CA.

SEIII
MX Magnum - Service Manual
Book 1 - Table of Contents

Description Book Section

Number Number
Standard Torque Specifications 1 1000
Safety, General Information/Maintenance Schedule 1 1001
General Specifications and Special Torques 1 1002
Engine Removal and Installation 1 2002
Fuel Tank Removal and Installation 1 3001

Rae 6-14200 <C> 2002 Issued 10-02

 MX Magnum
MX210. MX230. MX255. MX285

Rae 6·14200 <l:>2002 2

Issued 10-02
 Section
1000

Standard Torque Specification

CASE CORPORATION Cl 2002 Case Corporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 7-66611 November, 2002
1000-2

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 Grade 8 Bolts, Nuts, and Studs
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.
0 ® ©"
Pound- Newton
Size Inches metres
Grade 5 Bolts, Nuts, and Studs 114 inch 14410 180 161020
5/16 inch 288 to 348 33 to 39
0 0 @ :Winch 54010648 61 to 73
Pound- Newton
Size Inches metres Pound- Newton
1/4 inch 10810 132 12 to 15 Size Feet metres
5/16 inch 204 to 252 23 to 28 7116 inch 701064 9510 114
:Winch 42010504 481057 1/2 inch 110to132 149 to 179
9/18 inch 18010 192 21710280
Pound- Newton 5/8 inch 220 to 264 298 to 358
Size Feet metres 314 inch 38010456 51510618
7116 inch 541064 131067 7/8 inch 600 to 720 814 to 976
1/2 inch 80 to 96 109to130 1.0 inch 90010 1080 122010 1465
9/16 inch 11010132 14910 179 1-1 /8 inch 1280 to 1440 1736 to 1953
5/8 inch 150to180 203 to 244 1-114 inch 1820102000 2466102712
314 inch 27010324 36610439 1-318 inch 2380 to 2720 3227 to 3688
7/8 inch 400 to 480 542 to 651 1-11'2 inch 3180103580 4285104827
1.0 inch 58010696 76710944 NOTE: Use thick nuts with Grade 8 bolts.
1-1 /8 inch 800 to 880 1085 to 1193
1-1/4 Inch 1120 10 1240 1519101661
1-318 inch 1460 to 1680 1980 to 2278
1-112 inch 1640102200 2631102983

~.c 7-6861 1 Revised 2-99 Printed in U.S.A

 1000-3

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.
Grade 10.9 Bolts, Nuts, and Studs
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.
e
Pound- Newton
Size Inches metres
Grade S.S Bolts, Nuts, and Studs M4 361048 41115
M5 84 to 96 9 to 11

® Me
M8
132111156
324 to 384
1510 18
37 to 43
Pound- Newton
,Size Inches metres
M4 241036 31114 Pound- Newton
Size Feet metres
M5 60 to 72 7 to 8
Ml0 541064 731087
Me 9610 108 111012
M12 93to112 125to150
M8 228 to 276 26 to 31
M14 14810 179 20010245
Ml0 45810540 521081
M16 230 to 280 310 to 380
M20 45010540 61010730
Pound- Newton
Size Feet metres M24 780 to 940 1050 to 1275
M12 861079 90111107 M30 147010 1770 2000 to 2400
M14 106to127 144 to 172 M36 2580 to 3090 3500 to 4200
M16 16010200 21710271
M20 320 to 380 434 to 515 Grade 12.9 Bolts, Nuts, and Studs
M24 50010600 67510 815
M30 920 to 1100 1250 to 1500
M36 160010 1950 2175102600
Usually the torque values specified for grade 10.9 fasteners
can be used satisfactorily on grade 12.9 fasteners.

Rae 7-68611 Revised 2-99 Printed in U.S.A

1000-4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube 00 Thread Pound- Newton Tube 00 Thread Pound- Newton
Hose 10 Size Inches melres Hose 10 Size Inches metres
37 Degree Flare Fitting Straight Threads with O-ring
1/4 inch 7/16-20 72 10 144 810 18 114 inch 7/16-20 14410228 16 to 28
8.4mm 6.4mm
5/16 inch 1/2-20 9610192 111022 5/16 inch 1/2-20 192 to 300 22 to 34
7.9 mm 7.9mm
318 inch 9116-18 12010300 141034 318 inch 9116-16 30010480 341054
9.Smm 9.5mm
1/2 inch 314-16 18010504 20 to 57 1/2 inch 3/4-16 540 to 804 57 to 91
12.7 mm 12.7 mm
518 inch 716-14 30010696 341079
15.9mm Tube 00 Thread Pound- Newton
Hose 10 Size Feet metres
Tube 00 Thread Pound- Newton 518 inch 718--14 581092 7910 124
Hose 10 Size Feet metres 15.9mm
314 inch 1-1/16-12 401080 54 10 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0mm 19.0 mm
7/8 inch 1-3116-12 60 to 100 81 to 135 7/8 inch 1-3116-12 100 to 180 136 to 216
22.2 mm 22.2mm
1.0 Inch 1-5116-12 75 10 117 10210 158 1.0 inch 1-5/16-12 117to187 159 to 253
25.4mm 25.4 mm
1-1 /4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-516-12 18510 264 22410 357
31.8 mm 31.8mm
1-112 inch 1-716-12 21010250 26510338 1-1 /2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm

Split Flange Mounting Bolts

Pound- Newton
Size Inches metres
5116-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7116-14 42010540 47 to 61

Pound- Newton
Size Feet metres
112-13 55 to 85 74 to 88
5/8-11 140 to 150 190 to 203

ac 7-686 11 Revised 2-99 Printed in U.S.A

 1000·5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Nom.
SAE
Dash Thread Pound- New10n Thread Pound· New10n
Size Tube OD Size Inches metres Size Inches metres
Q·ring Boss End
Q·ring Face Seal End Fitting or Lock Nut
-4 114 inch 9116-18 12010 144 141016 7/16-20 20410240 231027
6.4mm
·6 318 inch 11/16·16 216 to 240 24 to 27 9/16·18 300 to 360 34 to 41
9.5mm
-8 112 inch 13116-16 38410480 431054 314-16 54010600 611068
12.7mm

Thread Pound· New10n

Size Feet metres
·10 518 inch 1·14 55210672 6210 76 718-14 601065 811068
15.9mm

Nom. 1·1/16·12 85 to 90 115to122

SAE
Dash Thread Pound· New10n 1-3116-12 9510 100 12910 136
Size Tube OD Size Feet metres
·12 314 inch 1-3116-12 651060 9010 110 1·5116·12 115t0125 156 to 169
19.0mm
·14 7/8 inch 1·3116·12 65 to 80 90toll0 1-518-12 15010 160 20310217
22.2 mm
·16 1.0 inch 1-7116-12 9210 105 12510 140 1·7/8·12 190 to 200 258 to 271
2S.4mm
·20 1-1/4 inch 1-11/16·12 125 to 140 170 to 190
31.8 mm
·24 1-112 inch 2·12 150 10 180 20010254
38.1 mm

Rac7-66611 Revised 2-99 Printed in U.S.A

 Section
1001

SAFETY, GENERAL INFORMATION I MAINTENANCE

SCHEDULE

CASE CORPORATION
C 2002 Case Corporation
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13960 November, 2002
1001-2

TABLE OF CONTENTS
SAFETY ................... ........................................................................................................... ................ ..................... 3

GENERAL INFORMATION ......................................................................................................... ............................ 5

Cleaning ............................................ .................... .................................. .... .................................. ....................... 5
Inspection ............................................................................................................................................................. 5
Bearings ....... ................ ...... .............. .................... ............ ......................................... ... ........................................ 5
Needle Bearings ....................... ........ ................................................................................. ................... ............... 5
Gears ................. ............................................................................................................................................. ..... 5
Oil Seals, O-rings and Gaskets ........................... ....... .......................................................................................... 5
Shafts ... ...................................................... .......... ........ ........................... ........ .... ............ ................................ ..... 5
Service Parts ........................................................................................... ....................................... .......... ............ 5
Lubrication ........................................................................... ........... ......................................................... ............ 5

MAINTENANCE SCHEDULE ......................................................................... ............................................. ............ 6

Rae 6-13960 Issued 11·02 Printed in U .S.A

 1001·3

SAFETY
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULL Y READ THE MESSAGE THA T
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B

To prevent injury always follow the Warning, Caution and

Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch
when servicing or repairing the machine. One warning tag is
supplied with each machine . Additional tags are available
from your service parts supplier.
Before servicing a machine, park the machine on hard level
ground . Turn off the engine, apply the parking brake and
remove the key from the key switch. Put blocks in front of and
behind either the front or rear wheels .
WARNING: Before starting engine study
Operators Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating. It is your
&. responsibility to understand and follow
manufacturers instructions on machine
operation, service, and to observe pertinent
laws and regulations. Operator and Service
Manuals may be obtained from your
equipment dealer. Ml03A

• • WARNING: If you wear clothing that is too

loose or do not use the correct safety
equipment for your job, you can be injured.
"" Always wear clothing that will not catch on
~ objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing. M492

Reason
See Other Side

WARNING: When working in the area of the

S .g ned by
C.ow- ... " ....
--
"' -
201L95
""
fan belt with the engine running, avoid loose
~ clothing if possible, and use extreme caution.
M493

WARNING: Read the operators manual to WARNING: When doing checks and tests
&. familiarize yourself with the correct control
functions. M489
""
on the equipment hydraulics, follow the
~ procedures as they are written. DO NOT
change the procedure. 1.1494

WARNING: Operate the machine and

"" equipment controls from the seat position WARNING: When putting the hydraulic
~ only. Any other method could result in cylinders on this machine through the
serious injury. M490 &. necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way. 1.1495

"" WARNING: This is one man machine, no

~ riders allowed. M491

Rae 6-13960 Issued 11 ...()2 Printed in U.S.A.

1001 ·4

WARNING: Always wear heat protective
.& gloves to prevent burning your hands when
handlmg heated parts. SM1 21 A
WARNING: Lower all attachments to the
A. ground or use stands to safely support the
ill attachments before you do any maintenance
or service. M496
WARNING: Hydraulic oil or diesel fuel
leaking under pressure can penetrate the
skin and cause infection or other injury.
To Prevent Personal Injury:
Relieve all pressure, before disconnecting
A. fluid lines. Before applying pressure, make
ill sure a/l connections are tight and
• components are in good condition.
Never use your hand to check for suspected
leaks under pressure.
Use a piece of cardboard or wood for this
purpose. If injured by leaking fluid, see your
doctor immediately. SM171 A
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
& a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer. M497
WARNING: When servicing or repairing the
machine. Keep the shop floor and operators
A. compartment and steps free of oil, water,
~ grease, tools, etc. Use an oil absorbing
material and or shop cloths as required. Use
safe practices at all times. M500
WARNING: Some components of this
"" machine are very heavy. Use suitable lifting
~ equipment or additional help as instructed in
the Service Manual. M501
WARNING: Engine exhaust fumes can
cause death . If it is necessary to start the
A. engine in a closed place, remove the exhaust
~ fumes from the area with an exhaust pipe
extension. Open the door and get outside air
into the area. M502
WARNING: When the battery electrolyte is
frozen, the battery can explode if (1), you try
to charge the battery, or (2), you try to jump
A. start and run the engine. To prevent the
~ battery electrolyte from freezing, try to keep
the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured. M503

WARNING: Batteries contain acid and

WARNING: When using a hammer to
remove and install pivot pins or separate
"" parts using compressed air or using a
~ grinder, wear eye protection that completely
.&
encloses the eyes (approved goggles or
other approved eye protectors). M498
explosive gas. Explosions can result from
sparks, flames or wrong cable connections.
To connect the jumper cables correctly to the
battery of this machine see the Operators
Manual. Failure to follow these instructions
can cause serious injury or death. M504

WARNING: Use suitable floor (service)

"" jacks or chain hoist to raise wheels or tracks
~ off the floor. Always block machine in placed
with suitable safety stands. M499

Rae 6·13960 Issued 11 ·02 Printed in U.S.A.


GENERAL IN FORMATION
Cleaning
Clean all metal parts except bearings, in mineral spirits or by
steam cleaning. Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts. Clean oil passages
with compressed air.
Inspection
Check all parts when the parts are disassembled. Replace all
parts that have excessive wear or are damaged. Small
scoring or grooves can be removed with a hone or crocus
cloth. Complete visual inspection for indications of wear,
pitting and the replacement of parts necessary will prevent
early failures.
Bearings
Clean bearings with a good clean solvent and permit to air
dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.
Check bearings for smooth easy action. II the bearing has a
loose fit or rough action, the bearing must be replaced.
Needle Bearings
Before you press needle bearings into a bore, always remove
any metal protrusions in the bore or the edge of the bore .
Before you press bearings into position , put petroleum jelly
on the inside and outside diameter of the bearing.
Rae 6-13960
1001-5
Gears
Check all gears for excessive wear or damage. Replace gears
as necessary.
Oil Seals, O-rings and Gaskets
Always install new oil seals, a-rings and gaskets. Put
petroleum jelly on seals and a-rings.
Shafts
Check all shafts for excessive wear or damage. Check the
bearing and oil seal surfaces on the shafts for excessive wear
or damage. Replace shafts as necessary.
Service Parts
Always install genuine Case service parts. When ordering
refer to the Parts Catalog for the correct part number of the
genuine Case replacement items. Failures due to the use of
other than genuine Case replacement parts are not covered
by warranty.
Lubrication
Use only the oils and lubrication specified in the Operators or
Service Manual. Failures due to the use of non specified oils
and lubricants are not covered by warranty.
Issued 11·02 Printed in U.S.A.
1001 · 6

MAINTENANCE SCHEDULE

Service Interval Maintenance Requirement Check Grease Change Clean

When Warning
Message Displays
Air Cleaner Element X
Engine Oil Level X
Every 10 Hours Or Daily Engine Coolant Level X
Transmission Oil Level X
Every 50 Hours Engine Primary Fuel FDter • Drain Water
Every 100 Hours Front Hitch (If Equipped) X
Battery Water Level X
Engine Air Intake Hoses X
Engine Coolant '--I-DeaeratIon Tank X
'Engine Oil And Filter X
Every 300 Hours
Front And Rear Wheel Bolt TorquM X
Front Axle And Rear Hitch (Note A) X
Fuel Tank - Drain Water
Differential And Planetary Oil Level (Note B) X
Engine Coolant Anttfraeze Protection X
Engine Coolant Filter X
Every 600 Hours Engine Coolant Hoses And Clamps X
Engine Fuel Filters X
Changeable PTO Internal Splines X
Engine Primary And Secondary Air Filter X
Every 1200 Hours Or
Engine Air PnocleaMr X
Annually
Differential and Planetary Oil X
Every 1200 Hours Engine valve AdlU8Iment (Model 210 & 230)
X
(Note C)
Every 1500 Hours Transmission Oil, Filter(s) and Breather X
Engine Coolant And Coolant Conditioner X
Engine Fuel Injection Nozzles and Pump See
Every 2400 Hours X
(Note C)
Engine Crankshaft Dampener (Note C) X
Cab Air And Recirculation Filters X X
Cab Air Filter Dust VaNe X
Engine Primary Air Filter X
As Required Grill Screens, Radiator, CondenserlFuel Cooler,
X
Oft Cooler, Air to Air Cooler
Serpentine Belt X
Tire Pressure X

Note A -In severe or wet conditions, Interval is every 10 hours or daily.

Note B - Perform initial service in first 50 hours of operation.

Rae 6·13960 Issued' ,-02 Printed in U.S.A.

 1001-7
Note C - Dealer must perform this service.
NOTE 1: Check the tractor for leaks, rubbing hoses, loose bolts and trash build up.
Repair all leaks, hoses and tighten loose bolts before operation.
NOTE 2: Check for wear and function .
NOTE 3: In dusty conditions the cab filter will require more frequent cleaning. (Renew as necessary).
NOTE 4: Also clean the filter element whenever the service monitor illuminates.
NOTE 5: Change at first 50 hours.
NOTE 6: In severe operating conditions grease daily.
NOTE 7: After any wheel adjustment, check after 30 minutes then every 10 hours until torques stabilize.
NOTE 8: Recommend Dealer Service Item.

Rae 6·13960 Issued 1'-02 Printed in U.s.A.

p
 Section
1002

GENERAL SPECIFICATIONS AND SPECIAL TORQUES

CASE CORPORATION C 2002 Case Corporation

700 State Street Pri nted in U.S.A.
Racine, WI 53404 U.S .A. Rae 6-13870 October 1 2002
 1002-2

TABLE OF CONTENTS
GENERAL SPECIFICATIONS .................................................................................................... ............................ 3
Fluid Capacities and Types .......................................................... .... ..................................................... ............... 3
Hydraulic Specifications ............................................. .............. ............................................................................ 3
Electrical Specifications ................................................... ..................................•....................... .......................... 3
Cab Fuse Identification and Amperage .............................................. ............................................. ............. ........ 4
Cab Relay Identification (Facing Rear Window) .................................................................................................. 5
Engine Compartment Fuse/Relay Identification (Power Distribution Box) ................................................ ........... 5
Lamps and Bulbs .. ...... .......................................................................... ................................................ ............... 6
Accessory Connectors ............................................................................................. ............................................ 6
Air Conditioner System Specifications .. ............................................................................................................... 7
Engine Specifications ................................................ ............. .............................................................................. 7
Transmission Specifications ................................................................................................................................ 7
Hitch Specifications ....... .... ....................................................................... ........... ............ ......... ........................ .... 7

SPECIAL TORQUES ...................................................... ... ..•. ....................................................................... ........... 8

II

Rae 6-13870 Issued 10-02 Printed In U. S.A

 1002-3

GENERAL SPECIFICATIONS
Fluid Capacities and Types
All fluid capacities listed are a guide to the quantities required. Always use dipsticks, sight glasses or level plugs to
ensure that the units are filled to the correct level.

Coolant Capacity
MX 210 and 230 ............................. ................. ............................... ..... 22.7 liters 6 U.S. gal
MX 255 and 285 .......................... ............ .... ....................................... . 24.6 liters 6.5 U.S. gal
Fluid Type .................................... ............. .................................................. 50 Percent Ethylene Glycol and Water

Engine Oil Capacity

With Filter Change ................................................................................. 21 liters 5.5 U.S. Gal
Without Filter Change ............. ... ...... ... ........... ............... ......................... 19 liters 5 U.S. Gal
. Oil Type .................................................. .......................................................... Case No. 1 Multi·Viscosity Engine Oil

Transmission/Hydraulic System Capacity

2WD and MFD ......................................................•.............................. 172 liters 45.5 U.S. gal
Oil Type ..... .............. ..... ............... ................................................................................. .............. Case Hy·Tran® Ultra

MFD Axle
Differential
10 Boll.. ........................................................................................ ..... 12.3 liters 13 quarts
12 Boll.. .................... .................................... ............ ...................... ... 11 .3 liters 12.3 quarts
Oil Type ................ ....................... Case 135 H EP Gear Lubricant, SAE 85W-140 with Limited Slip Additive B91246
Planetary (Each)
10 Boll.. ...... .................. ....................................................................... 1.3 liters 2.8 U.S. pints
12 Boll.. ........................ ....................................................................... 3.2 liters 6.8 U.S. pints
Oil Type .............. .... ............................................................................ Case 135 H EP Gear Lubricant, SAE 85W-140

Fuel Tank
Standard· MX 210 and 230 ............................................ .................. ....... 492 liters 130 U.S. gal
Standard· MX 255 and 285 (Optional· MX 210 and 230) ....................... 606 liters 160 U.S. gal
Fuel Type ....... ......................................................................................................... ................................. No. 2 Diesel

Hydraulic Specifications
Pump Type .. ...................................... ...... .................................. ......... Axial Piston, Pressure and Flow Compensated
Maximum Pressure at Rated Engine RPM at Pump .. ............ ................ ..... 224 bar 3250 psi
Maximum Flow at Remote Couplers at 2000 Engine RPM
Standard ...................................................................... ........... .............. 136 I/min 36gpm
Optional ........................................................... ..................................... 244 limin 64gpm

Electrical Specifications
Type of System .................................................................. ................................................... 12 Volt Negative Ground
Batteries .......................................................................... .............. Two 1000 CCA Low Maintenance, Group Size 31
Alternator ................................................... ...................................................... .................. ..... Bosch 135 Amp Output
Cranking Motor ............ .......... ...... ................................. ........ .............................................. Nipendenzo, 12 Volt, 4 kw

Rae 6- 13670 Issued 10-02 Printed in U .S.A.

1002-4

Cab Fuse Identification and Amperage

lsol CJ I 11"1 \W I'SAlls'l qJ I"AI 11CJ I 11541 CJ I 11551 CJ I 11 561 .:~~~~ ISA
53

110 I'SAIH 0 I'''IHCJI IH D FAI H 1)111 130~ H f:!I 2OAIH~()I H

43

1361 ~ I"AII 371 'c;:.~U H 13.1 'ol l'O A1 1391 ~l I'O AI H oo:~~·",I WAI H ¢ SAIH ¢ 1,0.1
AIH CJ I 11"1 '" I'OAI H':;:w~H 1""1'~P IW
I'_I ~ I'O SWB. AIi"! ~ SAII,SI CJ I I
1221 ~S H I·'I :rF 1 ,,,11·'1Eafll,o.l l·SIi}Ccr I20AI H ~:~' H 1.71CJ 11 28IC·~~~~·1 5A I
H 0 H2oAI'SI ~~U,:~~ HH b Hi's! lID 1,0AII'-I~!J HH A HH pEE H
W 1·1 =} 1 II -1 dJ 1'5AII ,ol¢~¢I'SAI I "1 l;?", I20AIH E:!J 13OAII 1 =} I30AIH CJ I I
13

::17" .....' . ."

I' I 0 HI ·ICJ I 1131fRJ FAI I' I rcfO I'MI ISI 53 I20A1 161 ~ I,Mil 710 1,0.1
RI02G018

Fuse Fuse Fuse

Fuse Circuit
Circuit No. Amp
No. Amp
24 Mirror/Radio 10
1 Electronic Governor (MX255 & MX28S) 5
Cruise Control 5 25 EtherIHom 20
2
Auto Climate Display (With Fuse; 'C,
3 Rear Fender WOIIdIgh1s 20 28 5
Without Fuse; ' F)
4 Beltline Worklights 10
29 Seat Heater 10
5 Roof WOIIdIgh1s 20
31 AFS (Switched) 10
6 WorklightiHeadlight Interlock 10
32 AFS (UnswItched) 10
7 Battery Power to Key Switch 5
33 RH ArmRest Controller (Switched) 10
Headliner Shelf Auxiliary Power/3-Pin!
8
Cigar Outlets (Unswitched)
20 34 True Ground Radar 5
35 Transmission Controller 20
9 Seat Power 15
Cab Pressurizer Blower (Continuous) 15 36 Remote Hydraulic Controller 15
10
37 Tractor Instrumentation (Switched)
Cigar UghterlRH Fender Console
11 20
(Unswitched) 38 PTOIOIffarential LockIMFO Controller 10
12 Exterior 7-Pin Connector (Switched) 30 39 Hitch Controller 10

13
RH Front PostIRH Fender 3-Pin
30 41 ea. Data Bus. Tractor 5
AwdUary Connectors (Unswilched)
42 Case Data Bus Diagnostic Connector 10
15 Governor (MX255 & MX285) 30
RH Front Poat/RH Fender 3-Pin
46 30
16 Tractor Instrumentation (Unswilched) 5 Connectors (SwitChed)
18 High Beam Relay 10 47 HVAC Controller 30
Dome UghIIMep UghtIRadio 5 Headliner Shelf 3-Pin ConnectolS
19 46 20
(UnswItched) (Switched)
20 Amber Flashers 20 49 HVAC Blower 30
21 Tail LIghts 5 51· Front WiperlWasher 15
22 Stoplights 5 52 Rear WiperlWasher 15

23 Strobe LightlBecon 15 56 Italian Brakes 5

(Unswitched) - Unswitched power (Continuous).

(Switched) - Power available when keyswitch is in "ON" position .
• = Circuit breaker.

Rae 6-13870 Issued 10·02 Printed in U.S.A.

 1002-5

Cab Relay Identification (Facing Rear Window)

RH02G061

1. BRAKE LAMPS 6. NEUTRAL RELAY 11. GOVERNOR (KEY SWITCH)

2. OPEN 7. OPEN 12. FENDER WORK LAMPS
3. REAR ROOF WORK LAMPS 8. BELTUNE WORK LAMPS 19. CONTROLLER POWER
4. WORK LAMP INTERLOCK 9. FRONT ROOF WORK LAMPS
5. PARK LATCH 10. CAB PRESSURIZER BLOWER

Engine Compartment Fuse/Relay Identification (Power Distribution Box)

0
CD
I~ 0~
25A I~~

."
(f)
is
30A I ~~ 0
c m
@ <:: 1

i0
."
."
@21 0 1
®dl~1 0~ 1
~i
25A 30A

0:n l 30A 0~ 1 15A

I
I~ 0
®~0;1 15A
I~ 0
~
~~ ~
®;)l 0; 1 15A 0&:0; 1 15A
(f)
(f)

RH02G062
1. CENTERED & SIDE 6. FUEL SHUT OFF RELAY 11. FUEL SHUT OFF RELAY 16. NOT USED - DIODE 1
WORKLAMP RELAY FUSE FUSE
2. HIGH/LOW BEAM & 7. STARTER RELAY FUSE 12. CENTERED AND SIDE 17. NOT USED - DIODE 2
BYPASS RELAYS FUSE WORKLAMP RELAY
3. STARTER RELAY FUSE 8. RH LO BEAM RELAY FUSE 13. HIGH BEAM RELAY
4. RH HI BEAM FUSE 9. LH LO BEAM RELAY FUSE 14. LOW BEAM RELAY
5. LH HI BEAM RELAY FUSE 10. STARTER RELAY 15. HIGH BYPASS RELAY

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1002-6

Lamps and Bulbs

Application G_E. Bulb No. (Watts)
Dome Lamp Bulb ..... " ... " .. " " ." ..... " " " ."" ...... ". " "" ... " ..".""."" " ...""." ".""""". Case Part No. 3050958R1, (10W)
Console Lamp Bulb .""." "'''''''''''''''' ''' ''''''''''''''"."" .. "" "".""""."" """""""" .." .""" "".".""".""""""""" No. 168
Flasher Lamp Bulb " "" .. "".""". """ .." ... """ " "" ".".".".""" .."" .. ""."" " " "." "." ... "" ""."""."" " .. " .. " .. "" No. 1156
Head Lamps "."".""" .. .". ". """" .. " .. " .."" "."". " ""." " .." ... "." " ". " " ""." ... ." ". "."""" No. H4, (55W/60W Halogen)
Brake Lamps """"""""""""." .. " .. " ""."""""" " .. ". """""" " " ." ".""" """" " .. """ .. """""" ."" ..""""" .". 3157 (37W)
Side Work Lamps ". " ."."".".""".""" ..""." ... " .""""" .. " .. ""."""" " ." .. "" ." " .. " "" "" .. " .. " .. "."."."" " . No. 885, (50W)
Front and Rear Flood Lamps,
Optional Fender/Rear RooflBeltline Flood Lamps .""."".""""""""" " " .""".""". """""""""""""",, No. H3, (55W)
Tail Lamp Bulbs ."."."""""." .. """"."""""""." .. "."". ""."""" """."."" ... "."". " " """.""" .. """".". No. 3157, (37W)
Fender Standard Work Lamp. " ""."."" .. " .. " "" ... " ." .. ""."""".". " ."""."" ."" ... ".""."."." .. """" .. " .. " No. 894 , (37W)
Front Roof Work Lamp " "" .. " .." "". " ."". " ...... "" .. "".""".".""""."." .. "." ""."".""" " """""""""." .". No. 894, (37W)
Center Grille Work Lamp " .. """.""""""."." .. " .. """ .. ""." " " """."." .. "."" " " ... " ." ... "."""""""""".".No. 885, (50W)
HID Center Work Lamp " "" " """ """"""""" " """" " .. "" " .""" ... "."."".""""".",,,,,,. Case Part N. 232455A2, (35W)
Strobe Light ......... ............ ............... .... ................................. ................................................................ No. 400, (80W)
Number Plate Lamp ."."" .. """" ." " ." .." .. ... ..""". "" ... " ." .."""""" """ ...... """" """ ."" .. " .""". Case Part No. P40556

Accessory Connectors
7 Terminal Electrical Outlet " """""" """"" ."""" "" .. " .""""""" """" ....."" ."""",,. Equipped for Directional Lamps,
Tail lamps and 12 Volt Power for
Implements with Fuse Protection
3 Pin Cab Connector (2 Standard) (2 Optional) ." " " " " "" " ".""."" "." """.""""""""." " " "."".12 volt Power with/or
with/out Key Switch
and Direct Ground for
Implement Controllers
and Monitors

WARNING: Do not look directly into the High Intensity Discharge Lamp. Eye damage can occur. M638

WARNING: Do not tamper with the ballast on the High Intensity Discharge Lamp as it contains high
voltage. Personal injury or death can occur. M639

Rae 6-13870 Issued 10·02 Printed in U .S.A

 1002-7

Air Conditioner System Specifications

Refrigerant
Type ......... ................. .........................................................•................................ HFC-134A Per ARI Standard 700
System Capacity ..... ...................... ................. ......... ......................... 2100 grams 4.631b
Compressor
Manufacture ...................................................•... ...... ................................................................................ SANDEN
Model ............................................................. ............. ............................................................. ...SD 7H15MD4609
Clutch Current Draw at 12 Volts ..................... ................................................................. ............................2 Amps
Clearance Between Front Plate and Pulley ........... ........................ 0.4 to 0.8 mm 0.016 to 0.32 inch

Engine Specifications
Make ..................................................................................................•....................................... .......................... CDC
Model .... ........................................ ....... .... ................. .................................................................. 6TAA - Magna Force
Firing Order ... ............................... ... ...................••.................................................................................. .. . 1-5-3-6-2-4
Bore and Stroke ........................................................... .................................................................. 114 mm x 135 mm
Displacement ................................................................................................................................................. 8.3 liters
Engine Speeds
High Idle
MX 210 .. ....... .. ...... ............................................... ............................ ............... ......................... 2195 to 2285 RPM
MX 230 ...... ......................................................................... .......... ........................................... 2175 to 2265 RPM
MX 255 and MX 285 ........................................................ .................................................. ..... 2230 to 2250 RPM
Rated Engine Speed All Engines ..................................................... ...................................................... 2000 RPM
Low Idle All Engines .............................................. ....................................................... .. .......... ..... 850 to 950 RPM
Valve Clearance-Engine Cold
Intake Valves ..... .......................... .......................................................... 0.25 mm 0.010 inch
Exhaust Valves ..... .......... ....................................................................... 0.50 mm 0.020 inch

Transmission Specifications
Number of Forward Speeds ........................... ...... .... .................... .................................. .............. 18 - Full Power shift
Reverse Speeds ..........................................•............................................................ ................................................. 4
Creeper Speeds (If Equipped) ........ •............................ ...............••............•.......................... 6 Forward and 2 Reverse

Hitch Specifications
Type Hitch .................... ................................................................. Three Point, Category III (Convertible to II or IIIN)
Lift Capacity at 24 Inch (610 mm) Behind Lift Point
Standard Hitch
MX 210 and 230 ................................................................................................................... 6 332 Kg (13 960 Ib)
MX 255 ................................................................................... .............................................. 6 789 Kg (14970 Ib)
MX 285 ................................................... .................................................. ............................ 7301 Kg (15 970 Ib)
Optional Hitch
MX 210 and 230 .. ................................................................................................................. 7301 Kg (15 970 Ib)
MX 255 and 285 ................................................................................................................... 8 138 Kg (17 920 Ib)
European Hitch
MX 210 .............................. ................................................................................................... 6283 Kg (13 850 Ib)
MX 230 and 255 ................................................................................................................... 6706 Kg (14780 Ib)
MX 285 ................................................................................................................................. 7 416 Kg (16 350 Ib)
Type Draft Arms
MX 210 and 230 ............. ............................. ....................... ................................................................. .Telescoping
MX 255 and 285 ................................................................................................. Rigid With Integral Quick Coupler
Position Control and Draft Control ...................................................................................... ......................... Electronic

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1002-8

SPECIAL TORQUES
Alternator
Mounting Bolts ......................................... ................................ ......... ..... 100 Nm 74 Ib ft
Pulley Retaining Nuts ....... ............................................. .................. 60 to 70 Nm 44 to 52 Ib ft

MFD Steering Cylinder and Axles

King Pin Retaining Bolts .............................................................. 156 to 170 Nm 115t01251b ft
Socket Clamp to Steering Cylinder ... ............... ..... .............. ..... ..... 95 to 108 Nm 70 to 80 Ib ft
Steering Cylinder Tapered Stud ... ..................... 10 Bolt - 190 1 12 Bolt - 272 Nm 10 Bolt 140 / 12 Bolt 200 Ib ft
Tie Rod Tapered Stud ..... ........................... ............................................ 275 Nm 200 Ib ft
Differential Housing to Axle Bolts .................... ............................ 122 to 135 Nm 90 to 100 Ib ft
Ring Gear Bolts ...................... ........................ ... ........ ........ .......... 163 to 190 Nm 120 to 140 Ib ft
Wheel Carrier to Knuckle Bolts ................................................... 110 to 125 Nm 89 to 90 Ib ft
Planetary Carrier to Wheel Hub Screws ......................................... 10 to 16 Nm 7 to 12 Ib ft
Wheel Hub Drain 1 Filler Plug ... ................................•.. ............................. 40 Nm 30 Ib ft
Front Wheel Disc to Rim Nuts - MFD ............. ........ .... ................. 298 to 366 Nm 220 to 270 Ib ft
Disc to Front Axle Hub Nut - MFD ................. .................... ... ....... 385 to 425 Nm 285 to 315 Ib ft
Front Wheel Bolts - 2WD .... ............. ............................... ............. 190 to 217 Nm 140 to 160 Ib ft

MFD
Drive Shaft Retaining Bolts ......... ............................................ ........ 58 to 63 Nm 78 to 85 Ib ft
MFD Output Shaft Bearing Cage
M20 X 60 - 12.9 ........................... ....................... ......................... 375 to 485 Nm 277 to 358 Ib ft
M20 X 150 - 12.9 .. ... .................................................................... 375 to 485 Nm 277 to 358 Ib ft
Drop Box to Speed Housing
M20 X 110 -10.9 ...... ................................... ............. ................... 430 to 486 Nm 317 to 3581b ft
M20 X 280 - 8.8 .. ...... ............ ..... ................ ......................... ..... .... 250 to 428 Nm 184 to 3161b ft
M16 X 70 - 8.8 ....................................................... ............ .......... 234 to 260 Nm 173 to 1921b ft

Transmission
Speed to Range Transmission Retaining Bolts
M16 X 60 - 8.8 ................... ....................................................... 234 to 260 Nm 173 to 192 Ib ft
M16 X 80 - 10.9 ....... ............................................................ ..... 220 to 250 Nm 162 to 1841b ft
M20 X 90 - 10.9 ........................................................................ 430 to 486 Nm 317 to 358 Ib ft
Range Transmission to Rear Frame
M16 X 60 - 8.8 ................... ............... .................. ... ............ ....... 232 to 262 Nm 171 to 1931b ft
M16 X 80 - 10.9 ................................ ............ ............................ 220 to 250 Nm 162 to 1841b ft
M16 X 110 -10.9 ................................... ................................... 220 to 250 Nm 162 to 184lb ft
Wheel to Hub Bolts ....... ..................... .............................................. 528 to 569 Nm 390 to 420 Ib ft
Wheel Bushing Bolts ..................... ............................................ ...... 300 to 350 Nm 220 to 260 Ib ft
Axle Carrier to Rear Frame - All ...................................................... 229 to 265 Nm 169 to 1951b ft
(Thru Axle Carrier Flange Into Rear Frame)

Differential and Differential Lock

Ring Gear Retaining Bolts ........................................ ................... 297 to 328 Nm 219 to 242 Ib ft
Differential Lock Clutch Cage Retaining Bolts ............... .............. 297 to 328 Nm 219 to 2421b ft

Hydraulic PTO
PTO Housing Retaining Bolts .......................... ....... ......... ......................... 55 Nm 40 Ib ft
PTO Speed Sensor ............................... ................ .......................... 16 to 22 Nm 12 to 16 Ib ft

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 1002-9
Hydraulics
Hydraulic Pump Mounting Bolts .................................................. 134 to 151 Nm 99t01121bft
Charge I Lubrication Pump Mounting Bolts ....... ..........•............... 134 to 151 Nm 99 to 1121bft
Solenoid Valve Installation Torque .... .............................................. 19 to 25 Nm 14 to 18.51b ft
Solenoid Valve Coil Retaining Nut... ........... ......................................... 5 to 8 Nm 4t06lbft
Remote Valve Retaining Nuts ......................................................... 61 to 69 Nm 45t0511bft
Load Check Valve Body .................................................................. 34 to 41 Nm 25 to 30 Ib ft
Load Check Poppet Spring Retainer ....... .... ........................................ 4 to 5 Nm 3t041bft
Check Valve Body ........................................................................... 16 to 19 Nm 12t0141bft
Check Valve Plug ................................................. ....... ..................... 4 to 4.5 Nm 3 to 3.5 Ib ft
PTO Spool End Plug ...... ............................................. .................... 19 to 25 Nm 14 to 18.5 Ib ft
Inching Spool End Plug ............. ........... ............................................ 19 to 25Nm 14 to 18.51b ft
Pressure Transducer ....................................................................... 19 to 25 Nm 14 to 18.51b ft
Rear Hitch
Top Link Mounting Bracket (M20) ......... .................................... ... 490 to 550 Nm 360 to 405 Ib ft
RH and LH "C" Bracket Casting Bolts (M24) ............................... 845 to 950 Nm 625 to 700 Ib ft
Rocker Tie Bolt (M24) ... ....... ........... ............ .......... .... .................. 490 to 550 Nm 360 to 405 Ib ft
Quick Coupler Latch Bolt (M 16) .................................................... 95 to 125 Nm 70 to 90 Ib ft

Air Conditioning
Compressor Clutch Retaining Nut... .............. ....... ............. ............... 15 to 20Nm 11t0151bft
Compressor Oil Fill Plug ................................................................. 15 to 24 Nm 11t0181bft
Dust Cover Screws ........... ................................................................. 7 to 11 Nm 5t081bft
Low I High Pressure Switch ............................................................ 14 to 20 Nm 10t0151bft

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 1002-10

Rae 6-13870
Issued 10-02 Printed in U.S.A.
 Section
2002

ENGINE REMOVAL AND INSTALLATION

CASE CORPORATION !C 2002 Case COrporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae &-13130 October 2002
I
2

TABLE OF CONTENTS
SPECIAL TORQUES ............... .............................................. .......................................................... ........................ 3
ENGINE REMOVAL ......................................... ....................................................................................................... 4
ENGINE INSTALLATION .................................................................. .............................................. .................... .. 12

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 3

SPECIAL TORQUES
Front Engine Mount Support Bolt .. .. ............................................................................. 101 to 113 Nm (75 to 83 Ib It)
Front Engine Mount Clamp Boll.. .............................. ...................................................... 59 to 106 Nm (44 to 78 Ib It)
Front Iso-mount Thru Boll.. ....................................................................................... 160 to 220 Nm (118 to 162 Ib It)
Fan Drive Mounting Bolt ............................ ....................................................................... 52 to 61 Nm (38 to 45 Ib It)
Drive Shalt Yoke Bolt (MX21 0 and MX230) ..... ...... .. ................ .. .. ..................... ................ 58 to 64 Nm (43 to 47 Ib It)
Drive Shalt Yoke Bolt (MX255 and MX285) ............ ................ ...................................... 101 to 113 Nm (75 to 83 Ib It)

Rae 6·131 30 Issued 10-02

4

ENGINE REMOVAL

STEP 1 STEP 3

Park the tractor on a hard , level surface . Put the
transmission shift lever in PARK. Turn off the engine
and remove the key. Place blocks in front of and
behind the rear wheels . Drain the radiator coolant
into a suitable, clean container.
Lift up and remove the air cleaner door from the left
side of the tractor. Remove the front windshield
washer hose (1) from the nozzle on the fi xed hood.
Remove the four nuts (2) and lift the fixed hood from
the right side of the tractor.

WARNING: Check and service cooling STEP 4

system according to maintenance
instructions. Hot coolant can spray out if the

.& deaeration tank cap is removed while system

is hot. To remove the adoration tank cap, let
system cool, turn to the first notch, then wait
until all the pressure is released. Scalding
can result from the fast removal of the
adoration tank cap. MBSS

STEP 2

Remove the left lower fi xed hood panel.

Remove the toolbox and battery cover. Disconnect

the negative (-) battery cable. Disconnect the positive
(+) battery cable.

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 5

STEP 5 STEP 8

Disconnect the main wiring harness connector. Remove the starter solenoid from the hood support.

STEP 6 STEP 9

Tag and disconnect the electrical plugs from the fuse Remove the windshield washer reservoir electrical
box. Remove the electrical plug for the tilt hood front connectors.
lamps. Remove the tilt hood. Refer to Section 9008 in
this service manual for the procedure.

STEP 7

Remove the passive terminator harness.

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l
6

STEP 10 STEP 11

On electronic injection pump models, remove the fuel On mechanical injection pump models, remove the
supply line (1) and the return line (2). Disconnect the optional foot throttle cable (1), if equipped , the hand
electronic injection pump wiring harness connector throttle cable (2) , the fuel supply line (3), and the
(3). engine wiring harness connector (4).

STEP 12

Disconnect the ether start tube from the intake

manifold on the left side of the engine.

Rae 6-13130 Issued 10-02


STEP 13
Disconnect the electrical connectors from the air filter
sensor (1) on the air cleaner outlet tube. Disconnect
the electrical plug (2) for the intake manifold
temperature sensor. Remove the three harness and
hose retainers (3) on the left side of the engine.
STEP 14
Remove the left and right fan shields by removing the
bolt (1) and pulling out on the shield.
STEP 15
Remove the air cleaner outlet tube at the
turbocharger elbow clamp (1). Loosen and remove
the turbocharger elbow at the turbo clamp (2).
Loosen the clamp (3) at the turbo outlet pipe.
Rae 6-13130
7
STEP 16
Remove the upper hose clamps (1) at the air-to-air
aftercooler. Remove the hose clamps (2) from the
aftercooler tubes to the intake manifold and the turbo.
Remove the aftercooler tubes. Tag and remove the
three hoses (3) from the deaeration tank. Remove
the air cleaner outlet tube (4) at the air cleaner rubber
elbow clamp.
STEP 17
Trace the line back to the injection pump, so the
correct line is removed . Disconnect the fuel return
line from the fuel injection pump at the fuel cooler.
Issued 10-02
8

STEP 18 STEP 20
- .........,---........

