Remove the keys and block the rear wheels. NOTE: Before removing the brake valve, remove the fixed hood.
Page 719: Disassembly
Section 33 - Brakes - Chapter 1 STEP 6 Disassembly STEP 7 RD02K119 Remove the three brake valve mounting bolts. Remove the brake valve and gasket from the firewall. RD02K106 Place the valve on a clean surface and remove the three Allen head screws.
Page 720 Section 33 - Brakes - Chapter 1 STEP 10 STEP 12 RD02K108 RD02K110 Remove the poppet (1) and outer feathering spring Remove both brake switches. Discard O-rings. (2) from the sleeve (3). Remove the sleeve from the Inspect for damage or wear. body.
Page 721: Assembly
Section 33 - Brakes - Chapter 1 Assembly RI02K072 1. BODY 6. SPOOL 11. POPPET 2. SWITCH 7. O-RING 12. GASKET 3. O RING 8. SEALRING 13. PLATE 4. SPRING 9. SLEEVE 14. SEAL 5. RETAINING RING 10. SPRING 15. SCREW STEP 14 STEP 15 RD02K109...
Page 722 Section 33 - Brakes - Chapter 1 STEP 16 STEP 19 RD02K108 RD02K107 Install the return spring (5) into the spool (4) and Install the firewall brake plate onto the brake body. install the spool into the sleeve (3). Lubricate the valve bore and sleeve seal and install the sleeve into STEP 20 the valve body.
Page 723: Installation
Section 33 - Brakes - Chapter 1 Installation STEP 23 STEP 21 101RS35A Install the right side air duct. Rd02K119 STEP 24 Install a new firewall to brake valve gasket and install the brake valve, making sure that the brake link rods (1) are installed into the poppet sleeves (2).
Page 724 Section 33 - Brakes - Chapter 1 STEP 26 102RS5 Install the right side cover. 33-1-9...
Page 725 Section 33 - Brakes - Chapter 1 33-1-10...
Page 726 Section 33 Chapter 2 BRAKE CYLINDERS January, 2006...
Page 727 Section 33 - Brakes - Chapter 2 TABLE OF CONTENTS SPECIAL TORQUES ............................33-2-3 SPECIFICATIONS ............................33-2-3 BRAKE CYLINDERS ............................33-2-3 Disassembly ..............................33-2-3 Assembly ..............................33-2-5 33-2-2...
Page 728 Section 33 - Brakes - Chapter 2 SPECIAL TORQUES Brake Cylinder Mounting Bolts ................177 to 179 Nm (130 to 145 lb. ft.) SPECIFICATIONS Friction Disc Minimum Thickness ....................3.45 mm (0.136 inch) BRAKE CYLINDERS Disassembly STEP 3 STEP 1 87-35 Lift the supply tubes out of the brake cover.
Page 729 Section 33 - Brakes - Chapter 2 STEP 5 STEP 8 T97947 T97952 Remove the remaining bolts and the brake cover R e m ove t h e t h r e e b r a ke a d j u s t e r s f r o m t h e from the rear frame.
Page 730 Section 33 - Brakes - Chapter 2 Assembly RH98B044 1. BEARING RETAINER 6. EXTERNAL RETAINING RING 11. PISTON 2. OIL SEAL 7. AXLE ASSEMBLY HOUSING 12. BRAKE COVER 3. SEPARATOR PLATE (4) 8. BRAKE ADJUSTER ASSEMBLY 13. O-RING 4. FRICTION PLATE (4) 9.
Page 731 Section 33 - Brakes - Chapter 2 STEP 11 STEP 13 T97970 A21050 Inspect the brake separator plates. If there is damage Use compressed air to push the brake piston out of or heavy wear, replace the plates. the brake cover. STEP 12 STEP 14 T97969...
Page 732 Section 33 - Brakes - Chapter 2 STEP 15 STEP 18 A21051 T97953 Lubricate the brake cover inner and outer piston Install the five locating pins in the differential carrier. seats with petroleum jelly. Start the piston into the cover evenly by hand. Gently tap the piston with a STEP 19 soft face hammer until the piston is fully seated.
Page 733 Section 33 - Brakes - Chapter 2 STEP 20 STEP 22 T97952 T98031 Install the three brake adjuster assemblies into the Install the adjuster return plate on the locating pins. differential carrier. The Belleville washer ends go into The tabs on the plate must contact the adjuster the differential carrier.
Page 734 Section 33 - Brakes - Chapter 2 STEP 25 STEP 27 87-35 RD02D050 Lubricate new O-rings with petroleum jelly and install See Rear Axle and Planetaries Section in this the O-rings on the supply tubes. Install the tubes into Service Manual for the installation of the rear axle the brake cover.
Page 735 Section 33 - Brakes - Chapter 2 33-2-10...
Page 736 ODD/EVEN CREEP DRIVE LUBE LUBE LEGEND RETURN T8000 SERIES TRACTORS PFC PISTON PUMP T8010, T8020, T8030 AND T8040 SUPPLY REGULATED CIRCUIT PUMP FLOW EURO HYDRAULIC SCHEMATIC SIGNAL CHARGE LUBE/LUBE PUMP FLOW WITH HYDRAULIC TRAILER BRAKES CASE RETURN TO TANK/SUMP POWER BEYOND...
Page 737 DROP BOX LUBE ODD/EVEN CREEP DRIVE LUBE LUBE RETURN LEGEND T8000 SERIES TRACTORS PFC PISTON PUMP T8010, T8020, T8030 AND T8040 SUPPLY MEGAFLOW PUMP SIGNAL EURO HYDRAULIC SCHEMATIC REGULATED CIRCUIT PUMP FLOW WITH HYDRAULIC TRAILER BRAKES CASE DRAIN POWER BEYOND...
Page 738 Section 35 Chapter 1 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC January, 2006...
Page 739 Section 35 - Hydraulic Systems, 3PT - Chapter 1 TABLE OF CONTENTS HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ............... 35-1-3 SIMPLE SCHEMATIC ..........................35-1-13 COMMON SYMBOLS ..........................35-1-15 35-1-2...
Page 740 Section 35 - Hydraulic Systems, 3PT - Chapter 1 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC Introduction Using Schematic Symbols Reservoirs Accurate diagrams of hydraulic circuits are essential to the man who must repair them. The diagram shows how the components will interact.
Page 741 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Lines, Tubes and Hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. RESERVOIR WITH SUCTION LINE ATTACHED AT THE BOTTOM 7108G A hydraulic line connected to the bottom of the reservoir may 710L8H...
Page 742 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Crossing or Joining Lines LINES THAT ARE NOT CONNECTED 711L8E 710L8L 710L8M VARIABLE DISPLACEMENT VARIABLE DISPLACEMENT PRESSURE COMPENSATED The shor test distance between two components that are 710L8s 710L8T connect is a straight line. There are lines that cross other A variable displacement pump is designated by drawing an lines but are not connected.
Page 743 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Hydraulic Motor Symbols PORT SINGLE ACTING CYLINDER 711L8P REVERSIBLE MOTOR PORTS NONREVERSIBLE MOTOR 711L8M 711L8N Hydraulic motor symbols are circles with black triangles, but opposite a pump the triangles point inward to show the motor is a receiver of oil.
Page 744 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Some cylinders have cushions built into them. The cushion Pressure Control Symbols slows down the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller The basic symbol is a square (which is called an envelope) rectangle on the piston.
Page 745 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Relief Valve Sequence Valve PRESSURE LINE SUPPLY LINE TO PRIMARY CYLINDER RELIEF VALVE PUMP SEQUENCE VALVE TO SECONDARY RELIEF VALVE PUMP CYLINDER 712L8F 712L8G A relief valve is shown as a nor mally closed symbol The normally closed symbol is also used for a sequence connected between the pressure line and the reservoir.
Page 746 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Composite Symbols Three Position Valves One Way Valves FREE FLOW FLOW MENTALLY VISUALIZE A BUILD UP OF PRESSURE ON THE RIGHT SIDE OF THE VALVE OPEN CENTER THREE POSITION VALVE 713L8A ONE WAY VALVE SHOWN IN THE CLOSED POSITION 714L8A...
Page 747 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve spools are controlled by levers, pedals, pilot oil, electric SOLENOID CONTROL WITH solenoids, etc., which are called actuating controls. These INTERNAL PILOT PRESSURE actuating controls are shown by symbols placed on the ends of the envelopes.
Page 748 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Accessories An oval with details inside indicate an accumulator. The details inside will tell you what type of accumulator it is; spring loaded, gas charged, or other features. Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the por t connection at the corners.
Page 749 Section 35 - Hydraulic Systems, 3PT - Chapter 1 NOTES 35-1-12...
Page 750 Section 35 - Hydraulic Systems, 3PT - Chapter 1 SIMPLE SCHEMATIC Now that you have completed hydraulic symbols, we have put some of the symbols together to form a simple hydraulic schematic. See if you can find your way around the schematic without reading the text for each valve. The text explains the function of each valve in the hydraulic system.
Page 751 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve A Valve C This valve is a three position valve. The spool is lever This valve is also similar to valve A but is designed to control operated and spring centered. It is an open center valve. a single acting cylinder.
Page 752 Section 35 - Hydraulic Systems, 3PT - Chapter 1 COMMON SYMBOLS Lines and Line Functions Mechanical Devices SOLID LINE MECHANICAL CONNECTIONS MAIN LINE TWO PARALLEL LINES 710L8H (SHAFTS, LEVERS, ECT) 730L8G DASHED LINE PILOT LINE 711L8A VARIABLE COMPONENT (RUN ARROW THROUGH SYMBOL AT 45 DEGREES DOTTED LINE EXHAUST OR DRAIN...
Page 753 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Cylinders HYDRAULIC MOTOR SINGLE ACTING FIXED DISPLACEMENT 711L8P 711L8M DOUBLE ACTING SINGLE ROD END 711L8P HYDRAULIC MOTOR VARIABLE DISPLACEMENT DOUBLE ACTING DOUBLE ROD END 730L8B 712L8A HYDRAULIC OSCILLATOR SINGLE ROD END FIXED CUSHION BOTH ENDS 730L8C 749L8EP...
Page 754 Section 35 - Hydraulic Systems, 3PT - Chapter 1 REGULATING OR SELECTOR VALVES 749L8A 749L8F PRESSURE REDUCING VALVE 712L8H 2 POSITION - 2 WAY VALVE 731L8C NON - ADJUSTABLE RESTRICTOR 716L8H 2 POSITION - 3 WAY VALVE 731L8D ADJUSTABLE RESTRICTOR 716L8B 2 POSITION - 4 WAY VALVE 731L8E...