Tag and remove the two wires (1) from the back of Hold the shaft (1) of the fan hub on the two flat areas.
the alternator and the battery cable. Remove the Remove the fan blade and fan drive by loosening the
upper radiator hose at the clamp (2). viscous fan drive adapter (2) .

IMPORTANT: The viscous fan drive adapter has a

STEP 19 left-hand thread. Loosen by turning clockwise.

STEP 21

Remove the lower radiator hose at the hose clamp

(1). Remove the heater return hose at the hose
clamp (2).
Disconnect the two electrical connectors from the air
conditioning compressor high pressure switch (1)
and the clutch. Remove the engine fan belt (2) .
Remove the three air conditioning compressor
mounting bolts (3).

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 9

STEP 22 STEP 24

Move the air conditioning compressor to the left side Remove the fixed hood support bolts (1) from both
of the tractor, with the hoses attached. Securely sides of the tractor. Properly support the air cleaner
support the compressor. assembly and the hood support and remove from the
tractor. Remove the turbo outlet pipe.

STEP 25
STEP 23

Remove the heater supply hose (1) from the fitting on

Remove the aspirator tube hose (1) at the exhaust
the engine block. Remove the cables from the starter
elbow. Loosen the lower clamp (2) on the exhaust
terminal (2) . Remove the harness and hose retainer
flex pipe.
attached to the flywheel shield behind the engine
block. Move the harnesses and hoses out of the way

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10

STEP 26 STEP 28

RD02F140

Remove the five bolts (1) for the left-hand hood Remove the drive shaft shield (1) and the flywheel
support bracket. Remove the four bolts for the right- shield (2). Refer to Section 6001 , Transmission Input
hand hood support bracket, along with the engine to Shaft and Drive Plate, for the procedure.
frame ground strap. Remove the brackets.

STEP 29
STEP 27

Make an alignment mark on the end of the drive shaft

Remove the oil cooler supply tube (1) and the oil connected to the engine for installation. Remove the
cooler return tube (2). four bolts attaching the front universal joint to the
drive plate. Slide the drive shaft back.

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 11

STEP 30 STEP 33

Rt01 H055

Attach suitable lifting equipment to the front and rear

engine lifting brackets. Put a small amount of tension
on the hoist.

STEP 31

RI01H052

Inspect the front engine mount support and the iso-

mount for damage or wear. Replace, if necessary.

R IQ1H053
STEP 34
Remove the two front engine mount clamp bolts.
Remove the clamp.

STEP 32

Inspect the two engine rear rubber mounts for

damage or wear. Replace, if necessary.

Remove the engine.

NOTE: Make sure all electrical wires and hoses are

disconnected before removing the engine.

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12

ENGINE INSTALLATION

STEP 35 STEP 37

RI01H052

Properly support the engine. Install the engine into

the tractor chassis.

NOTE: Make sure all electrical wires and hoses will

not be pinched or binding when installing the engine.

STEP 38

If removed, assemble the front engine iso-mount and

install the rear engine rubber mounts . Tighten the
front iso-mount thru bolt to a torque of 160 to 220 Nm
(11 8 to 1621b It).
o
STEP 36 RI0 1H053

Install the two front engine mount clamp bolts. Keep

tension on the lilting equipment until these bolts are
installed. Relieve the tension on the lilting equipment.
Tighten the bolts to a torque of 59 to 106 Nm (44 to
78 Ib It).

RI01H055

If removed , install the front engine mount support

and the iso-mount. Tighten the front engine mount
support bolts to a torque of 101 to 113 Nm (75 to 83
Ib It).

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 13

STEP 39 STEP 41

Using the alignment mark made during the removal, Install the oil cooler supply tube (1) and the oil cooler
pull the drive shalt forward and install the drive shalt return tube (2) .
to the drive plate. Tighten the drive shalt yoke bolts to
a torque of 58 to 64 Nm (43 to 47 Ib It) for the MX210
and the MX230, 101 to 113 Nm (75 to 83 Ib It) for the STEP 42
MX255 and the MX285 . Tighten the bolts in a
crossing pattern.

NOTE: Use a rubber mallet to lightly tap the outside

edge of the top bearing end cap to position it into the
keyway of the yoke. Do not use the bolts to pull the
bearing end caps into the yoke keyway.

STEP 40

Install the two bolts (1) for the left-hand hood support
bracket. Install the two bolts (2) for the flywheel
shield. Install the bolt (3) for the oil cooler tube clamp.
Install the four bolts for the right-hand hood support
bracket, along with the engine to frame ground strap.

Install the drive shalt shield (1) and flywheel shield

(2). Refer to Section 6001 in this manual ,
Transmission Input Shaft and Drive Plate , for the
procedure.

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14
STEP 43
Install the heater supply hose (1) on the engine block
fitting. Install the cables on the starter terminal (2).
Install the harness and hose retainer attached to the
flywheel shield, behind the engine block. Route the
harnesses and hoses as shown.
STEP 44
Install the turbo outlet pipe. Slightly tighten the clamp
at the turbo. Properly support the air cleaner
assembly and the hood support and lower into
position. Install the fixed hood support bolts (1) on
both sides of the tractor.
Rae 6-13130
STEP 45
Install the aspirator tube hose clamp (1) at the
exhaust elbow. Tighten the exhaust flex pipe lower
clamp (2).
STEP 46
Position the compressor and hoses on the engine .
Install the three air conditioning compressor
mounting bolts (1) along with the ground wire
terminal (2) . Install the engine fan belt. Connect the
two electrical connectors leading to the air
conditioning compressor high pressure switch and
the clutch.
Issued 10-02
 15

,
STEP 47
--..--..,...
STEP 49

RD02F173

Hold the shaft (1) of the fan hub on the two flat areas. Install the two wires on the back of the alternator (1) ,
Install the fan blade and fan drive by tightening the and the battery cable. Install the upper radiator hose
viscous fan drive adapter (2) . at the hose clamp (2).

IMPORTANT: The viscous fan drive adapter has a

left-hand thread . Tighten by turning STEP 50
counterclockwise. Do not over tighten the viscous fan
drive adapter on installation.

STEP 48

Connect the fu el return line from the fuel injection

pump to the fuel cooler.

Install the lower radiator hose at the hose clamp (1).

Install the heater return hose at the hose clamp (2).

Rae &1 3130 Issued 10-02

16

STEP 51 STEP 53

Install the three harness and hose retainers (1) on

the left side of the engine. Install the electrical plug
for the intake manifold temperature sensor (2). Install
the electrical connectors at the air filter sensor (3) on
the air cleaner outlet tube.

STEP 54

Install the three hoses (1) at the deaeration tank.

Install the aftercooler tubes at the intake manifold
and the turbo at the hose clamps (2). Install the air
cleaner outlet tube (3) at the air cleaner clamp. Install
the aftercooler tube upper hose clamps (4) at the air-
to-air aftercooler.

Connect the ether start tube to the intake manifold on

STEP 52 the left side of the engine.

Install the turbocharger elbow at the turbo clamp (1).

Install the air cleaner outlet tube at the turbocharger
elbow clamp (2) . Tighten the clamp (3) at the turbo
outlet pipe.

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 17

STEP 55 STEP 56

On mechanical injection pump models, install the On electronic injection pump models, install the fuel
optional foot throttle cable (1), if equipped, the hand supply line (1) and the return line (2). Connect the
throttle cable (2), the fuel supply line (3), and the electronic inject ion pump wiring harness at the
engine wiring harness connector (4). connector (3).

STEP 57

RD02F133

Install the windshield washer reservoir electrical

connectors.

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18

STEP 58 STEP 61
Close the petcock on the hose located under the
tractor radiator. Check and replace all filters , as
required. Fill the cooling system. Check the coolant
level at the coolant reservoir and the deaeration tank.
Check all fluid levels before starting the engine. Make
sure the transmission shift lever is in PARK. Start the
engine briefly. Shut the engine off and recheck all
connections and fluid levels. Restart and run the
engine. Turn the engine off and remove the key.

STEP 62

Install the starter solenoid on the hood support.

STEP 59

Install the tilt hood . Refer to Section 9008 for th e

procedure . Connect the electrical plug for the tilt
hood front lamps.

STEP 63
Connect the passive terminator harness.

Install the left and right fan shields and tighten the
bolt (1).

Connect the main wiring harness connector (1) .

Connect the remaining electrical plugs at the fuse
box (2).

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 19

STEP 64 STEP 66

Install the left lower fixed hood panel. Connect the positive (+) battery cable, first. Connect
the negative (-) battery cable. Install the battery cover
and toolbox.
STEP 65
STEP 67

Install the fixed hood on the right side of the tractor.

Install and tighten the four nuts (1). Install the front
windshield washer hose (2) on the nozzle of the fixed Remove the wheel blocks.
hood. Install the air cleaner door on the left side of
the tractor.

Rae 6-13130 Issued 10-02

 20

Rae 6-13130
Issued 10·02
 Section
3001

Fuel Tank Removal and Installation

MX Series Tractors

CASE CORPORATION !C 2002 Case Corporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-131 10 October, 2002
3001-2

TABLE OF CONTENTS
SPECIAL TORQUES ................................................ .............. ...... ........ .............................. ........................ ........ 3
FUEL TANK ....................... ............. ...... ......................... ..................... ........ ........................................ ............... 3
General ............................................................................... .. ............... ........................... ............. ................... 3
Removal ...................... ............... ............ ....... .... ......... ................................... ... ............................................. .. 3
Installation .......................................... ... ........................................... ........... ........ .................. ......... ................. 6

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 3001-3

SPECIAL TORQUES
Bolts on cab steps ........................................... .......... ................................ ....................... 37 to 67 Nm (27 to 49 Ib It)

FUEL TANK

General Removal

STEP 1 STEP 2

96A-28A
95-12
Before removing the fuel tank, do the following:
Remove the six step mounting bolts (1). Move the
1. Park the tractor on a hard, level surface. steps away from the tractor.
2. Place the transmission control lever in PARK.
3. Shut off the engine and remove the key. STEP 3
4. Put blocks in front of and in back of the rear
wheels.

4·25f

Drain the fuel tank. Fuel tank capacities are listed in

the chart below.

~ 210/230 2551285
Tank
Standard 492 L (130 gal) 605 L (160 gal)

Optional 605 L (160 g)

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3001-4

STEP 4 STEP 7

5O-23F

Move the left rear wheel out on the axle as far as Remove the pressure equalization hose at the front
possible to provide clearance when removing the left of the cab from the top left-hand fuel tank.
tank. The wheel can also be removed.

STEP 8
STEP 5

95-18 Remove two bolts from each of the two lockdown

Disconnect the connector for the fuel level sending plates.
unit. Remove the fuel vent hose (1).

STEP 9
STEP 6

,
t OtR-19"

With prybars, lift up on the main tank and move it out

Loosen hose clamp on crossover hose from the
a few inches. Insert a plug into the crossover hose as
bottom of the right fuel tank.
it comes off of the right tank . This will capture the
remaining fuel in the tank.

Rae 6-13110 Issued 10-02

 3001-5

STEP 10 STEP 13

91 -27CU RD02Bl05

Disconnect the fuel supply line (2). Disconnect the If the right tank is to be removed, remove the tool box
fuel return line. and battery cover.

NOTE: Right tank removed for photographic

purposes.
STEP 14

STEP 11

RD02Bt06

Remove the battery cables and move to the side.

Remove the batteries.
5027-3

Remove the left tank.

STEP 15

91-27CU

If not already removed, loosen the clamp (1) on the

38-5 fue l crossover hose. Slip the hose off the neck
Remove the fuel level sending unit (1) , crossover leading into tank.
hose (2), fuel supply fitting (3) and the fuel return
fitting (4). NOTE: Tank removed for photographic purposes.

Issued 10-02
3001 -6

STEP 16 Installation

STEP 19

5-20

Remove the two bolts from the lockdown plate on the

right tank.

Use a jack to lift the support bracket into position and

STEP 17 install and tighten all the retaining bolts (1).

NOTE: Left hand side shown.

STEP 20
,

10 1R-23A

Lift the right tank free of the support bracket and

remove the tank.

38-5ECUl
STEP 18 Install the fuel level sending unit. Connect the
crossover hose on the left tank while on the floor.

STEP 21

Use a jack to support the bottom of the tank support

bracket while removing the bolts (1) from the left- and
right-hand side of the bracket.
Install the fuel tank onto the support brackets with
NOTE: Bolts are shown on left side. enough room to attach fittings.

Rae 6- 1311 0 Issued 10-02

 3001-7

STEP 22 STEP 25

Connect the fuel supply hose (1) and fuel return Install the fuel vent hose (1) and reposition the hose
hose. clip. Install the connector for the fuel level sending
unit by the fuel vent line.

STEP 23
STEP 26

95-15R

Move the left fuel tank into final position. Install and 5-23
tighten two bolts through each of the two lockdown Position the wheels to the desired position on the
plates. rear axle.

STEP 24 STEP 27

95-24
Install the pressure equalization hose on the top front Move the right tank into position .
of the left tank. Tighten clamp.

Rac6-13110 Issued 10·02

3001-8

STEP 28 STEP 31

91-27CU

Connect the crossover hose (shown) and the loose Install battery cover and toolbox.
end of the pressure equalization hose connected to
the lelt tank.
STEP 32

STEP 29

95-12

Move steps into position. Install six bolts and tighten

5-20 to a torque of 37 to 67 Nm (27 to 49 Ib It).
Install and tighten the two bolts on the hold-down
plate.
STEP 33
Install fuel and check for leaks.
STEP 30

Install the batteries.

Rae 6- 13110 Issued 10-02

 MX Magnum - Service Manual
Book 2 - Table of Contents

Description Book Section

Number Number
Electrical System How it Works and Troubleshooting 2 4001

Issued 10-02
Rae 6-14210 ~2002
 MX Magnum
MX210, MX230, MX255, MX285

c 6-14210 1C>2002
2
Issued 10-02
 Section
4001

ELECTRICAL SYSTEM

How It Works And Troubleshooting

CASE CORPORATION C> 2002 Case Corporation

700 State Street Printed in U.S.A.
Rae 6-12740 September, 2002
Racine, WI 53404 U.S .A.
4001 -2

CONTENTS
SPECIAL TOOLS ... .................................... .............. ... ..... .. .......... ..... ... ......................................... .................. .... .... 4

FUSES AND RELAY IDENTIFICATION .................................. .. ... ............ ......... .................. .... ... .. .. ............... ..... ..... 5
Cab Fuses/Relay Location ........ .... .. ... .... ............... .... ........ ............. .. ... ....... .. .. ... .................................... ..... .. .. ... ... 5
...... ......... .. .... ... ....... ... ... ....... ....... ............. ....... ...... .. .. .. .. ...... ...... .... .. .. .......... .. .... ...... .. .... ..... ..... ... ............. .... .......... 5
Cab Fuses/Relay Location ........ ........................ ....... ... ..... ....................... .. .................. ... .. .. ............... .. .. ............... 6
Fuse Identification .... ... .. ... .......... ............. ............... .. .... ............ ........... .... ..... ......... .... .............................. .... .. ....... 6
Relays ............. .... ...... .. ..... .. ....... ....... ..................... .......... ... ...................... .. ............... .... ............. ...... ........ .. .......... 7

INSTRUMENTATION AND CONTROLS .. ..... .. ............ .......... ............... ............. ..................... ..... .. ........... ... .... ....... 9

CONNECTOR AND COMPONENT LOCATIONS .. ... ...... ........ ... ... .......... .................. ... .. ... ...... .... .. .. ...... .. ... ......... .. 14

ELECTRICAL CONNECTORS ................ ................. ....... ............................. ............... ..... ...... ... ........................ .. .. 35

ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ........................... ........ ... ....... .. ..... .. .. ..... ... ......... 129
Power Distribution System Circuit Operation ................ ......... .. .... ... ..................... ..................... .. ................. .... 129
Power Distribution Circuit Troubleshooting ............ .. ..... .. ................... .. .. ... ..... .... ................ ........ ....... .. .. .... ... .... 129
Power Distribution Schematic ........... ........................................ ... ... .. ... ................. ......................... .. ........... ..... 129

POWER DISTRIBUTION SYMPTOM CHART .. ... .......................................... ... .. .. ... ... ..... ... ... ....... .... ... ... .......... .. 130
Diagnostic Tests .. ...... .. ... .. ............. .................. ... ................... .... .. ....... ..... .. ... ... .. .. ....... .. .. .............................. ... 131

AUDIO SYSTEM ... ... .. .. .......... ... ... ..................... ....... ......... .................. ... ..... ............... .... .. ......... ......... .......... .... ... 133
Audio System Circuit Operation ........ ........... .......... ... ... ... .. ... .... ........ .. .... ... .... .. .................. ... .. ........... .. ....... ... ... 133
Audio System Circuit Troubleshooting ........................................... .. .. ................. .... .. ...... ...................... .. .... .. ... 133
Audio System Symptom Chart ... ... .. .... .. .. ....... ...... .. .. .. ... .... ... .. ... ... .......... .. .......................... .......... ............. .. ..... 133
Audio System Diagnostic Tests ............. ... .... .. ... .... .... ...................... ........... .............. ............. .. ...... ......... ... ..... . 135

CHARGING SYSTEM ........ ...... ... ........... ... ....... .. ... .... .. .... .... ............ ......................... ............ ................ ............... 139
Charging System Circuit Operation ......... ...... .. ... ... ................... .................. ..................................................... 139
Charging System Circuit Troubleshooting ... ............. ... ... ...... ..................... .. ........... ........................ ....... .. ........ 139
Charging System Symptom Chart .. .. ............. .. .. ..... .. .. ... .... ....... ... ... ... ..... ... .................... .... .................. ......... ... 140
Charging System Diagnostic Tests ....................... ...... ... .... .. ........................ ................... ............................... .. 141

EXTERIOR LIGHTING SYSTEM .. .. ............. ... .. ..... ................................ ....... .. .. ..... .. .................. .. ..................... .. 145
Exterior Lighting System Circuit Operation ...... ....... .. ... .... ................ .. ... .................................. ......................... 145
Exterior Lighting System Circuit Troubleshooting ............ .... .. ............... .... ................ ..................................... .. 145
Exterior Lighting System Symptom Chart ............ .. ........ .. .. ................ ............ .. .. ... ... ... .. ...................... .. .. .... .... . 146
Exterior Lighting System Diagnostic Tests ... .. ... .... .. ... .............. ......... .......... ... .. ... ... ........................... ... ... ... ..... 146

INSTRUMENTATION AND WARNING SYSTEM .. ..... .. ....... ..... ... ... ... .................. ........ .. .... .. .......... ... .. ..... ... ... .. .. . 151
Instrumentation and Warning System Circuit Troubleshooting .... .. .. ... ................ .......... .. ......... .... .. ... .. ... ...... ... . 151
Instrumentation and Waming System Symptom Chart .................. .. .. .. .. ................... ..... .. ................................ 151
Instrumentation and Waming System Diagnostic Tests .................... .. ... ............ .. ........... ............. ......... .. ........ 152

TERIOR LIGHTING AND HORN SYSTEM .......... .. .. ... .... .......................... ...................... .... .. ........... .............. . 156
Interior Lighting and Horn System Circuit Operation ......... ... ........................... ... .... ...... .... .. ... .................. ....... . 156
Interior Lighting and Hom System Circuit Troubleshooting ............... .. ... .. ......... .............................. ................ 156
Interior Lighting and Horn System Symptom Chart .... ... ...... .......... .. ........ ......... .. .. .................. .... ..................... 157
Interior Lighting and Hom System Diagnostic Tests ........................ .. ......... .......... ........... .. .. ...... ...................... 157

6-12740 Issued 9/02

 4001-3
POWER MIRROR SYSTEM ........................................................................................................................... .... . 161
Power Mi rror Ci rcuit Operation ................................................................................................. ......... ............. . 161
Power Mirror Circuit Troubleshooting ................................................................................... ................. .... ...... 161
Power Mirror System Symptom Chart ...................................................................... .......... .. ........................... 162
Power Mirror System Diagnostic Tests ................................................................... ........ ................................ . 164

POWER SEAT SYSTEM ......................................................... .... ...... ..... ................................... ................... ....... 173
Power Seat System Circuit Operation .............. .... .... .......................... ........ ................... .................................. 173
Power Seat System Circuit Troubleshooting ........ ........................................... ................................................ 173
Power Seat System Symptom Chart ............. ............... ................................................................................... 174
Power Seat System Diagnostic Tests ........................................... ................................................................... 175

START ING SYSTEM ............................... .... ........ .... ................................................................................... ......... 179
Starting System Circuit Operation ......... ................ ...................... ....................................... ............................ .. 179
Starter Motor Circuit Troubleshooting ............................................... ............................................ ...... ............. 179
Starting System Symptom Chart .................................. ..................... .... ........... .. ...... ........................................ 179
Starting System Diagnostic Tests ............ ............................ .... ..... .................... ......... ............. ........... .............. 181

WI PERIW ASH ER SY STEM ........................ ................................ ........... ................................. ....... ........ ............. 186
WiperlWasher System Circuit Operation ...... ........ ................ ........... .... ................................... ............. ............ 186
WiperlWasher System Circuit Troubleshooting .................... ........................................................................... 186
WiperlWasher System Symptom Chart .. ....................................... ................................ .................................. 187
WiperlWasher System Diagnostic Tests .................... .................... ......................................................... ..... .... 188

Rae 6- 12740 Issued 9/02

 4001·4

SPECIAL TOOLS

Electrical Connector and Terminal Repair Kit Digital Multimeter CAS· 1559.
AJ11400004. See the Parts Merchandiser Catalog for
ordering information and identification of
components.

I ac 6-12740
Issued 9/02
 4001-5

FUSES AND RELAY IDENTIFICATION

Cab Fuses/Relay Location

Fuses and relays are located to the rear of the operators seat, under the floor cover mat and metal cover.

Engine Fuse/Relay
Identification (Power Distribution Box)

Additional fuses and relays are located in the Power Distribution box on the left hand side of the tractor engine
compartment behind door.

Rae 6-12740 Issued 9/02

! •
 4001-6

Cab Fuses/Relay Location

Fuses and relays are located to the rear of the
operators seat, under the floor cover mat and metal
cover.

Fuse Identification

I Not Used 51 I 52
I Not Used Not Used
I Not Used I 56

I Not Used Not Used

I Not Used I 46 47
I 48 I 49

I 36 37
I 38 I 39 Not Used
I 41 I 42

I 29 Not Used
I 31 I 32 33
I 34 I 35

I 22
I 23
I 24 25 Not Used
I I NotUsed 28

15
I I 16
I Not Used 18 19
I I 20 21

I 8 I 9
I 10 11 12
I I 13 Not Used

I 1
I 2
I 3 4 5
I I 6 7

RH97K037

Fuse Number Circuit Fuse Amperage

1 Elect. Governor (MX255 & MX285) 5
2 Cruise Control 5
3 Rear Fender Worklights 20
4 Beltline Worklights 10
5 Roof Worklights 20
6 WorklightlHeadlight Interlock 10
7 Battery Power to Key Switch 5
8 Headliner Shelf Aux./3-Pin/Cigar Outlets (Unswitched) 20
9 Seat Power 15
10 Cab Pressurizer Blower (Continuous) 15
11 Cigar Lighter/RH Fender Console (Unswitched) 20
12 Exterior 7-Pin Connector (Switched) 30
13 RH Front PostlRH Fender 3-Pin Auxiliary Connectors 30
(Unswitched)
15 Governor (MX255 & MX285) 30
16 Tractor Instrument (Unswitched) 5
18 High Beam Relay 10

,fae6-12740 Issued 9/02

I
 4001-7

Fuse Number Circuit Fuse Amperage

19 Dome LightlMap LightlRadio (Unswitched) 5
20 Amber Flashers 20
21 Tail Lights 10
22 Stoplights 10
23 Strobe LightlBeacon 15
24 Mirror/Radio 10
25 Ether/Horn 20
28 Auto Climate Display (Install fuse for Celsius display) 5
29 Seat Heater 10
31 AFS (Switched) 10
32 AFS (Unswitched) 10
33 RH Arm Rest Controller (Switched) 10
34 True Ground Radar 5
35 Transmission Controller 20
36 Remote Hydraulic Controller 15
37 Tractor Instrumentation (Switched) 5
38 PTO/Diff LocklMFD Controller 10
39 Hitch Controller 10
41 Data Bus, Tractor 5
42 Data Bus Diagnostic Connector 10
46 RH Front PostlRH Fender 3-Pin Connectors (Switched) 30
47 HVAC Controller 30
48 Headliner Shelf 3-Pin Connectors (Switched) 20
49 HVAC Blower 30
"51 Front WiperlWasher 15
52 Rear WiperlWasher 15
56 Italian Brakes 5

(Unswitched) - Unswitched power (Continuous). (Switched) - Power available when key switch is in
"ON" position.
"=Circuit Breaker

Relays
The 20 Amp relays are located to the rear of the
operators seat, under the floor cover mat and metal
cover.

Rae 6-12740 Issued 9/02

 4001-8

Relay Identification (Facing Rear

Window) /'

1. BRAKE LAMPS 6. NEUTRAL RELAY 11 . GOVERNOR (KEY SWITCH)

2. OPEN 7. OPEN 12. FENDER WORK LAMPS
3. REAR ROOF WORK LAMPS B. BELTUNE WORK LAMPS 13. CONTROLLER POWER RELAY
4. WORK LAMP INTERLOCK 9. FRONT ROOF WORK LAMPS
5. PARK LATCH 10. CAB PRESSURIZER BLOWER

Engine Compartment Fuse/Relay

Identification (Power Distribution Box)
()

l :n~CD
I~ ~I
25A

(fl
30A 1 ~~0
"T1 0
m
c:
@g l
iCE
"T1
"T1
@~ I ~I
®cil~ 1
~!
25A 0:§ 1 30A
0:!l~ 1 30A 0:E 1 15A
I
I~ §
~ u; ! 15A
10 I~ "0
~
~~ jl!

10 10
(fl

~ u; 1 ~ U; I (fl
15A 15A

1. CENTER & SIDE WORK LAMP FUSE
2. HIGH/LOW BEAM & BYPASS RELAYS
FUSE
3. STARTER RELAY FUSE
4. RH HIGH BEAM FUSE
5. LH HIGH BEAM FUSE
6. FUEL SHUTOFF RELAY FUSE
7. STARTER RELAY FUSE
B. RH LOW BEAM RELAY FUSE
9. LH LOW BEAM RELAY FUSE
10. STARTER RELAY
11 . FUEL SHUTOFF RELAY
12. CENTER & SIDE WORK LAMP RELAY
13. HIGH BEAM RELAY
14. LOW BEAM RELAY
15. HIGH BYPASS RELAY
16. DIODE NO. 1 (IF EQUIPPED)
17. DIODE NO. 2 (IF EQUIPPED)

\ ac 6-12740 Issued 9/02

 4001-9

INSTRUMENTATION AND CONTROLS

STANDARD INSTRUMENTATION AND OPTIONAL PERFORMANCE MONITOR

1.. STANDARD INSTRUMENTATION 2. OPTIONAL PERFORMANCE MONITOR

INSTRUMENT PANEL CONTROLS

1. ETHER SWITCH 2. WORK LAMP SWITCH

Issued 9/02
Rae &-12740
4001 · 10

INSTRUMENT PANEL CONTROLS

1. ROAD LIGHTS! 2_ KEY SWITCH
FLASHERS SWITCH

STEERING COLUMN CONTROLS

1 _ TRANSMISSION CONTROL LEVER
2 _ DIRECTION TURN SIGNAL LEVER ; HORN
BUTTON; HIGH/LOW BEAM SWITCH
3 _ TURN SIGNAL INDICATORS

ac 6-12740 Issued 9/02

 4001-11

ARM REST CONTROLS

1. GEAR SELECTION SWITCH
2. HAND THROTTLE LEVER
3. REMOTE HYDRAULIC CONTROL LEVERS
4. REMOTE FUNCTION CONTROL
5. REMOTE HYDRAULIC CONTROL SWITCH
NUMBER FIVE
6. 5TH REMOTE FLOW CONTROL

ARM REST CONTROLS

7. CREEPER CONTROL
8. MFD SWITCH
9. DIFFERENTIAL LOCK SWITCH
10. HITCH UP/DOWN SWITCH
11 . HITCH POSITION CONTROL
12. HITCH LOAD CONTROL
13. PROGRAMMABLE SHIFT SWITCH
14. AUTO SHIFT SWITCH
15. SLIP LIMIT CONTROL SWITCH
16. PTO CONTROL SWITCH

Rae 6-12740 Issued 9/02

4001-12

RD98Fl03
ARM REST CONTROLS (SECONDARY PANEL)
1. HYDRAULIC FLOW CONTROLS
2. HYDRAULIC VALVE TIMER CONTROL
3. HITCH UPPER LIMIT
4. HITCH TRAVEL CONTROL
5. HITCH DROP SPEED CONTROL

STANDARD TEMPERATURE CONTROL SYSTEM

1. RIDE CONTROL SWITCH
2. SUSPENDED AXLE SWITCH
3. HAZARD SWITCH (EUROPE ONLY)
4. BEACON/STROBE SWITCH
5. CRUISE ON/OFF SWITCH
6. CRUISE INCREASE/DECREASE SWITCH
7. CIGAR LIGHTER
8. BLOWER SPEED CONTROL KNOB
9. TEMPERATURE CONTROL KNOB
10. FRONT WINDSHIELD WIPER CONTROL
11 . REAR WINDSHIELD WIPER CONTROL
12. POWER MIRROR SWITCH (if equipped)
13. CLIMATE CONTROL SWITCH

ac 6-12740 Issued 9/02

 4001-13

AUTOMATIC TEMPERATURE CONTROL SYSTEM (If Equipped)

1. RIDE CONTROL SWITCH
2. SUSPENDED AXLE SWITCH
3. HAZARD SWITCH (EU ROPE ONLY)
4. BEACON/STROBE SWITCH
5. CRUISE ON/OFF SWITCH
6. CRUISE INCREASE/DECREASE SWITCH
7. CIGAR LIGHTER
8. BLOWER SPEED CONTROL KNOB
9. TEMPERATURE CONTROL KNOB
10. FRONT WINDSHIELD WIPER CONTROL
11 . REAR WINDSHIELD WIPER CONTROL
12. POWER MIRROR SWITCH (if equipped)
13. CLIMATE CONTROL SWITCH
14. ATC DISPLAY MODULE

Rae 6-12740 Issued 9/02

4001-14

CONNECTOR AND COMPONENT LOCATIONS

REAR OF CAB
1. CONNECTOR NO.353 10. PASSIVE TERMINATOR CONNECTOR NO.175
2. CONNECTOR NO.350 11 . CONNECTOR NO.58
3. CONNECTOR NO.351 12. CONNECTOR NO.59
4. TRANSMISSION AND SUSPENSION AXLE CONTROLLER 13. CONNECTOR NO.54
5. HITCH SYSTEM CONTROLLER 14. CONNECTOR NO.53
6. AUXILIARY CONTROLLER (REMOTES) 15. CONNECTOR NO.56
7. PTO SYSTEM CONTROLLER 16. CONNECTOR NO.10
8. CONNECTOR NO.55 17. CONNECTOR NO.57
9. CONNECTOR NO.355 18. BACK UP ALARM

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae &-12740 Issued 9/02
 4001-15

LEFT SIDE ENG INE COMPARTMENT

1. ENGINE FUSE BOX 7. LIGHTING CONNECTOR NO.109 (GREEN)
2. POWER DISTRIBUTION-CONNECTOR NO.7 (BLACK) 8. STARTER RELAY
3. ENGINE CONNECTOR NO.l0B (GRAY) 9. FU EL SHUTOFF RELAY (ELITE ENGINE ONLY)
4. SWITCHED POWER CONNECTOR NO.64 (BLACK() 10. CENTER AND SIDE LIGHT RELAY
5. UNSWITCHED POWER CONNECTOR NO.65 (GRAY) 11 . HIGH BEAM RE LAY
6. AUXILIARY POWER CONNECTOR NO.121 (BLUE) 12. LOW BEAM RELAY

FUSES I DIODE
Fl- 30 AMP CENTER WORK LIGHT F6- 25 AMP FUEL SHUTOFF RELAY
F2- 30 AMP HIGH. LOW AND WORKLIGHT F7-1 5 AMP AUXILIARY POWER SWITCHED
F3- 15 AMP AU XILIARY UNSWITCHED POWER FB- 15 AMP LEFT HIGH BEAM
F4- LEFT LOW BEAM F9- 15 AMP RIGHT HIGH BEAM
F5- 15 AMP RIGHT LOW BEAM

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-16

AI02E086
TRANSMISSION SOLENOID LOCATIONS AND CONNECTOR IDENTIFICATIONS
1. POWERSHIFT VALVE ODD/EVEN 12. PTO SOLENOID (CONNECTOR NO. 159)
2. EVEN CLUTCH SOLENOID (CONNECTOR NO. 30) 13. MASTER CLUTCH SOLENOID (CONNECTOR NO. 35)
3. ODD CLUTCH SOLENOID (CONNECTOR NO. 29) 14. POWERSHIFT VALVE SPEED
4. CREEP CLUTCH SOLENOID (CONNECTOR NO. 39) 15. C1 CLUTCH SOLENOID (CONNECTOR NO. 31)
5. PARK BRAKE SOLENOID (CONNECTOR NO. 49) 16. C3 CLUTCH SOLENOID (CONNECTOR NO. 32)
6. PTO/DIFF LOCK VALVE 17. C5 CLUTCH SOLENOID (CONNECTOR NO. 33)
7. POWERSHIFT VALVE RANGE 18. REVERSE SOLENOID (CONNECTOR NO. 34)
8. MFD SOLENOID (CONNECTOR NO. 160) 19. SYSTEM PRESSURE TRANSDUCER (CONNECTOR NO. 44)
9. LOW CLUTCH SOLENOID (CONNECTOR NO. 36) 20. DIFF LOCK SOLENOID (CONNECTOR NO. 158)
10. MID CLUTCH SOLENOID (CONNECTOR NO. 37)
11 . HIGH CLUTCH SOLENOID (CONNECTOR NO. 38)

NOTE : Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-17

RH02H281

REMOTE AND HITCH VALVE CONNECTOR IDENTIFICATIONS

1. REMOTE SECTION NO.1 , TOP CONNECTOR 140, LOWER CONNECTOR 340
2. REMOTE SECTION NO.2, TOP CONNECTOR 141, LOWER CONNECTOR 341
3. REMOTE SECTION NO.3, TOP CONNECTOR 142, LOWER CONNECTOR 342
4. REMOTE SECTION NO. 4, TOP CONNECTOR 143, LOWER CONNECTOR 343
5. REMOTE SECTION NO.5, TOP CONNECTOR 144, LOWER CONNECTOR 344
6. HITCH LOWER - CONNECTOR 152
7. HITCH RAISE - CONNECTOR 151

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Issued 9/02
Rae 6-12740
 4001-18

RI99GOO2

~
:~ ----/l{jl-~

~!
Iii:
(I
,I :
I

>"
f
J
iii! \
'::1 (

L,
1

'L;

RT97K033
RT97K034
INCHING PEDAL
1. CONNECTOR NO. 50 - BOC SWITCH 3. INCHING PEDAL
2. CONNECTOR NO. 52 - CLUTCH POSITION
POTENTIOMETER

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
ae 6-12740
Issued 9/02
 4001-19

•••
~
1

ARMRST

RIGHT HAND CONSOLE

1. ARMREST CONTROLLER

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-20

LOWER FRONT CONSOLE

1. TO TRANSMISSION CONTROL LEVER

RD98G027

BOTTOM RH FRONT CORNER OF CAB

1. CONNECTOR NO. 60 - IN-LINE CONNECTOR (FRONT TO REAR HARNESS
2. BRAIDED GROUND STRAP
3. CAB MOUNT GROUNDS (NOT SHOWN, SEE CAB MOUNT)

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-21

INSTRUMENT CLUSTER (ICU) PERFORMANCE MONITOR (PMU)

1. CONNECTOR NO. 61 - INSTRUMENT CLUSTER (ICU) 3 . INSTRUMENT CLUSTER (ICU)
2 . CONNECTOR NO. 62 - PERFORMANCE MONITOR (PMU) 4. PERFORMANCE MONITOR (PMU)

TOP OF FUEL TANK

1. CONNECTOR NO. 66 - FUEL SENDER

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-22

BRAKE VALVE SWITCH CONNECTIONS

1. RIGHT BRAKE SWITCH-CONNECTOR 162 2. LEFT BRAKE SWITCH-CONNECTOR 163

LEFT HAND SIDE OF ENGINE

1. AIR TO AIR TEMP SENSOR-CONNECTOR NO.75

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-23

REAR OF TRACTOR
1. CONNECTOR NO. 312- CENTER REMOTE HITCH SWITCH (BEHIND BRACKET)

RD02H176

ALTERNATOR
1. ALTERNATOR 4. CONNECTOR NO. 85 - ALTERNATOR EXCITE (D+)
2. REGULATOR 5. CONNECTOR NO. 86 - ALTERNATOR W FREQUENCY
3. CONNECTOR NO. 77 - ALTERNATOR B+ (ENGINE RPM)

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-24

RIGHT HAND SIDE OF TRANSMISSION

1. CONNECTOR NO. SS - TRANSMISSION
FILTER RESTRICTION SENSOR

OPERATOR SEAT
1. ARMREST (ARM) 3. CONNECTOR NO. 137 - ARMREST CONTROLLER (ARM)
2. CONNECTOR NO. 133 - TO POWER SEAT

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-25

TOP REAR OF TRANSMISSION

1. CONNECTOR NO. 145 - TO PTO SHAFT SPEED 2. PTO SHAFT SPEED SENSOR
SENSOR

PTO SHAFT
1. CONNECTOR NO. 146 - TO PTO DUAL SPEED SENSOR 2. PTO DUAL SPEED SENSOR

RD98E019

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-26

RIGHT HAND SIDE NEAR AXLE

1. CONNECTOR NO. 153 - TO RH DRAFT PIN

LEFT HAND SIDE NEAR AXLE

1. CONNECTOR NO. 154 - TO LH DRAFT
PIN

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-27

RIGHT HAND SIDE AT ROCKSHAFT

1. CONNECTOR NO. 155 - ROCKSHAFT POTENTIOMETER (BEHIND COVER)

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
 4001-28

/
/

\ '\
'\
'\
'\

LfJJ'
RT97K036
BRAKE PEDALS
1. CONNECTOR NO. 162 - LEFT BRAKE
SWITCH
2. CONNECTOR NO. 163 - RIGHT BRAKE
SWITCH

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae &-12740
Issued 9/02
 4001-29

ROO2H225

LEFT HAND SIDE - SERVICE DOOR

1. CONNECTOR NO. 205 - FRONT
PASSIVE TERMINATOR
2. INTERMEDIATE STARTING RELAY
3. ENGINE HARNESS GROUND

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-30

NON-ELECTRONIC ENGINE
1. ENGINE OIL PRESSURE SWITCH

ELECTRONIC ENGINE
1. ENGINE OIL PRESSURE SWITCH

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
ac &- 12740 Issued 9/02
 4001-31

NEAR AlC COMPRESSOR

1. CONNECTOR NO. 215 - ENGINE 2. BLOCK HEATER (ALL ENGINES)
COOLANT TEMPERATURE SENSOR
(ELECTRONIC ENGINE)

NON-ELECTRONIC ENGINE
1. INJECTION PUMP SOLENOID - CONNECTOR NO.214
2. CONNECTOR NO. 215 - ENGINE COOLANT TEMPERATURE
SENSOR (NON-ELECTRONIC ENGINE)

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-32

LEFT SIDE OF ENGINE

1. CONNECTOR NO. 246-ENGINE SPEED SENSOR
2. CONNECTOR NO. 247- EN GINE POSITION SENSOR

LEFT SIDE OF ENGINE

1. INTAKE MANIFOLD AIR TEMP- CONNECTOR NO.253
2. INTAKE MANIFOLD BOOST PRESSURE SENSOR

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9102
 4001 -33

LEFT SIDE ELECTRONIC ENGIN E

1. ENGINE CONTROLLER CONNECTOR NO.244
2. CONNECTOR NO.20B- ENGINE CONTROL MODULE UNSWITCHED POWER
3. CONNECTOR NO. 207- ENGINE CONTROL MODULE GROUNDS
4. CONNECTOR NO. 209- ENGINE CONTROL KEYED POWER

LEFT SIDE ELECTRONIC ENGINE

1. FOOT THROTTLE CONNECTOR NO.256

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae 6-12740 Issued 9/02
4001-34

LEFT SIDE ELECTRONIC ENGINE

1. ENGINE HARNESS CONNECTOR NO. 333

AIR INTAKE
1. AIR FILTER RESTRICTION SWITCH

NOTE: Always positively identify individual connectors by checking wire numbers and colors.
Rae &-12740 Issued 9/02
 4001-35

ELECTRICAL CONNECTORS
CONNECTOR 1
RIGHT SIDE LIGHT
1 WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
HEADlAMP HARNESS
19843SA1 A 738D RIGHT HAND SIDE B+
B 178H GROUND

CONNECTOR 2
CAVITY A
RIGHT HEADLAMP
WIRE
CAV CIRCUIT REFERENCE
2 NUMBER
SOCKET HOUSING A 170G GROUND
HEADLAMP HARNESS
B 740A LOW BEAM
261702C1
C 741A HIGH BEAM
CAVITY B

CONNECTOR 3
CENTER LIGHT
3 WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
HEADLAMP HARNESS
19843SA1 A 738C CENTER B+
B 170F GROUND

CONNECTOR 4
CAVITY A
LEFT HEADLAMP
WIRE
CAV CIRCUIT REFERENCE
4 NUMBER
SOCKET HOUSING A 170E GROUND
HEAD LAMP HARNESS
261702C1 B 742A LOW BEAM
CAVITY B C 743A HIGH BEAM

CONNECTORS
LEFT SIDE LIGHT
S WI RE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
HEADlAMP HARNESS
A 738B LEFT HAND SIDE B+
19843SA1
B 170D GROUND

CONNECTOR 6
HID LIGHT
6 WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
HEADLAMPHARNESS
294250A1 1 170C GROUND
2 73BE HIDB+

Rae 6-12740 Issued 9/02

II
4001 - 36

CONNECTOR 7F
FRONT HITCH LAMPS
WIRE
CAY CIRCUIT REFERENCE
NUMBER
7F A 7508 FRONT HITCH POSITION
BLACK SOCKET
B 602C ICU SHUT DOWN (FUEL)
HOUSING
C 7280 LOW BEAM RELAY
40!m9A1
0 B9C START RELAY
E 172C START OUTPUT
F 792E CENTEAlSIDE RELAY
G 72&: HIGH BEAM RELAY
H 7280 HIGH DlODE/HIGH RELAY

9F
PIN HOUSING 9M
LOCATION: FRONT CONSOLE SOCKET HOUSING
22532OC1 225319C1

CONNECTOR 9F CONNECTOR 9M
TURN SIGNAL SWITCH TURN SIGNAL SWITCH
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 20A TURN SIGNAL COMMON (B+) 1 766B TURN SIGNAL COMMON (B+)
2 21A LEFT TURN SWITCH 2 768A LEFT TURN SWITCH
3 22A RIGHT TURN SWITCH 3 767A RIGHT TURN SWITCH
4 23A HEADLIGHT SWITCH (B+) 4 125A HEADLIGHT SWITCH (8+)
5 24A HIGH BEAM 5 12M HIGH BEAM
6 25A LOW BEAM 6 128A LOW BEAM
7 26A HEADLIGHT DIPPING 8+ 7 7060 HEADLIGHT DIPPING 8+
8 27A GROUND 8 178M GROUND

ae 6-12740 Issued 9/02

 4001-37
10M
SOCKET HOUSING
FLANGE
MAIN CHASSIS HARNESS
43755OA1
10F
437551Al
PIN HOUSING CAB

CONNECTOR 10M CONNECTOR 10M

CAB BULKHEAD CAB BULKHEAD
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 220A NEUTRAL RELAY B+ 33 547B CRUISE ON/OFF
2 OPEN 34 356B CRUISE INCREMENT
3 we TRAILER AUX B+ 35 489B CRUISE DECREMENT
4 787B FENDER WORKLIGHT B+ 36 267B HYDRAULIC FILTER
5 OPEN 37 267C TRANSMISSION FILTER
6 102P SWITCHED B+ 38 555A CLUTCH POT SIGNAL
7 204B ELECT GOV B+ 30A 39 556A CLUTCH POT B+ (8V)
8 OPEN 40 557C CLUTCH POT GND
9 SOOB EDC POWERB+ 41 754B RIGHT TURN LAMP
10 S09A LEFT BRAKE SW 42 752H RIGHT HAZARD
11 510A RIGHT BRAKE SW 43 101AA UNSWITCHED BATIERY B+
12 5SOA TRCU POWER B+ 44 753B LEFT TURN LAMP
13 OPEN 45 751H LEFT HAZARD
14 702A PTO BRAKE RELAY-EURO 46 755C RIGHT STOP
15 599A PTO POWER B+ 47 792D CENTERISIDE RELAY
16 5610 PARK RELAY (COMMON) 48 101CC UNSWITCHED BATIERY B+
17 158B ITALIAN BRAKE 49 1016B UNSWITCHED BATIERY B+
18 1568 ITALIAN BRAKE 50 726B HIGH BEAM RELAY
19 531F AXLE SENSOR B+ 51 726C LOW BEAM RELAY
20 114B UNSWITCHED B+ 12V 52 750E FENDER TAIL LIGHTS
21 536B AUTO SUSPENION LAMP 53 7SON FRONT HITCH POS LAMPS
22 159B ITALIAN BRAKE 54 177A CHASSIS GROUND
23 157B ITALIAN BRAKE 55 177B CHASSIS GROUND
24 532B AXLE LOCKIUNLOCK 56 724C HIGH BEAM
25 OPEN 57 755F TRAILER STOP
26 511B PARK SIGNAL SW 56 7nA AUTO HITCH (EURO)
27 OPEN 59 755.1 LEFT STOP
28 565A PNEUMATIC BRAKE B+ 60 POWER CAVITY NOT USED
29 293A PTO 'ON' ARMREST 61 OPEN
30 566B PNEU BRAKE IND-EURO 62 OPEN
31 OPEN 63 RED COB SATI (TRACTORO
32 OPEN 64 YELLOW CDB HI (TRACTOR)

Rae 6-12740 Issued 9/02

 4001 - 38
10M
SOCKET HOUSING
FLANGE
MAIN CHASSIS HARNESS
437558Al
lOF
437551Al
PIN HOUSING CAB

...,.