Page 755 Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve Actuators PRESSURE COMPENSATED SOLENOID 729L8H G731L8L PILOT PRESSURE REMOTE SUPPLY DETENT 731L8F 729L8 LIQUID SUPPLY SPRING 730L8J 731L8M Accessories MANUAL FILTER 729L8A 716L8E PUSH BUTTON COOLER 716L8F 729L8B HEATER PUSH PULL LEVER 731L8G 729L8C TEMPERATURE...
Page 756 Section 35 - Hydraulic Systems, 3PT - Chapter 1 REVERSING MOTOR PRESSURE SWITCH 730L8P 730L8K STATION OR TEST POINT QUICK DISCONNECTS (DISCONNECTED) 730L8L 731L8J PRESSURE INDICATOR QUICK DISCONNECTS (CONNECTED) 730L8M 731L8K TEMPERATURE INDICATOR 730L8N 35-1-19...
Page 757 Section 35 - Hydraulic Systems, 3PT - Chapter 1 35-1-20...
Page 758 Section 35 Chapter 2 HYDRAULIC SYSTEM HOW IT WORKS WITH TROUBLESHOOTING January, 2006...
Page 759 Section 35 - Hydraulic Systems, 3PT - Chapter 2 TABLE OF CONTENTS GENERAL INTRODUCTION .......................... 35-2-3 REAR CHARGE/LUBE PUMP PRESSURE TEST ..................35-2-19 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE ........35-2-21 FRONT/REGULATED SYSTEM PUMP FLOW TEST ................. 35-2-25 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE ..........35-2-27 STEERING SYSTEM PROBLEMS ......................
Page 760: General Introduction
Section 35 - Hydraulic Systems, 3PT - Chapter 2 GENERAL INTRODUCTION The tractor uses three hydraulic pumps which are driven through a drive housing on the right side of the range transmission. The pump drive housing gears are driven by the PTO driveline and all the pumps turn at approximately 1.33 times engine speed.
Page 761 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Optional High Flow PFC Piston Pump An optional high flow PFC piston pump is available. The high flow rate maximum pump flow rate at rated speed 2667 RPM (2000 engine speed) is 220 L/min (58 GPM). RI06A091 1.
Page 762 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Optional MegaFlow PFC Piston Pump The axial piston pump has a variable flow output and can operate at variable pressures.The pump matches the hydraulic power output to the actual load requirements to ensure maximum efficiency and the minimum use of fuel. The pump inlet is charged to prevent cavitation.
Page 763 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Standard Flow PFC Pump Layout RI06A090 RI06A074 1. REMOTE MANIFOLD LOAD SENSE 6. PFC PISTON PUMP 2. PFC PUMP TO PRIORITY REGULATOR VALVE 7. REMOTE MANIFOLD RETURN (TUBE) 3. REMOTE MANIFOLD RETURN (HOSE) 8.
Page 764 Section 35 - Hydraulic Systems, 3PT - Chapter 2 High Flow PFC Pump Layout RI06A077 RI06A074 1. REMOTE MANIFOLD LOAD SENSE 6. PFC PISTON PUMP 2. PFC PUMP TO PRIORITY REGULATOR VALVE 7. REMOTE MANIFOLD RETURN (TUBE) 3. REMOTE MANIFOLD RETURN (HOSE) 8.
Page 765 Section 35 - Hydraulic Systems, 3PT - Chapter 2 MegaFlow PFC Pump Layout RH02K092 RI06A099 1. REMOTE MANIFOLD RETURN (HOSE) 4. MEGAFLOW REMOTE MANIFOLD SUPPLY 2. MAIN FILTER ASSEMBLY 5. MEGAFLOW PFC PISTON PUMP 3. MEGAFLOW PFC PUMP LOAD SENSE LINE 6.
Page 766 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Charge Pump Layout RI02D107 RI02D109 1. DUAL GEAR PUMP ASSEMBLY 5. LUBE RELIEF VALVE ASSEMBLY 2. PRIORITY REGULATOR VALVE 6. PUMP INLET SCREEN 3. REGULATOR SECTION INLET 7. SUCTION SCREEN SHROUD 4.
Page 767 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Lubrication Circuit The lubrication flow is a combination of both dual gear pumps outputs. Filtered charge pump flow and filtered/ cooled excess regulated circuit flow. Inlet charge pressure and lubrication are limited to 5 bar (75 PSI) by a lube relief valve.
Page 768 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RI06A081 7. RIGHT BRAKE LUBE 10. LUBE RELIEF HOSE RI06A080 11. DROP BOX OUTPUT LUBE (WITHOUT CREEPER) 12. DROP BOX REAR BEARING LUBE 35-2-11...
Page 769 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Regulated Pressure Circuits The regulated circuit is supplied by the front dual gear pump. The pump flow passes through the regulated circuit filter housing and onto the priority regulator valve. The pressure regulator portion of the valve maintains the regulated pressure at 22.4 to 24.5 bar (325 to 355 PSI).
Page 770 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RI06A085 6. MASTER CLUTCH DIAGNOSTIC COUPLER RI06A084 2. SPEED TRANSMISSION CONTROL VALVE 9. REGULATED CIRCUIT ACCUMULATOR REGULATED SUPPLY-UPPER TUBE 10. SPEED TRANSMISSION CONTROL VALVE REGULATED SUPPLY-LOWER TUBE 35-2-13...
Page 771 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Steering And Brake Tube Layout RI06A083 RI06A082 1. STEERING RETURN TO FILTER 5. PARK BRAKE (LEFT HAND) 2. STEERING SENSE LINE 6. STEERING SUPPLY 3. BRAKE SUPPLY 7. PARK BRAKE (RIGHT HAND) 4.
Page 772 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Standard Brake Valve Plumbing Layout RI06A087 1. BRAKE VALVE RETURN TO SUMP 5. BRAKE SUPPLY TUBE (RIGHT SIDE) 2. BRAKE HOSE (RIGHT SIDE) 6. BRAKE SUPPLY TUBE (LEFT SIDE) 3. BRAKE VALVE SUPPLY 7.
Page 773 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Hitch System Plumbing Layout RI06A098 1. HITCH CYLINDER RIGHT HAND RETURN 4. HITCH CYLINDER LEFT HAND RETURN 2. HITCH CYLINDER RIGHT HAND SUPPLY 5. HITCH VALVE SECTION 3. HITCH CYLINDER LEFT HAND SUPPLY 35-2-16...
Page 774 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Power Beyond Layout RI06A064 RI06A065 / RH02J002 1. POWER BEYOND LOAD SENSE TUBE 7. POWER BEYOND RETURN FLOW COUPLER 2. POWER BEYOND SUPPLY TUBE 8. CHECK VALVE 3. POWER BEYOND RETURN TUBE 9.
Page 775 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Motor Return Layout RI06A064 RI06A076 1. MOTOR CASE DRAIN COUPLER 3. MOTOR RETURN TUBE 2. MOTOR RETURN COUPLER 35-2-18...
Page 776: Rear Charge/Lube Pump Pressure Test
Section 35 - Hydraulic Systems, 3PT - Chapter 2 REAR CHARGE/LUBE PUMP PRESSURE TEST Perform this test when experiencing problems with all the PFC pump circuits. All remote sections and the hitch system are not operating normally. The symptoms could be low flow, aerated oil, or unusually loud pump operation possibly due to cavitation.
Page 777 Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Charge Pressure Measurement - Place the transmission control lever in the “P” park position. - Start and run the engine at low idle. - Heat the transmission oil to a minimum of 120°F (49°C). - Place a piece of cardboard over the oil cooler to help heat the oil.
Page 778: Regulated System Pressure Test And Adjustment Procedure
Section 35 - Hydraulic Systems, 3PT - Chapter 2 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE Perform this test to verify the condition of the regulated system before adjusting the regulated pressure. Low regulated pressure can cause clutches to slip, hinder remote and hitch operation and decrease brake effectiveness.
Page 779 Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Regulated System Leakage Test A regulated system leak can be identified by a slight drop in regulated pressure at low engine RPM. As a regulated circuit is engaged and disengaged, the pressure reading on the gauge will dip slightly as each circuit is actuated. IMPORTANT: If the regulated pressure did not dip as a circuit is actuated, then that circuit is not functioning.
Page 780 Section 35 - Hydraulic Systems, 3PT - Chapter 2 PTO CIRCUIT C. Turn the PTO ON and back OFF. Pressure Reading with PTO ON at 1000 RPM:____________ If the pressure dipped when the circuit was actuated, but does not return to the Regulated Circuit Baseline Reading the PTO clutch is leaking.
Page 781 Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 3- Regulated Pressure Adjustment Test Fitting and Tool Requirements: • 1-1/4 Inch Crowfoot wrench and 7/16 Allen wrench. If the regulated pressure measurement recorded for Step 2 was out of specification adjust the pressure as follows: Regulated Pressure Specification: 325 to 355 PSI (22.4 to 24.5 bar) at 1500 RPM engine speed RI02D107 1.
Page 782: Front/Regulated System Pump Flow Test
Section 35 - Hydraulic Systems, 3PT - Chapter 2 FRONT/REGULATED SYSTEM PUMP FLOW TEST Always perform the Regulated System Pressure Test and adjustment procedure before this test. RI02F030 1. OUT OF FRONT PUMP SECTION TO 2. FROM OUTLET OF FLOWMETER TO REMOTE FLOWMETER INLET FLOW RETURN MANIFOLD TUBE NOTE: Right hand side view, tire removed for clear view.
Page 783 Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Flow Measurement NOTE: It is not necessary to heat the hydraulic system for this test, but the system should be near room temperature 70°F (21°C). - Place the transmission control lever into “P” park position. - Start and run the engine at 2000 RPM.
Page 784: Steering Relief Pressure Test And Adjustment Procedure
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE If excessive effort is required for steering, or steering is slow or sluggish the steering relief valve may be leaking or need adjustment. Test Fitting and Tool Requirements: •...
Page 785 Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 3 - Steering Relief Pressure Adjustment Test Fitting and Tool Requirements: • 1/4 inch Allen wrench • 15/16 inch wrench The steering relief valve is located in the priority/regulator valve. The priority/regulator valve is located on the top, right hand side of the range transmission.
Page 786: Steering System Problems
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEERING SYSTEM PROBLEMS PROBLEM: Excessive effort required for steering POSSIBLE CAUSE PROCEDURE A. Excessive load on front axle. A. Reduce load see Operator’s Manual. B. Mechanical interference in steering column. B. Inspect and correct, see Steering Column and Hand Pump Section.
Page 787 Section 35 - Hydraulic Systems, 3PT - Chapter 2 PROBLEM: Steering cylinder does not react when steered (freewheeling) POSSIBLE CAUSE PROCEDURE A. Internal steering hand pump leakage. A. Cap left and right steering cylinder supply lines and retest. If the rotation stays the same, the problem is in the steering hand pump.
Page 788: Priority And Regulator Valve
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PRIORITY AND REGULATOR VALVE The Priority/Regulator Valve is located on the top right side of the range transmission. The valve consists of the following components: priority spool, regulator spool, and steering relief valve. The front section of the dual gear pump and the PFC piston pump supply oil to the Priority/Regulator Valve in the following manner: Priority Spool (Supplied By PFC Piston Pump)
Page 789 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Steering Relief Valve The steering relief valve (9) is located in the Priority/Regulator Valve and is adjustable. The steering relief valve (9) is set to open at 2970 psi (205 bar) +/- 80 psi (5.5 bar). RD99M135 1.
Page 790 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RI02E009 1. PRIORITY/REGULATOR VALVE 8. REGULATED PRESSURE ADJUSTMENT 2. SUPPLY FROM PFC PISTON PUMP 9. STEERING RELIEF ADJUSTMENT 3. SUPPLY TO STEERING 10. STEERING SIGNAL TO HAND PUMP 4. REGULATED SUPPLY TO SYSTEM 11.
Page 791: Pfc Axial Piston Pump
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC AXIAL PISTON PUMP NOTE: The principles of operation for the optional high flow pump are the same as the standard flow pump. The artwork supporting the PFC pump operation depicts only the standard flow pump. Principal of Control All remote valves, the hitch control valve and the trailer brake option each contain a signal port.
Page 792 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B011 5. CONTROL PISTON 8. PUMP HOUSING 11. PISTON BLOCK LOADING SPRING 18. COMPENSATOR ASSEMBLY 6. CONTROL SPRING 9. SWASH PLATE 12. PISTON BLOCK 20. CONTROL PISTON ROD 7. DRIVE SET 10.
Page 793 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16.
Page 794 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Engine Start Up Before the engine is started, the pump swash plate angle will be at its maximum angle. Therefore, as soon as the engine is cranked by the starter the PFC axial piston pump will produce flow and, as explained above, pressure will build in the pump delivery passage.
Page 795 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16.
Page 796 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Increased Flow Demand When an additional control valve is operated, it will cause a slight pressure drop at the pump pressure passage. The compensator spool will move up and allow the oil behind the control piston to drain to tank. The swash plate will move and the pump flow will be increased until the extra demand for flow has been met.
Page 797 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B012 5. CONTROL PISTON 8. PUMP HOUSING 11. PISTON BLOCK LOADING SPRING 18. COMPENSATOR ASSEMBLY 6. CONTROL SPRING 9. SWASH PLATE 12. PISTON BLOCK 20. CONTROL PISTON ROD 7. DRIVE SET 10.
Page 798 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16.
Page 799 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Return to Low Pressure Standby The pump will remain in the high pressure standby mode until the valve in operation is returned to neutral. When this occurs, the feed into the signal line from that valve will be cut off. The signal pressure will drop because of the drain orifice plug passage is open to the pump case drain.
Page 800 Section 35 - Hydraulic Systems, 3PT - Chapter 2 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16.
Page 801: Pfc Pump High Pressure Standby Check And Adjustment Procedure
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE Perform this test when all remote circuits and hitch system do not operate with full power. This would be noticeable when maximum power is needed such as when lifting heavy hitch loads, or maximum pressure is required by a remote circuit.
Page 802: Pfc Piston Pump Flow Test
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PISTON PUMP FLOW TEST Perform this test when all remote circuits and the hitch system are not operating at full flow. This would be noticeable by slower operation of remote circuit systems along with a slower hitch raise time. - Set all the remote valve variable flow controls to the maximum flow position.
Page 803: Pfc Piston Pump Flow Compensator Setting
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PISTON PUMP FLOW COMPENSATOR SETTING Preparation Test Fitting Tool Requirements: • 17 mm wrench and 3 mm Allen wrench. • Two 5000 PSI (350 bar) gauges with hose. • CAS-10280 Flowmeter. Remove the plug from behind the high pressure compensation spool and install the diagnostic fitting from fitting kit 380040106 into the pump compensator.
Page 804 Section 35 - Hydraulic Systems, 3PT - Chapter 2 Flow Compensator Setting - Increase the engine speed to 2000 RPM. - Adjust the load valve on the flowmeter to 1000 PSI (69 bar) on the remote manifold gauge. - Adjust the remote valve variable flow control until the remote flow is approximately one half the maximum flow rate: Adjust flow to approximately 18 GPM for standard flow pump.
Page 805: Standard Pump Compensator Valve Inspection
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STANDARD PUMP COMPENSATOR VALVE INSPECTION Perform this inspection only after completing the high pressure standby check and the piston pump flow test. RH98D014 1. HIGH PRESSURE SPOOL 4. LOW PRESSURE SPOOL 2.
Page 806: Pfc Pump Operational Problems
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PUMP OPERATIONAL PROBLEMS POOR OVERALL HYDRAULIC PERFORMANCE - LOW FLOW TO HITCH AND ALL REMOTE VALVE CIRCUITS A. Low hydraulic oil level in transmission. B. Low charge/lube pressure. Perform rear charge/lube pump pressure test in this section. Complete the entire test procedure C.
Page 807 Section 35 - Hydraulic Systems, 3PT - Chapter 2 This Page Left Blank. 35-2-50...
Page 808 Section 35 Chapter 3 PTO AND DIFFERENTIAL LOCK VALVE January, 2006...
Page 809 Section 35 - Hydraulic Systems, 3PT - Chapter 3 TABLE OF CONTENTS SPECIAL TORQUES ............................35-3-2 SPECIFICATIONS ............................35-3-2 PTO AND DIFFERENTIAL LOCK VALVE ...................... 35-3-3 SPECIAL TORQUES Solenoid Valve Nut ......................... 5 to 8 Nm (4 to 6 lb. ft.) Plug ..........................
Page 810 Section 35 - Hydraulic Systems, 3PT - Chapter 3 PTO AND DIFFERENTIAL LOCK VALVE Troubleshooting STEP 1 STEP 2 If other regulated pressure functions such as braking or transmission control are not operating properly, Check the regulated pressure. See the Hydraulic Systems How It Works With Troubleshooting Section of this Service Manual.
Page 811 Section 35 - Hydraulic Systems, 3PT - Chapter 3 Removal STEP 3 RI02D105 1. INLET 4. DIFF LOCK SOLENOID 2. LUB INLET 5. MOUNTING BOLT 3. PTO PWM SOLENOID NOTE: Clean the surface of the PTO valve and all tube connections before doing any service work. Tag tube and electrical connections.
Page 812 Section 35 - Hydraulic Systems, 3PT - Chapter 3 Disassembly STEP 6 STEP 4 RD02E112 Remove the preload spring (1) from the spool assembly. Compress the modulation spring (2) by pushing on the retaining sleeve (3) and separate the RD02E110 Place the PTO valve on a clean workbench.
Page 813 Section 35 - Hydraulic Systems, 3PT - Chapter 3 Inspection STEP 9 66L7 1. Check the two PTO modulation spool springs with a compression tester. Check each spring for free length and for compressed load force per specifications in this section. 2.
Page 814 Section 35 - Hydraulic Systems, 3PT - Chapter 3 Assembly NOTE: Lubricate spools and cartridges with clean hydraulic fluid during assembly. RI98G167 1. DIFF LOCK SOLENOID 5. MODULATOR SPOOL 9. MODULATION SPRING 2. CARTRIDGE 6. STEEL BALL 10. PRELOAD SPRING 3.
Page 815 Section 35 - Hydraulic Systems, 3PT - Chapter 3 STEP 10 STEP 12 RD02E115 RI02E060 Install new O-rings on the solenoid cartridges. Install the cartridges and tighten to a torque of 12 to 18 Nm (9 to 13 lb. ft.) STEP 11 RD02E113 Assemble the modulator piston (1), modulation...
Page 816 Section 35 - Hydraulic Systems, 3PT - Chapter 3 Installation STEP 14 RI02E059 Apply petroleum jelly to new O-rings and install the O-rings onto the valve mounting plate. STEP 15 RI02D105 1. INLET 4. DIFF LOCK SOLENOID 2. LUB INLET 5.
Page 817 Section 35 - Hydraulic Systems, 3PT - Chapter 3 PTO And Diff Lock Valve Cross Section RT98A024 1. DIFF LOCK SOLENOID 6. MODULATOR PISTON PIN 2. CARTRIDGE 7. RETAINER SLEEVE 3. PTO SOLENOID 8. MODULATION SPRING 4. MODULATOR SPOOL 9. PRELOAD SPRING 5.
Page 818 Section 35 Chapter 4 REMOTE VALVE AND COUPLER SERVICE January, 2006...
Page 819 Section 35 - Hydraulic Systems, 3PT - Chapter 4 TABLE OF CONTENTS SPECIAL TORQUES ............................35-4-2 REMOTE VALVE AND COUPLER SERVICE ....................35-4-3 REMOTE VALVE REMOVAL AND SERVICE ....................35-4-5 REMOTE COUPLERS ..........................35-4-13 SPECIAL TORQUES Valve Section Mounting Bolts M12 x 100mm ......................
Page 820 Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE VALVE AND COUPLER SERVICE Load Check Inspection On The Tractor IMPORTANT: Always fully lower and disconnect any STEP 3 implements from the remote hydraulic couplers before doing service work on the remote valve sections.
Page 821 Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 5 STEP 7 RD98K201 RD98E128 Install the load check assembly and plunger into the valve section. Tighten the cap to a torque of 30 t0 41 Nm (22 to 30 lb. ft.). RD98K202 Remove the cap (1) from the load check body (2).
Page 822 Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE VALVE REMOVAL AND SERVICE Removal IMPORTANT: Always fully lower and disconnect any STEP 10 implements from the remote hydraulic couplers before doing service work on the remote valve sections. STEP 8 See the Remote Hydraulic System How it Works and Troubleshooting Section of this Service Manual before star ting remote valve service.
Page 823 Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 12 RI02E044 RD02D053 Remove the three mounting bolts and the 4th and 5th remote sections. NOTE: There are two signal check springs (1) on the mating side of each valve. Be sure that the springs are not lost during disassembly.