CONNECTOR 10M CONNECTOR 10M

CAB BULKHEAD CAB BULKHEAD
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
65 BLACK COB GNO (TRACTOR) 90 552A FNRP SHUITLE - R
66 GREEN COB LO (TRACTOR) 91 561A FNRP SWITCH 5V
67 RED COB BAIT (IMPLEMEND 92 558B PARK RELAY COIL

68 YELLOW COB HI (IM PLEMEND 93 OPEN

69 BLACK COB GN (IMPLEMEND 94 571A BACKUP ALARM B+
70 GREEN COB LO (IMPLEMENT) 95 179K CLEAN GROUND
71 1388 lS011783 SWITCHED B+ 96 OPEN

72 137 lS0 11783 UNSWITCHED B+ 97 OPEN

73 OPEN 98 OPEN

74 518A PICKUP HITCH LATCH 99 OPEN

75 512A RIDE CONTROL 100 OPEN

76 900E AUX CONTROLLER B+ 101 OPEN

n 223B GOV. ING. SW SIG. 102 OPEN

78 89B KEYBAITERY
79 172A FNRP START OUTPUT
80 722B HORN POWER B+
81 836B FRONT WASHER
82 845B REAR WASHER
83 283B RADAR B+
84 835B TO HVAC CLUTCH
85 195C CAB PRESSURE BLOWER
86 802B HVAC HIGH PRESS SW OUT
87 285B IMPLEMENT SWITCH
88 551A FNRP SHUTTLE - F
89 553A FNRP - NOT NEUTRAL

~ac 6-12740 Issued9!02

:;
 4001-39
10M
SOCKET HOUSING
FLANGE
MAIN CHASSIS HARNESS 437550Al
10F
437551 Al
PIN HOUSING CAB

CONNECTOR 10F CONNECTOR 10F

CAB BULKHEAD CAB BULKHEAD
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 220M NEUTRAL RELAY B+ 33 547A CRUISE ONIOFF

2 OPEN 34 35BA CRUISE INCREMENT

3 222B TRAILER AUX SWITCHED B+ 35 489A CRUISE DECREMENT

4 787A FENDER WORKLIGHT B+ 36 267A HYD FILTER RESTRICT

5 OPEN 37 267D TRANS FILTER RESTRICT

6 102C SWITCHEDB+ 3B 555D CLUTCH POT SIG

7 204A ELECT GOV B+ 30A 39 556D CLUTCH POT B+ (8V)

8 OPEN 40 557D CLUTCH POT GND

9 596A EDC POWER B+ 41 754A RIGHT TURN LAMPS

10 509B LEFT BRAKE B+ 42 752G RIGHT HAZARD

11 SlOB RIGHT BRAKE B+ 43 lOlA UNSWITCHED BAITERY B+

12 550C TRCU POWER B+ 44 753A LEFT TURN LAMPS

13 OPEN 45 751F LEFT HAZARD

14 311A PTO BRAKE RELAY EURO 46 755B RIGHT STOP

15 599B PTO POWERB+ 47 792C CENTERISIDE RELAY

16 581H PARK RELAY (COMMON) 4B lOIN UNSWITCHED BAITERY B+

17 ISBA ITALIAN BRAKE PRESSURESW 49 101P UNSWlTCHED BAITERY B+

18 ISBA ITALIAN BRAKE 50 726A HIGH BEAM RELAY

19 531B AXLE SENSOR B+ 51 728B LOW BEAM RELAY

20 114A TRANS CONT UNSW B+ 52 750D FENDER TAIL LAMPS

21 536A AUTO SUSPENSION LAMP 53 750M FRONT HITCH POS LAMPS

22 157A ITALIAN BRAKE SOL 54 177C CHASSIS GROUND

23 159A ITALIAN BRAKE HYD 55 1770 CHASSIS GROUND

24 532A AXLE LOCKAJNLOCK 56 724B HIGH BEAM

25 533A OPEN 57 755E TRAILER STOP

26 511A PARK SIGNAL SW 58 AUTO HITCH

27 588C BOT OF CLUTCH RLY (NC) 59 755H LEFT STOP

2B 585C PNEUMATIC BRAKE B+ 60 POWER CAVITY (NOT USED)

29 293B PTO 'ON" ARMREST 61 OPEN

30 5B6A PNEU BRAKE IND-EURO 62 OPEN

31 OPEN 63 REO CDB BAIT (TRACTOR)

32 OPEN 64 YELLOW CDB HI (TRACTOR)

Rae 6-12740 Issued 9/02

4001 - 40
10M
SOCKET HOUSING
FLANGE
MAIN CHASSIS HARNESS
437550Al
lOF

ri~
437551Al
PIN HOUSING CAB

~~
CONNECTOR 10F CONNECTOR 10F
CAB BULKHEAD CAB BULKHEAD
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
65 BlACK COB GND [TRACTOR) 94 OPEN

66 GREEN COB LO [TRACTOR) 95 179Y CLEAN GROUND

67 RED COB BATT (IMPLEMENT) 96 OPEN

68 YELLOW COB HI (IMPLEMENT) 97 OPEN

69 BlACK COB GND (IMPLEMENT) 98 OPEN

70 GREEN COB LO (IMPLEMENT) 99 OPEN

71 138C ISOl1783 SWITCHED Il+ 100 OPEN

72 137B ISOl1783 UNSWITCHED Il+ 101 OPEN

73 OPEN 102 OPEN

74 518B PICKUP HITCH lATCH

75 512C RIDE CONTROL
76 9000 AUX CONTROLLER Il+
77 223A GOV ING SW ING
78 89A KEY BATTERY
79 172B FNRP START OUTPUT
eo 722A HORN POWER Bt
81 83SA FRONT WASHER
82 B4SA REAR WASHER
83 283A RADAR Il+
B4 83SA TO HVAC CLUTCH
B5 195B CAB PRESSURE BLOWER
B6 B02A HVAC HIGH PRESS SW OUT
87 285A IMPLEMENT SWITCH
BB 5510 FNRP SHUTTLE· F
89 5530 FNRp· NOT NEUTRAL
90 5526 FNRP SHUTTLE· R
91 SOlB FNRP SWITCH 5V
92 55BA PARK RElAY COIL
93 OPEN

Rac 6·12740 Issued 9/02

 4001-41

CONNECTOR 11
HEADLIGHT SWITCH
WIRE
CAY CI RCUIT REFERENCE
NUMBER
11 I 70JA HAZARD LED
SOCKET HOUSING
CAB HARNESS 2 751G HAZARD SIGNAL
382391A1 3 703A 7036 HAZARD LED
4 725A 7256 ROAD LIGHTS
5 7066 UNSWITCHED B+
6 7076 7070 HAZARD /TAIL
7 176.1 LED GROUND
8 7036 HAZARD LED
9 OPEN
10 OPEN

CONNECTOR 12
CAVITY 1 ROTARY WORKLIGHT SWITCH
12 WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
CAB HARNESS
475083C1 61 7896 LOWER WORKLIGHT 6+
B2 789A 7896 WORKLIGHT B+
CAVITY 4 HIt 791A ROOF REAR WORKLIGHT
R 790A FRONT ROOF WORKLIGHT
T OPEN
W 792A LOWER WORKLIGHT

Rae 6-12740 155uOO9/02

4001 - 42

13M
PIN HOUSING
ROOF HARNESS
179483Al

SOCKET HOUSING
CAB HARNESS
196155Al

CONNECTOR 13F CONNECTOR 13M

ROOF HARNESS CAB HARNESS
WIR E WIRE
CAY CI RCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 7510 751E LEFT TURN Il+ A 751C LEFT ROOF HAZARDITURN+
B OPEN B OPEN
C 7520 752E RIGHT TURN Il+ C 752C RIGHT ROOF HAZARDITURN+
0 7630 763C A-POST WORKLIGHTS Il+ 0 763A A·POST WORKLIGHTS
E 764B FRONT ROOF WORKLIGHTS Il+ E 764A FRONT ROOF WORKLIGHTS
F 176l CHASSIS GROUND F 176H CHASSIS GROUND
G 793B 793C REAR WORKLIGHTS Il+ G 793A REAR WORKLIGHTS +
H 176B STROBEIBEACON + H 178A STROBEIBEACON
J 644B REAR WIPER BRAKE J 644A REAR WIPER BRAKE
K 641B REAR WIPER PARK K 841A REAR WIPER PARK
L 643B REAR L 643A REAR WIPER LOW
M 178G CHASSIS GROUND M 1760 CHASSIS GROUND
N 634B FRONT WIPER BRAKE N 634A FRONT WIPER BRAKE
P 631B FRONT WIPER PARK P 631A FRONT WIPER PARK
R 633B FRONT WIPER LOW R 633A FRONT WIPER LOW
S 632B FRONT WIPER HIGH S 632A FRONT WIPER HIGH
T 7260 726E RIGHT CONSOLE LIGHT & RADIO T 727B RIGHT CONSOLE LIGHT & RADIO
U 178N 176 RIGHT CONSOLE LIGHT & RADIO GND U 176C DOME. RADIO GROUND
V 671B 871C DOME LIGHT & RADIO UNSWITCHED B+ V 671A DOME, MAP, RADIO (UNSW Il+I
W 670C RADIO SWITCHED B+ W 870B 6700 CIGAR LIGHTER, RADIO SW Il+
X 135B ROOF AUX POWER IUNSWITCHED Il+) X 135A CIGAR AUXILIARY UNSW Il+
Y 1368 ROOF AUX POWER (SWITCHED Il+) Y 138A AUXILIARY SWITCHED Il+
l 134B AUXILIARY POWER GROUND, l 177M AUXILIARY GROUND

ac 6-12740 Issued 9/02

 4001·43

14M
SOCKET HOUSING
14F ROOF HARNESS
PIN HOUSING 22213SAI
LAMP
222136Al

CONNECTOR 14M CONNECTOR 14F

RIGHT A·POST WORKLIGHT RIGHT A·POST WORKLIGHT
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 783C B+ 1 LAMP B+
2 178AE GROUND 2 LAMP GROUND

15M

~
SOCKET HOUSING
ROOF HARNESS
15F 22213SAI
PIN HOUSING
LAMP 222136Al

CAVITY

CONNECTOR 15M CONNECTOR 15F

LEFT A·POST WORKLIGHT LEFT A·POST WORKLIGHT
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 7838 B+ 1 LAMP B+
2 17BAD GROUND 2 LAMP GROUND

Rae 6-12740 Issued 9/02

4001 - 44

16M
SOCKET HOUSING
ROOF HARNESS
245482C1

16F
P1N HOUSING
WORKLAMP
245483C1
CAVITY B

CONNECTOR 16M CONNECTOR 16F

LEFT REAR WORKLIGHT LEFT REAR WORKLIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 793C B+ A LAMP 8+
8 17BAl GROUND 8 LAMP GROUND

17F
SOCKET HOUSING
ROOF HARNESS
245482C1

17M
PIN HOUSING
WORKLAMP
245483C1
CAVITY B --./

CONNECTOR 17M CONNECTOR 17F

RIGHT REAR WORKLIGHT RIGHT REAR WORKLIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 7938 B+ A LAMP B+
8 17BAM GROUND 8 LAMP GROUND

CAVITY A
18
SOCKET HOUSING
ROOF HARNESS
239449A1

CONNECTOR 18
LEFT HAND FRONT ROOF WORKLIGHT
WIRE
CAY CIRCUIT REFERENCE
NUMBER
A 784C B+
8 17BAH GROUND

ac 6-12740 Issued 9/02

 4001-45

20F,21F,22F
PIN HOUSING
FENDER HARNESS
225350Ci
ceo
CAVITY I

20M, 21M, 22M

SOCKET HOUSING
N-o--""", AUXIPTO HARNESS
225351Cl
CAVITY 2

CONNECTOR 20F CONNECTOR 20M

RIGHT FENDER HARNESS RIGHT FENDER HARNESS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
I 767J RIGHT WORKLIGHT Il+ I 767N RIGHT WORKLIGHT Il+
2 754B RIGHT TURN 2 753 RIGHT TURN
3 752L WIDE MARKER LIGHT 3 751 WIDE MARKER LIGHT
4 755C STOP LIGHT 4 755 STOP LIGHT
5 750H RIGHTTAIL 5 750 RIGHTTAIL

CONNECTOR 21 F CONNECTOR 21 M
LEFT FENDER HARNESS LEFT FENDER HARNESS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
I 7670 LEFT WORKUGHT Il+ 1 767G LEFT WORKLIGHT Il+
2 753B LEFT WORKLIGHT GROUND 2 7530 LEFT WORKLIGHT GROUND
3 751M WIDE MARKER LIGHT 3 751P WIDE MARKER LIGHT
4 755.1 STOP LIGHT 4 755L STOP LIGHT
5 750F LEFT TAIL 5 750 LEFT TAIL

CONNECTOR 22F CONNECTOR 22M

FRONT HITCH LAMPS FRONT HITCH LAMPS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
I 743B LEFT HIGH BEAM I OPEN
2 7423B LEFT LOW BEAM 2 OPEN
3 738F WORKLIGHTS 3 736F WORKLAMPS
4 740B RIGHT LOW BEAM 4 OPEN
5 741B RIGHT HIGH BEAM 5 OPEN
6 160F CHASSIS GROUND 6 160F CHASSIS GROUND
7 176C CHASSIS GROUND 7 OPEN
6 744A PILOT 6 OPEN

Rae 6-12740 Issued 9/02

4001 - 46

LOCATION: CONNECTORS NO. 29 THRU 38

SCE CONNECTOR AND COMPONENT
LOCATIONS IN THIS SECTION. ALL ARE
PART NUMBER 371614Al CONNECTOR 29M
ODD SOLENOID
29M WIRE
CAY CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
TRANSMISSIONIHITCH 1 20181 HIGH SIDE
HARNESS
CAVITY 1 2 580A LOW SIDE

CONNECTOR 30M
EVEN SOLENOID
30M WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
NUMBER
TRANSMISSIONIHITCH
HARNESS 1 201E HIGH SIDE
2 581A LOW SIDE

CONNECTOR 31M
1 - 2 SOLENOID
31M WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
TRANSMISSIONIHITCH
HARNESS 1 201C HIGH SIDE
2 582A LOW SIDE

CONNECTOR 32M
3 - 4 SOLENOID
32M WIRE
CAY CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
TRANSMISSIONIHITCH
HARNESS 1 201FI HIGH SIDE
2 583A LOW SIDE

Issued 9/02
 4001-47

CONNECTOR 33M
5 - 6 SOLENOID
33M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
TRANSMISSIONIHITCH
HARNESS 1 2010 HIGH SIDE
2 5840 lOW SIDE

CONNECTOR 34M
REVERSE SOLENOID
34M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
TRANSMISSIONIHITCH
HARNESS 1 201G HIGH SIDE
2 585A lOW SIDE

CONNECTOR 35M
MASTER SOLENOID
35M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
199707Al
A 586A HIGH SIDE
B 2208 lOW SIDE

CONNECTOR 36M
36M LOW SOLENOID
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 587A HIGH SIDE
2 2200 lOW SIDE

CONNECTOR 37M
MEDIUM SOLENOID
37M
WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
1 588A HIGH SIDE
2 220C lOW SIDE

CONNECTOR 38M
38M HIGH SOLENOID
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 220E HIGH SIDE
2 589A lOW SIDE

Rae 6-12740 Issued 9/02

4001 - 48

CONNECTOR 39M
39M CREEP SOLENOID
SOCKET HOUSING WIRE
CAV CIRCUIT REFERENCE
NUMBER
1 210N HIGH SIDE
2 590A lOW SIDE

Rae 6-12740 Issued 9/02

 4001-49

40F AND 41F 40M AND41M

PIN HOUSING SOCKET HOUSING
182064Al 182066Al

CONNECTOR 40F CONNECTOR 40M

RIGHT FENDER GROUND RIGHT FENDER GROUND
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 174K GROUND A 174L GROUND

CONNECTOR 41F CONNECTOR 41 M

LEFT FENDER GROUND LEFT FENDER GROUND
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 174F GROUND A 174 GROUND

CAVITY A
CONNECTOR 44M
SYSTEM PRESSURE
WIRE
44M CAY CIRCUIT REFERENCE
NUMBER
SOCKET HOUSING
198456Al A 5578 SYSTEM PRESSURE GROUND
B 561C SYSTEM PRESSURE B+
CAVITYC
C 563A SYSTEM PRESSURE SIGNAL

Rae 6-12740 tssued9/02

4001 - 50

CONNECTOR 47M
47M RIGHT BRAKE PARK SOLENOID SWITCH #1
SOCKET HOUSING WIRE
FRONT TO REAR CAY CIRCUIT REFERENCE
HARNESS NUMBER
335461A1 A S61F PARK B+
B S67A TO SOLENOID

CONNECTOR 48M
48M LEFT BRAKE PARK SOLENOID SWITCH #2
SOCKET HOUSING WIRE
FRONT TO REAR CAY NUMBER
CIRCUIT REFERENCE
HARNESS
335461A1 A 561G PARK B+
B S67B TO SOLENOID

49F 49M
SOCKET HOUSING
FRONT TO REAR SOCKET HOUSING
HARNESS 225315C1 225316C1

CONNECTOR 49F CONNECTOR 49M

PARK SOLENOID PARK SOLENOID
WIRE WIRE
CAY
NUMBER
CIRCUIT REFERENCE CAY NUMBER CI RCUIT REFERENCE

1 5670 PARK B+ 1 567C PARK B+

2 179BT GROUND 2 179AE GROUND

CONNECTOR 49MM
49MM PARK SOLENOID
SOCKET HOUSING WIRE
225316C1 CAY NUMBER CI RCUIT REFERENCE

1 567G PARK B+
2 179CA GROUND

CAVITY A CONNECTOR 50
50 BOnOM OF CLUTCH SWITCH (PEDAL PRESSED)
SOCKET HOUSING WIRE
227429A1 CAY NUMBER CIRCUIT REFERENCE

A 553B BonOM OF CLUTCH

B 568A NOT NEUTRAL SIGNAL

Rae 6-12740 Issued 9/02

 4001 - 51

51F NOTE: KEYING IS DIFFERENT

PIN HOUSING FOR EACH COLOR CONNECTOR
FNRP HARNESS
223672Al
51M
SOCKET HOUSING
CAB HARNESS
223671 Al
CAVITY 12 ---""'t!!t'fY

CONNECTOR 51M CONNECTOR 51F

FNRPSWITCH FNRP SWITCH
WIRE WIRE
CAV CI RCUIT REFERENCE CAV CI RCUIT REFERENCE
NUMBER NUMBER
1 623A START INPlIT 1 STARTINPlIT
2 172B START OllTPlIT 2 START OllTPlIT
3 550J RUN INPUT 3 RUNINPlIT
4 511A FNRp· NOT PARK 4 FNRP · NOT PARK
5 552B FNRp·REVERSE 5 FNRp·REVERSE
6 5510 FNRp·FORWARD 6 FNRP·FORWARD
7 553F FNRp·NOT NElITRAL 7 FNRp·NOT NElITRAL
8 5618 FNRP GROUND 8 FNRP GROUND
9 723A HORN 9 HORN
10 178AB RTILTTURN COMMON GND 10 RTILTTURN COMMON GND
11 752A FNRP RIGHT TURN INDICATOR FNRP RIGHT TURN INDICATOR
12 751A FNRP LEFT TURN INDICATOR
"12 FNRP LEFT TURN INDICATOR

CONNECTOR 52
ELECTRIC CLUTCH
52 WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
CAB HARNESS
198550Al A 5570 CLlITCH POTENTIOMETER GROUND
B 5550 CLlITCH POSITION
CAVITY A
C 5560 SUPPLY (8V DC)

CONNECTOR 53M
Jl • REMOTE CONTROLLER (AUX) • GRAY
WIRE
CAV CIRCUIT REFERENCE
NUMBER
1 900A REMOTE (AUX) Bt . 1
2 179AR CLEAN GROUND· 1
3 AUX5 TOP 1 B+ REMOTE (AUX) 5 BRAISE
4 AUX5 BOT 1 Bt REMOTE (AUX) 5 A LOWER
53M 5 AUX4 TOP 1 Bt REMOTE (AUX) 4 BRAISE
SOCKET HOUSING
223671Al 6 AUX4 BOT 1 Bt REMOTE (AUX) 4 A LOWER
7 AUX4 BOT 2 RETURN REMOTE (AUX) 4 A LOWER
8 AUX4TOP2 RETURN REMOTE (AUX) 4 BRAISE
9 AUX5 BOT 2 RETURN REMOTE (AUX) 5 A LOWER
10 AUX5 TOP 2 RETURN REMOTE (AUX) 5 BRAISE
179AS CLEAN GROUND· 2
"
12 9008 REMOTE (AUX) B+ • 2

Rae 6- 12740 Issued 9/02

4001 - 52

CONNECTOR 54M
J2 - REMOTE CONTROLLER (AUX) - BLACK
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 AUX3TOP 1 B+ REMOTE IAUX) 3 BRAISE
2 AUX3 BOT 1 B+ REMOTE IAUX) 3 A LOWER

CAVITY 1 3 AUX2TOP 1 B+ REMOTE IAUX) 2 BRAISE

4 AUX2 BOT 1 B+ REMOTE IAUX) 2 A LOWER
54M
SOCKET HOUSING 5 AUXlTOP 1 B+ REMOTE IAUX) 1 BRAISE
223679Al 6 AUXl BOT 1 B+ REMOTE IAUX) 1 A LOWER
7 AUXl BOT 2 RETURN REMOTE IAUX) 1 A LOWER
8 AUX1 TOP 2 RETURN REMOTE IAUX) 1 BRAISE
9 AUX2 BOT 2 RETURN REMOTE IAUX) 2 A LOWER
10 AUX2 TOP 2 RETURN REMOTE IAUX) 2 BRAISE
11 AUX3 BOT 2 RETURN REMOTE IAUX) 3 A LOWER
12 AUX3TOP3 RETURN REMOTE IAUX) 3 BRAISE

CONNECTOR SSM
J3 - REMOTE CONTROLLER (AUX) - GREEN
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 917A SPARE IMP POT GROUND
2 919A IMPLEMENT POTENTIOMETER SIGNAL

CAVITY 1 3 920A IMPLEMENT POTENTIOMETER GND

4 920A IMPLEMENT POTENTIOMETER B+
SSM
SOCKET HOUSING 5 PLUG OPEN
2236a4Al 6 GREEN DATA BUS LOW (TRACTOR)
7 YELLOW DATA BUS HIGH (TRACTOR)
8 PLUG OPEN
9 PLUG OPEN
10 PLUG OPEN
11 916A SPARE IMP POT SIGNAL
12 915A SPARE IMP POT B+

ac 6-12740 Issued 9/02

 4001 ·53

CONNECTOR SSM
J1 • PTO CONTROLLER· GRAY
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 2160 ENG RPM
2 510A RIGHT BRAKE

CAVITY 1 3 509A LEFT BRAKE

4 PLUG OPEN
56M
SOCKET HOUSING 5 293A) PTO- 'ON'
225389C1 6 PLUG OPEN
7 YELLOW DATA BUS HIGH (TRACTOR)
B GREEN DATA BUS LOW (TRACTOR)
9 PLUG OPEN
10 295A PTD SPEED SHAFT
11 PLUG OPEN
12 294A PTO SPEED SIGNAL

CONNECTOR 57M
J2 . PTO CONTROLLER· BLACK
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 599A SWITCHED il+
2 PLUG OPEN

CAVITY 1 3 702A BRAKE LIGHT RELAY

4 597A PTO SOLENOID il+
57M
SOCKET HOUSING 5 59BA PTO SOLENOID RETURN
225402C1 6 PLUG OPEN
7 PLUG OPEN
CAVITY 12
B PLUG OPEN
9 530A DIFFERENTIAL SOLENOID il+
10 540A MFD SOLENOID il+
11 PLUG OPEN
12 179F CLEAN GROUND

Rae 6-12740 Issued9!02

4001 ·54

CONNECTOR S8M
J1 • HITCH CONTROLLER · GREEN
WIRE
CAV CI RCUIT REFERENCE
NUMBER
1 52BE HITCH SOLENOIO B+
2 527C HITCH SOLENOID UP

CAVITY 1 3 529C HITCH SOLENOID DOWN

4 PLUG OPEN
58M
SOCKET HOUSING 5 PLUG OPEN
225403C1 6 PLUG OPEN
7 51BA PICK UP HITCH LATCH
CAVITY 12 .../
B PLUG OPEN
9 513A REMOTE SWITCH UP
10 526A REMOTE SWITCH DOWN
11 179AC CLEAN GROUND
12 5000 HITCH & REMOTE B+

CONNECTOR S9M
J2 • HITCH CONTROLLER · BROWN
WIRE
CAV CIRCUIT REFERENCE
NUMBER
1 516A HITCH +BV
2 515A LEFT PIN SIGNAL

CAVITY 1 3 514A RIGHT PIN SIGNAl

4 GREEN DATA BUS LOW (TRACTOR)
S9M
SOCKET HOUSING 5 YELLOW DATA BUS HIGH (TRACTOR)
225465C1 6 506A ROCKSHAFT POTENTIOMETER· HIGH
7 S07A ROCKSHAFT POTENTIOMETER · SIGNAL
CAVITY 12
B SOBA ROCKSHAFT POTENTIOMETER • LOW
9 PLUG OPEN
10 PLUG OPEN
11 517A HITCH LOAD PIN GROUND
12 512A RIDE CONTROL

ac 6-12740 Issued 9/02

 4001 - 55

60F
PIN HOUSING
FRONT TO REAR
HARNESS
HDD2f>24-31PT

60M
SOCKET HOUSING
CAB HARNESS
HOO24-24-31ST

LOCATION : SEE CONNECTOR AND COMPONENT

LOCATIONS IN THIS SECTION.

CONNECTOR 60F CONNECTOR 60M

CHASSIS TO CAB CONNECTS WITH FRONT TO REAR HARNESS
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 NJA OPEN 1 235(Y) OPEN
2 216F ICU CLEAN GROUND 2 942 (DB) ICU CLEAN GAOUND
3 179L CLEAN GROUND 3 RED QUAD CLEAN GROUND
4 181B ICU SENSOR GND 4 GAEENQUAD ICU SENSOA GND
5 235B ENGINE COOLANTTEMP 5 266(Y) ENGINE COOLANTTEMP
6 945B FOOT THROTTLE SW 11 6 NfA FOOT THAOTTLE SW #1
7 2666 AlA FILTEA 7 NfA AlA FILTEA
8 234B FUELLEVE 8VDC 8 YELLOW QUAD FUEL LEVE 8VDC
9 944B FOOT THAOTTLE SIGNAL 9 BLACK QUAD FOOT THAOTTLE SIGNAL
10 121B ALTERNA TOR EXCITE 10 255(Y) ALTEANATOR EXCITE
11 641B ETHEA SOLENOID B+ 11 255 (R) ETHEA SOLENOID B+
12 216B ALTWFAEQ 12 121 ALTW FAEQ
13 236B FUEL LEVEL SIGNAl 13 722 FUEL LEVEL SIGNAL
14 602B FUEL RELAY SOLENOID 14 234(Y) FUEL RELAY SOL
15 215B WHEEL SPEED SIGNAL 15 234 (A) WHEEL SPEED SIGNAL
16 723B HORN AETURN 16 215(Y) FUEL RELAY SOL
17 943B FOOTTHROTTLE GND 17 267 (DG) WHEEL SPEED SIGNAL
18 AED CDB BATT (TR) 18 233 (W) COB BATT (TA)
19 942B FOOT THROTTLE B+ 19 NJA FOOT THRDTTLE GND
20 GAEEN CDB LO (TA) 20 216(Y) CDB LO (TA)
21 941B FOOT THROTTLE SW #2 21 941 (A) FOOT THROTTLE SW #2
22 264B TAANS OIL TEMP 22 941 (T) TRANS OIL TEMP
23 2566 ENG OIL PAESS SIG 23 941 (B) ENG OIL PRESS SIG
24 255B ENG OIL PAESS 5VDC 24 942 (T) ENG OIL PAESS 5VDC
25 1990 RADAA SIGNAL FAEQ 25 264 (V) RADAA SIGNAL FAEQ
26 240B AlA TO AlA 26 281 (Y) AlA TO AlA
27 YELLOW COB HI (TR) 27 282 (Y) COB HI (TR)
28 262B RADAR PAESENT 28 2401Y) RADAR PRESENT
29 BLACK CDBGND (TA) 29 641 (DB) CDB GND (TA)
30 OPEN 30 NfA OPEN
31 OPEN 31 1n(B) OPEN

Rae 6-12740 Issued 9/02

I t
4001 - 56

CONNECTOR 61
UPPER A-POST INSTRUMENT CLUSTER
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 121A ALTERNATOR EXCITE
2 GREEN DATA BUS LOW (TRACTOR)
3 PLUG OPEN
4 PLUG OPEN
5 267A TRANSMISSION FILTER RESTRICT
6 PLUG OPEN
7 235A ENGINE COOLANTTEMPERATURE
6 234A FUEL LEVEL 8VDC
9 216A ALTERNATOR W FREQUENCY
10 PLUG OPEN
11 602A FUEL RELAY SOLENOIO
12 PLUG OPEN
13 282 (Y) RADAR PRESENT
14 PLUG OPEN
15 267D TRANSMISSION FILTER RETRICTION
16 PLUG OPEN