Page 824 Section 35 - Hydraulic Systems, 3PT - Chapter 4 Disassembly NOTE: If there is heavy wear ar damage in a valve STEP 15 bore, the valve section must be replaced. STEP 13 RD02D056 Remove the main valve spool and washers. Note the end of the spool that is toward the load check cap end of the valve.
Page 825 Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 17 STEP 18 RD02E057 RD98K201 Remove the load check valve. Remove the plunger from the bore. Check for wear or damage. The plunger must move freely within the bore. RD98K202 Remove the cap (1) from the load check body (2).
Page 826 Section 35 - Hydraulic Systems, 3PT - Chapter 4 Assembly NOTE: Always replace damaged or heavily worn STEP 21 parts. If the parts are not serviceable, the entire valve section must be replaced. NOTE: Always install new O-rings, backup rings and seals during assembly.
Page 827 Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 23 STEP 25 RD02D055 RD02D054 Install new O-rings onto the solenoid bodies. Install Install new O-rings on the solenoids. Install the the two springs and a solenoid block onto each side solenoids and tighten the mounting screws.
Page 828 Section 35 - Hydraulic Systems, 3PT - Chapter 4 Installation STEP 27 STEP 29 RI02E044 RI02E042 Position the valve sections on the valve stack and Connect the wiring harness to the solenoids (1). install the three retaining bolts. Tighten the M10 bolt to Install the seven pin connector mounting plate (2).
Page 829 Section 35 - Hydraulic Systems, 3PT - Chapter 4 Remote Valve Cross Section RI02B027 1. SOLENOID 6. LOAD CHECK CAP 2. SOLENOID BLOCK 7. LOAD CHECK BODY 3. PRESSURE COMPENSATING FLOW CONTROL SPOOL 8. MAIN POPPET 4. MAIN SPOOL 9. LOAD CHECK PLUNGER 5.
Page 830 Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE COUPLERS RI02E027 1. COVER AND GASKET (ON EXPLODED VIEW) 6. CARTRIDGE 2. SPRING RETAINER 7. BODY 3. COIL SPRING 8. SLIPPER SEAL 4. SNAP RING 9. O-RING 5. SPRING 10. O-RING 1.
Page 831 Section 35 - Hydraulic Systems, 3PT - Chapter 4 Exploded View RI02E028 1. COVER AND GASKET 6. CARTRIDGE 2. SPRING RETAINER 7. BODY 3. COIL SPRING 8. SLIPPER SEAL 4. SNAP RING 9. O-RING 5. SPRING 10. O-RING 35-4-14...
Page 832 Section 35 Chapter 5 REMOTE HYDRAULIC SYSTEM How It Works and Troubleshooting January, 2006...
Page 833 Section 35 - Hydraulic Systems, 3PT - Chapter 5 TABLE OF CONTENTS REMOTE HYDRAULIC SYSTEM INTRODUCTION ..................35-5-3 REMOTE VALVE SYSTEM COMPONENTS ....................35-5-5 REMOTE VALVE SYSTEM CONTROLS ..................... 35-5-10 REMOTE VALVE OPERATION ........................35-5-14 REMOTE VALVE PROBLEMS AND WHERE TO LOOK ................35-5-23 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION ..........................
Page 834: Remote Hydraulic System Introduction
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE HYDRAULIC SYSTEM INTRODUCTION REMOTE CONTROLS STANDARD FLOW ARM REST HYDRAULIC INSTRUMENTATION CONTROLS CONTROLLER VALVE TIMER DATA BUS DATA BUS AUX-PTO- HITCH CONTROLLER (TMF) SUPPLY TO HITCH PCS = PROPORTIONAL CURRENT SOLENOID RI99F043 35-5-3...
Page 835 Section 35 - Hydraulic Systems, 3PT - Chapter 5 All remote hydraulic controls are located in the right- The remote controller will repor t any problems hand Armrest Control Console. These controls directly to the instrument controller. The instrument include the: controller will display any system faults or fault code information through the standard instrumentation Remote Hydraulic Control Levers...
Page 836: Remote Valve System Components
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM COMPONENTS RD02D042 1. REMOTE COUPLERS The remote valve assembly is located at the rear of the tractor. Remove the Controller cover to access the valve assembly by removing two bolts from each side of the cover (the bolts do not go through the fender assemblies). 35-5-5...
Page 837 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI06A062 RI02J006 1. PROPORTIONAL CURRENT CONTROL SOLENOIDS 5. REMOTE MANIFOLD ASSEMBLY 2. HIGH PRESSURE ACCUMULATOR 6. SIGNAL LINE 3. MANIFOLD SUPPLY (INLET) 7. HITCH VALVE 4. MANIFOLD RETURN TUBE 8. LOAD CHECKS 35-5-6...
Page 838 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02J007 THRU J010 AND RH02J047 1. REMOTE SECTION NO. 1 10. FLOW CALIBRATION DIAGNOSTIC PORT 2. REMOTE SECTION NO. 2 11. REMOTE MANIFOLD BASE (BOTTOM VIEW) 3. REMOTE SECTION NO. 3 12.
Page 839 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02D103 RI02D105 AND RH02J002 1. POWER BEYOND LOAD SENSE TUBE 7. POWER BEYOND RETURN FLOW COUPLER 2. POWER BEYOND SUPPLY TUBE 8. CHECK VALVE 3. POWER BEYOND RETURN TUBE 9. INTERNAL PLUG 4.
Page 840 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RD05M054 1. AUX - PTO - HITCH (TMF) 2. TRANSMISSION - FRONT AXLE REAR VIEW (CONTROLLERS) 35-5-9...
Page 841: Remote Valve System Controls
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM CONTROLS Remote Hydraulic Control Levers FLOAT There are three or four remote hydraulic control RETRACT DETENT levers (and a switch to control a 5th remote if equipped) on the arm rest control console depending MOMENTARY on the number of remote circuits on your tractor.
Page 842 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Full Function Position No Float Position RH97J002 RH97J002 Remote Valve Function Control - Remote Valve Function Control Full Function Position In the full function position the remote control lever will have full function including the float position. FLOAT FLOAT POSITION LOCKED OUT...
Page 843 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Loader Position Hydraulic Motor Position FLOAT FLOAT SHIFT HERE TO RETRACT DETENT OPERATE MOTOR RETRACT DETENT MOMENTARY MOMENTARY POSITIONS NEUTRAL LOCKED OUT NEUTRAL MOMENTARY MOMENTARY DETENT LOCKED EXTEND DETENT EXTEND DETENT Remote Control Lever Positions - Loader Position Remote Control Lever Positions - Hydraulic Motor Position...
Page 844 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Hydraulic Valve Timer Control Variable Flow Control The timer control located under the arm rest cover Each circuit of the five remote hydraulic system has a determines the amount of time a remote circuit has variable flow control.
Page 845: Remote Valve Operation
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE OPERATION General MAIN VALVE SPOOL - The main valve spool is When lowering, oil is fed to the left hand side of the spring centered in neutral and is positioned by the plunger.
Page 846 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Neutral All the remote valve sections function in the same A load check valve is installed into the extend port, way. In neutral the position of the main valve spool is which will prevent the settling of a load (in neutral) spring centered.
Page 847 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02C044 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORKING PRESSURE RETURN PRESSURE RI02E014 1. PROPORTIONAL SOLENOID VALVE ASSEMBLY 7. EXTEND 2. MAIN VALVE SPOOL 8. PROPORTIONAL SOLENOID VALVE ASSEMBLY 3. RETRACT PORT 9.
Page 848 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Extend The main valve spool can now direct flow from the intermediate pressure area to the work pressure area and on to the remote valve coupler. As oil flows When the remote hydraulic control lever is moved to across the main valve spool there is always a 100 the extend position, the main valve spool is shifted to PSI pressure drop.
Page 849 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02C046 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. PROPORTIONAL SOLENOID VALVE ASSEMBLY 7. EXTEND 2. MAIN VALVE SPOOL 8. PROPORTIONAL SOLENOID VALVE ASSEMBLY 3.
Page 850 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Retract poppet which allows the return oil to flow back to the inlet side of the filter base. (Differential pressure between the raise port and the spring side of the When the remote hydraulic control lever is moved to main poppet also contribute to unseating the main the retract position, the main valve spool is shifted to poppet).
Page 851 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02C048 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. PROPORTIONAL SOLENOID VALVE ASSEMBLY 7. EXTEND 2. MAIN VALVE SPOOL 8. PROPORTIONAL SOLENOID VALVE ASSEMBLY 3.
Page 852 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Float pressure standby pressure is direc ted to the backside of the load check plunger. The plunger moves to the right, unseating the load check main When the remote hydraulic control lever is moved to poppet.
Page 853 Section 35 - Hydraulic Systems, 3PT - Chapter 5 RI02D003 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. PROPORTIONAL SOLENOID VALVE ASSEMBLY 7. EXTEND 2. MAIN VALVE SPOOL 8. PROPORTIONAL SOLENOID VALVE ASSEMBLY 3.
Page 854: Remote Valve Problems And Where To Look
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE PROBLEMS AND WHERE TO LOOK RI02B027 1. PROPORTIONAL SOLENOID VALVE ASSEMBLY 8. EXTEND 2. MAIN VALVE SPOOL 9. PROPORTIONAL SOLENOID VALVE ASSEMBLY 3. FLOW CONTROL SPRING 10. SIGNAL CHECK TO PILOT RELIEF 4.
Page 855 Section 35 - Hydraulic Systems, 3PT - Chapter 5 Load Check Implements leak down. See load check inspection in this section. Signal Check To Pump Compensator If a single signal check is leaking. The leaky signal check remote section will function normally. The remaining remote sections will show reduced flow.
Page 856: Remote Valve Proportional Current Control (Pcc) Solenoid Operation
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION There is a proportional solenoid mounted on each The distance that the spool will shift is determined by end of a remote valve section. Each proportional the flow control setting for that remote section.
Page 857: Remote Valve System Testing
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM TESTING Each of the remote hydraulic system circuits is made Talk to the owner/operator about the problem. Gather up of four different systems. A problem with any one a s m u c h i n fo r m a t i o n a b o u t w h a t s h o u l d b e o f t h e s e s y s t e m s w i l l e f fe c t r e m o t e v a l v e happening versus what is happening.
Page 858: Remote Valve High Pressure Test
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE HIGH PRESSURE TEST • Test Fitting Tool Requirements: PFC pump high pressure standby is set low. • • Problem with PFC pump compensator valve. 5000 PSI (350 bar) gauge with male remote valve coupler tip.
Page 859: Pfc Pump High Pressure Standby Check And Adjustment Procedure
Section 35 - Hydraulic Systems, 3PT - Chapter 5 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE Perform this test when all remote circuits and hitch Test Procedure: system do not operate with full power. This would be - Install a 5000 PSI (350 bar) pressure gauge with noticeable when maximum power is needed such as hose onto the diagnostic fitting at the compensator.
Page 860: Pfc Piston Pump Flow Test
Section 35 - Hydraulic Systems, 3PT - Chapter 5 PFC PISTON PUMP FLOW TEST Perform this test when all remote circuits and the - Start and run the engine at 1000 RPM. hitch system are not operating at full flow. This would NOTE: Use 3/4 inch hose with a minimum working be noticeable by slower operation of remote circuit pressure of 3000 PSI (206 bar) for this flow test.
Page 861: Standard Pump Compensator Valve Inspection
Section 35 - Hydraulic Systems, 3PT - Chapter 5 STANDARD PUMP COMPENSATOR VALVE INSPECTION Perform this inspection only after completing the high pressure standby check and the piston pump flow test. RH02B010 1. HIGH PRESSURE SPOOL 4. LOW PRESSURE SPOOL 2.
Page 862: Remote Valve Signal Check And Hitch Signal Check
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK Each remote section and the hitch circuit are REMOTE SIGNAL CHECK LEAKING: All remaining equipped with a signal check. If any one signal check remote circuits and hitch are operating at reduced is leaking it will effect the performance of all the other flow.
Page 863: Remote Valve Coupler Test
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE COUPLER TEST − Remote valve couplers seal leaks will cause the Find out what type of male coupler tip is being used. following problem. − Check the male tip and make sure it is compatible with the •...
Page 864: Load Check Inspection
Section 35 - Hydraulic Systems, 3PT - Chapter 5 LOAD CHECK INSPECTION Remote Valve Load Check Valves The remote hydraulic valve is equipped with a single load check on all five remote sections on the “B” (extend) port. The load check is used in applications w h e r e a r e m o t e hy d r a u l i c c y l i n d e r m u s t b e hydraulically locked in position with a minimal amount of leak down.
Page 865: Operational Problems
Section 35 - Hydraulic Systems, 3PT - Chapter 5 OPERATIONAL PROBLEMS IMPLEMENT SETTLES OR LEAKS DOWN F. Bypass coupler to determine if the problem is with the remote valve/hydraulic system or A. Problem with implement cylinder. Raise coupler. Connect the flowmeter directly to implement and disconnect hoses to isolate the lower and raise tubes.
Page 866 Section 35 Chapter 6 PRIORITY AND REGULATOR VALVE January, 2006...
Page 867 Section 35 - Hydraulic Systems, 3PT - Chapter 6 TABLE OF CONTENTS SPECIAL TORQUES ............................35-6-3 PRIORITY VALVE AND REGULATOR ......................35-6-4 Removal ..............................35-6-4 Disassembly ..............................35-6-6 Assembly ..............................35-6-9 Installation ..............................35-6-12 CROSS SECTION OF PRIORITY AND REGULATOR VALVE ..............35-6-14 35-6-2...
Page 868: Special Torques
Section 35 - Hydraulic Systems, 3PT - Chapter 6 SPECIAL TORQUES Socket Head Plug ......................16 to 24 Nm (12 to 18 lb. ft.) PFC Pump Signal Orifice and Screen Plug ..............14 to 21 Nm (10 to 15 lb. ft.) Logic Check Valve Plug ....................
Page 869: Priority Valve And Regulator
Section 35 - Hydraulic Systems, 3PT - Chapter 6 PRIORITY VALVE AND REGULATOR Removal STEP 1 STEP 2 RD02E055 RD02D088 Remove the steering supply line (1). Remove the brake valve supply line (2). STEP 3 RD02E056 1. REMOTE HYDRAULIC 5. SIGNAL LINE TO MANIFOLD SUPPLY LINE REMOTE VALVE 2.
Page 870 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 4 STEP 5 RD02D089 RD02D093 Remove the three priority valve mounting bolts (1). Remove the pr ior ity valve from the top of the transmission. Remove the O-ring (1) in the top of the transmission housing and discard.
Page 871: Disassembly
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Disassembly STEP 6 STEP 9 RD02D112 RD02D106 Unscrew the logic check valve plug. Remove the four plugs from the priority and regulator valve and discard the O-rings. STEP 10 STEP 7 RD02D114 RD02D108 Remove the logic check valve plug and discard the...
Page 872 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 11 STEP 13 RD02D120 RD02D117 Remove the pilot relief valve assembly. Remove the steering line orifice fitting and discard the O-ring (1). Remove the priority valve spring and spool. Inspect the spring and spool for damage or STEP 14 wear.
Page 873 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 16 STEP 18 RD02D128 NOTE: Measure the distance from the adjustment RD02D134 end of the regulator spool to the body of the valve Remove and discard the O-ring from the adjusting before removing the lock nut.
Page 874: Assembly
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Assembly STEP 19 STEP 21 RD02D128 Install the regulator spool lock nut. Tighten the nut to RD02D134 a torque of 41 to 48 Nm (30 to 35 lb. ft.). Lubricate the adjusting plug O-ring with hydraulic fluid and install on the plug.
Page 875 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 23 STEP 25 RD02D124 RD02D119 Lubricate and install a new backup ring (1) and new Install the pilot relief valve lock nut. O-rings (2) on the pilot relief valve assembly. STEP 26 NOTE: Install the backup ring (1) before the O-ring, as shown.
Page 876 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 27 STEP 29 RD02D110 RD02D114 Apply a fine strip of Loctite® 242 adhesive on the Lubricate the logic check valve and the spring. Install internal land of the priority valve casting. Install the the check valve and the spring in the priority valve.
Page 877: Installation
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Installation STEP 32 STEP 34 RD02D093 RD02D104 Install a new O-ring (1) in the top of the transmission Install the PFC pump supply hose to the priority valve housing. Place the priority valve on the top of the (1).
Page 878 Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 36 STEP 37 Lower the cab. Refer to the information in this service manual for the cab lowering procedure. Check the tra c tor hy dr au li c f lu i d leve l a nd a dd f lu i d as necessary.
Page 879: Cross Section Of Priority And Regulator Valve
Section 35 - Hydraulic Systems, 3PT - Chapter 6 CROSS SECTION OF PRIORITY AND REGULATOR VALVE RI02E009 1. PRIORITY AND REGULATOR VALVE 5. PRIORITY VALVE SPOOL 9. LOCKING NUT 2. LOGIC CHECK VALVE ASSEMBLY 6. PLUG 10. ADJUSTING PLUG 3. ORFICE AND SCREEN PLUG 7.
Page 880 Section 35 Chapter 7 CHARGE PUMP January, 2006...
Page 881 Section 35 - Hydraulic Systems, 3PT - Chapter 7 TABLE OF CONTENTS CHARGE PUMP ............................. 35-7-3 Removal ..............................35-7-3 Installation ..............................35-7-4 35-7-2...
Page 882 Section 35 - Hydraulic Systems, 3PT - Chapter 7 CHARGE PUMP Removal STEP 3 STEP 1 RD02D009 Remove the charge pump outlet hose (1) to the filter head. Remove the outlet line to the priority valve (2). Remove the connector from the hydraulic filter RD02D002 The charge pump (1), is mounted to the hydraulic pressure sender (3).
Page 883 Section 35 - Hydraulic Systems, 3PT - Chapter 7 Installation STEP 4 RD02D009 Install the two charge pump to hydraulic pump drive mounting bolts. Install the charge pump outlet hose (1) to the filter head. Install the outlet line to the priority valve (2).
Page 884 Section 35 Chapter 8 PFC PISTON PUMP January, 2006...
Page 885 Section 35 - Hydraulic Systems, 3PT - Chapter 8 TABLE OF CONTENTS SPECIAL TORQUES ............................35-8-3 PFC PISTON PUMP ............................35-8-3 Removal ..............................35-8-3 Installation ..............................35-8-4 35-8-2...
Page 886 Section 35 - Hydraulic Systems, 3PT - Chapter 8 SPECIAL TORQUES Compensator Valve Orifice ..................1.7 to 2.3 Nm (15 to 20 lb. in.) Compensator Valve Inlet Port Plug................1.7 to 2.3 Nm (15 to 20 lb. in.) Filter Head Retaining Bolts..................... 62 to 80 Nm (46 to 59 lb. ft.) Hydraulic Piston Pump Split Flange Retaining Bolts ............
Page 887 Section 35 - Hydraulic Systems, 3PT - Chapter 8 Installation STEP 7 STEP 5 RD06A136 RD02D019 Install new O-rings on all hydraulic lines. Install and Install a new O-ring on the piston pump and install tighten all filter head hydraulic lines. Install the the two piston pump mounting bolts (1) to the pressure sensor connector and nut (1), do not over hydraulic pump drive cage.
Page 888 Section 35 Chapter 9 HITCH SYSTEM How it Works January, 2006...
Page 889 Section 35 - Hydraulic Systems, 3PT - Chapter 9 TABLE OF CONTENTS THREE POINT HITCH ........................... 35-9-3 ELECTRONIC HITCH CONTROL ........................35-9-4 ELECTRONIC HITCH CONTROL SYSTEM FEATURES ................35-9-7 HITCH CONTROL VALVE ........................... 35-9-14 SETUP / ADJUSTMENT SEQUENCE ......................35-9-22 35-9-2...
Page 890: Three Point Hitch
Section 35 - Hydraulic Systems, 3PT - Chapter 9 THREE POINT HITCH GENERAL DESCRIPTION - The Three Point Hitch consists of the rockshaft supports, rockshaft, upper link, lift links, draft arms and the external lift cylinders. The hitch conforms to ASAE standard dimensions for a Category III/IIIN hitch. The hitch is controlled with an electronic hitch system which provides position control of soil engaging implements.
Page 891: Electronic Hitch Control
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL GENERAL DESCRIPTION - The Electronic Hitch Control (EHC) system consists of the operator controls, electronic hitch controller, hitch position sensor, hitch control valve and the wiring harness. All operator commands except Remote Up/Down commands are sent to the Arm Rest Control Unit then relayed to the Hitch Controller by way of the Data Bus.
Page 892 Section 35 - Hydraulic Systems, 3PT - Chapter 9 35-9-5...
Page 893 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL POSITION CONTROL - In the Position Control Mode, the hitch position and movement is directly related to the position of the control lever. The Electronic Hitch Control (EHC) monitors the position of the hitch by signals received from a hitch position sensor on the hitch rockshaft and raises or lowers the hitch to match the signal from the hitch position control lever sensor.