CAVITY 1 17 240A AIR TO AIR

~~~y CAVITY 10
61 18 255A ENGINE OIL PRESSURE 5VDC
SOCKET HOUSING 19 199A RADAR SIGNAL FREQUENCY
CAB HARNESS
198459A1 20 202A ICU UNSWITCHED B+
21 PLUG OPEN
22 PLUG OPEN
23 303A SEAT SWITCH
24 724A HIGH BEAM INDICATOR
25 266A AIR FILTER
26 236A FUEL LEVEL (SIGNAL)
27 256A ENGINE OIL PRESSURE SIGNAL
28 215A WHEEL SPEED SIGNAL
29 PLUG OPEN
30 PLUG OPEN
31 YELLOW DATA BUS HIGH (TRACTOR)
32 PLUG OPEN
33 727A LIGHT SWITCH
34 PLUG OPEN
35 PLUG OPEN
36 264A TRANSMISSION OIL TEMPERATURE
37 161A ICU SENSOR GROUND
36 PLUG OPEN
39 216G CLEAN GROUND
40 203A ICU SWITCHED B+

ac 6-12740 Issued 9/02

 4001-57

CONNECTOR 62M
LOWER A-POST INSTRUMENT CLUSTER
WI RE
CAY CIRCUIT REFERENCE
NUMBER
1 PLUG OPEN
2 202C FUSED B+ (UNSWITCHED)

CAVITY 1 3 PLUG OPEN

4 PLUG OPEN
62M
SOCKET HOUSING 5 PLUG OPEN
22SoW2C1 6 YELLOW DATA BUS HIGH (TRACTOR)
7 GREEN DATA BUS LOW (TRACTOR)
8 PLUG OPEN
9 PLUG OPEN
10 285A IMPLEMENT SWITCH
11 200c PMU B+ (SWITCHED)
12 179U CLEAN GROUND

63F
PIN HOUSING 63M
280458A1 SOCKET HOUSING
280456A1

CONNECTOR 63M CONNECTOR 63F

FOOT THROTILE I CRUISE FOOT THROTILE I CRUISE
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 943C PEDAl GROUND 1 9430 PEDAL GROUND
2 945C IDLE SWITCH (NO) 2 9450 IDLE SWITCH (NO)
3 941C IDLE SWITCH (NC) 3 9410 IDLE SWITCH (NC)
4 942C PEDAL B+ 4 9420 PEDAL B+
5 944C PEDAL SIGNAL 5 9440 PEDAL SIGNAL
6 489C CRUISE INCREMENT 6 4890 CRUISE INCREMENT
7 358C CRUISE DECREMENT 7 3580 CRUISE DECREMENT
8 547C CRUISE ON I OFF 8 5470 CRUISE ON I OFF

Rae 6-12740 Issued 9/02

4001·58

66F
PIN HOUSING
FUEL SENDER
CAVITY A
245485C1

LOCATION: TOP Of FUEL TANK

66M
SEE CONNECTOR AND COMPONENT SOCKET HOUSING
LOCATIONS IN THIS SECTION FRONT TO REAR
HARNESS
245434C1

CONNECTOR 66M CONNECTOR 66F

FUEL SENDER FUEL SENDER
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 2346 FUEL SENDER 8V A SENDER FUEL SENDER 8V
6 2366 FUEL SENDER SIGNAL 6 SENDER FUEL SENDER SIGNAL
C 179P FUEL SENDER GROUND C SENDER FUEL SENDER GROUND

67F 67M
SOCKET HOUSING SOCKET HOUSING
FRONT TO REAR 225316C1
HARNESS
225316C1

CONNECTOR 67F CONNECTOR 67M

PNEUMATIC AIR SW1TCH PNEUMATIC AIR SWITCH
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 566C AIR SWITCH B+ 1 566B AIR SWITCH B+
2 179A6 AIR SWITCH GROUND 2 179BA AIR SWITCH GROUND

68F
PIN HOUSING
RADAR
245716C1

68M
SOCKET HOUSING
FRONT TO REAR
HARNESS
245715C1
CAVITYC}

CONNECTOR 68F CONNECTOR 68M

RADAR RADAR
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A RADAR WIRE RADAR GROUND A 179R RADAR GROUND
6 RADAR WIRE RADAR SIGNAL 6 1990 RADAR SIGNAL
C RADAR WIRE RADAR Bt C 2836 RADAR B+
0 RADAR WIRE RADAR PRESENT 0 2626 RADAR PRESENT

c 6-12740 Issued 9/02

 4001·59

69F
PIN HOUSING
SENSOR
245483C1
69M
SOCKET HOUSING
LOCATION: TOP OF TRANSMISSION FRONT TO REAR
SEE CONNECTOR AND COMPONENT HARNESS
LOCATIONS IN TIHIS SECTION 245482C1
CAVITY A

CONNECTION 69F CONNECTOR 69M

WHEEL SPEED WHEEL SPEED
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SENSOR WIRE WHEEL SPEED SIGNAL A 215 (V) WHEEL SPEED SIGNAL
B SENSOR WIRE WHEEL SPEED GROUND 6 215(6) WHEEL SPEED GROUND

70F CONNECTOR 70F

SOCKET HOUSING PNEUMATIC BRAKES
FRONT TO REAR
WIRE
HARNESS 245482C1 CAV NUMBER CIRCUIT REFERENCE
CAVITY B - " A 565D B+
6 17965 GROUND

CONNECTOR 70M
70M PNEUMATIC BRAKES
SOCKET HOUSING WIRE
CAV CIRCUIT REFERENCE
245482C1 NUMBER
A 565A B+

CAVlTY~ 6 17966 GROUND

71F 71M
SOCKET HOUSING SOCKET HOUSING
MAlE· 292549A 1 MALE· 292549A 1
FEMALE· 292548A 1 FEMAlE· 292548A 1

CONNECTOR 71F CONNECTOR 71M

COMPRESSOR HI·PRESSURE SWITCH COMPRESSOR HI·PRESSURE SWITCH
WIRE CAV WIRE
CAV CIRCUIT REFERENCE NUMBER CIRCUIT REFERENCE
NUMBER
A 179AJ CHASSIS GROUND A SWITCH CHASSIS GROUND
6 B02C AIC PRESSURE SWITCH IN 6 SWITCH AIC PRESSURE SWITCH IN

Rae 6-12740 Issued9i02

4001 - 60

72F
PIN HOUSING
245481Cl

72M
SOCKET HOUSING
ENGINE HARNESS
245480CI

CONNECTOR 72F CONNECTOR 12M

AlC COMPRESSOR CLUTCH AlC COMPRESSOR CLUTCH
CAV WIRE WIRE
NUMBER CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER
A NC COMPRESSOR CLUTCH B+ A B35C IVC COMPRESSOR CLUTCH B+

CAVITY A
73 CONNECTOR 73
SOCKET HOUSING ETHER
475075Cl WIRE
CAV NUMBER CIRCUIT REFERENCE
A SOOF ETHER GROUND
B 641C ETHER SOLENOID

74A&B
SOCKET
ENGINE HOUSING

CONNECTOR 74A CONNECTOR 74B

HORN GROUND HORN B+
WIRE WIRE CIRCUIT REFERENCE
CAV CIRCUIT REFERENCE CAV
NUMBER NUMBER
1 722C HORN GROUND 1 723C) HORN B+

CONNECTOR 75
75 AIR TO AIR SENSOR
PIN HOUSING
ENGINE HARNESS WIRE CIRCUIT REFERENCE
CAV NUMBER
182068Al
A 240C AIR TO AIR SENSOR
LOCATION: l.H. SIDE OF ENGINE
SEE CONNECTOR AND COMPONENT B lB1G AIR TO AIR GROUND
LOCATIONS IN THIS SECTION

Rae 6-12740 Issued9/02

 4001-61

76A&B
SOCKET
ENGINE HARNESS

CONNECTOR 76A CONNECTOR 76B

AIR FILTER RESTRICTION SWITCH AIR FILTER RESTRICTION SWITCH
WIRE CIRCUIT REFERENCE CAY WIRE CIRCUIT REFERENCE
CAY NUMBER
NUMBER
1 266A AIR FILTER RESTRICTION SW 1 600D AIR RESTRICT GROUND

CONNECTOR IT
ALTERNATOR OUTPUT B+

~
IT WIRE
ENGINE HARNESS CAY CIRCUIT REFERENCE
NUMBER
200338
1 120A B+

CONNECTOR 78

~
INTERMEDIATE STARTING RELAY
78
ENGINE HARNESS WIRE
CAY CIRCUIT REFERENCE
200338 NUMBER
1 62{)A B+

CONNECTOR 79

~
STARTER START TERMINAL
79 WIRE
ENGINE HARNESS CAY NUMBER CIRCUIT REFERENCE
200312
1 625A STARTER START TERMINAL

CONNECTOR 80F

~
RING TERMINAL
80 WIRE
ENGINE HARNESS CAY NUMBER CIRCUIT REFERENCE
225068C1
1 62{)A STARTING RELAY B+ (CONNECTOR 80)

CONNECTOR 81A
81A ALTERNATOR OUTPUT B+
RING TERMINAL
327175 WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 BATT B+

CONNECTOR 81F
81F ALTERNATOR OUTPUT
225068C1 WIRE
ENGINE HARNESS CAY CIRCUIT REFERENCE
NUMBER
1 12{)A B+

Rac 6-12740 Issued9/02

4001 - 62

CONNECTOR 81 F

~
81F ALTERNATOR OUTPUT
225068C1 WIRE
ENGINE HARNESS CAY NUMBER CIRCUIT REFERENCE

I 120A B+

CONNECTOR 82F

~
82F INTERMEDIATE SOLENOID IGNITION
446658 WIRE
ENGINE HARNESS CAY NUMBER CIRCUIT REFERENCE

1 622A B+

CONNECTOR 83F

~
83F RELAY GROUND
200329 WIRE
ENGINE HARNESS CAY NUMBER
CIRCUIT REFERENCE

I GOOA 8+

~
CONNECTOR 84F
84F STARTER START TERMINAL
225065C1
WIRE
ENGINE HARNESS CAY NUMBER
CIRCUIT REFERENCE

I 625A B+

CONNECTOR 85F

~
85F ENGINE RPM
200329 WIRE
ENGINE HARNESS CAY NUMBER
CIRCUIT REFERENCE

I 126 (W) B+

~
CONNECTOR 86F
86F
ALTERNATOR EXCITE
446658
WIRE
ENGINE HARNESS CAY NUMBER
CIRCUIT REFERENCE

1 121 (D) B+

CONNECTOR 87F
87F
225065C1 CHASSIS GROUND
ENGINE HARNESS WIRE
CAY NUMBER
CIRCUIT REFERENCE

I 600E GROUND

CONNECTOR 88F
88F TRANSMISSION FILTER RESTRICTION
225072C1 WIRE
FRONT TO REAR CAY NUMBER
CIRCUIT REFERENCE
HARNESS
1 267B GROUND

Rae 6-12740 Issued9/02

 4001-63
89M
FRONT TO REAR
HARNESS
89F 222135Al
FRONT TO REAR
HARNESS
222136Al

CONNECTOR 89F CONNECTOR 89M

RING TERMINAL RING TERMINAL
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
SENSOR TRANSMISSION OIL TEMPERATURE 1 2646 TRANSMISSION OIL TEMPERATURE
2 SENSOR ICU SENSOR GROUND 2 181D ICU SENSOR GROUND
CAVITY A CAVITY A
90F 90M
PIN HOUSING ~NHOUSING
FRONT TO REAR FRONT TO REAR
HARNESS HARNESS
87229OR1 872290Rl

CONNECTOR 90F CONNECTOR 90M

PRESSURIZATION BLOWER PRESSURIZATION BLOWER
WIRE CAY WIRE CIRCUIT REFERENCE
CAY CIRCUIT REFERENCE NUMBER
NUMBER
A 195C BLOWERB+ A BLOWER BLOWER Bt
B 179AY BLOWER GROUND B BLOWER BLOWER GROUND

~~=~G., ~ Bl 91M
SOCKET HOUSING
22m8Al

CAVITY A

CONNECTOR 91 F CONNECTOR 91M

ROOF AUXILIARY POWER ROOF AUXILIARY POWER
CAY WIRE WIRE
NUMBER CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER
A 134C AUXILIARY POWER GROUND A 134B AUXILIARY POWER GROUND
B 136C SWITCHED B+ B 136B SWITCHED Bt
C 135C UNSWITCHED B+ C 135B UNSWITCHED B+
CAVITY A

92M
PIN HOUSING 92F
SOCKET HOUSING

CONNECTOR 92M CONNECTOR 92F

RIGHT REAR SPEAKER RIGHT REAR SPEAKER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 874B SPEAKER t A SPEAKER SPEAKER t
B 874A SPEAKER· B SPEAKER SPEAKER·

Rae 6-12740 tssued9/02

4001 - 64

CAVITY A

93M
PIN HOUSING 93F
SOCKET HOUSING

CONNECTOR 93M CONNECTOR 93F

LEFT REAR SPEAKER LEFT REAR SPEAKER
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 8756 SPEAKER + A SPEAKER SPEAKER +
6 875A SPEAKER- 6 SPEAKER SPEAKER -

94F
SOCKET HOUSING 94M
291729Al SOCKET HOUSING
255442Cl

CONNECTOR 94F CONNECTOR 94M

RIGHT HAND CONSOLE LIGHT RIGHT HAND CONSOLE LIGHT
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A LIGHT LIGHT B+ A 7260 LIGHT B+
6 LIGHT GROUND 6 178N 178P GROUND

95A
SOCKET HOUSING
292495Al
Q
958
SOCKET HOUSING
292494Al
Q
CONNECTOR 95A CONNECTOR 958
DELCO RADIO DELCO RADIO
WIRE WIRE CIRCUIT REFERENCE
CAV CIRCUIT REFERENCE CAV NUMBER
NUMBER
1 OPEN 9 8746 SPEAKER +
2 OPEN 10 874A SPEAKER -
3 OPEN 11 8726 RR SPEAKER +
4 870C SWITCHED 6+ 12 872A RR SPEAKER-
5 OPEN 13 8736 RF SPEAKER +
6 727E DIMMER 14 873A RF SPEAKER-
7 8716 UNSWITCHED 6+ 15 8756 LF SPEAKER +
8 178M POWER GROUND 16 875A LF SPEAKER-

Rae 6-12740 Issued9/02

 4001 · 65

CAVITY A

96M
PIN HOUSING 96F
SOCKET HOUSING

CONNECTOR 96M CONNECTOR 96F

RIGHT FRONT SPEAKER RIGHT FRONT SPEAKER
WIRE WIRE CIRCUIT REFERENCE
CAY CIRCUIT REFERENCE CAY
NUMBER NUMBER
A B728 SPEAKER t A SPEAKER SPEAKER t
8 B72A SPEAKER· 8 SPEAKER SPEAKER·

CAVITY A

97M
PIN HOUSING 97F
SOCKET HOUSING

CONNECTOR 97M CONNECTOR 97F

LEFT FRONT SPEAKER LEFT FRONT SPEAKER
CAY WIRE WIRE
NUMBER CIRCUIT REFERENCE CAY NUMBER CIRCUIT REFERENCE
A B738 SPEAKER t A SPEAKER SPEAKER t
8 B73A SPEAKER· 8 SPEAKER SPEAKER·

CAVITYA ~

98F
PIN HOUSING 98M
SOCKET HOUSING
CAVITY B 245715C1

CONNECTOR 98F CONNECTOR 98M

REAR WIPER REAR WIPER
CAY WIRE WIRE
NUMBER CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER
A PLUG REAR WIPER HIGH A OPEN
8 843(0) REAR WIPER LOW 8 REAR WIPER LOW
C 841(0) REAR WIPER PARK C REAR WIPER PARK
0 844(0) REAR WIPER 8RAKE 0 REAR WIPER 8RAKE

Rae 6- 12740 Issued9/02

4001 - 66

99M
SOCKET HOUSING
ROOF HARNESS
2454SOC1

CONNECTOR 99M CONNECTOR 99F

REAR WIPER GROUND REAR WIPER GROUND
WIRE CAY WIRE
CAY CIRCUIT REFERENCE NUMBER CIRCUIT REFERENCE
NUMBER
A 178R GROUND A WIPER GROUND

CONNECTOR l00F
l00F DOOR SWITCH
SOCKET HOUSING
CAY WIRE
631801C1 CIRCUIT REFERENCE
NUMBER
A 715A GROUND

CONNECTOR 101F
101F DOOR SWITCH
SOCKET HOUSING
CAY WIRE
230227A1 NUMBER CIRCUIT REFERENCE
A 715A GROUND

CONNECTOR l02F
102F DOME LIGHT
SOCKET HOUSING
CAY WIRE CIRCUIT REFERENCE
631801C1 NUMBER
A 781C UNSWITCHED Il+

CONNECTOR 103F
103F RIGHT HAND CONSOLE LIGHT GROUND
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
230227Al NUMBER
A 178P GROUND

CONNECTOR l04F
l04F RIGHT HAND REAR TURN SIGNAL
1/4 FLAG TERM. WIRE
SOCKET CAY CIRCUIT REFERENCE
NUMBER
ROOF HARNESS
A 752E RIGHT HAND TURN SIGNAL B+

Rae 6-12740 Issued9/02

 4001 -67

CONNECTOR 105F
105F RIGHT HAND REAR TURN SIGNAL
SOCKET
WIRE CIRCUIT REFERENCE
ROOF HARNESS CAY NUMBER
A 178X GROUND

CONNECTOR l06F
l06F LEFT HAND REAR TURN SIGNAL
SOCKfT
WIRE
ROOF HARNESS CAY CIRCUIT REFERENCE
NUMBER
A 751E LEFT HAND REAR TURN SIG B+

CONNECTOR 107F
107F LEFT HAND REAR TURN SIGNAL
114 FLAG TERM. WIRE
SOCKET CAY CI RCUIT REFERENCE
NUMBER
ROOF HARNESS
A 178W GROUND

CONNECTOR 108M
RING TERMINAL
108M
CAB ROOF HARNESS WI RE
CAY NUMBER CIRCUIT REFERENCE
_AI
A OPEN
B OPEN
C 60lC FUEL SHUTOFF
0 7440 POSITION LAMPS
E 622A START RELAY
F OPEN
G OPEN
H OPEN

CONNECTOR 109M
ETHER SWITCH
WIRE
109M CAY NUMBER CIRCUIT REFERENCE
GREEN SOCKET
HOUSING A 170A GROUND
409105Al B 738A CENTER & SIDE
C 742A LEFT LOW BEAM
0 740A RIGHT LOW BEAM
E 741A RIGHT HIGH BEAM
F WORK LIGHTS
G 743A LEFT HIGH BEAM
H 170B GROUND

Rae 6- 12740 Issued9/02

4001 - 68

CONNECTOR 110M
ETHER SWITCH
CAV WIRE CIRCUIT REFERENCE
NUMBER
110M 1 OPEN
END SOCKET
2 720A SWrrCH B+
HOUSING
3 641A ETHER
429026Al
4 OPEN
5 OPEN
6 OPEN
7 <NONEXrrEN> OPEN
8 OPEN
9 OPEN
10 OPEN

111M

"" sc:a
SOCKET HOUSING
CAB HARNESS
225351Al

PIN HOUSING
22S35OAI

CAVITY 4

CONNECTOR 111 F CONNECTOR 111M

POWER MIRROR CONNECTOR POWER MIRROR CONNECTOR
WIRE WIRE
CAV NUMBER
CIRCUIT REFERENCE CAV NUMBER CIRCUIT REFERENCE

1 949A LEFT MIRROR VERTICAL 1 275A LEFT MIRROR VERTICAL

2 950A LEFT MIRROR COMMON 2 58B LEFT MIRROR COMMON
3 951A LEFT MIRROR HORIZONTAL 3 277A LEFT MIRROR HORIZONTAL
4 952A RIGHT MIRROR VERTICAL 4 278A RIGHT MIRROR VERTICAL
5 953A RIGHT MIRROR COMMON 5 SSC RIGHT MIRROR COMMON
6 954A RIGHT MIRROR HORIZONTAL 6 280A RIGHT MIRROR HORIZONTAL

~
112M
SOCKET HOUSING
276424Al
112F
PIN HOUSING
276426Al

CAVITY 1

CONNECTOR 112F CONNECTOR 112M

LEFT POWER MIRROR CONNECTOR LEFT POWER MIRROR CONNECTOR
WIRE WIRE
CAV NUMBER
CIRCUIT REFERENCE CAV NUMBER
CIRCUIT REFERENCE

1 951A LEFT MIRROR HORIZONTAL 1 MIRROR V LEFT MIRROR VERTICAL

2 950A LEFT MIRROR COMMON 2 MIRRORC LEFT MIRROR COMMON
3 949A LEFT MIRROR VERTICAL 3 MIRRORH LEFT MIRROR HORIZONTAL

Rae 6-12740 Issued9/02

 4001-69

113F
SOCKET HOUSING
276424Al

CAVITY 1

CONNECTOR 113F CONNECTOR 113M

RIGHT POWER MIRROR CONNECTOR RIGHT POWER MIRROR CONNECTOR
WIRE WIRE CIRCUIT REFERENCE
CAY CIRCUIT REFERENCE CAY
NUMBER NUMBER
1 954A RIGHT MIRROR HORIZONTAL 1 MIRROR CONN RIGHT MIRROR VERTICAL
2 953A RIGHT MIRROR COMMON 2 MIRROR CONN RIGHT MIRROR COMMON
3 952A RIGHT MIRROR VERTICAL 3 MIRROR CONN RIGHT MIRROR HORIZONTAL

114F
PIN HOUSING
222136Al
114M
SOCKET HOUSING
222135Al

CONNECTOR 114F CONNECTOR 114M

STROBEIBEACON STROBE/BEACON
CAY WIRE CIRCUIT REFERENCE WIRE
NUMBER CAY NUMBER CIRCUIT REFERENCE
1 LAMP WIRE STR08E1BEACON + 1 m(p) STR08E1BEACON +
2 LAMP WIRE GROUND 2 776 (6) GROUND

CAVITYC
115M
SOCKET HOUSING
ROOF HARNESS
245715Cl
CAVITYB

CONNECTOR 115M CONNECTOR 115F

FRONT WIPER FRONT WIPER
CAY WIRE WIRE
NUMBER CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER
1 8328 FRONT WIPER HIGH 1 FRONT WIPER HIGH
2 8338 FRONT WIPER LOW 2 FRONT WIPER LOW
3 8318 FRONT WIPER PARK 3 FRONT WIPER PARK
4 8348 FRONT WIPER 8RAKE 4 FRONT WIPER 8RAKE

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4001 - 70

116F
PIN HOUSING
2454alCl
116M
SOCKET HOUSING
ROOF HARNESS
245480Cl

CONNECTOR 116F CONNECTOR 116M

FRONT WlPER STROBEIBEACON
WIRE WIRE
CAY NUMBER CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER
A 830 (6) GROUND (FRONT WIPER) A WIPER GROUND

CONNECTOR 118F
118F
LEFT HAND FRONT TURN SIGNAL
1/4 FLAG TERM.
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
ROOF HARNESS NUMBER
1 7510 LEFT FRONT TURN SIGNALIl+

CONNECTOR 119M
RIDE CONTROL
WIRE CIRCUIT REFERENCE
CAY NUMBER
119M
WHITE 1 5186518C PICKUP HITCH LATCH
SOCKET HOUSING 2 531H 531J SWITCH Il+
42902SAl
3 512C 5120 RIDE CONTROL
4 OPEN
5 OPEN
6 OPEN
7 OPEN
8 OPEN
9 OPEN
10 OPEN

CONNECTOR 120F
120F
1/4 FLAG TERM.
LEFT HAND FRONT TURN SIGNAL
SOCKET HOUSING WIRE CIRCUIT REFERENCE
CAY NUMBER
ROOF HARNESS
1 178U GROUND (L FRONT TURN SIGNAL)

Rae &-12740 Issued9/02

 4001- 71

CONNECTOR 121M
AUX POWER
WIRE CI RCUIT REFERENCE
121M CAY NUMBER
BLUE
SOCKET HOUSING A UNSWITCHED B+
409107A1
B UNSWITCHED B+
C SWITCHED Bt
D SWITCHED Bt
E OPEN
F OPEN
G OPEN
H OPEN

CONNECTOR 122M
REAR WIPER
WIRE
122M CAY CIRCUIT REFERENCE
NUMBER
BLACK
SOCKET HOUSING 1 B44A BRAKE INPUT
CAB HARNESS
2 B43A WIPER ON
382391A1
3 841G WIPERB+
4 OPEN
5 845A WASHER ON
6 841G WASHERBt
7 OPEN
B OPEN
9 OPEN
10 OPEN

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4001 - 72

CONNECTOR 123M
CLIMATE CONTROL
WIRE
123M CAV CIRCUIT REFERENCE
NUMBER
BLUE SOCKET
HOUSING 1 OPEN
CAB HARNESS 2 OPEN
429029Al
3 OPEN
4 826C CLIMATE CONTROL AUTO
5 B01C BOlE CHASSIS GROUND
6 827C A/C ENABLE (DEHUMIDIFY)
7 OPEN
B OPEN
9 OPEN
10 OPEN

CAVITY A
124F
PIN HOUSING
245485Cl 124M
SOCKET HOUSING
245484Cl

CONNECTOR 124F CONNECTOR 124M

BLOWER AUTO TEMP CONT POT BLOWER AUTO TEMP CONT POT
CAV WIRE CIRCUIT REFERENCE CAV WIRE
NUMBER NUMBER CIRCUIT REFERENCE
A PLUG OPEN A PLUG OPEN
B 8508 ATC BLOWER SIGNAL B CONTWIRES ATC BLOWER SIGNAL
C B03C TEMP CONTROL (BLOWER) GROUND C CONTWIRES TEMP CONTROL (BLOWER) GROUND

Rae 6-12740 Issued9/02

 4001-73

CAVITY A
125F
PIN HOUSING
245485Cl 125M
SOCKET HOUSING
245484Cl

CONNECTOR 125F CONNECTOR 125M

HVAC TEMPERATURE CONTROL HVAC TEMPERATURE CONTROL
CAY WIRE WIRE
NUMBER CIRCUIT REFERENCE CAY NUMBER CIRCUIT REFERENCE
A PLUG OPEN A OPEN OPEN
8 CONTROL WIRES SIGNAL 8 807A SIGNAL
C CONTROL WIRES TEMPERATURE CONTROL GROUND C 8038 TEMPERATURE CONTROL GROUND

CONNECTOR 126F
HVAC BLOWER CONTROL
WIRE
CAY CIRCUIT REFERENCE
NUMBER
126F CAVITY 1 1 OPEN
SOCKET HOUSING 2 8200 B+
CAB HARNESS
449797Cl 3 8248 HIGH SPEED
CAVITY 6
4 8238 MEDIUM SPEED
5 8228 LOW SPEED
6 800B NGCLUTCH

CONNECTOR 127F
FRONT WIPER
CAY WIRE
NUMBER CIRCUIT REFERENCE
127F CAVITY 1
SOCKET HOUSING 1 OPEN
CAB HARNESS 2 836A 836C BATTERY (8)
449797Cl
CAVITY 6 3 833A 833C HIGH (H)
4 832A 832C MEDIUM (M)
5 834A 834C LOW(L)
6 8310 CLUTCH (C)

CONNECTOR 128
HVACCUTOUT
CAY WIRE
NUMBER CIRCUIT REFERENCE
1 OPEN
128 2
BLUE SOCKET
3 OPEN
HOUSING
CAB HARNESS 4 OPEN
429029Al
5 8018 CHASSIS GROUND
6 8268 NC AUTO ON
7 OPEN
8 OPEN
9 OPEN
10 OPEN

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4001 -74

CONNECTOR 129M
STROBEIBEACON
CAY WIRE
NUMBER CIRCUIT REFERENCE
129M
1 OPEN
SOCKET HOUSING
CAB HARNESS 2 821E SWITCH POWER
429026A1
3 776A SIGNAL, BEACONISTROBE
4 OPEN
5 OPEN
6 OPEN
7 177P LAMP GROUND
8 776C LAMP 8+
9 OPEN
10 OPEN

CONNECTOR 130
POWER MIRRORS
WIRE
CAY CIRCUIT REFERENCE
NUMBER
CAVITY 9 1 BLANK OPEN

130 2 BLANK OPEN

SOCKET HOUSING 3 177M GROUND
CAB HARNESS
375601A1 4 277A) lEFT MIRROR HORIZONTAL

CAVITY 3 5 2BOA RIGHT MIRROR HORIZONTAL

CAVITY 1 6 BLANK OPEN

7 58A MIRROR COMMON
8 275A lEFT MIRROR VERTICAL
9 870B MIRROR FUSE (B+)
10 278A RIGHT MIRROR VERTICAL

CONNECTOR 131A
131A CIGAR LIGHTER
SOCKET HOUSING
CAB HARNESS CAY WIRE CIRCUIT REFERENCE
27965BA1 NUMBER
A 821F UNSWITCHED 8+

CONNECTOR 131F
131F CIGAR LIGHTER
SOCKET CAY WIRE CIRCUIT REFERENCE
CAB HARNESS NUMBER
Bn291R1 A 177AN CHASSIS GROUND
B 207A UNSWITCHED 8+

Rae 6-12740 Issued9/02

 -~
4001-75

CAVITY A
132M
SOCKET HOUSING
ATC DISPLAY
245484Cl

CONNECTOR 132F CONNECTOR 132M

HV AC DISPLAY HVAC DISPLAY
WIRE WIRE CIRCUIT REFERENCE
CAY CIRCUIT REFERENCE CAY
NUMBER NUMBER
A 805B 5V DISPlAY PWR A DISPlAY WIRE 5V DISPlAY PWR
B 804B GROUND TO DISPlAY B DISPlAY WIRE GROUND TO DISPlAY
C 8068 DATA TO DISPlAY C DISPlAY WIRE DATA TO DISPlAY

CONNECTOR 133M
SEAT POWER
CAY WIRE CIRCUIT REFERENCE
NUMBER
1 73B SEAT POWER B+ (FEED)
2 73C SEAT POWER B+ (FEED)
CAVITY 1 3 mAC SEAT GROUND
133M
SOCKET HOUSING 4 mAD SEAT GROUND
CAB HARNESS
225389Cl 5 73D SEAT SWITCH OPS B+
6 303A SEAT SWITCH OPS RETURN
7 259A SEAT HEATER B+
8 mAE SEAT HEATER GROUND
9 PLUG OPEN
10 PLUG OPEN
11 PLUG OPEN
12 PLUG OPEN

CONNECTOR 134F
134F UNSWITCHED CAB B+
42913-2
RING TERMINAL WIRE
CAY CIRCUIT REFERENCE
NUMBER
101B 101C
1010 101E
I UNSWITCHED B+
101F 101G
101BB

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4001 - 76

CONNECTOR 135M
FLASHER
WIRE
135M CAY CIRCUIT REFERENCE
CAVITY 1 NUMBER
225402C1 1 753A LEFT TURN LAMP
SOCKET HOUSING CAB
HARNESS 2 754A RIGHT TURN LAMP
3 707C HAZARD
4 767A RIGHT TURN
5 768A LEFT TURN
6 177AK GROUND
7 7660 Il+
8 766C Il+
9 7528 RIGHT HAZARD LAMP
10 752N RIGHT HAZARD LAMP
11 7518 LEFT HAZARD LAMP
12 751J LEFT HAZARD LAMP

CONNECTOR 137M
RIGHT ARM CONSOLE
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 PLUG OPEN
2 PLUG OPEN
CAVITY 1
137M 3 PLUG OPEN
SOCKET HOUSING 4 YELLOW DATA 8US HIGH (TRACTOR)
CAB HARNESS
225389C1 5 GREEN DATA 8US LOW (TRACTOR)
6 PLUG OPEN
7 2938 PTOON
8 PLUG OPEN
9 PLUG OPEN
10 PLUG OPEN
11 179Z CLEAN GROUND
12 65A ARCU SWITCHED Il+

CONNECTOR 138A
SWITCHED 8+
138A WIRE
8MMSTUD CAY CIRCUIT REFERENCE
NUMBER
CAB HARNESS
102A 1028 102C
1 1020 102E 102F SWITCHED Il+
102M

CONNECTOR 1388
SWITCHEDB+
1388 WIRE
8MMSTUD CAY CIRCUIT REFERENCE
NUMBER
CAB HARNESS
1038 103C 1030 SWITCHED Il+
1
l03E l03F 103G

Rae 6-12740 IS5ued9/02

 4001-77

139F
PIN HOUSING
CAB HARNESS
179483A1

139M
SOCKET HOUSING
HVAC CONTROLLER
16156A1

CONNECTOR 139F CONNECTOR 139M

HVAC HVACAC UNIT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 800A AC CLUTCH FROM BLOWER SWITCH A OPEN
B 802A HVAC HIGH PRESSURE SWITCH OUT B 80 HI PRESSURE (-)
C 635A TO AC CLUTCH C 82 COMPRESSOR CLUTCH B+
0 822A BLOWER LOW SPEED FROM SWITCH 0 OPEN
E 823A BLOWER MED SPEED FROM SWITCH E OPEN
F 178B CHASSIS GROUND F 85 GROUND
G 824A BLOWER HIGH SPEED FROM SWITCH G OPEN
H B50A ATC BLOWER SIGNAL H 326 ATC BLOWER SIGNAL
J 177F ATC CHASSIS GROUND J 309 GROUND
K 820C B+ MTR PWM (ATC) K 261 B+ MTR PWM (ATC)
L 826A TO AC CUTOUT SW/AUTO L 136 TO AC CUTOUT SW/AUTO
M 827A AC IND LT (GND)lDEHUMIDIFY M 266 DEFAULT POSITION
N 179AV MODE DOOR GROUND (ATC) N 154 OPEN
P 179AU MODE DOOR GROUND (ATC) P 102 OPEN
R 82SA HVAC CONTROLLER B+ R 252 MODULE BATIERY B+
S 803A 803B TEMP CONTROL S 328 POTENTIOMETER GROUND
T 807A TEMP CONTROL POT. SIGNAL T 103 TEMPERATURE CONTROL
U 804A GROUND FOR DISPLAY U 122 DISPLAY GROUND
V 805A 5V DISPLAY PWR V 263 5V DISPLAY PWR
W 806A DATA TO DISPLAY W 262 DATA TO DISPLAY
X 76SA EURO CELCIUS (-) X 143 OPEN
Y OPEN Y OPEN
Z OPEN Z OPEN

Rae 6-12740 Issued9/02

4001 - 78

140, 141 , 142, 143,

144
SOCKET HOUSING
AUXIPTO HARNESS
291718Al

CONNECTOR 140 CONNECTOR 141

REMOTE (AUX) 1 MOTOR RAISE REMOTE (AUX) 2 MOTOR RAISE
WIRE WIRE
CAY NUMBER
CIRCUIT REFERENCE CAY NUMBER
CIRCUIT REFERENCE

AUXl B+ REMOTE (AUX) 1 BRAISE AUX2

1 TOP 1 B+ REMOTE (AUX) 2 BRAISE
TOP
AUXl RETURN REMOTE (AUX) 1 BRAISE AUX2
2 2 RETURN REMOTE (AUX) 2 BRAISE
TOP TOP

CONNECTOR 142 CONNECTOR 143

REMOTE (AUX) 3 MOTOR RAISE REMOTE (AUX) 4 MOTOR RAISE
WIRE WIRE
CAY CIRCUIT REFERENCE CAY NUMBER
CIRCUIT REFERENCE
NUMBER
AUX3 AUX4 B+ REMOTE (AUX) 4 BRAISE
1 B+ REMOTE (AUX) 3 BRAISE 1 TOP
TOP
AUX3 AUX4 RETURN REMOTE (AUX) 4 BRAISE
2 RETURN REMOTE (AUX) 3 BRAISE 2 TOP
TOP

CONNECTOR 144
REMOTE (AUX) 5 MOTOR RAISE
WIRE
CAY NUMBER
CIRCUIT REFERENCE

AUX5 B+ REMOTE (AUX) 5 BRAISE

1 TOP
AUX5 RETURN REMOTE (AUX) 5 BRAISE
2
TOP

Rae 6-12740 Issue<i9/02

 4001 -79

145F 145M
SOCKET HOUSING

~fi1r----
PIN HOUSING
245483C1 AUXIPTO HARNESS
245412C1

~ CAVITY A

CONNECTOR 145F CONNECTOR 145M

PTO SHAFT SPEED PTO SHAFT SPEED
WIRE WI RE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SENSOR WIRES PTO SHAFT SPEED A 295A PTO SHAFT SPEED
B SENSOR WIRES SENDER GROUND B 174E SENDER GROUND

146F 146M
PIN HOUSING SOCKET HOUSING
245485C1 AUXIPTO HARNESS
245484C1

- CAVITYA

CONNECTOR 146F CONNECTOR 146M

PTO DUAL SPEED PTO DUAL SPEED
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 294B PTO SPEED SIGNAL A 294A PTO SPEED SIG NAL
B 174D SENSOR GROUND B 174C SENSOR GROUND
C PLUG C PLUG OPEN

147M
147F SOCKET HOUSING
PIN HOUSING 182087A1
AUXIPTO HARNESS
182085A1

CONNECTOR 147F CONNECTOR 147M

TO TRAILER CONNECTOR TO TRAILER CONNECTOR
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 787S WORK LIGHTS A 787S WORK LIGHTS
B 751S LEFT TURN B 751K LEFT TURN
C 752M RIGHT TURN C 752J RIGHT TURN
D 755G STOP LIGHTS D 755F STOP LIGHTS
E 750S TAIL LIGHTS E 750G TAIL LIGHTS
F 222G AUXILIARY (UNSWITCHED B+) F 222C AUXILIARY (UNSWITCHED B+)

Rae 6-12740 IssuOO9/02

4001 - 80

CONNECTOR 147A
7-PIN TRAILER CONNECTOR
WIRE
TERMINAL 1 CAY CIRCUIT REFERENCE
147A NUMBER
SOCKET HOUSING 1 173A LEFT TURN
121645C1 TERMINAL 7
2 787S FIELD LIGHTS
3 751S CHASSIS GROUNE
TERMINALS
4 755G RIGHT TURN
TERMINAL 2 /
5 752M RH TAIL LIGHTS
TERMINAL 4 . . / 6 750S STOP LIGHTS
7 222G LH TAIL LIGHTS

150F 150M
PIN HOUSING SOCKET HOUSING
280453A1 AUXIPTO HARNESS
280451A1

CAVITY 1
CAVITY 3

CONNECTOR 150F CONNECTOR 150M

IMPLEMENT POT IMPLEMENT POT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
IMPLEMENT POTENTIOMETER SIG- IMPLEMENT POTENTIOMETER SIG-
1 PLUGGED 1 918A
NAL NAL
2 PLUGGED IMPLEMENT POTENTIOMETER B+ 2 920A IMPLEMENT POTENTIOMETER B+
IMPLEMENT POTENTIOMETER IMPLEMENT POTENTIOMETER
3 PLUGGED 3 919A
GROUND GROUND
4 PLUGGED SPARE SIGNAL 4 916A SPARE SIGNAL
5 PLUGGED SPARE B+ 5 915A SPARE B+
6 PLUGGED SPARE GROUND 6 917A SPARE GROUND

Rae 6-12740 Issued9/02

 4001 - 81

151M

PIN 151F
HOUSING ~ SOCKET HOUSING
TRANSMISSION!
225315Cl HITCH

/~
HARNESS
225316Cl

CAVITY1 ~
- CAVlTY2

CONNECTOR 151F CONNECTOR 151M

HITCH UP HITCH UP
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 SOLENOID WIRE HITCH SOLENOID (S+I 1 828B HITCH SOLENOID (S+ I
2 SOLENOID WIRE HITCH SOLENOID UP 2 527A HITCH SOLENDID UP

152F
152M ~ SOCKET HOUSING
TRANSMISSION!
PIN HOUSING HITCH
225315Cl HARNESS
/~ 225316Cl

CAVITYl ~CAVITY 2
CONNECTOR 152F CONNECTOR 152M
HITCH DOWN HITCH DOWN
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 SDLENOID WIRE HITCH SOLENOID (B+I 1 52eA HITCH SOLENOID (B+I
2 SOLENOID WIRE HITCH SOLENOID DOWN 2 529A HITCH SOLENOID DOWN

~
153F 153M
PIN HOUSING SOCKET HOUSING
225294Cl TRANSMISSION!
HITCH
HARNESS
225295Cl
CAVITY A
CAVITYC

CONNECTOR 153F CONNECTOR 153M

RIGHT HAND HITCH PIN RIGHT HAND HITCH PIN
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A POT WIRES GROUND A 517C GROUND
B POT WIRES SIGNAL 8 514A SIGNAL
C POT WIRES +8V C 5168 +8V

Rae 6·12740 Issued 9102

4001 - 82

~
154F 154M
PIN HOUSING SOCKET HOUSING
225294C1 TRANSMISSIONIIlITCH
HARNESS
225295C1

CAVITY A
CAVITYC

CONNECTOR 154F CONNECTOR 154M

LEFT HAND HITCH PIN LEFT HAND HITCH PIN
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A POT WIRES GROUND A 517B) GROUND
B POT WIRES SIGNAL B 515A) SIGNAL
C POT WIRES +8V C 516C +8V

CONNECTOR 155M
ROCKS HAFT POTENTIOMETER
155M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
TRANSMISSIOWHITCH
NUMBER
HARNES5-198SS0A1 A 506A HIGH
B 515A SIGNAL
C 50BA LOW

CONNECTOR 157F
157F IMPLEMENT AUXILIARY POWER
PIN HOUSING WIRE
225164C1 CAY CIRCUIT REFERENCE
NUMBER
1 540A MFD SOL - HIGH (8+)
CAVITY 1
2 175D MFD CHASSIS GROUND
CAVITY 3

CONNECTOR 158M
158M DIFFERENTIAL SOLENOID
SOCKET HOUSING
TRANSMISSIOWHITCH
~ CAY
WIRE
CIRCUIT REFERENCE
HARNESS -225316C1
NUMBER
1 530A DIFF SOLENOID - HIGH (8+)
CAVITY 1
2 mE GROUND

CONNECTOR 159M
159M
SOCKET HOUSING PTO SOLENOID
TRANSMISSIOWHITCH WIRE
HARNESS-199707A1 CAY CIRCUIT REFERENCE
NUMBER
CAVITY A A 597A HIGH 8+
B 598A LOW GROUND

Rae 6-12740 lssued9102

 4001 ·83

CONNECTOR 160M
160M MFD SOLENOID
SOCKET HOUSING WIRE
TRANSMISSIONIHITCH CAV CI RCUIT REFERENCE
HARNESS ·371614A1 NUMBER
1 540A MFD SOL· HIGH IB+)
2 1750 MFD CHASSIS GROUND

CONNECTOR 161F
IGNITION SWITCH
WI RE
CAV CIRCUIT REFERENCE
NUMBER
161F 1 B9A 107A BATTERY
SOCKET HOUSING
CAB HARNESS ·225253Cl 2 623A START INPUT
3 OPEN
CAVITY 3
4 OPEN
CAVITY 5
5 105A IGNITION
6 l06A 1066 IGNITION FEED

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4001 - 84

CONNECTOR 162M
LEFT BRAKE
162M CAVITY A
SOCKET HOUSING WIRE
CAV CIRCUIT REFERENCE
CAB HARNESS· 227429A 1 NUMBER
A 5096 lEFT BRAKE SWITCH
B 599C lEFT BRAKE B+

CONNECTOR 163M
RIGHT BRAKE
163M CAVITY A
SOCKET HOUSING WIRE
CAV CIRCUIT REFERENCE
CAB HARNESS· 227429Al NUMBER
A 599D RIGHT BRAKE B+
B SlOB RIGHT BRAKE SWITCH

CONNECTOR 164M
FOOT THROTTLE
WIRE
CAV CIRCUIT REFERENCE
164M NUMBER
SOCKET HOUSING
CAB HARNESS· 225351Cl I 179AD IVS GROUND IClN)
2 945A IVS'l
3 944A FOOT THROTIlE SIGNAL
4 943A FOOT THROTIlE GROUND
5 942A) FOOT THROTIlE B+
6 941A IVS#2

CONNECTOR 165M
AUXILIARY POWER (A·POST)
165M WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
CAB HARNESS· 227728A 1
A 142C SWITCHED B+
B 141C UNSWrrCHED B+
C 177E GROUND

ac 6-12740 Issued 9/02

 4001-85

167M
SOCKET HOUSING
SHELF HARNESS
229nSAI
____ CAVITY A

CONNECTOR 167F CONNECTOR 167M

AUXILIARY POWER #1 AUXILIARY POWER #1
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 136H SWITCHED Bt A 1360 SWITCHEOB+
B 135H UNSWITCHED Bt B 135D UNSWITCHED B+
C 134H GROUND C 134D GROUND

168M

PIN~~~ING ~
SOCKET HOUSING
SHELF HARNESS
229n8Al

~~=-
EXTENSION HARNESS
227729Al
____ CAVITY A

CONNECTOR 168F CONNECTOR 168M

AUXILIARY POWER #2 AUXILIARY POWER #2
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 136J SWITCHEDB+ A 136E SWITCHED Bt
B 135J UNSWITCHED B+ B 135E UNSWITCHED Bt
C 134J GROUND C 134E GROUND

CONNECTOR 169
CAVITY A AUXILIARY POWER #3
169M
SOCKET HOUSING WIRE
CAV CI RCUIT REFERENCE
SHELF HARNESS NUMBER
225259Cl
A 134F GROUND
B 135F UNSWITCHED Bt

CONNECTOR 170M
MAP LIGHT
170M
SOCKET HOUSING WIRE
CAV CI RCUIT REFERENCE
SHELF HARNESS NUMBER
225259Cl
A 135G UNSWITCHED B+
CAVITY 1
CAVITY3~ B PLUG OPEN
C 134G GROUND

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4001 - 86

CONNECTOR 171M
CAVITY A RADAR
171M
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
CAB HARNESS - Sn291Rl NUMBER
A 179T SIGNAL FREQUENCY TO ICU
B 199A 199B CLEAN GROUND

172F & 173F

RING TERMINAL CAB
HARNESS - 200338

CONNECTOR 172F CONNECTOR 173F

CHASSIS GROUND CHASSIS GROUND
CAY
WIRE
NUMBER
CIRCUIT REFERENCE CAY
WIRE
NUMBER
CIRCUIT REFERENCE •
17BB17BC lnElnF
1 GROUND
1 17BD 17BF GROUND lnG
178.1 17BH

CONNECTOR 174M
CDB TRACTOR DIAGNOSTICS
WIRE
CAY CIRCUIT REFERENCE
NUMBER
A 177AM CHASSIS GROUND
B 152A DIAGNOSTIC Il+ (UNSWITCHED)
174M
SOCKET HOUSING C YELLOW COB HIGH (TRACTOR)
310057Al 0 GREEN COB LOW (TRACTOR)
E
F
G
H YELLOW COB HIGH (IMPLEMENT)
J GREEN COB LOW (IMPLEMENT)

CONNECTOR 175
CAVITY 1 PASSIVE TERMINATOR
WIRE
CAV CIRCU)T REFERENCE
175 NUMBER
SOCKET HOUSING 1 RED QUAD COB BAnERY (TRACTOR)
225325Cl
2 YELLOW COB HIGH (TRACTOR)
LOCATION: REAR OF CAB
3 BLACK QUAD COB GROUND (TRACTOR)
SEE CONNECTOR AND COMPONENT CAVITY 3
LOCATION IN THIS SECTION 4 GREEN COB LOW (TRACTOR)

ac 6-12740 Issued9102
 4001 -87

CONNECTOR 176M
RADIO
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 NOT USED REMOTE AMP ON
2 NOT USED AMP SENSE
3 NOT USED RSA ENABLE
4 NOT USED CEll TELL MUTE
5 NOT USED ASWC
6 NOT USED RSACONTROL

178F
PIN HOUSING
.. 178M
SOCKET HOUSING
221393Al 221392Al

CONNECTOR 178F CONNECTOR 178M

FRONT WIPER FRONT WIPER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 832C HIGH A WHITE HIGH
B 833C LOW B YELLOW LOW
C 836C WASHER C BROWN WASHER
0 177AU GROUND 0 BLACK GROUND
E 831E BATIERY E RED BATIERY
F 834C PARK F BLUE PARK

179F 179M
PIN HOUSING SOCKET HOUSING
222136Al 222135Al

CONNECTOR 179F CONNECTOR 179M

SELF CANCEL SELF CANCEL
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 R Bt 1 706E Bt
2 N GROUND 2 178AC GROUND

Rae 6-12740 Issued 9102

j'
4001 - 88

181M
ORANGE SOCKET
HOUSING
429028Al

CONNECTOR 181M
AXLE REGULATION SW
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 OPEN
2 531C 5310 SWITCH B+
3 532A LOCKAJNLOCK
4 OPEN
5 OPEN
6 OPEN
7 536A LAMP GROUND
8 5310 LAMP B+
9 OPEN
10 OPEN

183M & 184M

SOCKET HOUSING
371614Al

CONNECTOR 183M CONNECTOR 184M

SUS RAISE (1) SUS LOWER (2)
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 538C FSUS RAISE 1 537C FSUSLOWER
2 179BK RETURN 2 179BL RETURN

185F 185M
PIN HOUSING SOCKET HOUSING
225294C1 225294Cl

- CAVITY A
CAVITYC

CONNECTOR 185F CONNECTOR 185M

FRONT AXLE POS SENSOR FRONT AXLE POS SENSOR
WIRE WI RE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 531F B+ A 543C B+
B 179CL CLEAN GROUND B 1799C CLEAN GROUND
C 544A SENSOR SIGNAL C 544C SENSOR SIGNAL
ac 6·12740 Issued 9102
 4001-89

186M & 187M

SOCKET HOUSING
371614A1

CONNECTOR 186M CONNECTOR 187M

UPPER LOCK (30) LOWER LOCK (31)
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
541B B+ A 542B B+
2 548B RETURN B 546B RETURN

188M
188F
SOCKET HOUSING
PIN HOUSING
2454aOC1
245481C1

CONNECTOR 188F CONNECTOR 188M

POSITION LAMPS POSITION LAMPS
WIRE WIRE
CAV CIRCUIT REFERENCE CIRCUIT REFERENCE
NUMBER CAV NUMBER
A LAMP B+ A 744D LAMP B+

CONNECTOR 189F
CLEAN GROUND
WIRE
CAV CIRCUIT REFERENCE
NUMBER
1
lTlA 174A
lTlB CLEAN GND

CONNECTOR 191F
191F SELF CANCEL SENSOR
SOCKET HOUSING
WIRE
CAV CIRCUIT REFERENCE
NUMBER
20 20A RIGHT TURN OUT
20 20A TURN COM IN
21 21A LEFT TURN IN
21 21A LEFT TURN OUT
22 22A RIGHT TURN IN
22 22A TURN COM OUT
N N SELF CNCL GND
R R SELF CNCL B+

Rae 6-12740 Issued 9/02

,I
4001 - 90

192F 192M
PIN HOUSING SOCKET HOUSING
280458A1 280456A1

CONNECTOR 192F CONNECTOR 192M

FRONT AXLE SOL FRONT AXLE SOL
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 53BC S1 SOL B+ (RAISE) 1 538A S1 SOL B+ (RAISE)
2 179BK Sl SOL GNO (RAISE) 2 179BG Sl SOL GNO (RAISE)
3 357C S2 SOL B+ (LOWER) 3 357A S2 SOL B+ (LOWER)
4 179BL S2 SOL GNO (LOWER) 4 179BH S2 SOL GNO (LOWER)
5 542B LOWER LOCK SOL 5 542A LOWER LOCK SOL
6 546B LOWER LOCK SOL 6 546A LOWER LOCK SOL
7 541B UPPER LOCK SOL 7 548A UPPER LOCK SOL
8 5488 UPPER LOCK SOL B 541A UPPER LOCK SOL

CONNECTOR 193M
193M
SOCKET HOUSING AXLE SENSOR
291719A1 WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 179BC GROUND
2 543C OUTPUT
3 544C SUPPLY VOLTAGE

CONNECTOR 194M
IMP PASSIVE TERM
194M
WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
NUMBER
239451A1
1 REO COB B+ (IMP)
2 YELLOW COBHI (IMP)
3 BLACK COB GNO (IMP)
4 GREEN COB LOW (IMP)

Issued 9102
 4001 -91

195M CAVITY A
SOCKET HOUSING
239449A1
196M
SOCKET HOUSING
239449A1

CONNECTOR 195M CONNECTOR 196M

LEFT FRONT ROOF WORKUGHT RIGHT FRONT ROOF WORKLIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 7B4E B+ A 7B4F B+
B 178AF GROUND B 17aAG GROUND

CONNECTOR 198F
198F
RING TERMINAL CLEAN GROUND
225065C1 WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 603A CLEAN GND

CONNECTOR 200F
200F RING TERMINAL
FRONT TO REAR
HARNESS WIRE
CAY CIRCUIT REFERENCE
NUMBER
179A 179J 179M
1 CHASSIS GROUND
179AF

CONNECTOR 201 F
201F SECONDARY TRANS FILTER
RING TERMINAL
WIRE
2250nC1 CAY CIRCUIT REFERENCE
NUMBER
1 267C GROUND

CONNECTOR 202F
202F INTERMEDIATE STARTING RELAY
RING TERMINAL
WIRE
225065C1 CAY CIRCUIT REFERENCE
NUMBER
1 620B B+

Rae 6-12740 Issued9lO2

II
4001 - 92

CONNECTOR 203F
203F RING TERMINAL
RING TERMINAL
WIRE
378852Al CAY CIRCUIT REFERENCE
NUMBER
1 216F ICU CLEAN GROUND

CONNECTOR 205A & 205B

PASSIVE TERMINATOR
WIRE
20SA& 205B CAY CIRCUIT REFERENCE
NUMBER
SOCKET HOUSING
239451Al 1 RED QUAD CDS SATIERY (TRACTOR)
2 YELLOW CDS HIGH (TRACTOR)
LOCAT1ON: LH. SIDE SERVICE DOOR
SEE CONNECTOR AND COMPONENT CAVITY 3 3 SLACK QUAD CDS GROUND (TRACTOR)
LOCATlON IN THIS SECT10N 4 GREEN CDS LOW (TRACTOR)

206M
SOCKET HOUSING
206F
PIN HOUSING
225326Cl

~ CAVITY2

CONNECTOR 206F CONNECTOR 206M

COB GOVERNOR (TRACTOR) COB GOVERNOR (TRACTOR)
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 RED QUAD CDS SATIERY (TRACTOR) 1 RED QUAD CDS BATIERY (TRACTOR)
2 YELLOW CDS HIGH (TRACTOR) 2 YELLOW CDS HIGH (TRACTOR)
3 SLACK QUAD CDS GROUND (TRACTOR) 3 SLACK QUAD CDS GROUND (TRACTOR)
4 GREEN CDS LOW (TRACTOR) 4 GREEN CDS LOW (TRACTOR)

Issued 9102
 4001-93

~
207M
SOCKET HOUSING
207F ENGINE HARNESS
PIN HOUSING
ENGINE HARNESS
~ 245486Cl
245487Cl

CAVITY A CAVITY D

CONNECTOR 207F CONNECTOR 207M

ENGINE CONTROL MODULE GROUND ENGINE CONTROL MODULE GROUND
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 179Al GROUND 1 A E014 GROUND 1
8 179AM GROUND 2 8 E021 GROUND 2
C 179AN GROUND 3 C E022 GROUND 3
0 179AP GROUND 4 0 E039 GROUND 4

~
208M
208F SOCKET HOUSING
PIN HOUSING ENGINE HARNESS
ENGINE HARNESS ~ 245486Cl
245487Cl

CAVITY A -./ CAVITY D

CONNECTOR 208F CONNECTOR 208M

COOLANT LEVEL SHORTING PLUG ENGINE CONTROL MODULE B+
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A E030 8+1 A 2040 8+1
8 E031 8+2 8 204E 8+2
C E032 8+3 C 204F 8+3
0 E035 8+4 0 204G 8+4

2~F ~
~M
SOCKET HOUSING
245482Cl

PIN HOUSING ~~~'"

245483Cl
CAVITY A

CONNECTOR 2~F CONNECTOR 2~M

KEY SWITCH KEY SWITCH
WI RE WIRE
CAV CI RCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A EOOI GOViKEY SWITCH SIGNAL 8+ A mc GOViKEY SWITCH SIGNAL 8+
8 PLUG OPEN 8 PLUG OPEN

Rae 6-12740 Issued 9102

4001 - 94

"" ~
211M
SOCKET HOUSING
245482Cl

PIN HOUSING ~~l.&...

245483CI
~ CAVITYA

CONNECTOR 211F CONNECTOR 211M

IMPLEMENT ICU IMPLEMENT ICU
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SWITCH WIRE Il+ FROM ICU A 285B Il+ FROM ICU
B SWITCH WIRE GROUND B 179AT GROUND

CONNECTOR 212M
212M FRONT WASH
SOCKET HOUSING WIRE
FRONT TO REAR CAV CIRCUIT REFERENCE
HARNESS - 877291Rl NUMBER
A 600H GROUND
B 836D FRONIT WASH Il+

CONNECTOR 213M
213M CAVITY A REAR WASH
SOCKET HOUSING
FRONIT TO REAR WIRE
CAV CIRCUIT REFERENCE
HARNESS - 877291Rl NUMBER
A 600G GROUND
B B45C REAR WASH Il+

ac 6-12740 Issued 9102

 4001 - 95

214F 214M
SOCKET HOUSING
PIN HOUSING
ENGINE HARNESS
4ll988Al
4ll986Al

CONNECTOR 214F CONNECTOR 214M

INJECTION PUMP SOLENOID INJECTION PUMP SOLENOID
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SOl WIRE (W) FUEL SHUT-OFF (HOLD IN) A 601A FUEL SHUT-OFF (HOLD IN)
B SOlWIRE(W) STARTER RELAY (PULLIN) B 604A STARTER RELAY (PULLIN)
C SOL WIRE (B) GROUND C 603A GROUND

215F 215M
PIN HOUSING SOCKET HOUSING
ENGINE HARNESS SENSOR
l820611Al l82069Al

CONNECTOR 215F CONNECTOR 215M

COOLANT TEMP SENDER COOLANT TEMP SENDER
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SENSOR COOLANTTEMP A 235C COOLANTTEMP
B SENSOR COOLANT TEMP GND B 179BC COOLANTTEMP GND

CONNECTOR 216M
ENGINE OIL PRESSURE
216M WIRE
CAV CIRCUIT REFERENCE
SOCKET HOUSiNG NUMBER
198456Al
A 181H OIL PRESSURE GROUND
CAVITY A
B 255C OIL PRESSURE t5V
CAVITYC
C 256C OIL PRESSURE SIGNAL

CONNECTOR 217
217 RING TERMINAL
ENGINE HARNESS
WIRE
CAV CIRCUIT REFERENCE
NUMBER
1 604A START RELAY·FUEL SHUTOFF PULLIN

Rae 6-12740 Issued 9/02

4001 - 96

CONNECTOR 218F
218F CHASSIS GROUND
RING TERMINAL
WIRE
CAY CIRCUIT REFERENCE
22S065C1 NUMBER
1 173A GROUND

219F CONNECTOR 219F

SOCKET HOUSING
ELOBAV 815100
FNRP MODULE
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 1 FNRP - R
2 2 RUN INPUT
3 3 FNRP - N
4 4 START INPUT
5 5 START OUTPUT
6 6 FNRP - F
7 7 FNRP - P
8 8 FNRP - GROUND

CONNECTOR 220A
220A UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 20A TURN SIGNAL COMMON

CONNECTOR 2208
2208 UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 21A TURN SIGNAL COMMON

CONNECTOR 220C
UNIVERSAL SWITCH
220C
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 22A TURN SIGNAL COMMON

CONNECTOR 2200
2200 UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 23(8) TURN SIGNAL COMMON

6·12740 Issued9/o2
 4001 -97

CONNECTOR 220E
UNIVERSAL SWITCH
220E WIRE
SOCKET CAV CIRCUIT REFERENCE
NUMBER
, 24(6) TURN SIGNAL COMMON

CONNECTOR 220F
220F UNIVERSAL SWITCH
SOCKET WIRE
CAV CIRCUIT REFERENCE
NUMBER
, 25(6) TURN SIGNAL COMMON

CONNECTOR 220G
2200 UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
, 26(6) TURN SIGNAL COMMON

CONNECTOR 220H
220H UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
, 9(6) TURN SIGNAL COMMON

CONNECTOR 220J
220J UNIVERSAL SWITCH
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
, 27(6) TURN SIGNAL COMMON

Rae 6·12740 Issued 9102

It
4001 - 98

221F
PIN HOUSING TURN
221M
INDICATORS SOCKET HOUSING
GHW 16183 GHW 16182

CONNECTOR 221 F CONNECTOR 221 M

INDICATOR LIGHTS UNIVERSAL SWITCH
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 LAMP COM COMMON 1 010A COMMON

2 R LAMP RIGHT TURN 2 011A RIGHT TURN

3 L LAMP LEFT TURN 3 012A LEFT TURN

CONNECTOR 222M
CD PLAYER
WIRE
CAY CIRCUIT REFERENCE
NUMBER
222M 7 OPEN
SOCKET HOUSING TO 8 OPEN
CD CHANGER
319421A1 9 CLEAR SHIELD GROUND
10 WHITE RIGHT AUDIO
11 RED LEFT AUDIO
12 BLACK AUDIO COMMON
13 BLACK GROUND
LIGHT
14 E&CDATA
GREEN
15 ORANGE BATIERY

CONNECTOR 223M
CD PLAYER
WIRE
CAY CIRCUIT REFERENCE
NUMBER
223M 13 RED LEFT AUDIO
SOCKET HOUSING LIGHT
TO RADIO 14 E&CDATA
GREEN
380431A1 15 ORANGE BATIERY
16 WHITE RIGHT AUDIO
17 CLEAR SHIELD GROUND
18 BLACK GROUND
19 BLACK AUDIO COMMON
20 OPEN

Rae 6-12740 Issued 9102

 4001-99

CONNECTOR 224
RIGHT FRONT TURN SIGNAL
224
SOCKET WIRE
CAY CI RCUIT REFERENCE
NUMBER
1 7520 Il+

CONNECTOR 225
225 RIGHT FRONT TURN SIGNAL
SOCKET WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 17BV GROUND

CONNECTOR 226M
PASSIVE TERMINATOR
226M
WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
239451Al NUMBER
1 REO COB SATIERY (TRACTOR)
2 YELLOW COB HIGH (TRACTOR)
3 BLACK COB GROUND (TRACTOR)
4 GREEN COB LOW (TRACTOR)

CONNECTOR 227
CAVITY A
RIGHT SIDE LIGHT
227
WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
239449Al NUMBER
EURO
A Bt
ONLY
EURO
B GROUND
ONLY

CONNECTOR 228M
LEFT TURNfTAIL LIGHT
228M
SOCKET HOUSING WIRE
CAY CIRCUIT REFERENCE
FENDER HARNESS NUMBER
375602Al A 755 TURN
B 750 TAil
CAVITY A
C 174 GROUND

Rae 6·1 2740 Jssued9102

4001·100

229M
229F SOCKET HOUSING
PIN HOUSING 222135A1
222136A1

CAVITY 1- - - "_ 1"7

CONNECTOR 229F CONNECTOR 229M

LEFT FENDER REAR MARKER LIGHT LEFT FENDER REAR MARKER LIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 751 MARKER LIGHT B+ 1 751 R MARKER LIGHT B+
2 174 GROUND 2 174X GROUND

230M
230F SOCKET HOUSING
PIN HOUSING 222315C1
222315C1

CAVITY 1 --...:::,~ftP

CONNECTOR 230F CONNECTOR 230M

OPTIONAL L R FENDER WORKLAMP OPTIONAL L R FENDER WORKLAMP
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 LAMP WIRE WORK LIGHT 1 787 WORK LIGHT
2 LAMP WIRE GROUND 2 174 GROUND

CONNECTOR 232M
CAVITY A
232M STANDARD RIGHT FENDER WORKLAMP
SOCKET HOUSING WIRE
FENDER HARNESS
CAY CIRCUIT REFERENCE
NUMBER
239449A1
EURO
A WORK LIGHT B+
ONLY
EURO
B GROUND
ONLY

CONNECTOR 233M
233M RIGHT TURNITAIL LIGHT

D
SOCKET HOUSING WIRE
FENDER HARNESS
CAY CIRCUIT REFERENCE
NUMBER
375602A1
A 755 TURN

CAVITY A B 750 TAIL

G 174 GROUND

Rae 6-12740 Issued 9102

 4001-101

234M
234F SOCKET HOUSING
PIN HOUSING 222135Al
222136Al

CAVITY 1 ---">..ct.:l!o'V

CONNECTOR 234F CONNECTOR 234M

RIGHT FENDER WIDE MARKER LIGHT RIGHT FENDER WIDE MARKER LIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 751 MARKER LIGHT B+ 1 754F MARKER LIGHT
2 174 GROUND 2 174U GROUND

235F
235M SOCKET HOUSING
PIN HOUSING 222135Al
222136Al

CAVITY 1 --""-.~~.'V

CONNECTOR 235F CONNECTOR 235M

RIGHT FENDER REAR WORKLAMP RIGHT FENDER REAR WORKLAMP
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 LAMP LEADS WORK LIGHT B+ 1 787 WORK LIGHT B+
2 LAMP LEADS GROUND 2 174 GROUND

236M
236F
SOCKET HOUSING
PIN HOUSING 222135Al
222136Al

CAVITY 1 --""-.~'lJ,!!

CONNECTOR 236F CONNECTOR 236M

LEFT FENDER WIDE MARKER LIGHT LEFT FENDER WIDE MARKER LIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 7S1R MARKER LIGHT B+ 1 LAMP LEADS MARKER LIGHT B+
2 174X GROUND 2 LAMP LEADS GROUND

Rae 6-12740 Issued 9102

\,
4001 - 102

237M
237F
SOCKET HOUSING
PIN HOUSING 2221 35Al
2221 36Al

CAVITY 1 ---">..;~/J;V

CONNECTOR 237F CONNECTOR 237M

RIGHT FENDER WIDE MARKER LIGHT RIGHT FENDER WIDE MARKER LIGHT
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 754F MARKER LIGHT I LAMP LEADS MARKER LIGHT Il+
2 174U GROUND 2 LAMP LEADS GROUND

CONNECTOR 239F
239F RING TERMINAL
CAB HARNESS WIRE
CAY NUMBER CIRCUIT REFERENCE

I I04A IGNITION FEED

CONNECTOR 240F
240F RING TERMINAL
CAB HARNESS WIRE
CAY NUMBER CIRCUIT REFERENCE

I lOlA UNSWrrCHED Il+

CONNECTOR 241F
CONTROLLER RELAY
WI RE
CAY NUMBER CIRCUIT REFERENCE

AI 1nH COILGND
A2 I06A 106C IGNITION FEED
A3 I02A SWrrCHED Il+
A4 8+ (NORMALLY CLOSED)
A4 200A Il+ (NORMALLY OPEN)
81 OPEN
82 OPEN
83 OPEN
84 OPEN
85 OPEN

Issued 9/02
 4001 - 103

CAVITY 10
CAVITY 1

244
SOCKET HOUSING

LOCATION: L.H. SIDE Of ENGINE

SEE CONNECTOR AND COMPONENT
LOCATION IN THIS SECTION
CAVITY 41

CONNECTOR 244 CONNECTOR 244 (CONT.)

ELECTRONIC ENGINE CONTROLLER ELECTRONIC ENGINE CONTROLLER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 OPEN 26 OPEN
2 YELLOW DATA BUS IHIGH) 27 E020 COOLANT LEVEL HIGH SIGNAL
3 OPEN 26 E021 BATTERY 1-)
4 OPEN 29 E022 BATTERYI-)
5 EOOl KEY SWITCH INPUT 30 E023 GROUND
6 E002 ICV SOLENOID It) 31 E024 FRONT PVC SOLENOID It )
7 E003 ICV SOLENOID 1-) 32 OPEN
6 EOO4 ENGINE SPEED It) 33 E025 OIL PRESSURE SIGNAL
9 EOO5 ENGINE POSITION SIGNAL 34 E026 AIR TEMPERATURE SIGNAL
10 EOO6 ENGINE POSITION t5V DC 35 E027 ACCUMULATOR FUEL TEMP SIGNAL
11 EOO7 LIFT PUMP It ) 36 E026 ICV IDENTIFIER It)
12 GREEN DATA BUS ILOW) 37 E029 COOLANT LEVEL LOW SIGNAL
13 OPEN 36 E030 BATTERY It)
14 EOO9 ICV IDENTIFIER 1-) 39 E031 BATTERY It)
15 E010 ENGINE SPEED 1-) 40 E032 BATTERY It )
16 OPEN 41 OPEN
17 EOll ENGINE SPEED SIGNAL 42 OPEN
16 E012 ENGINE SPEED 1-) 43 OPEN
19 E01 3 ENGINE POSITION 1-) 44 OPEN
20 E014 BATTERY 1-) 45 E033 INTAKE MANIFOLD PRESSURE
21 E015 FRONT PVC SOLENOID 1-) 46 ACCUMULATOR FUEL PRESSURE
22 E016 LIFT PUMP It) 47 OPEN
23 E01 7 COOLANT TEMPERATURE SIGNAL 46 OPEN
24 OPEN 49 E034 CooLANTLEVEL It)
25 E019 REAR PVC SOLENOID It) 50 E035 BATTERY It )

Rae 6-12740 Issued 9102

jI
4001 - 104

245M
245F SOCKET HOUSING
PIN HOUSING 239451A1
225326C1

CONNECTOR 245F CONNECTOR 245M

INJECTION CONTROL VALVE INJECTION CONTROL VALVE
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 VALUE Ive SOLENOID (-) 1 EOO3 Ive SOLENOID (-)
2 VALUE Ive SOLENOID (t) 2 EOO2 Ive SOLENOID (t)
3 JUMPER IVC IDENTIFIER 3 E028 lVe IDENTIFIER
4 JUMPER Ive IDENTIFIER 4 E008 Ive IDENTIFIER

CONNECTOR 246M
ENGINE SPEED SENSOR
246M WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
NUMBER
182(173A1
A EOO4 ENGINE SPEED (t)
B E012 ENGINE SPEED (-)
e EOll ENGINE SPEED SIGNAL

CONNECTOR 247M
ENGINE POSITION SENSOR
247M WIRE
SOCKET HOUSING
CAY CIRCUIT REFERENCE
NUMBER
182(173A1
A E038 ENGINE POSITION t5VOC

CAVITY A
B E013 ENGINE POSITION (-)
e E005 ENGINE POSITION SIGNAL

CONNECTOR 248M
LIFT PUMP
248M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
225316C1 NUMBER
A E036 LIFT PUMP (t)
B E037 GROUND

Rae 6-12740 Issued9102

 4001 -105

249M
SOCKET HOUSING
249F 239451Al
PIN HOUSING
225326CI
CAVITY 4 _~::--~

CONNECTOR 249F CONNECTOR 249M

PUMPING CONTROL VALVE SOLENOID PUMPING CONTROL VALVE SOLENOID
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SOLENOID FRONT PVC SOLENOID (-) A E015 FRONT PVC SOLENOID (-)
B SOLENOID FRONT PVC SOLENOID (+) B E024 FRONT PVC SOLENOID (+)
C SOLENOID REAR PVC SOLENOID (+) C E019 REAR PVC SOLENOID (+)
D SOLENOID REAR PVC SOLENOID (-) D E010 REAR PVC SOLENOID (-)

CONNECTOR 250
COOLANT TEMPERATURE
250 WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
l82069Al NUMBER
A E045 GROUND
CAVITY B E017 COOLANT TEMPERATURE SIGNAL

251M
SOCKET HOUSING
2454MCl
251F
PIN HOUSING
245487Cl
CAVITY A

CONNECTOR 251F CONNECTOR 251 M

COOLANT LEVEL SHORTING PLUG COOLANT LEVEL SHORTING PLUG
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A BLACK WIRE COOLANT LEVEL LOW SIGNAL A E029 COOLANT LEVEL LOW SIGNAL
B BLACK WIRE GROUND B Em GROUND
C BLACK WIRE COOLANT LEVEL B+ C E034 COOLANT LEVEL B+
D BLACK WIRE COOLANT LEVEL HIGH SIGNAL D E020 COOLANT LEVEL HIGH SIGNAL

Rae 6-12740 Issued 9102

 4001 - 106

CONNECTOR 252
OIL PRESSURE
252 WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
NUMBER
198456A1
A E040 ENGINE POSITION +5VDC
CAVITY A
B E041 GROUND
CAVITY
C E025 OIL PRESSURE SIGNAL
•

CONNECTOR 253
INTAKE MANIFOLD AIR TEMPERATURE
253
WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
1821169A1 NUMBER
A E044 GROUND
CAVITY B E026 AIR TEMPERATURE SIGNAL

CONNECTOR 254
ACCUMULATOR FUEL PRESSITEMP
WIRE
CAV CIRCUIT REFERENCE
254 NUMBER
SOCKET HOUSING A BLACK WIRE GROUND
1820nA1
B BLACK WIRE GROUND
C BLACK WIRE ACCUMULATOR FUEL PRESSURE
CAVITY D BLACK WIRE ACCUMULATOR FUEL TEMP SIGNAL

CONNECTOR 256M
CAVITY 10 FOOT THROTTLE
CAVITY 1 WIRE
CAV CIRCUIT REFERENCE
256M NUMBER
SOCKET HOUSING 7 35BC CRUISE RESUME I INCREMENT
242580A1
13 4B9C CRUISE SET I DECREMENT
19 943C PEDAL GROUND

CAVITY 41 25 945C IDLE SWITCH (NO)

26 941C IDLE SWITCH (NC)
28 547C INTERM SPEED CONT 1
29 942C PEDALSV Il+
30 944C PEDAL SIGNAL

Rae 6-12740 Issued9/02

- I
 4001-107

CONNECTOR 257F
CRUISE, ON I OFF
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 OPEN
257F 2 OPEN
WHITE SOCKET
HOUSING CAB 3 OPEN
HARNESS 4 OPEN
429025A1 1798R
5 CLEAN GROUND
6 547A ONIOFF SIGNAL
7 OPEN
8 OPEN
9 OPEN
10 OPEN

CONNECTOR 258F
CRUISE, INCREMENT I DECREMENT
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 489A DECREMENT SIGNAL
179BP
258F 2 179BR CLEAN GROUND
GREEN SOCKET
HOUSING CAB 3 358A INCREMENT SIGNAL
HARNESS 4 OPEN
429025A1 5 OPEN
6 OPEN
7 OPEN
8 OPEN
9 OPEN
10 OPEN

~
259M
SOCKET HOUSING

~
AUXJPTO HARNESS
259F 24548OC1
PIN HOUSING
245481C1

CONNECTOR 259F CONNECTOR 259M

TO AUXILIARYIPTO HARNESS TO AUTO HITCH
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A AUTO HITCH A mA AUTO HITCH

Rae 6-12740 Issued 9102

4001 - 108

CAVITY Bl

261
FUSE BLOCK

CAVITY A14

CAVITY 014
MRE NUMBERS
IDENTIAED AS A
..J" NUMBER, ARE
JUMPER MRES ON
THE FUSE BLOCK

FUSE BLOCK 261 FUSE BLOCK 261

WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
Al 76511 FUSE #28 TEMP DISPLAY GROUND - Cl
DEGREES C INSTALLED, DEGREES F NOT USED
i'2 179AW C2
REMOVED
C3 141A FUSE #13 FRONTIREAR AUXILIARY
A3
NOT USED C4 101K POWER (UNSWITCHED)
A4
C5 222B FUSE #12 TRAILER AUXILIARY
A5 531A FUSE #26
C8 103E (SWITCHED)
A6 JUMPER SUSPENDED AXLE
C7 207A FUSE #11
A7 720A FUSE #25
C8 1010 CIGAR LIGHTER (UNSWITCHED)
A8 102L ETHEAIIlORN
C9 19511 FUSE '10
A9 8700 FUSE #24
Cl0 101M BLOWER CAB PRESSURE
Al0 l06B MIRRORIRADIO (SWITCHED)
Cll 73A
All 821C FUSE #23 FUSE #9 SEAT/OPS
C12 l02F
A12 JUMPER BEACON/STROBE
C13 13511 FUSE'8
A13 312A
(STOP LIGHTS) C14 lOlL SHELF AUXILIARY (UNSWITCHED)
A14 l03F
01 107A FUSE 17
Bl 750C FUSE #21
D2 101C KEY BATTERY
LEFT AND RIGHT TAIL LIGHTS !POSITION
82 707A UGHTS D3 241A FUSE #6
83 766A FUSE #20 D4 JUMPER WORKLIGHT INTERLOCK
B4 101F FLASHER
05 78BA FUSE #5
85 871 A FUSEI19 DOMELlGHT,MAP,ANDRADIO OS 102E ROOF WORKLIGHTS
86 JUMPER (UNSWITCHED)
07 794A FUSE #4
B7 706A FUSE #18 OS JUMPER 8ELT LINE (A-POSn WORKLIGHTS
B8 lOlA HEADLIGHTS
D9 795A FUSE 13
B9 722A 010 103G REAR FENDER WORKLIGHTS
HORN
810 JUMPER 013 26BA FUSE #1
Bll 202B FUSE '16 INSTRUMENT CLUSTER UNIT & 014 102G GOVERNOR KEYSWITCH
812 1018 PERFORMANCE MONITOR UNIT (UNSW)
B13 204A FUSEm
B14 101J GOVERNOR

Rae f).12740 Issued 9102

 4001 -109

CAVITY 81

262
FUSE BLOCK

CAVITY A14

CAVITY D14
WIRE NUMBERS
IDENTlRED AS A
"J" NUMBER, ARE
JUMPER WIRES ON
THE FUSE BLOCK

FUSE BLOCK 262 FUSE BLOCK 262 (CAB)

WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
Al FUSE #54 Cl 152A FUSE 142 DATA 6US DIAGNOSTIC
A2 ITALIAN BRAKE C2 101G CONNECTOR POWER
A3 C3 69A FUSE 141
NOT USED
A4 C4 1020 DATA BUS TRACTOR

A5 NOT USED C5 138C FUSE 140

A6 C6 200E ECU
A7 NOT USED C7 S96A FUSE #39
A8 C8 JUMPER ELECTRON IC DRAFT CONTROL (HITCH)

A9 841C FUSE #52 C9 599E FUSE 138

Al0 JUMPER REAR WIPEAlWASHER Cl0 200C PTO

All 831C CIRCUIT 6REAKER #51 Cll 203B FUSE #37

A12 102K FRONT WIPEAlWASHER C12 JUMPER ICU I PMU (SWITCHED)
A13 C13 9000 FUSE 136
NOT USED
A14 C14 2006 AUXILIARY

Bl 820A 01
FUSE #49 HVAC BLOWER NOT USED
B2 1030 D2
B3 136A FUSE 148 OJ 283A FUSE 134
64 l03C SHELF AUXILIARY POWER (SWITCHED) D4 JUMPER RADAR

B5 102M 05 6SA FUSE 133 ARM-REST CONTROL UNIT

FUSE 147 HVAC CONTROLLER
B6 142A D6 200F (ARU) (SWITCHED)

B7 142A FUSE'46 07 345 (R) FUSE #32

68 1036 FRONTIREAR AUXILIARY (SWITCHED) OS 327 (R) TRANS UNSW B+
69 D9 344A FUSE 131 ADVANCED FARMING SYS-
Bl0 010 1378 TEM B+ (SWITCHED)

Bll 550C FUSE 144 011

NOT USED
61 2 JUMPER TRANS CONTROL UNIT 012
613 550K FUSE '43 013 259A FUSE 1129
614 2000 TRANS CONTROL UNIT 014 102J SEAT HEATER

Rae 6·12740 Issued9!02

 4001 -110

263F
RELAY BLOCK

264F
RELAY BLOCK

CONNECTOR 263F CONNECTOR 264F

RELAY BLOCK RELAY BLOCK

WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A1 750K POS I HAl COIL B+ A1 3120 SWITCHED B+
1>2 mAS COIL GROUND 1>2 mAT COIL GROUND
A3 241A WORK LIGHTS INTERLOCK A3 195A UNSWITCHED B+
A4 7B9A ROTARY WORKLIGHTS A4 OPEN
AS OPEN AS 195B BLOWERB+
B1 558A PARK RELAY COIL B1 104B GOVSWCOIL
B2 mAS mAW COIL GROUND B2 117AT mAL COIL GROUND
B3 550F PARK RELAY COMMON B3 268A GOV KEYSWITCH
B4 OPEN B4 OPEN
B5 561H PARK RELAY (NO) B5 223A GOV IGN SW SIGNAL
C1 56BB FNRP·NO NEUTRAL COIL C1 792B 792C FENDER WORKLIGHTS COIL
C2 mx mAW COIL GROUND C2 177W mAL COIL GROUND
C3 550G NEUTRAL RELAY COMMON C3 795A FENDER WORK LIGHTS
C4 OPEN C4 OPEN
C5 220M NEUTRAL RELAY (NO) C5 7B7A REAR FENDER WORK LIGHTS
01 79M ROOF WORKLIGHTS COIL 01 790A FRONT ROOF WORK LIGHTS COIL
D2 mx mAR COIL GROUND 02 177V mw COIL GROUND
D3 7BBA 7BBB ROOF WORKLIGHTS B+ 03 7BBB FRONT ROOF WORK LIGHTS COIL
D4 OPEN D4 OPEN
05 793A REAR ROOF WORKLIGHTS 05 7B4A FRONT ROOF WORK LIGHTS COIL
E1 OPEN E1 792A 792B LOWER WORK LIGHTS COIL
E2 mAP mAR COIL GROUND E2 mu 177V COIL GROUND
E3 OPEN E3 794A BELTLINE WORK LIGHTS
E4 OPEN E4 OPEN
E5 OPEN E5 7BM BELTLINE WORK LIGHTS
F1 3HA PTOSIGNAL F1 ITAllAN BRAKE
F2 my mAP COIL GROUND F2 177U 177V COIL GROUND
F3 312B BRAKE B+ F3 OPEN
F4 565C PNEUMATIC SIG F4 OPEN
F5 755A BRAKE LAMP SIG F5 OPEN

Rae 6-12740 Issued9102

- I
 4001-111

266
DIODE
266M 113699A1
SOCKET HOUSiNG
6318l11C1

CONNECTOR 266M CONNECTOR 266F

RECTIFIER ASSEMBLY RECTIFIER ASSEMBLY
WIRE WI RE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 105A IGNITION SWITCH A 104A 104B IGNITION FEED

267
DIODE
267M 113699A1
SOCKET HOUSING
6318l11C1

267F
SOCKET HOUSING
73907OC1

CONNECTOR 267M CONNECTOR 267F

RECTIFIER ASSEMBLY RECTIFIER ASSEMBLY
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 724A 724B HIGH BEAM DlMMINGIINDICATOR A 727D HIGH BEAM DIMMING

~~
268
DIODE
268M 113699A1
SOCKET HOUSING
6318l11C1

268F

~
SOCKET HOUSING
73907OC1

CONNECTOR 268M CONNECTOR 268F

RECTIFIER ASSEMBLY RECTIFIER ASSEMBLY
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 728A 728B LOW BEAM DIMMING A 727C LOW BEAM DIMMING

Rae 6·12740 Issued 9102

4001-112

CONNECTOR 269M
TO AUXILIARY POWER CONNECTOR
269M WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
CAB HARNESS NUMBER
225164Cl 1 142B SWrrCHED B+
CAVITY 1 2 141B UNSWITCHED B+
CAVITY 3 3 mAF GROUND

CONNECTOR 270
IMPLEMENT AUXILIARY POWER
270 WIRE
PIN HOiJSlNG CAV CIRCUIT REFERENCE
EXTENSION HARNESS
NUMBER
225164Cl 1 136H swrrCHED B+
2 135H UNSWITCHED B+
3 134H GROUND

CONNECTOR 271
IMPLEMENT AUXILIARY POWER
271 WIRE
PIN HOUSING CAV CI RCUIT REFERENCE
EXTENSION HARNESS
NUMBER
225164Cl o 1 136J swrrCHED B+

CAVITY 1
CAVITY 3
.J 2
3
135,J
134J
UNSWITCHED B+
GROUND

NOTE, KEYING IS DIFFERENT

FOR EACH COLOR CONNECTOR
273F
PIN HOUSING 273M
AFS INSIDE CAB SOCKET HOUSING
22J672Al CAB HARNESS
223671Al

CAVITY1 ?-~~W

CONNECTOR 273F CONNECTOR 273M

CAB/ISO 11783 CABIISO 11783
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 344E UNswrrCHED B+ 1 344E UNSWITCHED B+
2 RADAR SIGNAL 2 RADAR SIGNAL
3 swrrCHED B+ 3 swrrCHED B+
4 179GB CLEAN GROUND 4 179GB CLEAN GROUND
5 RED COB BATT B+ (IMP) 5 RED COB BATT B+ (IMP)
6 YELLOW CDBHI (IMP) 6- YELLOW COB HI (IMP)
7 BLACK COB GND (IMP) 7 BLACK COB GND (IMP)
B GREEN COB LOW (IMP) B GREEN COB LOW (IMP)
9 OPEN 9 OPEN
10 OPEN 10 OPEN
11 OPEN 11 OPEN
12 OPEN 12 OPEN

Rae &-.12740 Issued 9102

 4001-113

CONNECTOR 279
279 RING TERMINAL
CAB HARNESS WIRE
CAY CIRCUIT REFERENCE
NUMBER
177J CHASSIS GROUND

280M
SOCKET HOUSING
305678A1
280F
ptNHOUSING CAVITY A
3056nA1 I M
CAVITY N
CAVITY P
' - CAIIiTY F

CONNECTOR 280F CONNECTOR 280M

TO AFS INTERNAL CAB HARNESS TO AFS EXTERNAL CAB HARNESS
WIRE WI RE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A OPEN A PLUG OPEN
B OPEN B OPEN
C PLUG OPEN C PLUG OPEN
D PLUG OPEN D PLUG OPEN
E REDOUAD DATA BUS BATIERY (IMP) E REDOUAD DATA BUS BATIERY (IMP)
F YELLOWD DATA BUS HIGH (IMP) F YELLOW DATA BUS HIGH (IMP)
G BLACK QUAD DATA BUS GROUND (IMP) G BLACKOUAD DATA BUS GROUND (IMP)
H GREEN DATA BUS LOW (IMP) H GREEN DATA BUS LOW (IMP)
J mc SWITCHED CONTROLLER B+ J 137A SWITCHED CONTROLLER B+
K 138A UNSWITCHED B+ K 138B UNSWITCHED B+
L 179C CLEAN GROUND L 179BJ CLEAN GROUND
M PLUG OPEN M PLUG OPEN
N PLUG OPEN N PLUG OPEN
P 787M IMPL FLOOD LIGHTS P 7B7K IMPL FLOOD LIGHTS
R 751N LEFT TURN R 7S1L LEFT TURN
S 752P RIGHT TURN S 752K RIGHT TURN
T 7ffJV TAIL LIGHTS T 7ffJR TAIL LIGHTS
U PLUG OPEN U PLUG OPEN
V PLUG OPEN V PLUG OPEN

Rae 6-12740 Issued 9102

4001 -114

CAVITY 1 CONNECTOR 281M

VIDEO TERMINAL
281M WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
223671Al NUMBER
1 YELLOW CANHI
2 GREEN CANLI
3 RS232TX
4 RS232 RX
5 CANH2
6 CANl2
7 OPEN
8 SPEAKER +
9 SPEAKER-
10 344G ECU PWR
11 179CE ECUGND
12 344F KEY PWR

CONNECTOR 282M
TRACTOR ECU
WIRE
CAV CIRCUIT REFERENCE
NUMBER
282M
SOCKET HOUSING 1 YELLOW CAN H (IMP)
UB 390011 3-3412 2 GREEN CAN L (IMP)
3 CAN SHEILD
4 YELLOW CAN H (ITR)
5 GREEN CAN L (TR)
6 CAN SHIELD
7 RS232 RX
8 RS232TX
9 RS232 GND
10 4010 ECU PWR
11 179CH ECUGND
12 403A PWR CONTROL RELAY
13 404A PWR CONTROL RELAY RTN
14 406A ECU PWR RELAY
15 405A ECU PWR RELAY RTN
16 138A KEY SWITCH
17 787M IMPLEMENT FLOOD
18 OPEN
19 752P RIGHT TURN
20 750V TAIL LIGHTS
21 407A CHASSIS GROUNO
22 751N LEFT TURN
23 OPEN
33 WARNING LIGHT SWITCH
34 OPEN

Rae 6-12740 Issued 9102

 4001-115

CONNECTOR 283M
BREAKAWAY
283M
WIRE
SOCKET HOUSING CAV CIRCUIT REFERENCE
225316C1 NUMBER
137G ECU PWR
2 179CG ECUGNo

285M
...,

~
0''0 l)
r 'M'~
CONNECTOR 285M
DGPS
WIRE
CAV CIRCUIT REFERENCE
NUMBER
1 OPEN
2 OPEN
3 OPEN
4 OPEN
5 OPEN
6 OPEN
7 YELLOW COB LOW (IMP)
B OPEN
9 GREEN COB HIGH (IMP)
10 137H ECU PWR
11 179CC ECU GNO
12 OPEN

CONNECTOR 286M
TASK CONTROLLER
WIRE
CAV CIRCUIT REFERENCE
NUMBER
286M
1 344H ECU PWR
SOCKET HOUSING
225319C1 2 YELLOW CAN La (IMP)
3 OPEN
4 OPEN
5 OPEN
6 OPEN
7 GREEN CAN HI (IMP)
B 179CO ECUGND

Rae 6·12740 Issued 9102

4001 -116

CONNECTOR 288M
BREAKAWAY
CAVITY 1
WIRE
288M CAY CIRCUIT REFERENCE
NUMBER
SOCKET HOUSING
239451A1 I RED CANTBC PWR
2 YELLOW CAN LO (IMP)
CAVITY 3 3 BLACK CANTBC RTN
4 GREEN CAN HI (IMP)

CONNECTOR 291M
BREAKAWAY
WIRE
CAY CIRCUIT REFERENCE
NUMBER
1 407C CHASSIS GROUND
2 4076 ECUGROUND
3 402A POWER
291M 4 1370 ECU POWER
SOCKET HOUSING
5 OPEN
323597A1
6 TBC POWER
7 TBC RETURN
8 CAN HIGH (IMP)
9 CAN LOW (IMP)

CONNECTOR 292M
ISO 11783 POWER RELAY
292M WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
297910Al NUMBER
30 401A LOW IMP B+ SWITCH
85 405A COILB+
86 406A IMP POWER ACT
87 137E COM IMP Bt SWITCH
87A PLUG NIC

CONNECTOR 293M
ISO 11783 POWER RELAY
WIRE
293M CAY CIRCUIT REFERENCE
SOCKET HOUSING NUMBER
AFS INSIDE CAB 30 400A IMPB+
310220A1
85 403A IMP POWER ACT
86 404A SWITCHED B+
87 402A UNSWITCHED B+

ac 6-12740 Issued 9/02

 4001-117

CONNECTOR 297F
297F RING TERMINAL
RING TERMINAL a CAY
WIRE
NUMBER
CIRCUIT REFERENCE
200338
1 407A 407B 407C CLEAN GROUND

301 F, 302F, 303F,

AND304F
1/4 FLAG TERM. ~
CONNECTOR 301 F CONNECTOR 302F
TURN SIGNAL TURN SIGNAL
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 754C B+ 1 GROUND

CONNECTOR 303F CONNECTOR 304F

TURN SIGNAL TURN SIGNAL
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 B+ 1 GROUND

CONNECTOR 312M
312M, 312MA & CENTER REMOTE HITCH SYSTEM
312MB
SOCKET HOUSING
TRANSMISSION I ~ CAY
WIRE
NUMBER
CIRCUIT REFERENCE

~
HITCH HARNESS
II A 526F LOWER (DOWN)
198550A1
CAVITY A
B SOOH CENTER B+
C 513F RAISE (UP)

CONNECTOR 312MA CONNECTOR 312MB

CENTER REMOTE HITCH SYSTEM CENTER REMOTE HITCH SYSTEM
WIRE WI RE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
A 513G LOWER (OOWN) A 526E LOWER (DOWN)
B 500J CENTER B+ B SOOK CENTER B+
C 526G RAISE (UP) C 513E RAISE (UP)

It Rae 6-12740 Issued 9102

i
4001-11 8

314F & 315F 314M, 315M

PIN HOUSING SOCKET HOUSING
225295Cl
225294Cl

CAVITY A

CONNECTOR 314F CONNECTOR 314M

REMOTE HITCH SYSTEM REMOTE HITCH SYSTEM
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CI RCUIT REFERENCE
NUMBER NUMBER
A 513C RAISE REMOTE UP A 513F 513G RAISE REMOTE UP
B 5000 COMMON B+ B 500H 500J COMMON B+
C 526C LOWER REMOTE OOWN C 526F 526G LOWER REMOTE DOWN

CONNECTOR 315F CONNECTOR 315M

REMOTE HITCH SYSTEM REMOTE HITCH SYSTEM
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CI RCUIT REFERENCE
NUMBER NUMBER
A 526B RAISE REMOTE UP A 526E RAISE REMOTE UP

B 500E COMMON B+ B SOOK COMMON B+

C 513B LOWER REMOTE OOWN C 513E LOWER REMOTE DOWN

acEH2740 Issued 9/02

 4001-119

CONNECTOR 317F
PNEUMATIC PARK SOLENOID
WIRE
317F CAV CI RCUIT REFERENCE
NUMBER
SOCKET HOUSING
2253t6Ct A 567H CIRCUIT REFERENCE
B 179BW AUTO HITCH B+

318M
SOCKET HOUSING
2454l12Ct
318F
PIN HOUSING
24S483Ct

CAVITY B
CONNECTOR 318F CONNECTOR 318M
LEFT BRAKE SOLENOID L BRAKE PARK SOLENOID SW #2
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A 567F PARK BREAK FEEDBACK A 567H PARK BRAKE FEEDBACK
B 179BV CLEAN GROUND B t79aW CLEAN GROUND

CONNECTOR 319M
319M PARK SOLENOID
SOCKET HOUSING WIRE
2253t6Ct CAV CIRCUIT REFERENCE
NUMBER
t 567E SOLENOID B+
2 t79BU SOLEOID GROUND

CONNECTOR 320M
320M PNEUMATIC INDICATOR
SOCKET HOUSING WIRE
225250Ct CAV CIRCUIT REFERENCE
NUMBER
A 3t2C PNEUMATIC_BRAKE_8+
B 566A INDICATOR_GROUND

Rae 6·12740 Issued 9/02

4001 - 120

322F
PIN HOUSING
AIC HARNESS
198832Al

322M CAV 1
SOCKET HOUSING
CAB HARNESS
194785Al

CAVA

CAVS

CONNECTOR 322M CONNECTOR 322F

CONNECTS WITH FRONT TO REAR HARNESS CONNECTS WITH ENGINE HARNESS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 8208 BATIERY (6+) 1 8200 BATIERY (B) (CCM EXT ONLy)
2 824A HIGH (H) 2 824B HIGH (H) (CCM EXT ONLY)
A 827A LAMP TO CONTR. I (DEHUMIDIFY) A 827C LAMP TO CONTR. I (DEHUMIDIFY)
B 821A 6+ FOR LAMP B 6+ FOR LAMP
C 177Z CHASSIS GROUND C 801BOR 801C CHASSIS GROUND
D 828A TO AIC CUTOUT SWITCH/AUTO 0 826B OR 826C TO AIC CUTOUT SWITCH/AUTO
E OPEN· PLUG IF SEAL IS PIERCED E OPEN· PLUG IF SEAL IS PIERCED
F 850A ATC BLOWER SIGNAL F 850B ATC BLOWER SIGNAL (ATC EXT ONLY)
G 80JA TEMP CONTROL (BLOWER) GROUND G 803C TEMP CONTROL (BLOWER) GROUND
H 80SA 5V DISPLAY POWER H 805B 5V DISPLAY POWER (ATC EXT ONLY)
J 804A GROUND TO DISPLAY J 804B GROUND TO DISPLAY (ATC EXT ONLY)
K 80M DATA TO DISPLAY K 806B DATA TO DISPLAY (ATC EXT ONLY)
L 800A CLUTCH (C) L 800B CLUTCH (C) (CCM EXT ONLY)
M 822A LOW(L) M 8228 LOW (L) (CCM EXT ONLY)
N 82JA MEDIUM (M) N 823B MEDIUM (M) (CCM EXT ONLY)

Rae 6-12740 Issued 9/02

 4001 -121

325A& 325B
AMP 41274-0

CONNECTOR 325A CONNECTOR 325B

PNEUMATIC AIR SWITCH TURN SIGNAL
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 566C Il+ 1 179A6 GROUND

CONNECTOR 326F
RING TERMINAL
326F
RING TERMINAL WIRE
CAV CIRCUIT REFERENCE
2OO3:NI NUMBER
1 400c 401C ISO 11783 Il+

CONNECTOR 327M CONNECTOR 328M

ISO 11783 FUSE ISO 11783 FUSE
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 4006 UNSWITCHED Il+ 1 4016 UNSWITCHED Il+
2 400c UNSWITCHED Il+ 2 401C UNSWrTCHED Il+

Rae 6-12740 Issued9J02

4001 - 122

~
AVITY 1 _""""" 331M &HOUSING
SOCKET 332M
331F & 332F 2394S1Al
PIN HOUSING
22532iiCl
CAVITY 4 -~::---~

CONNECTOR 331F CONNECTOR 331M

RIGHT FRONT HITCH LAMPS RIGHT FRONT HITCH LAMPS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 740B LOW BEAM B+ 1 LAMP LOW BEAM B+
2 741B HIGH BEAM B+ 2 LAMP HIGH BEAM B+
3 744C PILOT 3 LAMP PILOT
4 176E GROUND 4 LAMP GROUND

CONNECTOR 332F CONNECTOR 332M

LEFT FRONT HITCH LAMPS LEFT FRONT HITCH LAMPS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 742B LOW BEAM B+ 1 LAMP LOW BEAM B+
2 743B HIGH BEAM B+ 2 LAMP HIGH BEAM B+
3 744B PILOT 3 LAMP PILOT
4 176D GROUND 4 LAMP GROUND

Rae 6-12740 Issued 9/02

 4001-123

333M
PIN HOUSING
H0P24-24-29PE

0°:60
00'b 0 333F
aCPaq,V SOCKET HOUSING
~ i:::::",\l ~g<b"go
00°
HOP26-24-29SE

CONNECTOR 333M CONNECTOR 333F

ENGINE TO CHASSIS CHASSIS TO ENGINE
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
102N SWITCHEDB+ 1 102P SWITCHEDB+
2 601C FUEL SHUT OFF SOL HOLD 2 601B FUEL SHUT OFF SOL HOLD
3 3
4 4
5 89C KEYBATIERY 5 89B KEY BATIERY
6 172C FNRP START OUTPUT 6 172A FNRP START OUTPUT
7 266C AIR FILTER 7 266B AIR FILTER
8 602C FUEL RELAY SOL 8 602B FUEL RELAY SOL
9 846C REAR WASHER PUMP 9 845B REAR WASHER PUMP
10 121 _0 ALTERNATOR EXCITE 10 121B ALTERNATOR EXCITE
11 641C ETHER B+ 11 641B ETHER B+
12 126_W ALTERNATOR RPM 12 216C ALTERNATOR RPM
13 802C HIGH PRESS SW 13 802B HIGH PRESS SW
14 561E PARK BRAKE SOL SIG 14 5610 PARK BRAKE SOL SIG
15 835C ACCOMP 15 835B ACCOMP
16 723C HORN RETURN 16 723B HORN RETURN
17 722C HORN B+ 17 722B HORNB+
18 RED COB BATI (TR) 18 RED COB BATI(TR)
19 8360 FRONT WASHER PUMP 19 836B FRONT WASHER PUMP
20 GREEN CDBBATI (TR) 20 GREEN COB BATI (TR)
21 567J PARK BRAKE SOL 21 567K PARK BRAKE SOL
22 750B FRONT HITCH POS LAMPS 22 750N FRONT HITCH POS LAMPS
23 7280 LOW BEAM RELAY 23 728C LOW BEAM RELAY
24 792E CENTEA/SIDE RELAY 24 7920 CENTEA/SIDE RELAY
25 7240 HIGH BEAM 25 724C HIGH BEAM
26 726C HIGH BEAM RELAY 26 726B HIGH BEAM RELAY
27 YELLOW COB HIGH (TR) 27 YELLOW COB HIGH (TR)
28 179AJ AC COMP SW RETURN 28 179AH AC COMP SW RETURN
29 BLACK COB GND (TR) 29 BLACK COB GNO (TR)

Rae 6-12740 Issued 9102

4001 - 124

334M
PIN HOUSING
HDP24-24-29PE

I ~)
og~gq, 334F
SOCKET HOUSING

~
~ vOoOo
02/ 0
~o
HDP24·24-29PE

CONNECTOR 334M CONNECTOR 334F

CHASSIS TO ENGINE ENGINE TO CHASSIS
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
6018 FUEL SHOT OFF SOL HOLD 1 601A FUEL SHOT OFF SOL HOLD
2 179AG CLEAN GROUND 2 179AK CLEAN GROUND
3 181C ICU SENSOR GND 3 181E ICU SENSOR GND
4 2048 ElECTGOV 8+ 4 204C ELECT GOV 8+
5 2238 GOV ING SW SIG 5 me GOV ING SW SIG
6 6
7 2358 ENGINE COOL TEMP 7 235C ENGINE COOL TEMP
8 2408 AIR TO AIR B 240C AIR TO AIR
9 2558 ENG Oil PRES 5VDC 9 255C ENG OIL PRES 5VDC
10 9458 FOOT THROTIlE SW #1 10 945D FOOT THROTILE SW #1
11 9448 FOOT THROTIlE SIGNAL 11 944D FOOT THROTILE SIGNAL
12 9438 FOOT THROTIlE GND 12 9430 FOOT THROTILE GND
13 9428 FOOT THROTIlE B+ 13 942D FOOT THROTILE 8+
14 9418 FOOT THRomE SW #2 14 9410 FOOT THROmE SW #2
15 4898 CRUISE DECREMENT 15 489D CRUISE DECREMENT
16 3588 CRUISE INCREMENT 16 358D CRUISE INCREMENT
17 5478 CRUISE ON I OFF 17 5470 CRUISE ON I OFF
18 18
19 19
20 20
21 21
22 2568 ENG Oil PRESS SIG 22 255C ENG OIL PRESS SIG
23 23
24 24
25 25
26 26
27 27
28 28
29 29

ac 6-12740 Issued 9102

 4001-125

335M
SOCKET HOUSING
335F 225351C1
PIN HOUSING
22535OC1

CAVITY 4 .-/
CONNECTOR 335F CONNECTOR 335M
AUXIUARY CONTROLLER AUXIUARY CONTROLLER
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 179AR CLEAN GND 1 179H CLEANGND
2 528C HITCH Il+ 2 528E HITCH Il+
3 179AS CLEANGND 3 179G CLEANGND
4 527A HITCH UP 4 527C HITCH UP
5 529A HITCHOOWN 5 529C HITCH DOWN
6 900C CDNTRDLLER Il+ 6 900E CONTROLLER B+

336F 336M
PIN HOUSING SOCKET HOUSING
245483C1 245482C1

~
CAVITYB~
CONNECTOR 336F CONNECTOR 336M
DUAL SPEED PTO DUAL SPEED PTO
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
A SENSOR PTO SHAFT SPEED A 249B PTO SHAFT SPEED
B SENSOR SENDER GROUND B 174D SENDER GROUND

337A& 337B
RING TERMINAL
22S05aC1

CONNECTOR 337A CONNECTOR 337B

BACKUP ALARM BACKUP ALARM
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 571B ALARM POWER 1 174H CHASSIS GROUND

Aae 6-12740 Issued 9/02

! ,(
4001 - 126

338F 338M
PIN HOUSING SOCKET HOUSING
22531SCI 22531SCI

CONNECTOR 338F CONNECTOR 338M

DUAL SPEED PTO DUAL SPEED PTO
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
I 571A ALARM POWER I 571B ALARM POWER
2 174G ALARM GND 2 174H ALARM GND

CONNECTOR 340F
340F, 341F, 342F, AUX 1 MOTOR LOWER
343F AND 344F WIRE
SOCKET HOUSING CAY CIRCUIT REFERENCE
NUMBER
291718Al
1 AUXI BOTl B+ AUX 1 A LOWER
2 AUXI BOT2 RETURN AUX 1 A LOWER

CONNECTOR 341F CONNECTOR 342F

AUX 2 MOTOR LOWER AUX 3 MOTOR LOWER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 AUX2 BOTl Bt AUX 2 BLOWER 1 AUX3 BOri Bt AUX 3 BLOWER
2 AUX2 BOT2 RETURN AUX 3 A LOWER 2 AUX3 BOT2 RETURN AUX 3 A LOWER

CONNECTOR 343F CONNECTOR 344F

AUX 4 MOTOR LOWER AUX 5 MOTOR LOWER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 AUX4 BOTl Bt AUX 4B LOWER I AUX5 BOTl Bt AUX 5 BLOWER
2 AUX4 BOT2 RETURN AUX 4 A LOWER 2 AUX5 BOT2 RETURN AUX 5 A LOWER

ac 6-12740 Issued 9/02

 4001·127

353M
350M CN2TYCO
CN1·A TYCO POLARITY 2 KEYING
POLARITY 1 KEYING SOCKET HOUSING
SOCKET HOUSING
3-1 437290-8
3-1437290-7

CONNECTOR 350M CONNECTOR 353M

PWM CONTROLLER AUXILIARY CONTROLLER
WIRE WIRE
CAY CIRCUIT REFERENCE CAY CIRCUIT REFERENCE
NUMBER NUMBER
1 550B SWITCHED B+ 12V 1 5B1A EVEN CLUTCH LOW SIDE
2 5500 SWITCHED B+ 12V 2 544A AXLE SENSOR SIGNAL
3 550H SWITCHED B+ 12V 3 590A CREEP CLUTCH LOW SIDE
4 558B PARK BRAKE CONTROL 4 220B MASTER CLUTCH LOW SIDE
5 5B6A MASTER CLUTCH HIGH SIDE 6 5B2A Cl-2 CLUTCH LOW SIDE
6 201C Cl-2 CLUTCH HIGH SIDE 7 548A SUS AXLE UPPER LOCK
7 201F C3-4 CLUTCH HIGH SIDE 8 SBOA ODD CLUTCH LOW SIDE
8 550M SWITCHED B+ 12V 9 OPEN
9 201B ODD CLUTCH HIGH SIDE 10 OPEN
10 201E EVEN CLUTCH HIGH SIDE 13 5B3A C3-4 CLUTCH LOW SIDE
11 201N CREEP CLUTCH SIDE 18 536B SUS INDICATION LED
13 541A SUS AXLE UPPER LOCK 21 175F CHASSIS GROUND
14 114B UNSWITCHED B+ 12V 26 175G CHASSIS GROUND
15 YELLOW CAN + HIGH SIDE
16 GREEN CAN - HIGH SIDE
19 175K GROUND
20 220F B+ 12V FROM NEUTRAL RELAY
23 557A CLEAN GROUND
24 OPEN
25 175.1 CHASSIS GROUND
26 175H CHASSIS GROUND

Rae 6-12740 Issued 9/02

4001 - 128

355M
351 M CNloB TYCO
CN1-B TYCO POLARITY 2 KEYING
POLARITY 1 KEYING SOCKET HOUSING
SOCKET HOUSING 4·1437290-1
4·1437290-0

CONNECTOR 351M CONNECTOR 355M

PWM CONTROLLER PWM CONTROLLER
WIRE WIRE
CAV CIRCUIT REFERENCE CAV CIRCUIT REFERENCE
NUMBER NUMBER
1 555A MASTER CLUTCH SIGNAL 1 584A C5-6 CLUTCH LOW SIDE
2 OPEN 2 585A REVERSE CLUTCH LOW SIDE
11 563A SYSTEM PRESSURE SIGNAL 3 546A FSUS LOWER LOCK
12 552A REVERSE SIGNAL 4 589A HIGH CLUTCH LOW SIDE
13 551A FORWARD SIGNAL 5 201G REVERSE CLUTCH LOW SIDE
16 5610 FNRP SWITCH 5V 6 201G MID CLUTCH HIGH SIDE
17 556A MASTER CLUTCH POT 5V 7 537A FSUS LOWER
22 511B NOT PARK SIGNAL 8 538A FSUS RAISE
23 553A NOT NEUTRAL 9 572A BACKUP ALARM POWER
24 OPEN 10 220C MID CLUTCH LOW SIDE
26 532B SUS LOCK I UNLOCK 13 2010 C3-4 CLUTCH HIGH SIDE
27 OPEN 14 587A LOW CLUTCH HIGH SIDE
28 567L PARK BRAKE FEEDBACK 15 5719 BACK UP ALARM (POWER)
33 216E ENGINE ALT SPEED 16 220E HIGH CLUTCH LOW SIDE
34 2150 TRANS WHEEL SPEED 18 220D LOW CLUTCH LOW SIDE
25 220G B+ 12V FROM NEUTRAL RELAY
34 220H NEUTRAL RELAY +12

Rae &-12740 Issued 9/02

 4001-129

ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS

Power Distribution System Circuit Operation

Power distribution consists of the following:

1. Unswitched battery power. Unswitched power is available at all times. The battery positive terminal is
connected to the unswitched power bus from which all unswitched power circuits are energized.

Power is available to all ofthefollowingluses 7,8, 10, 11, 13, 15, 16, 17, 18, 19, 20, 32, and 42 regardlessol
the ignition switch position. II equipped with an AFS harness, luses 327 and 328 also see unswitched power.
These luses are contained in a fuse holder that is part 01 the AFS harness.

2. Switched battery power. This power is supplied to the system when the ignition system is ON. This switching is
controlled by relay.

When the ignition is switched ON the cab power relay is energized, supplying battery power to the switched
power bus which in tum supplies power to luses 1,2, 3, 4, 5,6, 9, 10, 12, 20,22,23,24,25, 26, 29,31,37,39,
41 , 43, 44,45, 46, 47, 48, 49 and 52. Additionally the controller relay is energized and power is distributed to
luses 33, 36, 38, 40, and 43.

The front wiper/wash circuit is also supplied with switched power through circuit breaker 51 .

Power Distribution Circuit Troubleshooting

Belore troubleshooting the power distribution system make sure that the lollowing operating conditions are met:

1. The batteries are lully charged and all connections are clean and tight.

2. Transmission in neutral or park.

3. Check all connectors lor lull installation, loose , corroded or pushed out terminals.

4. Determine il the power source being investigated is switched or unswitched.

5. II the power source problem is a switched power source, the relay controlling the circuit needs to be determined
and tested.

Power Distribution Schematic

See NAO Electrical Schematic RAC 6-12750.

Rae 6-12740 Issued 9/02

4001-130

POWER DISTRIBUTION SYMPTOM CHART

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause ReferencelTest

No power at one fuse. Power supply to fuse Go to fuse/circuit chart to
determine power supply circuit.
No power at switched fuses Cab power relay Go to cab power relay test.
1,2,3,4,5, 6,9,12,20, 22,
23, 24, 25, 26,29,31,37,39,
41 , 43, 44,45,46,47,48,49
or 52.
No power at switched fuses Controller relay Go to controller relay test.
30, 33, 34, 35, 36, 38, 40 and
43.
Cab power relay Go to cab power relay test

Rae 6-12740 Issued 9/02

 4001-131

Diagnostic Tests
NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these
tests.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
~ park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Cab Power Relay Test

Test Point Good Reading Possible Cause of Bad Reading
1 Check for 12 volts at cab 12 volts Open circuit 101 A(R).
power relay terminal 240. If good reading, continue
with next step.

2 Ignition ON. 12 volts Open 105A(R), diode 266, or 104A(R)

Check for 12 volts at cab
power relay terminal 239.
If good reading, continue
with next step.
circuit between ignition switch
connector 161 terminal 5 and cab power
relay terminal 239, or
12 volts not available from terminal 5 of
ignition switch connector 161. Refer to
ignition switch test.

3 Check for chassis ground Less than 1 ohm Open 177J(B) circuit from cab power
at cab power relay terminal resistance. relay terminal 279 to ground.
279. If good reading continue
with next step.

4 Check for 12 volts at cab 12 volts Faulty cab power relay.

power relay terminal 138. If good reading, cab power
relay is operating properly.

Rae 6-12740 Issued 9/02

4001 -132
Test Point
1 Unplug the Controller relay
from the relay base.
Ignition switch in Run.
Check for 12 volts at
controller relay base
terminal A3.
2 Ignition switch in Run or
Acc.
Check for 12 volts at
controller relay base
terminal A2.
3 Check for chassis ground
at relay terminal A 1.
NOTE: If all three checks are good. Replace relay
Flac 6-12740
B - Controller Relay Test
Good Reading
12 volts
If good reading, continue
with next step.
12 volts
If good reading, continue
with next step.
Less than 1 ohm
resistance between
controller relay terminal A 1
and chassis ground.
Possible Cause of Bad Reading
Open 102A(R) circuit between controller
relay terminal A3 and switched power
bus.
Open 106A(R) circuit between ignition
switch connector 161 terminal 6 and
controller relay terminal A2, or
12 volts not available from terminal 6 of
ignition switch connector 161. Refer to
ignition switch test.
Open 177H(8) circuit from controller
relay terminal A 1 to ground.
Issued 9/02
 4001-133

AUDIO SYSTEM

Audio System Circuit Operation

The audio system is a four speaker AM/FM stereo with cassette. The audio system is energized by switched power.
The audio system display is linked to the instrument panel light so that it dims when the instrument panel lights are
dimmed.

Audio System Circuit Troubleshooting

Before troubleshooting the Audio system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.
B. Transmission in neutral or park.
C. Check all connectors for full installation, loose, corroded , pushed out, or bent terminals.
D. Check fuses #19, 24
E. Refer to NAO Electrical Schematic RAC 6-12750, schematic sections 63 & 64.

Audio System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause ReferenceiTest

Audio unit is inoperative Fuse/Power Supply A - Audio System Power and
Ground Supply Test
Audio Unit If A - Audio System Power and
Ground Supply Test results are
good, Audio unit is bad.
Blank display, radio/tape Audio unit
player operates
Audio operates, tape player Audio unit
does not operate
Audio unit illumination Illumination circuit F - Audio System Illumination
inoperative Test
Audio unit If F - Audio System Illumination
Test results are good, Audio
unit is bad.
Noisy reception Antenna G - Antenna Test
Audio Unit If G - Antenna Test is good,
audio unit is bad.

Rae 6-12740 Issued 9/02

4001-134
Symptom
Noisy reception, FM only
Poor quality/distorted
sound-One or more
speakers
Poor quality/distorted sound
from all speakers
No sound from speakers
Rae 6-12740
Possible Cause ReferenceITest
Antenna G - Antenna Test
Audio unit If G - Antenna Test is good,
audio unit is bad.
Poor reception area
Audi o speaker H - Speaker Resistance Test
Substitute known good
speaker{s).
Circuit Perform relevant speaker
circuit test{s).
Audio unit If speaker{s) and circuit{s) are
good, audio unit is bad.
Audio speakers H - Speaker Resistance Test
Substitute known good
speaker{s).
Circuit Perform relevant speaker
circuit test{s).
Audio unit If speaker{s) and circuit{s) are
good, audio unit is bad.
Speakers H - Speaker Resistance Test
Substitute known good
speaker{s).
Circuit Perform relevant speaker
circuit test{s) .
Audio unit If speaker{s) and circuit{s) are
good, audio unit is bad.
Issued 9/02
 4001-135

Audio System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Audio System Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Measure resistance Less than 1 ohm Open 178M(B) or 178C(B) circuit.

between radio connector If good reading, go to test
95A, terminal 8 and ground. point 3. Continue with next test point.

2 Measure resistance Less than 1 ohm Open 178M(B) circuit from connector
between connector 95A, If good reading, repair 95A to connector 13M.
terminal 8 and connector open in 178C(B) circuit to Repair open .
13M, terminal U. ground.

3 Measure voltage at radio 12 volts Blown fuse #19, or

connector 95A, terminal 7.
If good reading, go to test
point 5.
Open 871 A(R) or 871 B(R) circuit from
connector 95A, terminal 7 to
unswitched B+.
Check fuse.
Continue with next test point.

4 Will the dome light Yes. Fuse 19 and Continue with next test point.
illuminate? connector 13 are okay.
Locate the open in 871 B
(R)

5 Ignition switch in Run 12 volts Open 870 circuit between radio

position. If good reading, power and connector 95A, terminal 4 and
Measure voltage at radio grounds to audio system switched B+.
connector 95A, cavity 4. are operating properly. Continue with next test point.

6 Measure voltage at 12 volts Open 870D(R) circuit between

connector 13F, terminal W. If good reading, repair connector 95A, terminal 4 and
open in 870C(R) circuit. switched B+.
Continue with next test point.

7 Measure voltage at fuse 24 12 volts Open in jump wire 106B(0) to ignition.

If good reading , repair
open in 870D(0).

Rae 6-12740 Issued 9/02

4001-136

B - Left Front Speaker Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Disconnect connector 959 Less than 1 ohm Open/short to ground in circuit 8739(0)
from the radio , and between connectors 959 and 97F.
connector 97F from the left
front speaker.
Continue with next test point.
Measure resistance If good reading, go to test
between radio connector point 2.
959, terminal 13 and left
front speaker connector
97F, terminal A.

2 Measure resistance Less than 1 ohm Open/short to ground in circuit 873A(9)

between speaker between connectors 959 and 97F(9).
connector 97F, terminal 9
If good reading, left front
and radio connector 959,
speaker wiring is okay.
terminal 14.

C - Right Front Speaker Circuit

Test point Good Reading Possible Cause of Bad Reading

1 Disconnect connector 959 Less than 1 ohm Open/short to ground in circuit 8729(0)
from the radio, and between connectors 959 and 96F.
connector 96F from the
right front speaker.
Measu re resistance If good reading, go to test
between radio connector point 2.
959, terminal 11 and right
front speaker connector
96F, terminal A.

3 Measure resistance Less than 1 ohm Open/short to ground in circuit 872A(9)

between speaker If good reading, right front between connectors 959 and 96F.
connector 96F, terminal 9 speaker wiring is okay.
and radio connector 959,
terminal 12.

o - Right Rear Speaker Circuit Test

Test point Good Reading Possible Cause of Bad Reading
•
1 Disconnect connector 959 Less than 1 ohm Open/short to ground in circuit 8749(0)
from the radio, and between connectors 959 and 92F.
connector 92F from the
right rear speaker.
Continue with next test point.
Measure resistance If good reading, go to test
between radio connector point 2.
959, terminal 9 and left
front speaker connector
92F, terminal A.

Rae 6-1 2740 Issued 9/02


D - Right Rear Speaker Circuit Test
Test point
2 Measure resistance
between speaker
connector 92F, terminal B
and radio connector 95B,
terminal 10.
E - Left Rear Speaker Circuit Test
Test point
1 Disconnect connector 95B
from the radio, and
connector 93F from the left
rear speaker.
Measure resistance
between radio connector
95B, terminal 15 and left
rear speaker connector
93F, terminal A.
2 Measure resistance
between speaker connector
97F, terminal B and radio
connector 95B, terminal 16.
F - Audio System Illumination Test
Test point
1 Access connector 95A.
Attach test light to ground and
probe cavity 6.
Turn head lamps on and off.
Test point
1 Disconnect antenna from
radio.
Measure resistance
between center terminal of
antenna (radio end) and
antenna mast.
Rae 6-12740
Good Reading
Less than 1 ohm
If good reading, right rear
speaker wiring is okay.
Good Reading
Less than 1 ohm
If good reading, go to test
point 2.
Less than 1 ohm
If good reading, left front
speaker wiring is okay.
Good Reading
Test lamp will glow full
bright with headlights off,
and glow dimly with
headlights on.
If good reading audio
system illumination circuits
operating properly.
G - Antenna Test
Good Reading
Less than 1 ohm
If good reading, go to next
test point.
4001-137
Possible Cause of Bad Reading
Open/short to ground in circuit 874A(B)
between connectors 95B and 92F(B).
Possible Cause of Bad Reading
Open/short to ground in circuit 875B(O)
between connectors 95B and 93F.
Continue with next test point.
Open/short to ground in circuit 875A(B)
between connectors 95B and 93F(B).
Possible Cause of Bad Reading
Check for loose, damaged, pushed
out, corroded, or bent terminals, or
Open in dimmer circuit from
connector 95A terminal 6 to
instrument cluster.
Possible Cause of Bad Reading
Antenna.
Issued 9/02
4001 -138

G - Antenna Test
Test point Good Reading Possible Cause of Bad Reading

2 Measure resistance from Less than 1 ohm Open circuit between antenna and
antenna ground wire to Antenna is good . frame ground.
chassis ground.

H - Speaker Resistance Test

Test point Good Reading Possible Cause of Bad Reading

1 Disconnect suspect Between 4 and 8 ohms Bad circuit in speaker.

speaker electrical
connector.
Measure resistance If good reading, speaker
between the A and B good electrically.
terminals of the speaker.

Rae 6-12740 Issued 9/02

 4001-139

CHARGING SYSTEM

Charging System Circuit Operation

The altemator B+ terminal is connected to the battery via terminal 81 F on the starter motor.

The alternator is grounded by its mounting frame.

Terminal 86 (D+) of the alternator receives field excitation voltage from connector 333F, terminal 10 of the
Instrument cluster (ICU). Charging system output is controlled by an integral voltage regulator/brush assembly. The
regulator is set to 14.2 volt regulation. The alternator is temperature compensated so that output will drop as the
alternator warms up.

If alternator output goes below or above specification, the reconfigurable display will show an ISO symbol for the
charging system and a message of "High or Low." Additionally a short audible alarm will sound

Terminal 85 sends a pulsed rpm signal to connector 333F, terminal 12 of the instrument cluster (leU) . The ICU
uses this signal to determine engine rpm.

Charging System Circuit Troubleshooting

Before troubleshooting the starting system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.

B. Transmission in neutral or park.

C. Check all connectors for full installation, loose , corroded, pushed out, or bent terminals.

D. Refer to NAO Electrical Schematic RAC 6-12750, schematic sections 19 and 20.

Rae &-12740 Issued 9/02

4001-140

Charging System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) ~or these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test Iightcan
cause damage to components in this system.

WARNING: Before performing any of the electrical tests, be sure all operating controls are in neu tralor
& park lock position. This will eliminate accidental movement of the machine or start-up of power driven
eqUIpment.

Symptom Possible Cause ReferencelTest

System not charging or
charging poorly. Battery goes
dead.
System overcharging
High or Low message and
symbol in reconfigurable
display
Alternator belt See engine repair section of
Service Manual to replace or
adjust belt.
B+ circuit A - Charging System Output
Test, test points 2-4.
D+ circuit B - Excitation Circuit (D+) Test.
Excitation control D - Instrument Cluster (ICU)
Excitation Control Test.
Alternator A - Charging System Output
Test, test points 4-6.
D+ circuit Check for short to power in
Excitation Circuit (D+).
Excitation Control D - Instrument Cluster (ICU)
Excitation Control Test.
Alternator belt See Engine Repair section of
Service Manual to replace or
adjust belt.
B+ circuit A - Charging System Output
Test, test points 2-4.
D+ circuit B - Excitation Circuit (D+) Test.
Excitation control D - Instrument Cluster (ICU)
Excitation Control Test.
Altemator A - Charging System Output
Test.

Rae &12740 Iss uad 9/02

 4001-141

Charging System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ill park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Charging System Output Test

Test Point Good Reading Possible Cause of Bad Reading

1 Place transmission in 12.8-14.5 volts High resistance between battery and B+

PARK. " good reading, charging terminal at alternator.
Start engine and set at system is operating
1000 rpm. properly. Go to next test point.
Measure voltage at
battery.

2 Place negative lead of
OVOM to battery positive
terminal and positive lead
to starter terminal 80.
Read voltage.
Less than 0.4 volts
" good reading, circuit is
good. Go to next test point.
High resistance between battery and
starter terminal 80. Repairlreplace
wiring as needed.

3 Attach negative lead of
OVOM to starter terminal
80 and positive lead to
starter terminal 81 .
Read voltage .
Less than 0.4 volts
"good reading, circuit is
good. Go to next test point.
High resistance in starter solenoid.
Clean connections, repairlreplace as
needed.

4 Attach positive lead of Less than 0.4 volts High resistance in circuit 120A(R).
OVOM to B+ terminal of Repair/replace wiring as needed.
altemator and negative
" good reading, go to next
lead to terminal 81 of
test point.
starter.
Read Voltage.

5 Measu re voltage at
alternator terminal 86 (0+)
while turning various load
on and off (lights, heater
fans etc.)
Voltage varies between
12.8 and 14.5 volts in
response to load applied.
" good reading go to next
test point.
1210(Y) circuit between alternator (0+)
and instrument cluster connector 61,
terminal 1, or
Excitation circuit, Perform B - Excitation
Circuit (0+) Test, or
Voltage regulator

6 Measure resistance Less than 1 ohm High resistance from alternator to

between alternator " good reading, charging chassis ground. Clean surfaces
housing and chassis system is operating between alternator and frame. Ensure
ground. properly. that all mountings are clean and tight.

Rae 6-1 2740 Issued 9/02

4001-142

B - Excitation Circuit (0+) Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition in Off position . Less than 1 ohm Open 121 D(Y) circuit between
Disconnect wiring form alternator and instrument cluster.
alternator connector 86 If good reading, excitation
(D+) and instrument circuit wiring is okay. Continue with next test point.
cluster connector 61 .
Measure resistance
between connector 86 and
connector 61 terminal 1.

2 Measure resistance Less than 1 ohm Open 121 D(Y) circuit between
between alternator connector 86 and connector 333.
connector 86 and in-line
If good reading, go to next
connector 333M , terminal
test point.
10.

3 Measure resistance Less than 1 ohm Open 121 B(Y) circuit between
between in-line connector connector 333 and connector 60.
333 terminal 10, and in-line
If good reading, go to next
connector 60M terminal
test point.
10.

4 Measure resistance
between in-line connector
60M ,terminall0, and
instrument cluster
connector 61 , terminal 1.
Less than 1 ohm Open 121 A(Y) circuit between
connector 60 and connector 61 .
If good reading, check all
connectors for full
installation , loose,
corroded , pushed out, or
bent terminals.

Rae 6-12740 Issued 9/02

 4001-143

C - RPM Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition in Off position. Less than 1 ohm Open circuit in altemator rpm circuit.
Disconnect alternator
connector 85 and If good reading, alternator Check all connectors for full installation,
instrument cluster rpm circuit wiring okay. loose corroded, pushed out, or bent
connector 61 . terminals.
Measure resistance
between alternator Continue with next test point.
connector 85 and
instrument cluster
connector 61 , terminal 9.

2 Measure resistance Less than 1 ohm Open 126W(DG) circuit between

between alternator connector 85 and connector 333.
connector 85 and in-line If good reading, go to next
connector 333M terminal test point.
12.

Measure resistance Less than 1 ohm Open 216C(Y) circuit between

3
between in-line connector connector 333 and splice F6.
333F, terminal 12 and If good reading, go to next
splice F6. test point.

Measure resistance Less than 1 ohm Open 2168(Y) circuit between splice F6
4
between splice F6 and in- and connector 60.
line connector 60M, If good reading, go to next
terminal 12. test point.

Measure resistance Less than 1 ohm Open 216A(Y) circuit between

5
between in-line connector connector 60 and connector 61 .
60, terminal 12 and If good reading, alternator
Instrument Cluster (ICU) rpm circuit wiring okay. Check all connectors for full installation,
connector 61 , terminal 9. loose, corroded, pushed out, or bent
terminals.

Issued 9/02
Rae & 12740
4001 -144

D - Instrument Cluster (ICU) Excitation Control Test

Test point Good Reading Possible Cause of Bad Reading

1 Place transmission in Voltage varies between Instrument Cluster (lCU).

PARK. 12.8 and 14.5 volts in
Start engine and set at response to load applied.
1000 rpm.
6ackprobing at Instrument If good reading, excitation
Cluster (ICU) connector 61 control circuit is operating
terminal 1 and measure properly.
voltage.
Turn on various loads
(lights, heaters, etc.)

Rae &12740 Issued 9/02


EXTERIOR LIGHTING SYSTEM
Exterior Lighting System Circuit Operation
Exterior lighting consists of the following :
• Headlights (high beam, low beam and center)
• Turn signals front and rear
• Taillights
• Left and right marker lights
• Cab fender work lamps
• Cab front roof work lamps
• High intensity discharge lamp (optional)
• Cab rear fender work lamps (optional)
• Cab beltline work lamps (optional)
• Cab rear roof work lamps (optional)
The various lamps are controlled by switches and
operated via relays as follows:
Exterior Lighting System Circuit Troubleshooting
Before troubleshooting the Exterior Lighting system
make sure that the following operating conditions are
met:
• The batteries are fully charged and all connec-
tions are clean and tight.
• Transmission in neutral or park.
• Check all connectors for full installation, loose,
corroded, pushed out, or bent terminals.
NOTE: Refer to NAO Electrical Schematic RAG 6-12750, schematic sections 28 through 35.
Rae 6-12740
4001-145
• Head lamps use unswitched power and are
usable whether the ignition is On or Off.
• The road lights/flashers (Headlight) switch has
three positions, Off, On and Headlights.
• When the headlight switch is in the On or Head-
light position the left and right tail fender lights,
roof waming lights and the left and right marker
lights are On.
• The work lamp (Rotary) switch controls the
optional beltline work lamps, center and optional
fender work lamps, center and side work lamps,
rear work lights and front roof work lamp and
high beams.
• The rotary switch controlled lamps are locked out
when the headlight switch is On.
• Fuses # 2, 3, 5, 6, 18, 20, 21 , 23, 53, 54, 55 and
56 are intact and have power.
• If one of the work lamp circuits is not working, try
swapping a relay from a working system for a
quick and easy relay check. Otherwise, follow the
circuit diagnostic tests to determine the fault.
• If a bulb is not working, substitute with a known
good bulb to verify circuit operation.
Issued 9/02
4001-146

Exterior Lighting System Symptom Chart

NOTE: The batteries must be fully charged and all
connections clean and tight. Use a multimeter
(OVOM) for these tests.
IMPORTANT: DO NOT use a self-powered test light
for any of these tests. Use of a self-powered test light
can cause damage to components in this system.
WARNING: Before performing any of the
electrical tests, be sure all operating controls
If'.
are in neutral or park lock position. This will
~ eliminate accidental movement of the
machine or start-up of power driven
equipment.

Exterior Lighting System Diagnostic Tests

NOTE: The batteries must be fully charged and all
connections clean and tight. Use a multimeter
(OVOM) or an unpowered test light for these tests.
IMPORTANT: DO NOT use a self-powered test light
for any of these tests. Use of a self-powered test light
can cause damage to components in this system.
WARNING: Before performing any of the
electrical tests, be sure all operating controls
If'.
ar~ i~ neutral or park lock position. This will
~ elIminate accIdental movement of the
machine or start- up of power driven
equipment.

Work Lamp Switch Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position . 12 volts Open circuit from switched B+.

Headlight switch Off. If good reading, go to test Go to next test point.