Page 894: Electronic Hitch Control System Features
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES HITCH POSITION CONTROL KNOB - The Position Control knob (1) is used to raise and lower implements, and select the maximum working depth of the implement. To lift an implement with the three point hitch, the Position Control Knob is rotated clockwise.
Page 895 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL RD05J154 / RD05J116 1. HITCH POSITION CONTROL KNOB 5. UPPER LIMIT CONTROL 2. LOWER LIMIT STOP RING 6. DROP SPEED TRANSPORT LOCK 3. UP DOWN SWITCH 7. TRAVEL CONTROL KNOB 4.
Page 896 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES UPPER LIMIT CONTROL - The Upper Limit Control (5) limits the amount of upward travel when the hitch is raised. The control knob is mounted under the armrest cover on the armrest control console and has number settings from “1”...
Page 897 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES RD05J154 / RD05J116 1. HITCH POSITION CONTROL KNOB 5. UPPER LIMIT CONTROL 2. LOWER LIMIT STOP RING 6. DROP SPEED /TRANSPORT LOCK 3. UP DOWN SWITCH 7.
Page 898 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES TRAVEL CONTROL KNOB - The TRAVEL CONTROL KNOB (7) is located under the arm rest control console cover. Travel Control varies the range of hitch corrections in response to load variations when operating in the LOAD CONTROL MODE.
Page 899 Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES RD05J154 / MT04M013 / RD05J116 1. HITCH POSITION CONTROL KNOB 6. DROP SPEED /TRANSPORT LOCK 2. LOWER LIMIT STOP RING 7. TRAVEL CONTROL KNOB 3. UP DOWN SWITCH 8.
Page 900 Section 35 - Hydraulic Systems, 3PT - Chapter 9 EHC SYSTEM FEATURES END OF ROW FUNCTION - The END OF ROW feature involves the Differential Lock and the Front Wheel Drive (FWD) (if equipped) and the Brake Switches. The FWD and Diff Lock control systems are equipped with an automatic function that disengages both Diff Lock and FWD when the hitch is raised for a turn around and re- engages them when the hitch is lowered after the turn.
Page 901: Hitch Control Valve
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE General The hitch control valve is a closed center valve that receives oil from the PFC hydraulic system. To control the pump during hitch operations, signal pressure is sent from the valve to the PFC pump. The raise and lower functions of the valve are operated by regulated pressure received from the regulated hydraulic system.
Page 902 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE RI02B003 1. RAISE SOLENOID 10. LOAD CHECK BALL 2. LOWER SOLENOID 11. PFC PUMP SUPPLY 3. RAISE PILOT SPOOL 12. REGULATED PRESSURE SUPPLY 4. LOWER PILOT SPOOL 13. RETURN PORT 5.
Page 903 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Neutral Function and Troubleshooting FUNCTION Hitch Control Valve in Neutral - The hitch control valve is a closed-center valve. In neutral there will be no electric current supplied to the raise or lower solenoids (1) and (2) and no oil flow through the valve. The pilot spools (3) and (4) are blocking the supply of oil from the regulated circuit.
Page 904 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE - NEUTRAL RI02B003 1. RAISE SOLENOID 10. LOAD CHECK BALL 2. LOWER SOLENOID 11. PFC PUMP SUPPLY 3. RAISE PILOT SPOOL 12. REGULATED PRESSURE SUPPLY 4. LOWER PILOT SPOOL 13.
Page 905 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Raise Function and Troubleshooting FUNCTION Hitch Control Valve in Raise - To raise the hitch, the hitch raise solenoid (1) must be energized by the Electronic Hitch Controller. When the solenoid is energized, the armature in the solenoid moves toward the valve contacting a control pin (14) which moves the raise pilot spool (3) inward.
Page 906 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Raise Function and Troubleshooting RI02B006 1. RAISE SOLENOID 10. LOAD CHECK BALL 2. LOWER SOLENOID 11. PFC PUMP SUPPLY 3. RAISE PILOT SPOOL 12. REGULATED PRESSURE SUPPLY 4. LOWER PILOT SPOOL 13.
Page 907 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Lower Function and Troubleshooting FUNCTION Hitch Valve in Lower - To lower the hitch, the lower solenoid (2) must be energized by the Electronic Hitch Controller based on the commands entered by the operator. Activation of the PFC system is not required to lower the hitch.
Page 908 Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Lower Function and Troubleshooting RI02B007 1. RAISE SOLENOID 10. LOAD CHECK BALL 2. LOWER SOLENOID 11. PFC PUMP SUPPLY 3. RAISE PILOT SPOOL 12. REGULATED PRESSURE SUPPLY 4. LOWER PILOT SPOOL 13.
Page 909: Setup / Adjustment Sequence
Section 35 - Hydraulic Systems, 3PT - Chapter 9 SETUP / ADJUSTMENT SEQUENCE AS THE DRAFT SET POSITION TURN LOAD MOVE POSITION TO FINE TUNE LOAD VARIES, THE CONTROL ABOUT 1 CONTROL CCW TO CONTROL LEVER TRAVEL, TURN THE HITCH CONTROL TO 2 INCHES WHERE PLOW DEEPER THAN...
Page 910 Section 35 Chapter 10 HITCH CONTROL VALVE January, 2006...
Page 911 Section 35 - Hydraulic Systems, 3PT - Chapter 10 TABLE OF CONTENTS HITCH CONTROL VALVE ........................... 35-10-3 Removal ..............................35-10-3 Disassembly .............................. 35-10-5 Assembly ..............................35-10-7 Installation ..............................35-10-9 HITCH CONTROL VALVE CROSS SECTION ................... 35-10-11 35-10-2...
Page 912: Hitch Control Valve
Section 35 - Hydraulic Systems, 3PT - Chapter 10 HITCH CONTROL VALVE Removal STEP 3 STEP 1 RD02D043 If equipped, remove the power beyond supply line to help obtain access to the hitch valve to case return line. RD02D041 The hitch control valve is located on the left hand side of the remote valve stack (viewed from rear).
Page 913 Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 6 STEP 9 RD02D045 RI02D045 Disconnect the hitch valve load sensing signal lines. Remove the three hitch valve mounting bolts and remove the hitch valve. STEP 7 RD02D046 If equipped, remove the hydraulic trailer brake line mounting clamp.
Page 914: Disassembly
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Disassembly STEP 13 STEP 10 RD02D037 Remove the raise spool. Discard the O-ring. Inspect for heavy wear or damage. Replace the valve assembly if necessary. RD02C198 Place the hitch valve on a clean work surface. STEP 14 STEP 11 RD02D038...
Page 915 Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 16 STEP 18 RD02F148 RD02D040 Inspect the check for debris and that the check ball Remove the poppet body, lower pilot and spring moves freely. assembly and lower poppet. Discard the three O-rings and backup ring.
Page 916: Assembly
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Assembly STEP 21 STEP 19 RD02F148 Install the load sense check into the valve. RD02D040 STEP 22 Lubricate the new O-rings and backup ring with petroleum jelly. Install two new O-rings on the poppet body.
Page 917 Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 24 STEP 26 RD02D037 RD02C199 Lubricate the new O-ring with petroleum jelly. Install Install the coils and coil nuts. Tighten the coil nuts to the O-ring onto the plug. Lubricate the raise spool a torque of 2 to 4 Nm (17 to 35 lb.
Page 918: Installation
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Installation STEP 29 STEP 27 RI02D067 Install and tighten the case drain line. RI02D046 Apply petroleum jelly to the new O-rings and install STEP 30 them to the back of the hitch valve. STEP 28 RD02D046 If equipped, install the hydraulic trailer brake line...
Page 919 Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 32 STEP 35 RD02D047 RD02D042 Connect the valve supply line. If removed, install the seven pin connector mounting bracket. STEP 33 RD02D044 Connect the hitch valve solenoids to the wire harness.
Page 920: Hitch Control Valve Cross Section
Section 35 - Hydraulic Systems, 3PT - Chapter 10 HITCH CONTROL VALVE CROSS SECTION RI02B003 1. RAISE SOLENOID 10. LOAD CHECK BALL 2. LOWER SOLENOID 11. PFC PUMP SUPPLY 3. RAISE PILOT SPOOL 12. REGULATED PRESSURE SUPPLY 4. LOWER PILOT SPOOL 13.
Page 921 Section 35 - Hydraulic Systems, 3PT - Chapter 10 35-10-12...
Page 922 Section 35 Chapter 11 TRACTOR HITCH January, 2006...
Page 923 Section 35 - Hydraulic Systems, 3PT - Chapter 11 TABLE OF CONTENTS SPECIAL TORQUES ............................ 35-11-3 TRACTOR HITCH ............................35-11-3 EDC PIN ASSEMBLY ..........................35-11-20 POTENTIOMETER (HITCH POSITION SENSOR) ..................35-11-21 CAM SWAY LIMITER ..........................35-11-23 CAM BUMPERS FOR DRAFT ARM ......................35-11-25 DRAWBAR, HIGH VERTICAL CAPACITY ....................
Page 924: Special Torques
Section 35 - Hydraulic Systems, 3PT - Chapter 11 SPECIAL TORQUES Nut for Position Locator Bracket ................490 to 555 Nm (362 to 410 lb. ft.) Bolts for Hitch Support C-Bracket................845 to 950 Nm (624 to 700 lb. ft.) Nuts for Hitch Potentiometer Bushing.................
Page 925 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Rear Hitch Disassembly INF4691 IMPORTANT: Position round area of pin toward the wire exit in cover. 1. COVER 7. SILICONE SEALANT (3 PLACES) 2. EDC PIN 8. ANTI-SEIZE COMPOUND 3. TUBE 9.
Page 926 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 4 STEP 6 26-35 R e m o v e t h e e l e c t r o n i c d r a f t c o n t r o l ( E D C ) components as follows: DRAFT ARMS 1.
Page 927 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 8 STEP 9 VERTICAL LIFT LINK 27-12 Remove the hydraulic lines to the hitch lift cylinder as follows: 1. Be prepared to catch hydraulic fluid as the hydraulic system is opened. 2.
Page 928 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 11 STEP 13 36S21 36S15 Remove the two bolts that attach the linkage shield to If necessary remove the three nuts from the bolts that the hitch support C-bracket. attach the hitch potentiometer bushing to the sensor bracket and sensor.
Page 929 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Hitch Position Sensor NOTE Link assembly shown in position with hitch down. NOTE Items 1,2,3,4,5,7 & make up the sensor subassembly. “Potentiometer (Hitch Position Sensor)” later in this section for details. INF6913 1.