Rotary switch Off. point 4.
Measure voltage at rotary
switch terminal B1.

2 Measu re voltage at rotary 12 volts Open circuit from switched B+.

switch connector 12 If good reading , repair Go to next test point.
terminal B2. open in 780(P).

3 Measure voltage at wor!< 12 volts Open circuit from switched B+.

lamp interlock relay (relay If good reading, repair
#4) terminal 4. open in 780K(P).

4 Rotary switch in second 12 volts Rotary switch

position. If good reading, go to nex1
Measu re voltage at rotary test point.
switch connector 12,
terminal W.

5 Rotary switch in third 12 volts Rotary switch

position . If good reading, go to nex1
Measure voltage at rotary test point.
switch connector 12,
terminal W.

ac 6-12740 Issued 9/02

 4001-147

Work Lamp Switch Test

Test point Good Reading Possible Cause of Bad Reading

6 Measure voltage at rotary 12 volts Rotary switch

switch connector 12, If good reading , go to next
terminal HL. test point.

7 Rotary switch in fourth 12 volts Rotary switch

position. If good reading, go to next
Measu re voltage at rotary test point.
switch connector 12,
terminal W.

8 Measure voltage at rotary 12 volts Rotary switch

switch connector 12, If good reading, go to next
terminal HL. test point.

9 Measure voltage at rotary 12 volts Rotary switch

switch connector 12, If good reading, rotary
terminal R. switch is operating
properly.

Electronic Flasher Test

Test point Good Reading Possible Cause of Bad Reading

1 Measure voltage at 12 volts Open in unswitched B+ supply circuit.

electronic flasher If good reading, go to test Go to next test point.
connector 136 terminal 3. point 3.

2 Measure voltage at fuse 12 volts Fuse #20, or

#20 . If good reading, repair Open in 769B(P) circuit from
open in 769(R) circuit. unswitched B+.

3 Measure resistance from Less than 1 ohm Open in circuit from connector 135
electronic flasher If good reading, go to next terminal 5 to ground.
connector 135 terminal 5 test point.
to ground.

4 Headlight switch in any 12 volts Open in 765(P) circuit.

position (except Off). If good reading, go to next
Measure voltage at test point.
electronic flasher
connector 135 terminal 6.

Rae 6-12740 Issued 9/02

IJ
4001-148

Electronic Flasher Test

Test point Good Reading Possible Cause of Bad Reading

5 Headlight switch Off. 12 volts Open circuit between electronic flasher

Universal switch in left turn If good reading, go to test and universal switch.
position. point 10. Go to next test point.
Measu re voltage at
electronic flasher
connector 135 terminal 2.

6 Measure voltage at in-line 12 volts Open circuit between electronic flasher

connector 9 terminal 2. If good reading, repair and universal switch.
open in 770A(P) circuit. Go to next test point.

7 Measure voltage at 12 volts Open circuit between electronic flasher

universal switch terminal If good reading, repair and universal switch.
2208. open in 21 (8 ) circuit. Go to next test point.

8 Measure voltage at 12 volts Open circuit between electronic flasher

universal switch terminal If good reading, replace and universal switch.
220A. universal switch. Go to next test point.

9 Measure voltage at in-line 12 volts Open in 769A(R) circuit from in-line

connector 9 terminal 1 . If good reading, repair connector 9 terminal 1 to electronic
open in 20(8) circuit. flasher connector 136 terminal 3.

10 Headlight switch Off. 12 volts Open circuit between electronic flasher

Universal switch in right If good reading, go to test and universal switch.
turn position. point 15. Go to next test point.
Measure voltage at
electronic flasher
connector 135 terminal 1 .

11 Measure voltage at in-line 12 volts Open circuit between electronic flasher

connector 9 terminal 3. If good reading, repair and universal switch.
open in 7708(P) circuit. Go to next test point.

12 Measure voltage at 12 volts Open circuit between electronic flasher

universal switch terminal If good reading, repair and universal switch.
220C. open in 22(8) circuit. Go to next test point.

13 Measure voltage at 12 volts Open circuit between electronic flasher

universal switch terminal If good reading, replace and universal switch.
220A. universal switch. Go to next test point.

14 Measure voltage at in-line 12 volts Open in 769A(R) circuit from in-line

connector 9 terminal 1. If good reading, repair connector 9 terminal 1 to electronic
open in 20(8) circuit. flasher connector 136 terminal 3.

Rae 6-12740 Issued 9/02


Test point
15 Backprobe electronic
flasher connector 135
terminal 4 with test light.
16 Universal switch in left turn
position.
Backprobe electronic
flasher connector 135
terminal 3 with test light.
17 Headlight switch in any
position (except Off) .
Backprobe electronic
flasher connector 136
terminal 2 with test light.
18 Backprobe electronic
flasher connector 136,
terminal 1 with test light.
Test point
1 Disconnect electrical
connector from universal
switch.
Place universal switch in
left tum position.
Measure resistance
between terminals 220A
and 220B.
2 Place universal switch in
right turn position.
Measure resistance
between terminals 220A
and 220 C.
3 Place universal switch in
high beam position.
Measure resistance
between tenminals 220D
and 220E.
Rae 6-12740
IJ
4001-149
Electronic Flasher Test
Good Reading Possible Cause of Bad Reading
Test light flashes. Electronic flasher.
If light flashes, go to next
test point.
Test light flashes. Electronic flasher.
If light flashes, go to next
test point.
Test light flashes. Electronic flasher.
If light flashes, go to next
test point.
Test light flashes. Electronic flasher.
If light flashes, electronic
flasher operating properly.
Universal Switch Test
Good Reading Possible Cause of Bad Reading
Less than 1 ohm. Open circuit in universal switch.
If good reading, go to next
test point.
Less than 1 ohm. Open circuit in universal switch.
If good reading, go to next
test point.
Less than 1 ohm. Open circuit in universal switch.
If good reading, go to next
test point.
Issued 9/02
4001-150

Universal Switch Test

Test point Good Reading Possible Cause of Bad Reading

4 Place universal switch in Less than 1 ohm. Open circuit in universal switch .
low beam position.
Measure resistance If good reading, go to next
between terminals 220D test point.
and 220F.

5 Place universal switch in Less than 1 ohm. Open circuit in universal switch.
head lamp dipping
position .
If good reading, go to next
Measure resistance test point.
between terminals 220E
and 220G.

6 Press horn button. Less than 1 ohm. Open circuit in universal switch.
Measure resistance
between terminals 220H If good reading, universal
and 220J. switch is okay.

ac 6-12740 Issued 9/ 02
 4001-151

INSTRUMENTATION AND WARNING SYSTEM

Instrumentation and Warning System Circuit Troubleshooting

Before troubleshooting the Instrumentation and Warning system make sure that the following operating conditions
are met:

1. The batteries are fully charged and all connections are clean and tight.
2. Transmission in neutral or park.
3. Check all connectors for full installation , loose, corroded, pushed out, or bent terminals.
4. Fuses #16 and #30 intact and receiving power.

NOTE: Refer to NAO Electrical Schematic RAG 6-12750, schematic sections 24, 25 & 26.

Instrumentation and Warning System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position.This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause ReferencefTest

Coolant temperature gauge
does not operate
Oil pressure gauge does not
operate
Fuel level gauge does not
operate
Sending unit B - Engine Coolant Temperature
Sender Circuit Test
Instrument cluster A - Instrumentation and Warning
System Power and Ground
Supply Test
Gauge unit B - Engine Coolant Temperature
Sender Circuit Test
Circuit B - Engine Coolant Temperature
Sender Circuit Test
Sending unit C - Engine Oil Pressure Sender
Circuit Test
Instrument cluster A - Instrumentation and Warning
System Power and Ground
Supply Test
Gauge unit C - Engine Oil Pressure Sender
Circuit Test
Circuit C - Engine Oil Pressure Sender
Circuit Test
Sending unit D - Fuel Sender Circuit Test
Instrument cluster A - Instrumentation and Warning
System Power and Ground

1 Gauge unit
Supply Test
D - Fuel Sender Circuit Test
Circuit D - Fuel Sender Circuit Test

t
J
Rae 6-12740 Issued 9/02
4001-152

Instrumentation and Warning System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Instrumentation and Warning System Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Measu re voltage at 12 volts Open in unswitched B+ circuit.

instrument cluster If good reading, go to test Go to next test point.
connector 61 terminal 20. point 4.

2 Measure voltage at splice 12 volts Open in unswitched B+ circuit.

C20. If good reading, repair Go to next test point.
open in 202A(R) circuit.

3 Measure voltage at fuse 12 volts Fuse #16, or

#16. If good reading, repair Open in 101 B(R) circuit from
open in 202B(R) circuit. unswitched B+.

4 Ignition in Run position. 12 volts Open in unswitched B+ circuit.

Measu re voltage at If good reading, go to test Go to next test point.
instrument cluster point 9.
connector 61 tenminal 40.

5 Measure voltage at splice 12 volts Open in unswitched B+ circuit.

C23. If good reading, repair Go to next test point.
open in 200D(R) circuit.

6 Measure voltage at fuse 12 volts Fuse #37, or

#30. If good reading, repair Open in unswitched B+ circuit.
open in 203A(R) circuit. Go to next test point.

7 Measure voltage at splice 12 volts Open in unswitched B+ circuit.

C9.(schematic section If good reading, repair Go to next test point.
21) open in 200B(R) circuit.

S Measure voltage at 12 volts Controller Relay.

controller relay tenminal If good reading, repair
A5. open in 200A(R) circuit.

Rae 6-12740 Issued 9/02

I
 4001-153

A - Instrumentation and Warning System Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

9 Measure resistance from Less than 1 ohm Open in circuit from connector 61
instrument cluster If good reading. terminal 39 to ground.
connector 61 terminal 39 Instrumentation and
to ground. Warning System power
and ground supply
circuits okay.

B - Engine Coolant Temperature Sender Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Remove electrical If good reading go to next Engine coolant temperature sender.

connector 215 from engine test point.
coolant temperature
sender.
Measure resistance from
engine coolant
temperature sender
terminal to ground.

2 Ignition in Run position. 5 volts Open in 235(Y) circuit from instrument

Measure voltage at engine If good reading. engine cluster.
coolant temperature coolant temperature Go to next test point.
sender connector 215. sender circuits okay.

3 Measure voltage at in-line 5 volts Open in 235(Y) circuit from instrument

connector 334 terminal 7. If good reading. repair cluster.
open in 235C(Y) circuit. Go to next test point.

4 Measure voltage at in-line 5 volts Open in 235(Y) circuit from instrument

connector 60 terminal 5. If good reading. repair cluster.
open in 235B(Y) circuit. Go to next test point.

5 Backprobe instrument 5 volts Instrument Cluster.

cluster connector 61 to If good reading. repair
measure voltage at open in 235A(Y) circuit.
terminal 7.

Rae 6-12740 Issued 9/02

t I
4001-154
C - Engine Oil Pressure Sender Circuit Test
Test point
1 Ignition in Run position.
Remove electrical connector
216 from engine oil pressure
sender.
Measure voltage at engine
oil pressure sender
connector 216 terminal B.
2 Measure voltage at in-line
connector 334 terminal 9.
3 Measure voltage at in-line
connector 60 terminal L.
4 Measure voltage at
instrument cluster connector
61 terminal 18.
5 Measure resistance from
engine oil pressure sender
connector 216 terminal A to
ground.
6 Ignition Off.
Remove electrical connector
61 from instrument cluster.
Measure resistance from
engine oil pressure sender
connector 216 terminal C to
instrument cluster connector
61 terminal 27.
7 Measure resistance from
in-line connector 334
terminal 22 to instrument
cluster connector 61
terminal 27.
8 Measure resistance from in-
line connector 60 terminal
23 to instrument cluster
connector 61 terminal 27.
ac 6- 12740
Good Reading
5 volts
If good reading. go to test
point 5.
5 volts
If good reading. repair
open in 255C(R).
5 volts
If good reading. repair
open in 255B(R).
5 volts
If good reading. repair
open in 255A(R).
Less than 1 ohm
If good reading. go to next
test point.
Less than 1 ohm
If good reading. circuits
okay. Replace engine oil
pressure sender.
Less than 1 ohm
If good reading. repair
open in 256C(Y) circuit.
Less than 1 ohm
If good reading. repair
open in 256B(Y) circuit.
Possible Cause of Bad Reading
Open in 255(R) signal circuit from
instrument cluster.
Go to next test point.
Open in 255(R) signal circuit from
instrument cluster.
Go to next test point.
Open in 255(R) signal circuit from
instrument cluster.
Go to next test point.
Instrument cluster.
Open in circuit from connector 216
terminal A to ground.
Open in 256(Y) circuit from instrument
cluster.
Go to next test point.
Open in 256(Y) circuit from instrument
cluster.
Go to next test point.
Open in 256A(Y) circuit.
Issued 9/02
 4001-155

o - Fuel Sender Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position. 8 volts Open in 234(R) circuit from instrument

If good reading, go to test cluster.
Remove electrical
connector 66 from fuel point 4. Go to next test point.
sender.
Measure voltage at
connector 66 terminal A.

2 Measure voltage at in-line 8 volts Open in 234(R) circuit from instrument

connector 60 terminal 8. If good reading, repair cluster.
open in 234B(R) circuit. Go to next test point.

3 Measure voltage at 8 volts

instrument cluster If good reading, repair
connector 61 terminal 8. open in 234A(R) circuit.

4 Measure resistance from Less than 1 ohm Open in circuit from connector 66
fuel sender connector 66 If good reading, go to next terminal C to ground .
terminal C to ground. test point.

5 Remove electrical Less than 1 ohm Open in 234(Y) circuit from instrument
connector 61 from If good reading, fuel cluster.
instrument cluster. sender circuits are okay. Go to next test point.
Measure resistance from Replace fuel sender.
fuel sender connector 66
terminal B to connector 61
terminal 26.

6 Measure resistance from Less than 1 ohm Open in 236A(Y) circuit.

in-line connector 60 If good reading, repair
terminal 13 to instrument open in 236B(Y) circuit.
cluster connector 61
terminal 26.

Issued 9102
Rae 6-12740
4001-156

INTERIOR LIGHTING AND HORN SYSTEM

Interior Lighting and Horn System Circuit Operation

Interior lighting consists of a switchable dome light with door switch , a switchable map light, and a console light
which operates in conjunction with the Instrument Cluster lighting.

The dome light can be set to either come on when the door opens or it can be switched on with an integral switch.
The power source is unswitched, so the dome light can be operated at any time.

The power supply for the hom is switched. When the key is in the ON position the circuit is energized. To operate
the horn, ground is provided by pressing the hom button on the universal switch.

Interior Lighting and Horn System Circuit Troubleshooting

Before troubleshooting the Interior Lighting and Horn system make sure that the following operating conditions are
met:
A. The batteries are fully charged and all connections are clean and tight.

B. Transmission in neutral or park.

C. Check all connectors for full installation , loose, corroded, pushed out, or bent terminals.

D. Fuses # 8, 16, 17, and 19 are good .

ae 6-12740 Issued 9/02

 4001-157

Interior Lighting and Horn System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
~ park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Interior Lighting and Horn System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
& park lock position. This will eliminate accidental movement of the machine or start-up of power driven
eqUipment.

A - Horn System Circuit Test

Test Point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position . 12 volts Open in switched B+ circuit to horn .

Measure voltage at horn If good reading, go to test Go to next test point.
connector 74A. point 7.

2 Measure voltage at in-line 12 volts Open in switched B+ circuit to horn.

connector 333 terminal 17. If good reading, repair Go to next test point.
open in 722C(R) circuit.

3 Measure voltage at in-line 12 volts Open in switched B+ circuit to horn.

connector 10 terminal 80. If good reading, repair Go to next test point.
open in 722B(R) circuit.

4 Measure voltage at fuse 12 volts Fuse #17, or

#17. If good reading, repair Open in switched B+ circuit.
open in 722A(R) circuit. Go to nex1 test point.

5 Measure voltage at splice 12 volts Open in 101 B(R) circuit from switched
fuse 16. If good reading, repair B+.
open in J9 circuit.

Rae 6-12740 Issued 9/02

I d
4001-158

A - Horn System Circuit Test

Test Point Good Reading Possible Cause of Bad Reading

6 While pressing horn switch Less than 1 ohm Open in switched ground circuit from
(on universal switch) . If good reading. horn horn.
measure resistance from power and ground circuits Go to next test point.
horn connector 74B to okay. If horn does not
ground. work. replace horn.

7 While pressing horn Less than 1 ohm Open in switched ground circuit from
switch. measure If good reading. repair horn.
resistance from in-line open in 723C(B) circuit. Go to next test point.
connector 333 terminal 16
to ground.

8 While pressing horn Less than 1 ohm Open in switched ground circuit from
switch . measure If good reading. repair horn.
resistance from in-line open in 723B(B) circuit. Go to next test point.
connector 60 terminal 16
to ground.

9 While pressing hom Less than 1 ohm Open in switched ground circuit from
switch. measure If good reading. repair horn.
resistance from in-line open in 723(A) circuit. Go to next test point.
connector 51 terminal 9 to
ground.

11 While pressing hom Less than 1 ohm Open in switched ground circuit from
switch. measure If good reading. repair horn .
resistance from universal open in 9A(B) circuit. Go to next test point.
switch terminal 220H to
ground.

12 Measure resistance from Less than 1 ohm Open in circuit from universal switch
universal switch terminal If good reading. replace terminal 220J to ground.
220J to ground. universal switch .

Rae 6-12740 Issued 9/02

 4001-159

B - Dome Lamp and Switch Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Measure voltage at dome 12 volts Open in unswitched B+ circuit.

lamp connector 102. If good reading, go to test Go to next test point.
point 6.

2 Measure voltage at in-line 12 volts Open in unswitched B+ circuit.

splice between dome lamp If good reading, repair Go to next test point.
connector 102, and in-line open in 871C(R) circuit.
connector 13 terminal V.

3 Measure voltage at in-line 12 volts Open in unswitched B+ circuit.

connector 13 terminal V. If good reading, repair Go to next test point.
open in 871 C(R) circuit.

4 Measure voltage at fuse 12 volts Open in unswitched B+ circuit.

#19. If good reading, repair Go to next test point.
open in 871 A(R) circuit.

5 Measure voltage at fuse 12 volts Open in 101 H(R) circuit from

#18. If good reading, repair unswitched B+.
open in J 1(R) circuit.

6 Switch dome lamp to door 12 volts Bulb, or

operation. If good reading, go to next Dome lamp and switch assembly.
Measu re voltage at test point.
connector 101 of switch .

7 Remove electrical connector 12 volts Open in 715A(V) circuit.

100 from door switch. If good reading, go to next
Measure voltage at test point.
connector 100.

S Open door. Less than 1 ohm Door switch , or

Measure resistance to If good reading, go to next Ground connection of door switch.
ground at terminal of door test point.
switch.

9 Switch dome lamp to On Less than 1 ohm Open in circuit from connector 103 to
pOSition. If good reading, dome ground.
Measure resistance from lamp and switch circuits
dome lamp and switch okay. If dome lamp does
connector 103 to ground. not operate properly,
replace dome lamp and
switch assembly.

Rae 6-12740
Issued 9/02
4001-160

C - Map Light Circuit Test

Test point Good Reading Possible Cause of Bad Reading

1 Measure voltage at map 12 volts Open in circuit from unswitched B+.

light connector 170 I! good reading, go to test Go to next test point.
terminal A. point 6.

2 Measure voltage at splice 12 volts Open in circuit from unswitched B+.

SH3. I! good reading , repair Go to next test point.
open in 135G(R) circuit.

3 Measure voltage at in-line 12 volts Open in circuit from unswitched B+ .

connector 91 terminal C. I! good reading, repair Go to next test point.
open in 135C(R) circuit.

4 Measure voltage at in-line 12 volts Open in circuit from unswitched B+.

connector 13 terminal X. I! good reading, repair Go to next test point.
open in 135B(R) circuit.

5 Measure voltage at fuse 12 volts Fuse #8, or

#8. I! good reading, repair Open in 101 L(R) circuit from unswitched
open in 135A(R) circuit. B+.

6 Measure resistance from Less than 1 ohm Open in circuit from map light connector
map light connector 170 I! good reading, go to next 70 terminal 3 to ground.
terminal C to ground. test point.

7 Remove electrical Continuity Map light bulb, or

connector 170 from map I! good reading, map light Map light switch .
light. circuits and assembly
With map light in On okay.
position , check for
continuity between
terminals A and C of map
light assembly.

ae 6-12740 Issued 9/02

 4001-161

POWER MIRROR SYSTEM

Power Mirror Circuit Operation

Switched power is supplied to the power mirror switch from fuse #24. Power is supplied to the mirror switch
connector 130.

Chassis ground is supplied to the mirror switch connector 130.

The mirror switch can be set to control either left or right mirrors. This action changes the contacts within the switch
in order to operate either the left or the right mirror. Only one mirror can be operated at a time.

There are two motors in each mirror assembly. Power and ground are supplied to the motors through three wires
for each mirror assembly, one wire for each motor and one wire in common , therefore the motors can only be
operated in one mode at a time; up only, down only, in only, or out only.

Change in mirror motor direction is accomplished by reversing current flow through the motors.

Power Mirror Circuit Troubleshooting

Before troubleshooting the power mirror system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.

B. Check fuse #24.

C. Transmission in neutral or park.

D. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.

E. Refer to NAO Electrical Schematic RAC 6-12750.

Rac 6-12740 Issued 9/02

4001-162

Power Mirror System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) ~orthese
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test Iightcan
cause damage to components in this system.

&,
WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutralor
park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause ReferencefTest

Mirrors totally inoperable
Left mirror inoperable
Right mirror inoperable
Right mirror, up/down
inoperable
No power or ground to switch A - Power Mirror Switch Power
and Ground Supply Test
Mirror Switch B - Power Mirror Switch Test
Circuit to mirrors C - First Circuit Test and
D - Second Circuit Test
Mirror Switch B - Power Mirror Switch Test, test
points 1, 2, 7, 8, 9, 10, 15, 16,
17, and 18. •
Mirror Assembly F - Left Mirror Assembly Test
Circuit between switch and C - First Circuit Test,
mirror test points 1 thru 3, and
D - Second Circuit Test test
points 1 thru 3.
Mirror Switch B - Power Mirror Switch Test,
test points 1 thru 6, and 11 thru
14.
Mirror Assembly E - Right Mirror Assembly Test
Circuit between switch and C - First Circuit Test,
mirror test points 4 thru 6, and
D - Second Circuit Test,
test points 4 thru 6.
Mirror Switch B - Power Mirror Switch Test,
test points 1, 2, 5, 6, 13 and 14.
Right Mirror assembly E - Right Mirror Assembly Test,
test points 3, 4, 7, and 8.
Circuit between switch and C - First Circuit Test,
mirror test points 5 and 6, and
D - Second Circuit Test,
test points 4 and 5.

~ac &-12740 Iss ued 9102

 4001-163

Symptom Possible Cause ReferenceITest

Right mirror, in/out inoperable
Left mirror, up/down
inoperable
Left mirror, in/out inoperable
Mirror Switch B - Power Mirror Switch Test,
test points 1, 2, 3, 4, 11 and 12.
Mirror Assembly E - Right Mirror Assembly Test,
test points 1, 2, 5 and 6.
Circuit between switch and C - First Circuit Test,
mirror test points 5 and 6, and
D - Second Circuit Test,
test points 4 and 5.
Mirror Switch B - Power Mirror Switch Test,
test points 1, 2, 9,10, 17 and 18.
Mirror Assembly F - Left Mirror Assembly Test,
test points 3, 4, 7 and 8.
Open circuit between switch and C - First Circuit Test,
mirror test points 2, 3 and 4, and
D - Second Circuit Test,
test points 2 and 3.
Switch Faully B - Power Mirror Switch Test,
test points 1, 2, 7, 8, 15 and 16.
Open circuit between switch and C - First Circuit Test,
mirror test points 1 and 2, and
D - Second Circuit Test,
test points 1 and 2.
Mirror Assembly F - Left Mirror Assembly Test,
test points 1, 2, 5 and 6.

Rac 6-12740 Issued 9/0.(

 4001-164

Power Mirror System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Power Mirror Switch Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position. 12 volts Open in circuit from switched B+.

Measure voltage at power If good reading, go to test Go to next test point.
mirror switch connector point 5.
: 130 terminal 9.

2 Measure voltage at splice 12 volts Open in circuit from switched B+.

between power mirror If good reading, repair Go to next test point.
switch connector 130 open in 870B(0) circuit.
tenninal 9 and in-line
connector 13 terminal W.

3 Measure voltage at fuse 12 volts Fuse #24, or

#24. If good reading , repair Open in circuit from switched B+.
open in 870D(0) circuit. Go to next test point.

4 Measure resistance from Less than 1 ohm Open in circuit from power mirror
power mirror connector If good reading, power connector 130 tenninal 3 to ground .
130 terminal 3 to ground. mirror switch power and
ground supply circuits
okay.

c 6-12740 Issued 9/02


Test point
1 Ignition in Run position.
Measure voltage at power
mirror switch connector
130 terminal 9.
2 Measure resistance from
power mirror switch.
connector 130 terminal 3
to ground.
3 Set mirror selector to Right
mirror.
Hold mirror switch in IN
position.
Measure voltage at power
mirror switch connector
130 terminal 10.
4 Hold mirror switch in OUT
position.
Measure voltage at power
mirror switch connector
130 terminal 7.
5 Hold mirror switch in UP
position.
Measure voltage at power
mirror switch connector
130 terminal 5.
6 Hold mirror switch in
DOWN position.
Measure voltage at power
mirror switch connector
130 terminal 7.
7 Set mirror selector to Left
mirror.
Hold mirror switch in IN
position.
Measure voltage at power
mirror switch connector
130 terminal 8.
Rae 6-12740
4001-165
B - Power Mirror Switch Test
Good Reading Possible Cause of Bad Reading
12 volts Open in circuit from switched B+.
If good reading. go to next Perform A - Power Mirror Switch Power
test point. and Ground Supply Test
Less than 1 ohm Open in circuit from power mirror switch
If good reading. power connector 130 terminal 3 to ground.
mirror switch power and
ground supply circuits
okay.
12 volts Open in power mirror switch.
If good reading. go to next
test point.
12 volts Open in power mirror switch.
If good reading. go to next
test point.
12 volts Open in power mirror switch.
If good reading. go to next
test point.
12 volts Open in power mirror switch.
If good reading. go to next
test point.
12 volts Open in power mirror switch.
If good reading. go to next
test point.
Issued 9/02
4001-166

B - Power Mirror Switch Test

Test point Good Reading Possible Cause of Bad Reading

8 Hold mirror switch in OUT 12 volts Open in power mirror switch.

position . If good reading, go to next
Measure voltage at power test point.
mirror switch connector
130 terminal 7.

9 Hold mirror switch in UP 12 volts Open in power mirror switch .

position . If good reading, go to next
Measure voltage at power test point.
mirror switch connector
130 terminal 8. •
10 Hold mirror switch in 12 volls Open in power mirror switch.
DOWN position . If good reading, go to next
•
Measure voltage at power test point.
mirror switch connector
130 terminal 7.

11 Set mirror selector to Right Less than 1 ohm Open in power mirror switch .
mirror. If good reading, go to next
Hold mirror switch in IN test point.
position.
Measure resistance from
power mirror switch
connector 130 terminal 7
to ground.

12 Hold mirror switch in OUT Less than 1 ohm Open in power mirror switch.
position. If good reading, go to next
Measure resistance from test point.
power mi rror switch
connector 130 terminal 10
to ground.

13 Hold mirror switch in UP Less than 1 ohm Open in power mirror switch .
pOSition. If good reading, go to next
Measure resistance from test point.
power mirror switch
connector 130 terminal 7
to ground.

14 Hold mirror switch in Less than 1 ohm Open in power mirror switch .
DOWN position . If good reading, go to next
Measure resistance from test point.
power mi rror switch
connector 130 terminal 5
to ground.

c 6-12740 Issued 9/02

 4001-167

B - Power Mirror Switch Test

Test point Good Reading Possible Cause of Bad Reading

15 Set mirror switch to control Less than 1 ohm Open in power mirror switch.
LEFT mirror. If good reading, go to next
Hold mirror switch in IN test point.
position.
Measure resistance from
power mirror switch
connector 130 terminal 7
to ground.

16 Hold mirror switch in OUT Less than 1 ohm Open in power mirror switch.
position . If good reading, go to next
Measure resistance from test pOint.
power mirror switch
connector 130 terminal 8
to ground.

17 Hold mirror switch in UP Less than 1 ohm Open in power mirror switch.
position. If good reading, go to next
Measure resistance from test point.
power mirror switch
connector 130 terminal 7
to ground.

18 Hold mirror switch in If all tests have been Open in power mirror switch.
DOWN position. successfully completed,
Measure resistance from switch is good.
power mirror switch
connector 130 terminal 4
to ground .

Rae 6-12740 Issued 9/02

4001-168

C - First Circuit Test (Mirror Switch Connector 130 to In-line Connector 111
Test point Good Reading Possible Cause of Bad Reading

1 Remove connector 130 Continuity Open in 275A(0) circuit.

from power mirror switch. If good reading. go to next
Disconnect in-line test point.
connector 111 M from in-
line connector 111 F.
Set DVOM to test
continuity.
Check for continuity
between connector 111 F
terminal 1 and connector
130 terminal 8.

2 Check for continuity Continuity Open in circuit between connector 111 F

between connector 111 F If good reading. go to test terminal 2 and connector 130 terminal
terminal 2 and connector point 4. 7.
130 terminal 7. Go to next test point.

3 Check for continuity Continuity Open in 588(0) circuit.

between connector 111 F If good reading. repair
terminal 2 and splice C6. open in 58A(0) circuit.

4 Check for continuity Continuity Open in 277A(0) circuit.

between connector 111 F If good reading. go to next
terminal 3 and connector test point.
130 terminal 4.

5 Check for continuity Continuity Open in 278A(0) circuit.

between connector 111 F If good reading. go to next
terminal 4 and connector test point.
130 terminal 10.

6 Check for continuity Continuity Open in 58(0) circuit.

between connector 111 F If good reading. go to next
terminal 5 and connector test point.
130 terminal 7.

7 Check for continuity Continuity Open in 280A(0) circuit.

between connector 111 F If good reading. circuits
terminal 6 and connector between connector 130
130 terminal 5. and in-line connector 111 F
are okay

ac 6-12740 Issued 9/02


o - Second Circuit Test (Mirror Assembly Connectors 112 and 113 to
In-line Connector 111)
Test point
1 Remove connector 112 from left
mirror assembly.
Disconnect in-line connector
111 M from in-line connector
111 F.
Set DVOM to test continuity.
Check for continuity between
connector 111 M terminal 1 and
connector 112 terminal 3.
2 Check for continuity between
connector 111 M terminal 2 and
connector 112 terminal 2.
3 Check for continuity between
connector 111 M terminal 3 and
connector 112 terminal 1.
4 Remove connector 113 from
right mirror assembly.
Disconnect in-line connector
111 M from in-line connector
111 F.
Set DVOM to test continuity.
Check for continuity between
connector 111 M terminal 4 and
connector 113 terminal 3.
S Check for continuity between
connector 111 M terminal 5 and
connector 113 terminal 2.
6 Check for continuity between
connector 111 M terminal 6 and
connector 113 terminal 1 .
Rae 6-12740
.
4001-169
Good Reading Possible Cause of Bad Reading
Continuity Open in 949A(O) circuit.
If good reading, go to
next test point.
Continuity Open in 950(DG) circuit.
If good reading, go to
next test point.
Continuity Open in 951 A(Y) circuit.
If good reading, circuits
between in-line
connector 111 M and left
mirror connector 112
okay. Go to next test
point.
Continuity Open in 952A(O) circuit.
If good reading, go to
next test point.
Continuity Open in 953A(DG) circuit.
If good reading, go to
next test point.
Continuity Open in 954A(Y) circuit.
If good reading, circuits
between in-line
connector 111 M and
right mirror connector
113 okay.
Issued 9/02
4001-170
E • Right Mirror Assembly Test
Test point
1 Perform A - Power Mirror
Switch Power and Ground
Supply Test.
Ignition in Run position.
Set mirror selector to Right
mirror.
Hold mirror switch in IN
position .
Measure voltage at
terminal 3 of right mirror
connector 113.
2 Hold mirror switch in OUT
position.
Measure voltage at
terminal 2 of right mirror
connector 113.
3 Hold mirror switch in UP
position.
Measure voltage at
terminal 1 of right mirror
connector 113.
4 Hold Mirror switch in
DOWN position.
Measure voltage at
terminal 2 of right mirror
connector 113.
5 Ignition Off.
Set DVOM to measure
continuity.
Hold mirror switch in IN
position .
Check for continuity from
right mirror connector 113
terminal 2 to ground.
6 Hold mirror switch in OUT
position.
Check for continuity from
right mirror connector 113
terminal 1 to ground.
Rae 6-1 2740
Good Reading Possible Cause of Bad Reading
12 volts Open circuit between connector 113
If good reading, go to next and mirror switch.
test point. Perform C - First Circuit Test,
test poi nt 7, and
D - Second Circuit Test,
test point 6.
12 volts Open circuit between connector 113
If good reading , go to next and mirror switch .
test point. Perform C - First Circuit Test,
test points 2, 3 and 6, and
D - Second Circuit Test,
test point 5.
12 volts Open circuit between connector 113
If good reading, go to next and mirror switch .
test point. Perform C - First Circuit Test,
test point 5, and
D - Second Circuit Test,
test point 4.
12 volts Open in power mirror switch .
If good reading, go to next
test point.
Continuity Open in power mirror switch.
If good reading, go to next
test point.
Continuity Open in power mirror switch.
If good reading, go to next
test point.
Issued 9/02

E - Right Mirror Assembly Test
Test point
7 Hold mirror switch in UP
position.
Check for continuity from
right mirror connector 113
terminal 2 to ground.
8 Hold mirror switch in
DOWN position.
Check for continuity from
right mirror connector 113
terminal 3 to ground.
F - Left Mirror Assembly Test
Test point
1 Perform A - Power Mirror
Switch Power and Ground
Supply Test.
Ignition in Run position.
Set mirror selector to Left
mirror.
Hold mirror switch in IN
position.
Measu re voltage at
terminal 3 of right mirror
connector 112.
2 Hold mirror switch in OUT
position.
Measure voltage at
terminal 2 of right mirror
connector 112.
3 Hold mirror switch in UP
position.
Measure voltage at
terminal 1 of right mirror
connector 112.
Rae 6-1 2740
I,
4001-171
Good Reading Possible Cause of Bad Reading
Continuity Open in power mirror switch.
If good reading, go to next
test point.
Continuity Open in power mirror switch.
If good reading, and right
mirror does not operate
properly, replace right
mirror assembly.
Good Reading Possible Cause of Bad Reading
12 volts Open circuit between connector 112
If good reading , go to next and mirror switch.
test point. Perform C - First Circuit Test,
test point I , and
D - Second Circuit Test,
test point 1.
12 volts Open circuit between connector 112
If good reading , go to next and mirror switch.
test point. Perform C - First Circuit Test,
test point 2, and
D - Second Circuit Test,
test point 2.
12 volts Open circuit between connector 112
If good reading, go to next and mirror switch.
test point. Perform C - First Circuit Test,
test point 4, and
D - Second Circuit Test,
test point 3.
Issued 9/02
4001-172

F - Left Mirror Assembly Test

Test point Good Reading Possible Cause of Bad Reading

4 Hold Mirror switch in 12 volts Open in power mirror switch.

DOWN position . If good reading, go to next
Measure voltage at test point.
terminal 2 of right mirror
connector 112.

5 Ignition Off. Continuity Open in power mirror switch.

Set DVOM to measure If good reading, go to next
continuity . test point.
Hold mirror switch in IN
position.
Check for continuity from
left mirror connector 112
terminal 2 to ground.

S Hold mirror switch in OUT Continuity Open in power mirror switch.

position. If good reading, go to next
Check for continuity from test point.
left mirror connector 112
terminal 3 to ground.

7 Hold mirror switch in UP Continuity Open in power mirror switch.

position. If good reading, go to next
Check for continuity from test point.
left mirror connector 112
terminal 2 to ground.

8 Hold mirror switch in Continuity Open in power mirror switch .

DOWN position. If good reading, and left
Check for continuity from mirror does not operate
left mirror connector 112 properly, replace left mirror
terminal 1 to ground. assembly.

Rae 6-12740 Issued 9/02

 4001-173

POWER SEAT SYSTEM

Power Seat System Circuit Operation

The seat system has a power seat height adjustment using an air motor adjustment. Additionally the seat has
provision for seat and back cushion heating.

The seat height is adjusted with air pressure controlled with a switch . The seat cushions are heated and controlled
by a switch. The switch operates as follows: The seat heaters are OFF with the heater switch in the 0 position. Turn
the thumb wheel from the lowest position of ' 1" to the highest position of "6" to achieve heat control.

Seat adjustment and heating is available whenever the ignition switch is ON.

Power Seat System Circuit Troubleshooting

Before troubleshooting the Seat system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.

B. Transmission in neutral or park.

C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.

D. Check fuses #9 (seat adjustment) and #29 (seat heater).

E. The ignition is in RUN or ACCESSORY position .

F. Refer to NAO Electrical Schematic RAC 6-12750, schematic section 68.

Rae 6-12740 Issued 9/02

4001-174

Power Seat System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

IA. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ill park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause Referencerrest

Height adjustment not Height adjustment switch B - Height Adjustment Circuit

operating Test

Power and ground supply A - Seat System Power and

Ground Supply Test

Seat air pump compressor B - Height Adjustment Circuit

Test

Air system leaking Check air lines for leakage

Seat heater not functioning Heater switch D - Heater Switch and Relay
Power and Ground Supply
Test

Operator presence not Operator presence switch C - Operator Presence

indicated Switches Circuit Test

Instrument cluster C - Operator Presence

Switches Circuit Test

f1ac &-12740 Issued 9/02

 4001-175

Power Seat System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service. see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A. WARNING: Before performing any of the electrical tests. be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Seat System Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position. 12 volts Open in circuit from switched B+.

Measure voltage at seat I! good reading. go to next Go to test point 5.
connector 133 terminal 1. test point.

2 Measure voltage at seat 12 volts Open in circuit from switched B+.

connector 133 terminal 2. If good reading. go to next Go to test point 6.
test point.

3 Measu re voltage at seat 12 volts Open in circuit from switched B+.

connector 133 terminal 5. I! good reading. go to next Go to test point 7.
test point.

4 Measure voltage at seat 12 volts Open in circuit from switched B+.

connector 133 terminal 7. I! good reading. go to test Go to test point 9.
point 11.

5 Measure voltage at splice 12 volts Open in circuit from switched B+.

C15. I! good reading. repair Go to test point B.
open in 73B(R) circuit.

6 Measure voltage at splice 12 volts Open in circuit from switched B+.

C15. I! good reading. repair Go to test point B.
open in 73C circuit.

7 Measure voltage at splice 12 volts Open in circuit from switched B+.

C15. I! good reading. repair Go to test point B.
open in 73D(R) circuit.

8 Measure voltage at fuse 12 volts Fuse #9. or

#9. I! good reading. repair Open circuit 290A(R) circuit from
open in 73A(R) circuit. switched B+.

9 Measure voltage at fuse 12 volts Open in circuit from switched B+.

#29. I! good reading. repair Go to next test point.
open in 259A(R) circuit.

Rae 6-12740 Issued 9/02

.
4001 -176
A - Seat System Power and Ground Supply Test
Test Point
10 Measure resistance from
seat connector 133
terminal 3 to ground.
11 Measure resistance from
seat connector 133
terminal 4 to ground.
12 Measure resistance from
seat connector 133
terminal 8 to ground.
B - Height Adjustment Circuit Test
Test point
1 Ignition in Run position.
Press height adjustment
switch.
2 Separate electrical
connector 133F and 133M.
Engage seat height adjust
switch and check for
continuity from connector
133F terminal 1 to 2.
3 Engage seat height adjust
switch and check for
continuity from connector
133F terminal 1 to 4.
4 Engage seat height adjust
switch and check for
continuity from connector
133F terminal 2 to 3.
5 Engage seat height adjust
switch and check for
continuity from connector
133F terminal 2 to 4.
Rae 6-12740
Good Reading
Less than 1 ohm
If good reading, go to next
test pOint.
Less than 1 ohm
If good reading, go to next
test point.
Less than 1 ohm
If good reading, seat
system power and ground
supplies okay.
Good Reading
Seat height adjustment air
compressor runs.
If compressor runs, but
seat does not adjust,
check for air line leakage.
Continuity
Go to next test point.
Continuity
Go to next test point.
Continuity
Go to next test point.
Continuity
Go to next test point.
Possible Cause of Bad Reading
Open in circuit from seat connector 133
terminal 3 to ground.
Open in circuit from seat connector 133
terminal 4 to ground.
Open in circuit from seat connector 133
terminal 8 to ground .
Possible Cause of Bad Reading
Open in seat height adjustment circuits.
Go to next test point.
Seat adjust switch,
Seat air pump compressor, or
Related circuits within seat assembly.
Seat adjust switch,
Seat air pump compressor, or
Related circuits within seat assembly.
Seat adjust switch,
Seat air pump compressor, or
Related circuits within seat assembly.
Seat adjust switch,
Seat air pump compressor, or
Related circuits within seat assembly.
Issued 9/02

B - Height Adjustment Circuit Test
Test point
6 Check seat height
adjustment power and
grounds.
Perform A - Seat System
Power and Ground Supply
Test, test points 1, 2, 10,
and 11 .
C - Operator Presence Switches Circuit Test
Test point
1 Separate electrical connector
133F and 133M.
While sitting in operator seat,
check for continuity between
connector 133F terminals 5
and 6.
2 Check for continuity between
connector 133M terminals 5
and 6 with operator seat
empty.
3 Check operator presence
switches power supply.
Perform A - Seat System
Power and Ground Supply
Test, test point 3.
4 Remove electrical connector
61 from instrument cluster.
Check for continuity from
connector 61 terminal 23 to
connector 133 terminal 6.
Rae 6-1 2740
,!
4001-177
Good Reading Possible Cause of Bad Reading
II power and ground Open in seat power and ground supply
supplies okay, seat height circuits.
adjust switch and air pump
compressor circuits have
continuity, but height
adjustment does not
operate, replace seat air
pump compressor.
Good Reading Possible Cause of Bad Reading
Continuity Open in operator presence switches
If good reading , go to next and/or circuits within seat assembly.
test point.
Open circuit Short in operator presence switches
If good reading, go to next and/or circuits within seat assembly.
test point.
If power supply circuits Open in circuit from switched B+.
okay, go to next test point.
Continuity Open in 303A(T) circuit.
If good reading, operator
presence switches and
circuits okay. Replace
instrument cluster
Issued 9/02
4001-178

D - Heater Switch and Relay Power and Ground Supply Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition in Run position. 12 volts Open in circuit from switched B+.

Measure voltage at seat If good reading. go to test Go to next test point.
connector 133 terminal 7. point 4.

2 Measure voltage at fuse 12 volts Open in circuit from switched B+.

#29. If good reading. repair Go to next test point.
open in 259A(R) circuit.

3 Measure voltage at splice 12 volts Open in 102B(R) circuit from switched

C21 . If good reading. replace B+.
fuse #29. or repair open in
102J(R) circuit.

4 Measure resistance from Less than 1 ohm Open in circuit from seat connector 133
seat connector 133 If good reading. heater terminal 8 to ground .
terminal 8 to ground. switch and relay power
and ground supplies okay.

Rae &-12740 Issued 9/02

 4001-179

STARTING SYSTEM

Starting System Circuit Operation

Unswitched battery power, B+ is supplied through fuse #7 to the ignition switch connector 161. When the key is