Page 930 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Basic Hitch Assembly 12. HITCH SUPPORT C-BRACKET 21. ROCKER PIN 13. ROCKSHAFT 22. FLAG PLATE 14. BOLT 23. BOLT 15. PIN 24. BOLT 16. RETAINER 25. SEAL 17. WASHER 26. BOLT 18.
Page 931 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 14 STEP 16 RD03F019 36-9 Support the nut that attaches the position locator bracket to the tie rod. NOTE: Right side nut (shown) should be held in place while nut on left side is removed. STEP 17 RD03g003 Remove the bolt, washer, spacer and nut (1).
Page 932 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 18 STEP 20 36-2 35-21 Remove the split ring washer that holds the pin-to- Use a long piece of wood to reach through the rockshaft retainer in place. Remove the tie rod rockshaft and contact the rocker pin.
Page 933 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 22 STEP 24 35-14 35-8 When both rockshaft pins are removed, lift and set Remove the seven attaching bolts that pass through aside the rockshaft casting. the hitch support C-brackets into the rear frame housing.
Page 934 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Installation of the 3-Point Hitch STEP 27 STEP 29 35-5 35-10 All six mating surfaces of the hitch support C-bracket Remove the sling and hoist. and rear frame must be clean and free of paint, oil, grease, anti-seize, etc.
Page 935 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 31 STEP 34 35-18 79S9 Pins must be clean and free of oil, grease, antiseize, Install the tie bolt. Install the washer and M24 nut on compound, etc. Orient pin with bearing surface the opposite (left hand) side.
Page 936 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Bolt Tightening Sequence Note 1: Numbers 3-9 on bolt heads denote bolt torque sequence. Note 2: Use same sequence on both sides. Note 3: Bolts tightening sequence numbers 1 and 2 are for nuts on both ends of the tie rod (not shown here) (performed in Step 38).
Page 937 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 37 STEP 39 36-28 36-18 Attach the hitch lift cylinder as follows: Install the nut for the link assembly. Tighten to a torque of 18 to 23 Nm (14 to 17 lb. ft.). 1.
Page 938 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 41 STEP 43 RD03F074 27-12 Insert a holding pin as follows: Attach the hydraulic line to the top of the hitch. Repeat for the other hitch lift cylinders. 1. Pin must be clean and free of oil, grease, anti- seize.
Page 939 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 45 STEP 46 26-21 26-33 Install the hex-head bolt, washer, spacer and nut. Insert a hitch swivel pin through the inside hole at the Tighten it to a torque of 82 to 106 Nm (60 to 78 lb. bottom of the vertical lifting link.
Page 940 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 48 STEP 49 27-5 26-16 Install the EDC components (refer to exploded view Check hitch operation as follows: for Step 4) as follows: 1. Turn on the ignition key. 1. Move a lower draft arm into position for installation. 2.
Page 941: Edc Pin Assembly
Section 35 - Hydraulic Systems, 3PT - Chapter 11 EDC PIN ASSEMBLY STEP 50 26-36 Install electronic draft control (EDC) pin and pin wire tube as shown in the exploded view for Step 4. Continue installation as follows: 1. Apply RTV sealant on the inner surface of the cover, lower end of tube, and grommet.
Page 942: Potentiometer (Hitch Position Sensor)
Section 35 - Hydraulic Systems, 3PT - Chapter 11 POTENTIOMETER (HITCH POSITION SENSOR) U n u s e d h o l e subassembly Section A-A RIGHT SIDE OF VEHICLE INF6913 31. BRACKET 35. RING 39. SHIELD 32. SENSOR 36. NUT 40.
Page 943 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Disassembly Assembly NOTE: Be sure to remove the M8 nut that attaches STEP 55 the link to the position locator bracket located on the rockshaft. Lubricate the link and slide it into the bushing as far as possible.
Page 944: Cam Sway Limiter
Section 35 - Hydraulic Systems, 3PT - Chapter 11 CAM SWAY LIMITER Removal INF5577A 42. CAM 44. CLEVIS PIN 43. PIVOT BOLT 45. LOCKING PIN STEP 59 Remove the sway limiter cam as follows: 1. Place a suitable support under the sway limiter cam to stop the cam from dropping when the bolt is removed.
Page 945 Section 35 - Hydraulic Systems, 3PT - Chapter 11 Installation STEP 60 27-27 Install the sway limiter cam as follows: 1. Move cam into position. 2. Install the pivot bolt. Turn the bolt until bolt head contacts the drawbar support bracket. Back out the pivot bolt by 1/8th turn.
Page 946: Cam Bumpers For Draft Arm
Section 35 - Hydraulic Systems, 3PT - Chapter 11 CAM BUMPERS FOR DRAFT ARM 6166H2 1. DRAFT ARM (LOWER LINK) ASSEMBLY 4. BUMPER 2. SHIM 5. LOCKING BOLT 3. SPACER Removal Installation NOTE: Each cam bumper is located on a lower draft STEP 62 arm of the hitch.
Page 947: Drawbar, High Vertical Capacity
Section 35 - Hydraulic Systems, 3PT - Chapter 11 DRAWBAR, HIGH VERTICAL CAPACITY RH98H044 6. HEAVY-DUTY DRAWBAR 17. M20X150 BOLT 7. SAFETY CHAIN SUPPORT 18. HAMMERSTRAP LATCH 8. DRAWBAR STRAP SPACER 19. HAMMERSTRAP LATCH SPACER 9. HAMMERSTAP SPACER 20. BOLT 10.
Page 948 Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 66 Installation Tighten the three M20 x 150 bolts to a torque of 485 STEP 65 to 620 Nm (358 to 458 lb. ft.). Install the spacers and hammerstrap. Install the two M20 x 260 bolts and Install the pin retainer and washer;...
Page 949 Section 35 - Hydraulic Systems, 3PT - Chapter 11 This Page Left Blank. 35-11-28...
Page 950 Section 41 Chapter 1 STEERING COLUMN AND STEERING HAND PUMP REMOVAL AND INSTALLATION January, 2006...
Page 951 Section 41 - Steering - Chapter 1 TABLE OF CONTENTS SPECIAL TOOLS ............................41-1-2 SPECIAL TORQUES ............................41-1-3 STEERING COLUMN REMOVAL ........................41-1-3 STEERING HAND PUMP SERVICE ......................41-1-6 STEERING COLUMN ASSEMBLY ........................ 41-1-8 SPECIAL TOOLS 380000795 - Steering Line Quick Disconnect Tool 41-1-2...
Page 952 Section 41 - Steering - Chapter 1 SPECIAL TORQUES Bolt for Steering Hand Pump Bracket and Isolator ............32 to 36 Nm (24 to 27 lb. ft.) Lock Nut for Steering Column Base ................29 to 32 Nm (22 to 24 lb. ft.) Nut for Steering Wheel ....................
Page 953 Section 41 - Steering - Chapter 1 STEP 5 STEP 7 RD02C095 RD02C098 Remove the retaining screw from the steering column upper control housing. STEP 8 RD02C093 Use a Torx screwdriver to remove the upper and lower steering column covers. RD02C096 STEP 6 R e m o ve t h e t w o s t e e r i n g c o l u m n e l e c t r i c a l...
Page 954 Section 41 - Steering - Chapter 1 STEP 10 STEP 12 RD02C109 RD02C111 Remove the boot support washer (1). Remove the Remove the four steering column lock nuts and steering column boot (2) along with the boot support washers at the column base. Support the steering plate and wire stiffener.
Page 955 Section 41 - Steering - Chapter 1 STEERING HAND PUMP SERVICE STEP 13 STEP 16 114S26 114S9 Mark the position of the pump bracket and isolator on Remove and replace the outer seal of the steering the steering hand pump. Loosen the bolts and hand pump, if necessary.
Page 956 Section 41 - Steering - Chapter 1 STEP 19 STEP 20 114S26 114S29 Check the pump bracket to make sure it is not Tighten the pump bracket bolts evenly in a crossing war ped or bent. Using the marks made during pattern to a torque of 32 to 36 Nm (24 to 27 lb.
Page 957 Section 41 - Steering - Chapter 1 STEERING COLUMN ASSEMBLY RI02G035 1. BELLOW SET 5. STEERING COLUMN 2. COVER SET 6. SEGMENT SET 3. RELEASE DEVICE SET 7. SPRING SET 4. BEARING SET 41-1-8...
Page 958 Section 41 - Steering - Chapter 1 STEP 21 STEP 23 RD02C111 RD02C109 Support the steering column in the cab while an Place the boot (1) with wire stiffener and boot plate assistant installs the steering hand pump. Install the installed, over the steering column.
Page 959 Section 41 - Steering - Chapter 1 STEP 25 STEP 27 RD02C096 RD02C090 C o n n e c t t h e t w o s t e e r i n g c o l u m n e l e c t r i c a l Use the steering wheel position mark made during connectors (1).
Page 960 Section 41 - Steering - Chapter 1 STEP 29 STEP 31 RD02C085 RD02C075 Pull up on the cab floor mat and install the left Connect the electrical plugs to the ignition switch and console heat duct into the cab floor duct. Install the the light switch.
Page 961 Section 41 - Steering - Chapter 1 41-1-12...
Page 962 Section 41 Chapter 2 WHEEL TOE IN SETTING SuperSteer FWD Axle January, 2006...
Page 963 Section 41 - Steering - Chapter 2 TABLE OF CONTENTS WHEEL TOE IN SETTING ..........................41-2-3 WHEEL TOE IN SETTING DIAGRAM ......................41-2-9 SPECIAL TOOL LAYOUT DRAWINGS ....................... 41-2-10 41-2-2...
Page 964 Template Name: OML_2_col Rac 0-00000 Template Date: 2001_03_06 Section 41 - Steering - Chapter 2 WHEEL TOE IN SETTING NOTE: The toe in setting must be done on a clean, level surface. NOTE: See the special tool layout drawings at the end of this section to fabricate the required spacer tubes and straightedge before starting wheel setting procedure.
Page 965 Section 41 - Steering - Chapter 2 STEP 4 Steer the axle until the string (1) hangs vertically and bisects the dowel hole (2) and threaded hole (3) in the drag link. The axle will then be “Dead Centered”. NOTE: The string must hang freely between the drag link and weight support bracket.
Page 966 Section 41 - Steering - Chapter 2 STEP 7 Be sure the rim surface in the nut area is free of dirt rust or debris as this will affect the accuracy of future measurements. Install and tighten the measured washers and nuts. RD05E083 STEP 8 Install the two fabricated threaded spacer tubes onto...
Page 967 Section 41 - Steering - Chapter 2 STEP 10 Make sure that the wheel/rim is positioned so that the straightedge is parallel to the floor when mounted on the spacer tubes. RD05E086 STEP 11 Locate two points about 500 mm (20 in.) apart on the machine frame milled surface.
Page 968 Section 41 - Steering - Chapter 2 STEP 13 M e a s u r e a n d r e c o r d t h e d i s t a n c e f r o m t h e straightedge to point “B”.
Page 969 Section 41 - Steering - Chapter 2 Setting Verification Verification of the toe in setting is done by taking plumb bob measurements from the rims. Be sure the axle is still dead centered before starting the checking procedure. STEP 15 Install a magnetic base (1) for a dial indicator on the front inside of the rim.
Page 970 Section 41 - Steering - Chapter 2 WHEEL TOE IN SETTING DIAGRAM Top View Of Front Axle RI05E015 1. MAINE CHASSIS FRAME 5. STRAIGHTEDGE 2. AXLE 6. 500 MM (20 IN.) 3. AXLE DEAD CENTERED 7. MACHINED FRAME PADS 4. SPACER TUBES 41-2-9...
Page 971 Section 41 - Steering - Chapter 2 SPECIAL TOOL LAYOUT DRAWINGS RI05F002 1. 30 TO 38 MM (1-1/4 TO 1-1/2 INCH) BARSTOCK 2. 300 MM (12 INCHES) 3. M16 X 2.0 X 30 MM DEEP INTERNAL THREAD (TUBES MUST BE WITHIN 0.05 MM) RI05F001 1.
Page 972 Section 50 Chapter 1 AIR CONDITIONING SYSTEM Troubleshooting and Fault Codes January, 2006...
Page 973 Section 50 - Climate Control - Chapter 1 TABLE OF CONTENTS SAFETY PROCEDURES ..........................50-1-5 SPECIAL TOOLS ............................50-1-6 A/C THERMAL OPERATION ......................... 50-1-7 A/C SYSTEM COMPONENTS ........................50-1-9 Cab HVAC Box Components - Automatic Temperature Control ..............50-1-9 Chassis Components ..........................50-1-11 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ..............
Page 974 Section 50 - Climate Control - Chapter 1 Blower Speed And Temperature Control Potentiometers ................. 50-1-45 Background ............................. 50-1-45 Possible Failure Modes - Fault Codes 120, 121 ..................50-1-45 Electrical Test ............................50-1-46 Common Control Potentiometer and Circuit Test Procedure ..............50-1-46 BLOWER AND BLOWER SPEED DRIVER .....................
Page 975 Section 50 - Climate Control - Chapter 1 Blower Speed Switch And Blower Motor ....................50-1-80 Background ............................. 50-1-80 Power and Ground Circuit ........................50-1-80 Possible Failure Modes ........................... 50-1-80 Blower Speed Switch and Power Circuit Test ..................50-1-81 Blower Motor Power, and Control Circuit Test ..................50-1-81 Evaporator Temperature Sensor ......................
Page 976: Safety Procedures
Section 50 - Climate Control - Chapter 1 SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified 3.
Page 977: Special Tools
Section 50 - Climate Control - Chapter 1 SPECIAL TOOLS RD99K079 299L7C 1. COMPRESSOR DIPSTICK Belt Tension Tool CAS10808 Compressor Tool Set, CAS10747A The compressor dipstick can be found in the Compressor Tool Set or purchased separately - CAS10747-19. 299L7B 9 Inch Stem Type Thermometer A22094 0°...
Page 978: A/C Thermal Operation
Section 50 - Climate Control - Chapter 1 A/C THERMAL OPERATION The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, receiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant.
Page 979 Section 50 - Climate Control - Chapter 1 LOW PRESSURE GAS LOW PRESSURE LIQUID HIGH PRESSURE GAS HIGH PRESSURE LIQUID 209L95 1. COMPRESSOR 3. RECEIVER-DRIER 5. EVAPORATOR 2. CONDENSOR 4. THERMAL EXPANSION VALVE 50-1-8...
Page 980: A/C System Components
Section 50 - Climate Control - Chapter 1 A/C SYSTEM COMPONENTS Cab HVAC Box Components - Automatic Temperature Control RI05H007 RI05H008 1. BLOWER SPEED DRIVER 4. HEATER CONTROL VALVE 7. EVAPORATOR TEMPERATURE SENSOR 2. ATC CONTROLLER 5. BLOWER MOTOR ASSEMBLY 8.
Page 981 Section 50 - Climate Control - Chapter 1 Cab HVAC Box Components - Automatic Temperature Control RI00A009 1. LID ASSEMBLY 8. A/C SUCTION LINE TUBE 15. THERMAL EXPANSION VALVE 2. ATC CONTROLLER 9. A/C LIQUID LINE TUBE 16. DRAIN HOSE 3.
Page 982: Chassis Components
Section 50 - Climate Control - Chapter 1 Chassis Components RIGHT HAND SIDE FRONT 1. RECEIVER DRYER 2. CONDENSER 3. COMPRESSOR 4. HIGH PRESSURE SWITCH 5. PRESSURE TUBE 6. SUCTION TUBE 7. HEATER SUPPLY 8. HEATER RETURN RRI06A027/RI06028/RI06029 50-1-11...
Page 983: Automatic Temperature Control (Atc) Operation
Section 50 - Climate Control - Chapter 1 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION The ATC controller is a closed loop control device The operator selects a desired cab temperature with which takes the data from a variety of inputs and the temperature control.
Page 984 Section 50 - Climate Control - Chapter 1 RD05J039 Manual selection of blower A. Blower OFF 1. Blower Speed Control speed which overrides B. Maximum Blower Speed controller selection C. Automatic Mode 2. ATC Switch Selects operational mode D. OFF E.
Page 985 Section 50 - Climate Control - Chapter 1 4. Instrument Cluster Displays temperature setpoint Display and system status RD05J048 G. Digital Temperature Display: Displays current setpoint selected by the operator for desired cab temperature. On start-up flashes “88” for short time to indicate that the controller is initializing.
Page 986: Operation Modes
Section 50 - Climate Control - Chapter 1 Operation Modes Automatic Mode Maximum Heating in Automatic Mode - Maximum heating is selected by moving the Temperature Automatic mode is selected by placing the three Control Knob fully clockwise. In that mode, the position mode switch in Auto mode (down position).
Page 987: Automatic Operation Summary
Section 50 - Climate Control - Chapter 1 Automatic Operation Summary (ATC switch set to “Auto,” and “Auto” displays on the Instrument Cluster Display. No fault codes active.) Controller needs a 2°F (1°C) difference between the setpoint and temperature sensed Temperature at cab sensor before responding - engaging the compressor or opening the heater Argument...
Page 988: Defog/Dehumidify Operation Summary
Section 50 - Climate Control - Chapter 1 Defog/Dehumidify Operation Summary (Defog/Dehumidify switch “ON”, Defog light ON. No fault codes active.) Controller needs a 2°F (1°C) difference between the setpoint and temperature sensed Temperature at cab sensor before responding - engaging the compressor or opening the heater Argument valve.
Page 989: Atc Fault Codes
Section 50 - Climate Control - Chapter 1 ATC Fault Codes ATC fault codes display on the Instrument Cluster display. The display toggles between the current cab temperature setpoint and the fault code. ATC fault codes are not recorded or stored. If more than one fault code is active, the codes display sequentially on the Instrument Cluster Display and alternate with the temperature setpoint.
Page 990: Atc Fault Code 112
Section 50 - Climate Control - Chapter 1 ATC Fault Code 112 Cab temp sensor shorted to ground Cause: Wire harness/connector failure Temperature sensor failure ATC module failure Possible failure modes: ATC module defaults to manual mode. Solution: 1) Disconnect cab temp sensor and check its resistance. It should measure around 10K Ohms at room temperature.
Page 991: Atc Fault Code 116
Section 50 - Climate Control - Chapter 1 ATC Fault Code 116 Evap temp sensor shorted to ground Cause: Wire harness/connector failure Temperature sensor failure ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Disconnect evap temp sensor and check its resistance. It should measure around 10K Ohms at room temperature.
Page 992: Atc Fault Code 128
Section 50 - Climate Control - Chapter 1 ATC Fault Code 121 Temperature select pot open or shorted to power Cause: Wire harness/connector failure Temperature pot failure ATC module failure Possible failure modes: ATC module defaults to 72 F (22 C) setpoint.
Page 993: Atc Fault Code 130
Section 50 - Climate Control - Chapter 1 ATC Fault Code 125 High pressure switch (+) shorted to power Cause: Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the short could be on either leg of the switch.
Page 994: Atc Fault Code 132
Section 50 - Climate Control - Chapter 1 ATC Fault Code 127 High pressure switch (-) shorted to power Cause: Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the short could be on either leg of the switch.
Page 995: Atc Fault Code 134
Section 50 - Climate Control - Chapter 1 ATC Fault Code 129 High pressure switch cycling error (2 times in 1 minute) Cause: Incorrect charge in system Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the failure could be on either leg of the switch.
Page 996 Section 50 - Climate Control - Chapter 1 ATC Fault Code 131 Low pressure switch (+) shorted to ground Cause: Wire harness/connector failure NOTE: If system is properly charged, then the low pressure switch will be closed and the short could be on either leg of the switch.
Page 997 Section 50 - Climate Control - Chapter 1 ATC Fault Code 133 Low pressure switch (-) shorted to ground Cause: Wire harness/connector failure NOTE: If system is properly charged, then the low pressure switch will be closed and the short could be on either leg of the switch.
Page 998: Locating System Problems Without Fault Codes
Section 50 - Climate Control - Chapter 1 Locating System Problems Without Fault Codes Controller-Based Resistance Tests Pin ID 36-Pin Wire/ Fault Conn Description Color Code Expected Result/Reference --> Can Low CAN LO --> Can High HIGH If open line, see Heater Control Valve. -->...
Page 999 Section 50 - Climate Control - Chapter 1 C/F Ground Selection 143-N Blower Input 326-Or Set Point Input 103-Or Air Direction Input 154-Or DEFSW- Defog Switch Cab Pressure Input OPEN High Pressure + Input 80-Or High Pressure - Input HP-Bk Low Pressure + Input LP-Or Low Pressure - Input...
Page 1000: Atc Controller Test (Connector J8 Test Points)
Section 50 - Climate Control - Chapter 1 ATC Controller Test (Connector J8 Test Points) The following tests determine whether the ATC controller requires replacement, since it tests primary input and output circuits. Some test steps isolate system problems to specific circuits which can simplify general troubleshooting.

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New Holland T8010 Manual

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