turned to the START position current is supplied to the FNRP Module connector 219. If the transmission is in
neutral or park current flows to the buss box starter relay, and onto the intermediate starter relay which energizes
the starter relay.

Starter Motor Circuit Troubleshooting

Before troubleshooting the starting system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.

B. Check fuse #7.

C. Transmission in neutral or park.

Starting System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (OVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

At.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause Referencerrest

Engine does not crank when
key is turned to start
Fuse #7 A - Ignition Switch Power Supply
Test, test point 1
Ignition switch A - Ignition Switch Power Supply
Test, and
B - Ignition Switch Test,
test points 1 and 2.
FNRP Module C - FNRP Module test.
Refer to Transmission Section of
Service Manual and check
Neutral Safety switch adjustment.
Starter relay o - Starter Relay Test
Intermediate starter relay E - Intermediate Starter Relay
Test
Starter motor F -Starter Motor Test

Rae 6-12740 Issued 9/02

4001-180
Symptom
Click is heard when key is
turned but engine does not
crank
Engine cranks slowly
Starter motor continues to
operate when key is released
from START to RUN position
ac 6-12740
Possible Cause ReferenceITest
Starter motor F -Starter Motor Test
Starter relay D - Starter Relay Test
Intennediate starter relay E - Intermediate Starter Relay
Test
Starter motor F -Starter Motor Test,
test points 3, 4 and 5.
Engine mechanical problem Refer to Engine Section in
Service Manual.
Ignition switch . B - Ignition Switch Test, and
confirm that switch tums off when
key is released.
Starter relay D - Starter Relay Test,
test point 6, and
confirm that relay turns off when
key is released.
Intennediate starter relay E - Intermediate Starter Relay
Test, and
confirm that relay turns off when
the key is released.
Starter solenoid F - Starter Motor Test test point 2
and confinn that 12 volts are not
present at tenninal 79 when key
is released. If starter continues to
run when 12 volts are removed,
replace starter.
Issued 9/02
 4001-181

Starting System Diagnostic Tests

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system

At.. WARNING : Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Ignition Switch Power Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Measure voltage at ignition 12 volts Open in circuit from unswitched B+.

switch connector 161 If good reading, ignition Go to next test point.
terminal 1. switch power supply okay.

2 Measure voltage at fuse 12 volts Fuse #7, or

#7. If good reading, repair Open in 101 C(R) circuit from
open in 107A(R) circuit. unswitched B+.

B - Ignition Switch Test

Test point Good Reading Possible Cause of Bad Reading

1 Remove electrical Continuity Ignition switch.

connector 161 from If good reading, go to nex1
ignition switch . test point.
While holding ignition
switch in Start position,
check for continuity from
connector 161 terminal 1
to terminal 2.

2 While holding ignition Continuity Ignition switch.

switch in Start position , If good reading, go to nex1
check for continuity from test point.
connector 161 tenminal1
to tenminal 5.

3 Ignition switch in Run Continuity Ignition switch.

position. If good reading, go to nex1
Check for continuity from test point.
connector 161 terminal 1
to terminal 5.

Rae 6-12740 Issued 9/02

4001 -182

B - Ignition Switch Test

Test point Good Reading Possible Cause of Bad Reading

4 Ignition switch in Run Continuity Ignition switch.

position. If good reading, go to next
Check for continuity from test point.
connector 161 terminal 1
to terminal 6.

5 Ignition switch in Continuity Ignition switch.

Accessory position. If good reading, go to next
Check for continuity from test point.
connector 161 terminal 1
to terminal 6.

6 Ignition switch in Off No continuity Ignition switch.

position. If good reading, ignition
Check for continuity from switch operating properly.
connector 161 terminal 1
to terminals 2, 3, 4, 5, 6.

C - FNRP Module Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition switch in Run 12 volts Open in B+ circuit from ignition switch.

position. If good reading , go to test Go to next test point.
Measure voltage at FNRP point 4.
module connector 219
terminal 1.

2 Measure voltage at in-line 12 volts Open in B+ circuit from ignition switch.

connector 51 terminal 1. If good reading , repair Go to next test point.
open in 1(A) circuit.

3 Measure voltage at ignition 12 volts Open in B+ circuit from ignition switch.

switch connector 161 If good reading , repair Perform A - Ignition Switch Power
terminal 2. open in 623A(W) circuit. Supply Test, and
B - Ignition Switch Test

4 Transmission control lever 12 volts Park/neutral position switch, or

in Park. If good reading, go to next FNRP module
Measure voltage at FNRP test point.
module connector 219
terminal 2.

ae 6-12740 Issued 9/02

 4001-183

C - FNRP Module Test

Test point Good Reading Possible Cause of Bad Reading

5 Transmission control lever 12 volts Park/neutral position switch, or

in Neutral. If good reading, FNRP FNRP module
Measure voltage at FNRP module okay.
module connector 219
terminal 2.

NOTE: Before performing the starter relay test procedure - replace the starter relay with a known good relay. If
tractor start troubleshooting is complete. If does not start continue with starter relay test.

D - Starter Relay Test

Test point Good Reading Possible Cause of Bad Reading

1 Ignition switch in Start 12 volts Open in B+ circuit from FNRP module.

position. If good reading, go to next Perform C - FNRP Module Test
Remove the starter relay. test point.
Measure voltage at starter
relay (relay #15) terminal
1.

2 Measure voltage at starter 12 volts Open in unswitched B+ circuit.

relay terminal 3. If good reading, go to test Go to next test point.
point 4.

3 Measure voltage at ignition 12 volts Open in unswitched B+ circuit.

switch connector 161 If good reading, repair Perform A - Ignition Switch Power
terminal 1. open in 89A(R) circuit. Supply Test, test point 2.

4 Measure resistance from Less than 1 ohm Open in circuit from starter relay
starter relay terminal 2 to If good reading, go to next terminal 2 to ground.
ground. test point.

Rae 6-12740 Issued 9/02

4001-184

E - Intermediate Starter Relay Test

Test Point Good Reading Possible Cause of Bad Reading

1 Ignition switch in Start 12 volts Open in B+ circuit from starter relay.

position. If good reading, go to test Go to next test point.
Measure voltage at point 5.
intermediate starter relay
connector 82.

2 Disconnect connector 12 volts Open in B+ circuit from starter relay.

108(grey) from the buss If good reading, repair Perform D Starter Relay Test.
box. open in 622A(W) circuit.
Measure voltage at pin E
on buss box connector
108.

3 Measure voltage at 12 volts Open in B+ circuit from battery.

intermediate starter relay If good reading, go to test Go to neX1 test point.
connector 78. point 7.

4 Measure voltage at starter 12 volts Open in B+ circuit from battery to starter

motor connector 80. If good reading, repair motor connector 80.
open in 620A(R) circuit.

S Measure resistance from Less than 1 ohm Open in circuit from intermediate
intermediate starting relay If good reading, go to neX1 starting relay connector 83 to ground.
connector 83 to ground. test point.

6 If switch in start position. 12 volts Intermediate starter relay.

Measure voltage at If good reading,
intermediate starter relay intermediate starter relay
connector 84. is operating properly.

c 6-12740 Issued 9/02

 4001-185

F - Starter Motor Test

Test Point Good Reading Possible Cause of Bad Reading

1 Measure voltage at 12 volts Open circuit between starter terminal 80

terminal 80 of starter If good reading, go to next and battery positive terminal.
motor. test point. Caution: When performing continuity
test on this circuit, ensure that the cable
is disconnected from the battery positive
terminal. Failure to do so can result in
damage to the test meter.

2 Ignition switch in Start 12 volts Open in B+ circuit from starter relay.

position. If good reading, go to test Go to next test point.
Measure voltage at starter point 4.
terminal 79.

3 Ignition switch in Start 12 volts Open in B+ circuit.

position. If good reading, repair Perform E - Intermediate Starter Relay
Measure voltage at open in 625A(W) circuit. Test.
intermediate starter relay
terminal 84 .

4 Measure resistance from Less than 1 ohm Check contact surface of starter motor
starter motor case to If good reading, go to next with engine. Ensure starter motor is
ground. test point. mounted securely. Check ground strap
between engine and chassis.

5 Set DVOM to read voltage. If less than 0.4 volts More than 0.4 volts showing on
Attach positive lead to shown, and starter motor voltmeter, replace cable between
battery positive terminal. does not operate, replace battery positive terminal and starter
starter motor. terminal 80.
Attach negative lead to
terminal 80 of starter
motor.
Tum key to START
position.
Less than 0.4 volts should
show on voltmeter.

Rae &1 2740 Issued 9/0;

4001-186

WIPERIWASHER SYSTEM

WiperlWasher System Circuit Operation

The wiper/washer system consists of two separate systems, front and rear.

Each system has a two speed motor and a separate washer motor and reservoir.

The two systems are energized by switched power.

WiperlWasher System Circuit Troubleshooting

Before troubleshooting the WiperlWasher system make sure that the following operating conditions are met:

A. The batteries are fully charged and all connections are clean and tight.

B. Transmission in neutral or park.

C. Check all connectors for full installation, loose, corroded or pushed out terminals.

Rae 6-12740 Issued 9/02

 4001-187

WiperlWasher System Symptom Chart

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these
tests. For battery testing and service, see the battery section in the service manual.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

A WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
~ park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

Symptom Possible Cause ReferencelTest

Front wiper motor is Power/Ground Supply Diagnostic test A.
inoperative Wiper Switch Diagnostic test C.
Wiper Motor Diagnostic test D.
Front wiper motor does not Wiper Motor Test point E-12.
park, stops when switch is Wiper Switch Test point E-10.
turned off
Front wiper motor, low speed Wiper Motor Test point E-6.
only Wiper switch Test point E-4.
Front wiper motor, high Wiper Motor Test point E-9.
speed only Wiper switch Test point E-7.
Front washer inoperative Washer Switch Test point F-1 .
Washer Motor Test point F-3
Washer Fluid Supply Check reservoir and fluid lines.
Rear wiper motor is Power/Ground Supply Diagnostic test B.
inoperative Wiper Switch Diagnostic test D.
Wiper Motor . Diagnostic test G.
Rear wiper motor does not Wiper Motor Test point G-8.
park, stops when switch is Wiper Switch Test point G-6.
turned off
Rear washer inoperative Washer Switch H-1 .
Washer Motor H-3.
Washer Fluid Supply Check reservoir and fluid lines.

Rae 6-12740 Issued 9/02

4001-188

WiperlWasher System Diagnostic Tests

r
NOTE:
• The batteries must be fully charged and all connections clean and tight.
• Use a multimeter (DVOM) for these tests.
• Check fuse 52 and circuit breaker 51.
• Check Power Distribution section if fuse and circuit breaker are good.
• For battery testing and service, see the battery section in the service manual.
• Check all listed connectors for loose, damaged corroded or pushed out terminals.

IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.

h.. WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or
ili park lock position. This will eliminate accidental movement of the machine or start-up of power driven
• equipment.

A - Front Wiper System Power and Ground Supply Test

Test Point Good Reading Possible Cause of Bad Reading

1 Access connector 127 on Wiper switch power supply Go to next test point.
front wiper switch. good, go to test point 4.
Ignition ON.
Check for 12 volts at cavity
6.

2 Check for 12 volts at inline Go to next test point. Open circuit 831C (R). Check inline
connector 13, cavity P. Check inline splice if sent splice C31 and circuit 831A (0).
here by test point 1, bad
reading.

3 Check for 12 volts at front Front wiper motor power Open circuit 831 B (0)
wiper motor connector supply good. Go to next
115, cavity C. test point.

4 Check for chassis ground Ground circuit OK. Go to next test point.
at front wiper motor
connector 116, cavity A.

ac 6-12740 Issued 9/02

 4001-189

B - Rear Wiper System Power and Ground Supply Test

Test point Good Reading Possible Cause of Bad Reading

1 Access connector 122 on
rear wiper switch.
Ignition ON .
Check for 12 volts at cavity
3 and 6.
Rear wiper switch power Go to next test point.
supply good. Go to next
test point.

2 Check for 12 volts at inline Go to next test point. Check inline splice C38 and check
connector 13, cavity K. Check inline splice if sent circuit 641 C (0) for open between splice
here by test point -1 , bad and fuse 52.
reading.

3 Check for 12 volts at rear Rear wiper motor power Open circuit 841 B (0).
wiper motor connector 98, supply good. Go to next
cavity C. test point.

4 Check for continuity to Ground circuit OK. Go to next test point.

chassis ground at rear
wiper motor connector 99,
cavity A.

C - Front Wiper/Washer Switch Test

Test point Good Reading Possible Cause of Bad Reading

1 Key ON . Go to next test point. Go to test point E-4.

Select low speed on front
wiper switch.
Does front wiper motor
operate at low speed?

2 Select high speed on front Go to next test point Go to test point E-7.
wiper switch.
Does front wiper motor
operate at high speed?

3 Operate front washer Front wiper/washer switch Go to test point F-1 .

switch. good.
Does front washer motor
operate?

Rae 6-12740 Issued 9/02

4001-190

D - Rear WiperlWasher Switch Test

Test point Good Reading Possible Cause of Bad Reading

1 Key ON. Go to next test point. Go to test poi nt G-3.

Select low speed on rear
wiper switch.
Does rear wiper motor
operate at low speed?

2 Tum rear wiper switch Go to next test point. Go to test point G-9.
OFF.
Does rear wiper PARK?

3 Operate rear washer Rear wiper/washer switch Go to test point H-l .

switch. good.
Does rear washer motor
operate?

E - Front Wiper Motor Test

Test point Good Reading Possible Cause of Bad Reading

1 Key ON. Go to next test point. Go to test point E-4.

Select low speed on front
wiper switch .
Does front wiper motor
operate at low speed?

2 Select high speed on front Go to next test point Go to test point E-7
wiper switch .
Does front wiper operate at
high speed?

3 Turn front wiper switch OFF. Wiper motor good. Go to test point E-l0.
Do wipers PARK.

4 Access front wiper switch Go to next test point. Confirm switch power supply, test
connector 127. point A-l. If power supply is good,
Check for 12 volts at cavity replace switch.
3.

5 Check for 12 volts at inline Go to next test point. Open circuit B33A (0).
connector 13, cavity R.

6 Check for 12 volts at front Confirm front wiper motor Open circuit B339 (0) .
wiper motor connector 115, ground, test point A-4. If
cavity 9. ground is good, replace
front wiper motor.

ac 6-12740 Issued 9/02


Test point
7 Check for 12 volts at front
wiper switch connector 127,
cavity 4.
8 Check for 12 volts at inline
connector 13, cavity S.
9 Check for 12 volts at front
wiper motor connector 115,
cavity A.
10 Wiper switch in OFF
position.
Check for 12 volts at front
wiper switch connector 127,
cavity 5.
11 Check for 12 volts at inline
connector 13, cavity N.
12 Check for 12 volts at front
wiper motor connector 115,
cavity A.
Test point
1 Operate front washer
switch.
Check for 12 volts at front
wiper/washer switch
connector 127, cavity 2.
2 Check for 12 volts at inline
connector 333F, cavity 18.
3 Check for 12 volts at inline
connector 10, cavity 81.
4 Check for 12 volts at front
washer motor connector
212, cavity 8 .
Rae 6-12740
.
4001-191
E - Front Wiper Motor Test
Good Reading Possible Cause of Bad Reading
Go to next test point. Confirm switch power supply, test
point A-l . If power supply is good,
replace switch.
Go to next test point. Open circuit 832A (0).
Confirm front wiper motor Open circuit 8328 (0).
ground, test point A-4. If
ground is good, repl ace
front wiper motor.
Go to next test point Confirm switch power supply, test
point A-1 . If power supply is good ,
replace switch.
Go to next test point. Open circuit 830A (0).
Confirm front wiper motor Open circuit 8328 (0 ).
ground, test point A-4. If
ground is good, replace
front wiper motor.
F - Front Washer Motor Test
Good Reading Possible Cause of Bad Reading
Go to next test point. Confirm switch power supply, test point
A-l. If power supply is good, replace
switch.
Go to next test step. Open circuit 836A (0).
Go to next test step. Open circuit 8368 (0).
Go to next test point. Open circuit 8360 (0).
Issued 9/02
4001 -192

F - Front Washer Motor Test

Test point Good Reading Possible Cause of Bad Reading

5 Disconnect front washer Replace front washer Open circuit to chassis ground SOOH
motor connector 212. motor. (0) .
Check for chassis ground
at cavity A.

G - Rear Wiper Motor Test

Test point Good Reading Possible Cause of Bad Reading

1 Key ON . Go to next test point. Go to test point G-3.

Operate rear wiper switch .
Does front wiper motor
operate?

2 Turn rear wiper switch Wiper motor good. Go to test point G-S.
OFF .
Does rear wiper PARK.

3 Access rear wiper switch Go to next test point. Confirm switch power supply, test point
connector 122. B-1. If power supply ·is good , replace
Check for 12 volts at cavity switch.
2.

4 Check for 12 volts at inline Go to next test point. Open circuit 843A (0) .
connector 13, cavity L.

5 Check for 12 volts at rear Confirm rear wiper motor Open circuit 843B (0).
wiper motor connector 98, ground, test point B-4. If
cavity B. ground is good , replace
rear wiper motor.

S Check for 12 volts at rear Go to next test point. Confirm switch power supply, test point
wiper switch connector B-1 . If power supply is good, replace
122, cavity 3. switch.

7 Check for 12 volts at inline Go to nex1 test point. Open circuit 844A (0).
connector 13, cavity J .

8 Check for 12 volts at rear Confirm rear wiper motor Open circuit 844B (0) .
wiper motor connector 98, ground, test point B-4. If
cavity D. ground is good , replace
rear wiper motor.

Rae 6-12740 Issued 9/02

 4001-193

H - Rear Washer Motor Test

Test point Good Reading Possible Cause of Bad Reading

1 Check for 12 volts at rear Go to next test point. Confirm switch power supply, test point
wiper/washer switch 9-1. If power supply is good, replace
connector 122, cavity 3 & switch.
6.

2 Check for 12 volts at inline Go to next test step. Open circuit 845A (0).
connector 10, cavity 82.

3 Check for 12 volts at rear Go to next test point. Open circuit 845A (0).
washer motor connector
213, cavity 9 .

4 Check for con 333, cavity Go to next test point. Open circuit 8459 (0).
9.

5 Disconnect rear washer Replace rear washer Open circuit to chassis ground 600G
motor connector 213. motor. (0).
Check for chassis ground
at cavity A.

Rae 6-12740 Issued 9/02

 r

(
 MX Magnum - Service Manual
Book 3 - Table of Contents

Section
Description
Number
Steering Column and Steering Hand Pump 5001
Powershift Transmission System
6000
How it Works and Troubleshooting
Transmission Input Shaft and Drive Plate 6001
Input Drop Box 6002
Engine Frame and Input Drop Box Split 6003
Speed to Range Transmission Split 6005
Speed Transmission 6006
Range Transmission to Rear Frame Split 6007
Range Transmission 6008
Transmission Control Valves and Inching Valve 6009

Rae 6-14221 II:> 2003 Issued 10-02 1 Revised 4-03

 ;

MX Magnum
MX210. MX230. MX255. MX285

Rae 6-14221 © 2003 2 Issued 10-02 1 Revised 4-03

 Section
5001

STEERING COLUMN AND STEERING HAND PUMP

MX Series Tractors

CASE, LLC
Q 2003 Case, LLC
700 State Street
Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13321 April , 2003
5001-2

TABLE OF CONTENTS
SPECIAL TOOLS .................................................. ...................................... .......................................... .................. 2
SPECIAL TORQUES ............................................................................. ...................................... ............................ 3
STEERING COLUMN AND STEERING HAND PUMP ........................................................................................... 3
Removal .............. ............................................................................................... .......................... ......... ............... 3
Steering Hand Pump Service ..................................... ... ........................................................ ..... .......................... 7
STEERING COLUMN ASSEMBLY ....................................................................................................... .. ................ 9
Installation ... .................................................... .................... ............................... ............. ................................... 10

SPECIAL TOOLS
380000795 - Steering line Quick Disconnect Tool

Rae 6-13321 Revised 04-03

 5001-3

SPECIAL TORQUES
Bolt for Steering Hand Pump Bracket and Isolator ................. ........ .................................. 32 to 36 Nm (24 to 27 Ib It)
Lock Nut for Steering Column Base ................... ....................................... .....•.. ..... .... ............. 29 to 32 (22 to 24 Ib It)
Nut for Steering Wheel ............. .......................... ..................... ............ ................. ........... .45 to 54 Nm (33 to 40 Ib It)

STEERING COLUMN AND STEERING HAND PUMP

Removal STEP 3

STEP 1

Remove the th ree retaining screws (1) on the left

Park the tractor on a hard level surface . Put the
transmission shilt lever in PARK. Turn the engine off
and remove the key. Place blocks in front of and
behind the rear wheels.
lower console panel. Lilt up on the mat and remove
the left lower console panel. Repeat this procedure
for the right lower console panel.
STEP 4

STEP 2

Disc o nnect th e el ectrical connectors from the

switches on the upper console panel and remove the
panel.
Remove the two retaining screws that attach the lelt
and right lower console panels.

Rae 6-13321 Revised 04-03

5001-4

STEP 5 STEP 8

RD02G208
Remove the heat duct retaining screw on the left Remove the steering wheel with a swift, upward pull.
heat duct. Lift up on the cab floor mat and remove
NOTE: If the steering wheel cannot be removed by
the duct. Removal of the right heat duct is not
the method above, use a steering wheel puller.
necessary.
STEP 9
STEP 6

Remove the retaining screw from the steering

column upper control housing.
Remove the horn button.
STEP 10
STEP 7

ROO2G207
Remove the steering wheel nut and washer. Mark
the position of the steering wheel on the column for
reassembly.
Lift the housing and disconnect the electrical
connector (1) for the turn signal indicator lamps.
Loosen the socket head cap screw (2) for the
transmission control switch clamp.

Rae 6·13321 Revised 04-03

 5001-5

STEP 11 STEP 12

RD02G212

Use a Torx screwdriver to remove the upper and
lower steering column covers.
Remove the electrical connector (1) for the
transmission control switch at the steering column
harness. Disconnect the two steering column
electrical connectors (2) for the turn signal switch.
Pull the harnesses through the steering column boot,
and remove the lower control housing assembly from
the steering column. Remove the cable clip with pin
(3) from the steering column tilt mechanism cable.
Loosen the cable lock nuts (4) from the anchor
bracket, and move the cable aside.

Rae 6-13321 Revised 04·03

5001-6

STEP 13 STEP 15

ROO2Cl09
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. column in the cab while an assistant removes the
steering hand pump from the cab firewall. Remove
the steering column.
STEP 14

Tag and remove the four hydraulic steering hoses (1)

and the steering sensing line (2) from the steering
hand pump. Cap the lines and open fittings. If your
tractor is equipped with quick disconnect fittings. use
special tool 380000795 to disconnect the lines.

Rae 6·13321 Revised 04-03

 5001·7

Steering Hand Pump Service STEP 19

STEP 16

11459
Remove and replace the outer seal on the steering
hand pump, if necessary.
114526

Mark the position of the pump bracket and isolator on

the steering hand pump. Loosen the bolts and STEP 20
remove as a unit.

STEP 17

'14512
Install a new shaft noise seal.

114515 STEP 21
Remove the four washers.

STEP 18

1'4515
Install the four washers.

11 4512

Remove the shaft noise seal.

Rae 6·13321 Revised 04-03

 STEP 23

114S26 114529

Check the pump b racket to make sure it is not Tighten the pump bracket bolts evenly in a crossing
warped or bent . Using the marks made during pattern to a torque of 32 to 36 Nm (24 to 27 Ib It).
disassembly, install the pump bracket and isolator on Lubricate the internal splines of the steering hand
the steering hand pump. pump with grease.

NOTE: The pump bracket must be squarely aligned

with the housing of the pump. Otherwise, the steering
column may bind and not properly center. If this
happens, the steering wheel will move constantly
back and forth, trying to center.

Rae 6-13321 Revised 04·03

 5001-9

STEERING COLUMN ASSEMBLY

A---~
RI02G035
1. BELLOW SET 5. STEERING COLUMN
2. COVER SET 6. SEGMENT SET
3. RELEASE DEVICE SET 7. SPRING SET
4. BEARING SET

Rae 6·13321 Revised 04-03

5001-10

Installation STEP 26

STEP 24

~U
"-~
(.\
1 -.....~i"
~':o.' ,
' ..'\
•

:~ .. 'x . ~
.~.
• t. •.

Support the steering column in the cab while an
assistant installs the steering hand pump. Install the
steering column over the lour studs and into the
steering hand pump. Install the lour washers and
hand tighten the lour new lock nuts at the column
base. Install the steering wheel on the column just lar
enough to engage the steering mechanism.
Place the boot (1) with wire stiffener and boot plate
installed, over the steering column . Partially install
the boot support washer (2) . Install the lower control
housing wiring harnesses through the protruding
opening in the boot (3). Fully install the washer (2).
STEP 27

STEP 25

Install the lour hydraulic steering hoses (1) and the

steering sensing line (2) on the steering hand pump.
Check the hydraulic oil level. Temporarily install the
ignition switch . Start the tractor. Turn the steering
wheel to one stop, then the other. Re-center the
steering wheel. Turn the engine off and unplug the
ignition switch . Mark the top 01 the steering column
shalt to identily the centered position. Tighten the
lock nuts to a torque 01 29 to 32 Nm (22 to 24 Ib It).
Remove the steering wheel. Connect the two steering column electrica l
connectors (1) lor the turn signal switch. Install the
cable clip with pin (2) for the steering column tilt
mechanism cable. Install the cable into the anchor
bracket and tighten the lock nuts (3). Install the
electrical connector (4) for the transmission control
switch.

Rae 6· 13321 Revised 04-03


STEP 28
Use a Torx screwdriver to install the upper and lower
steering column covers.
STEP 29
Install the lower control housing assembly. Make
sure the alignment tab on the transmission control
switch clamp is located in the hole on the steering
column collar. Tighten the socket head cap screw (1)
for the transmission control switch clamp. Connect
the electrical connector (2) for the turn signal
indicator lamps.
Rae 6-13321
5001-11
STEP 30
Install the upper control housing and tighten the
retaining screw.
STEP 31
AD02G207
Using the steering wheel position alignment mark
made during disassembly, and the steering column
shaft centering mark, install the steering wheel.
Install the steeri ng wheel retaining nut and flat
washer. Tighten the nut to a torque of 45 to 54 Nm
(33 to 40 Ib It). Install the horn button.
Revised 04-03
5001-12
STEP 32
RD02G205
Lift up on the cab floor mat. Position the left console
heat duct into the floor duct and install the retaining
screw.
STEP 33
Install the electrical connectors on the switches in the
upper console panel and carefully install the panel.
STEP 34
Lift up on the mat and install the left lower console
panel. Install the three retaining screws (1). Repeat
this procedure for the right lower console panel.
Rae 6·13321
STEP 35
Install the two retaining screws that attach the left
and right lower console panels.
STEP 36
Make sure the transmission shift lever is in PARK.
Start the engine and check the operation of the
steering hand pump. Check the hydraulic fluid level.
Add fluid as needed. Turn the engine off and remove
the key. Remove the blocks in front of and behind the
rear wheels.
NOTE: Do not hold the steering wheel during
startup.
Revised 04·03
 Section
6000

POWERSHIFT TRANSMISSION SYSTEM

How It Works and Troubleshooting

CASE CORPORATION
700 State Street C 2002 Case Corporation
Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-12760 July, 2oo2
6000-2

TABLE OF CONTENTS
TRANSMI SSION SYSTEM INTRODUCTION .... ...... ...... ......................................................................................... 3

TRANSMISSION SYSTEM CONTROLS ................... ..... ..................... ................................................................... 5

TRANSMI SSION SYSTEM COMPONENTS ................ .................. ................... .... .. .......................... ...................... 6

TRANSM ISS ION LUBE AND DISTRIBUTION TUBES ........... .... ... .... ... ........ .......................................................... 8

MX MAGNU M POWERSHIFT TRANSMISSION CLUTCH LAYOUT ..................................................... .............. 10

POWERSHI FT VALVE CLUTCH ENGAGEMENTS .................................. ..........••.......................... .................. ... 11

MX MAGNUM .............. ............... .......................... .................... ............. .... ............ ................ ................ ..... ....... .... 13
Powershift Transmission Clutch Layout with Pump Drive, PTO, MFD, and Creeper Drive ............................... 13

POWER FLOW (REVERSE SPEEDS) ..... .............................. ................. ................. ............................................ 30

Powershift Transmission Clutch Layout with Pump Drive, PTO, MFD, and Creeper Drive ............................... 31

POWER FLOW (REVERSE SPEEDS) .. ...... ..... ...................................... .................... ................................ .......... 32

POWER FLOW (FORWARD CREEPER DR IVE SPEEDS) ............... ........ ........... .... ................................. ........... 34

POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) ......... .... ............... ..... ...... •............. .. ............................ 40

INCHING VALVE OPERATION ............... ................. ..... .. ................................................................ ................... ... 42

TRACTOR MONITOR - TRANSMISSION LEAKAGE CHECK ..........••....................................... .......... ................ 46

MASTER CLUTCH PRESSURE CHECK .... ............ ......... ................ .................. .......... ................................ ......... 49

Rae 6-12760 Issued 7·02

 6000-3

TRANSMISSION SYSTEM INTRODUCTION

I ENGINE SPEED SENSOR r---- STANDARD INSTRUMENTATION

PROGRAMMABLE DISPLAY AND
CONTROLLER
TRANSMISSION
SPEED SENSOR
I SEAT SWITCH
f----
R.H. ARMREST , , ENGINE
CONTROLLER CONTROLLER)
I I I I
GEAR CREEP
SELECTION SWITCH TRANSMISSION
SWITCH CONTROL LEVER
(FNRP)
TRANSMISSION
CONTROLLER
BOTTOM OF CLUTCH ,
I SWITCH I SYSTEM PRESSURE
SIGNAL FROM
TRANSDUCER
INCHING PEDAL
POTENTIOMETER

I
,-- c
M H P 0 E
L M I R
1 3 5 R F E
A E 0 V M.
0 G R E c.
0 W 0 E 0
H K p N

TRANSMISSION TRANSMISSION TRANSMISSION

CONTROL VALVE INCHING VALVE
CONTROL VALVE CONTROL VALVE
(SPEED) (RANGE) (OD D / EVE N)

SUPPLY TO OTHER
REGULATED CIRCUITS
PRIORITY
REGULATOR
VALVE

.. l

Rae 6-12760 Issued 7-02

6000-4
The full powershift transmission is controlled by the transmission controller. The transmission has 18 forward
speeds and 4 reverse speeds. The optional creeper transmission is electro-hydraulically operated and provides 6
additional forward speeds and 2 additional reverse speeds.

It is not necessary to use the inching pedal when shifting between gears or in and out of neutral, with a full
powershift transmission. It is necessary to shift to neutral when engaging and disengaging the optional creeper
transmission. The transmission is also equipped with an electro-hydraulically operated park brake mechanism that
is applied when power is removed.

The transmission controller either directly or through the Data Bus monitors the state/value of the following items:
Transmission Control Lever
Gear Selection Switch
Bottom of Clutch Switch
Seat Switch
Creep Switch
Engine Speed Sensor
Transmission Speed Sensor

The transmission controller will report any problems directly to the standard instrumentation controller. The
standard instrumentation controller will display any system faults or fault code information through the
programmable display.

When a fault occurs, a 3 second continuous audible alarm will sound. The audible alarm will stop after 3 seconds.
Once the fault has been corrected, depress the "Reset" button on the programmable display to clear the fault.

NOTE: The following warning is of a critical nature and the tractor engine should be shutdown immediately and the
cause of the problem checked. If your tractor is equipped with the Performance Monitor, the tractor will
automatically shutdown in 30 seconds after the warning is displayed. The warning below cannot be shut off by
pushing the reset button.

Display Description Corrective Action

!0J
ID TRANS
OIL TEMP
High transmission oil tempera Shut the tractor engine OFF immediatel'1
ture and check for cause.

The following faults will not cause immediate damage to the tractor or shut the tractor down, but may make other
systems inoperative. Pushing the "Reset" button will clear the fault, however the fault will be displayed again after
ten minutes if not corrected.

Display Description
@! TRANS
OFFLINE
Transmission Bus Off fault.

•(i) TRANS
Transmission diagnostic fault.

o o OFF LINE

TRANS
CONF/CAL
TACU . Config/CAL required (bi
in system status) .

0 SIT
DOWN
TRCU re-enable required .

Rae 6-12760 Issued 7· 02

 6000-5
TRANSMISSION SYSTEM CONTRO LS

RH02F017

1. THROTTLE HAND LEVER 5. DIFF LOCK SWITCH

2. GEAR SELECTION SWITCH 6. TRANSMISSION CONTROL LEVER
3. CREEPER CONTROL SWITCH 7. INCHING PEDAL
4. MFD CONTROL SWITCH

Rae 6-12760 Issued 7·02

6000-6
TRANSMISSION SYSTEM COMPONENTS

18
@@

RI02E087 and 068

Rae 6-12760 Issued 7-02

 6000-7

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. PARK BRAKE SOLENOID 20. POWERSHIFT VALVE SPEED
6. PTO/DIFF LOCK VALVE 21. C1 CLUTCH SOLENOID
7. PRIORITY REGULATOR VALVE 22. C3 CLUTCH SOLENOID
8. REGULATED PRESSURE TO POWERSHIFT VALVES 23. C5 CLUTCH SOLENOID
9. POWERSHIFT VALVE RANGE 24. REVERSE SOLENOID
10. MFD SOLENOID 25. SYSTEM PRESSURE TRANSDUCER
11 . LOW CLUTCH SOLENOID 26. TO PARK BRAKE
12. MID CLUTCH SOLENOID 27. PARK BRAKE PUMP
13. HIGH CLUTCH SOLENOID 28. DIFF LOCK SOLEBNOID
14. PTO SOLENOID
15. MASTER CLUTCH SOLENOID

Rae 6-12760 Issued 7-02

 6000-8

TRANSMISSION LUBE AND DISTRIBUTION TUBES

o
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. SPEED C3 CLUTCH DISTRIBUTION TUBE 15. ODD CLUTCH DISTRIBUTION TUBE
4. SPEED C5 CLUTCH DISTRIBUTION TUBE 16. EVEN CLUTCH DISTRIBUTION TUBE
5. SPEED REVERSE CLUTCH DISTRIBUTION TUBE 17. SPEED INPUT SHAFT BEARING CAGE
6. RANGE INPUT SHAFT BEARING CAGE 18. SPEED COUNTERSHAFT BEARING CAGE
7. CREEPER CLUTCH SUPPLY 19. MASTER CLUTCH SOLENOID
8. MASTER CLUTCH, SPEED OUT AND RANGE INPUT LUBE 20. ODD I EVEN POWERSHIFT MOUNTING PLATE
9. HIGH CLUTCH DISTRIBUTION TUBE 21 . INCHING VALVE MOUNTING PLATE
10. MID CLUTCH DISTRIBUTION TUBE (BEHIND HIGH) 22. MASTER CLUTCH DIAGNOSTIC PORT
11 . MASTER CLUTCH SUPPLY DISTRIBUTION TUBE
12. CREEPER LUBE SUPPLY

Rae 6-12760 Issued 7-02

 6000-9

RH98C089

Top Rear View

Rae 6·12760 Issued 7-02

6000-10
MX MAGNUM POWERSHIFT TRANSMISSION CLUTCH LAYOUT
Neutral

DROP BOX

MFDCLUTCH
(SPRING ENGAGED)

KEY RT96A016
I 0 Inactive Clutches
m Pressurized Clutches
~ Non-Torque TransmiUing Parts
• Torque Transmitting Parts
RT98A064

NEUTRAL - In Neutral only C3 and C5 clutches are pressurized.

Rae 6·12760 Issued 7-02

 6000-11

POWERSHIFT VALVE CLUTCH ENGAGEMENTS

CLUTCHES

GEAR MASTER ODD EVEN 1-2 3-4 5-6 LOW MID HIGH REVERSE CREEP
" -,
m::v ' , .j,;,:?;.;, , ,l!, .ll ",<' .' L ;. ~:-~ .,'
PARK
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"I" '-,;.,,';~ :, . .,:,
2 X X X X
3 ,~ X X, JU -:-" A
X "
" "" " :' I",' "
, ,

4 X X X X

•
6
" I"~ X
X
X
X
': ,lL
X
X
X
,
,' '. " ,; "
,

7 X X , X "
X ,

8 X X X X

10
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X
X ;,
X
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X
X
X
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"
11, ,~ X X ,,'
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.
12 X X X X
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14
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X
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X
,<, ~;,i " '"

,:15 , I X X i;~t , • J[., I';~,",,: X ~ ,; , .. -',,; ;.

16 X X X X
, 17 ;, b -t X X I~:., I i ',' I·.•;,,: ,:!, ; I " · ,1 ' '" ' ','.'
18 X X X X
., -"i";,,,..:
~" IT , ',~ I '-'':'~~~ , I:, I-'~! I , ", k · I ',' I ,';'" , '
" REV-1 X X X X
REM , ' Rj X ',', l,:#h , ' " ' /; I ," " X :' .,,' ", I '"
, X
REV-3 X X X X
flEV.4 \ , ';"':., X .1,.tX , ' , .; X X ,
','

-,

CR1 X X X X
"
CR2 X X X X
CRa , X o'
X X X
CR4 X X X X
CM X X X X
CR6 X X X X
. ,

RCR-1 X X X X

ReM "" j" X ";~" 1;" X X X

Rae 6-12760 Issued 7·02

6000-12

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.
Since the countershaft gears are in constant mesh with the output shaft gears, power flows from the countershaft
gear, to the engaged first-speed clutch pack gear, along the speed output shaft, to the master clutch . With the
master clutch engaged, power is transmitted across the range transmission input shaft to the low-range drive gear.
Power then flows to the low-range clutch pack gear, across the range countershaft, to the constant mesh gear set.
Power flow is delivered to the opinion shaft by this constant mesh gear set in all speeds.

SECOND GEAR - As the operator selects second speed with the gear selection switch, the odd-speed clutch is
disengaged and the even-speed clutch is engaged. Power then flows from the speed transmission input shaft,
through the even-speed clutch gear, the countershaft, the first-speed clutch gear, along the speed output shaft, to
the master clutch. Power flow through the range transmission is the same for speeds one through six.
The drive train consists of six separate housings:

- Drop Box Housing

- Speed Transmission Housing

- Range Transmission Housing

- Rear Frame Housing

- Two Final drive Housings

Rae 6-12760 Issued 7-02

 6000-13

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No.1

..
DROP BOX

HI

..
MFD CLUTCH
(SPRING ENGAGED)
RT96A017

Gear No.2

..
DROP BOX

..
MFDCLUTCH
o Inactive Clutches
(SPRING ENGAGED) m Pressurized Clutches

~ Non-Torque Transmitting Parts

• Torque Transmitting Parts

RT98A064
RT98A022

Rae 6·12760 Issued 7-02

6000-14

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. Power flow through the range transmission is the same
for speeds one through six.

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

Rae 6·1 2760 Issued 7-02

 6000-15

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No. 3

..
DROP BOX

..
MFD CLUTCH
(SPRING ENGAGED)
RT96A026

Gear No. 4

..
DROPBDX

..
o Inactive Clutches
MFD CLUTCH
(SPRING ENGAGED) I m Pressurized Clutches
~ Non-Torque Transmitting Parts
• Torque Transmitting Parts
Rr.....,..
ATgeA027

Rae 6·12760 Issued 7-02

6000-16

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 . Power flow through the range transmission is the same for
speeds one through six.

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

Rae 6-12760 Issued 7-02

 6000-17

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No.5

DROP BOX
MASTER CLUTCH

MFD CLUTCH
(SPRING ENGAGED)
AT96A028

Gear No.6

DROP BOX

D Inactive Clutches
MFDCLUTCH
(SPRING ENGAGED) IT] Pressurized Clutches

~ Non-Torque TransmiHing Parts

• Torque Transmitting Parts
RT98A064

RT96A029

Rae 6·12760 Issued 7-02

 6000-18

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. Power then flows from the speed transmission input shaft
through the odd-speed clutch, the countershaft, the first speed clutch, and across the output shaft to the master
clutch. With the master clutch engaged, power is transmitted across the range transmission input shaft to the
medium-range clutch. Power then flows to the range countershaft driven gear across the countershaft to the
constant mesh gear set. Power flow is delivered to the pinion shaft by the constant mesh gear set in all speeds.

EIGHTH GEAR - As the operator selects eighth speed, the odd-speed clutch is disengaged, and the even-speed
clutch is engaged. Power then flows, from the speed transmission input shaft through the even-speed clutch, the
counters haft, the first speed clutch, and across the output shaft to the master clutch. Power flow through the rang e
transmission is the same for speeds seven through twelve.

I
'I

Rae 6-12760 Issued 7-02

 6000-19

MX MAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No.7

DROP BOX

..
MFD CLUTCH
(SPRING ENGAGED)
RT9BA030
Gear No.8

I..
DROP BOX
MASTER CLUTCH

SPEED
OUTPUT SHAFT

SPEED
INPUT SHAFT
I

..
o Inactive Clutches
rn Pressurized Clutches
~ Non·Torque Transmitting Parts
• Torque Transmitting Parts

RT96A031

Rae 6-12760 Issued 7-02

6000-20

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 clu tch 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 . Power flow through the range transmission is the
same for speeds seven through twelve.

TENTH GEAR - As the operator selects tenth speed, the odd-speed clutch is disengaged , and the even-speed
clutch is engaged. Power then flows from the speed transmission input shaft through the even-speed clutch, the
countershaft, the third speed clutch, and across the output shaft to the master clutch. Power flow through the rang e
transmission is the same for speeds seven through twelve.

Rae 6-12760 Issued 7-02

 6000-21

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No.9

DROP BOX
MASTER CLUTCH

HI

..
MFDCLUTCH
(SPRING ENGAGED)
RT98A032

Gear No. 10

..
DROP BOX

..
o Inactive Clutches
MFD CLUTCH
(SPRING ENGAGED) m Pressurized Clutches
~ Non-Torque Transmitting Parts
• Torque Transmitting Parts
RT98A064
RT96A033

Rae 6·12760 Issued 7-02

/
6000-22

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. Power flow through the range transmission is the
same for speeds seven through twelve.

1WELFTH GEAR - As the operator selects twelfth speed , the odd-speed clutch is disengaged , and the even-speed
clutch is engaged. Power then flows from the speed transmission input shaft through the even-speed clutch, and
the countershaft, the fifth speed clutch, and across the output shaft to the master clutch . Power flow through the
range transmission is the same for speeds seven through twelve.

Rae 6-12760 Issued 7·02

 6000-23

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No. 11

..
DROP BOX

HI

..
MFD CLUTCH
(SPRING ENGAGED)
RT98A034

Gear No. 12

..
DROP BOX

..
o Inactive Clutches
MFD CLUTCH
(SPRING ENGAGED)
~
.
~
Pressurized Clutches

~ Non-Torque Transmitting Parts

• Torque Transmitting Parts
AT98A064

AT9BAQ35

Rae 6·12760 Issued 7-02

6000-24

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. Power then flows from the speed
transmission input shaft through the odd-speed clutch, the countershaft, the first speed clutch, and across the
output shaft to the master clutch. With the master clutch engaged, power is transmitted across the range
transmission input shaft to the high-range clutch. Power then flows to the range countershaft driven gear across the
counters haft to the constant mesh gear set. Power flow is delivered to the pinion shaft by the constant mesh gear
set in all speeds.

FOURTEENTH GEAR - As the operator selects fourteenth speed, the odd-speed clutch is disengaged, and the
even-speed clutch is engaged. Power then flows from the speed transmission input shaft through the even-speed
clutch, the countershaft, the first speed clutch, and across the output shaft to the master clutch. Power flow through
the range transmission is the same for speeds thirteen through eighteen.

Rae 6-12760 Issued 7-02

 6000-25

MX MAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No. 13

DROP BOX

MFD CLUTCH
(SPRING ENGAGED)
AT96A043

Gear No. 14

DROPBDX

I-
MASTER CLUTCH

o Inactive Clutches
MFO CLUTCH
(SPRING ENGAGED)
t:1_
~
Pressurized Clutches

~ Non-Torque TransmiHlng Parts

• Torque Transmitting Parts

RT98A044

Rae 6-12760 Issued 7-02

6000-26

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 . 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. Power flow through the range
transmission is the same for speeds thirteen through twelve.

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

Rae 6-12760 Issued 7-02

 6000-27

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No_ 15

..
DROP BOX

..
MFDCLUTCH
(SPRING ENGAGED)
AT96A045

Gear No. 16

..
DROP BOX

..
o Inactive Clutches
~~~~~~~AGED) ill Pressurized Clutches
~ Non· Torque Transmitting Parts
• Torque Transmitting Parts
AT98A064
RT98A046

Rac 6-12760
6000-28

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 . Power then flows from the speed transmission input shaft through the odd-speed clutch , the
CQuntershaft, the third speed clutch, and across the output shaft to the master clutch. Power flow through the range
transmission is the same for speeds thirteen through eighteen.

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

Rae 6-12760 Issued 7-02

 6000-29

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Gear No. 17

..
DROP BOX

..
MFD CLUTCH
(SPRING ENGAGED)
RT98A047

Gear No. 18

..
DROP BOX

..
D Inactive Clutches
MFD CLUTCH
(SPRING ENGAGED)
~
lo.l
Pressurized Clutches

~ Non-Torque Transmitting Parts

• Torque Transmitting Parts
RT98A064

RT98A0048

Rae 6-12760 Issued 7-02

6000-30

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. Since the countershaft gears are in constant mesh with the output shaft gears, power flows
forward from the countershaft, through the even-speed driven gear to even-speed drive gear (idler gear). to the
engaged reverse-sped clutch pack. Power is then directed across the output shaft to the master clutch. The
addition of an idler gear for first-reverse and creeper-reverse 1 (creeper option) speeds causes the speed output
shaft and every1hing rearward of the pinion shaft to reverse rotation compared to the forward gear rotation. With the
master clutch engaged, power is transmitted across the range transmission input shaft to the low range drive gear.
Power then flows to the low range clutch pack gear and across the range countershaft to the constant mesh gear
set. Power flow is delivered to the pinion shaft by this constant mesh gear set in all speeds.

SECOND REVERSE GEAR - As the operator selects second reverse speed , the odd-speed clutch is disengaged ,
and the even-speed clutch is engaged . Power then flows from the speed transmission input shaft, through the
even-speed clutch, directly to the reverse-speed clutch. Since the countershaft is not used to transmit power in
second reverse, the direction of rotation provided to the speed output shaft is opposite that which occurs in the
forward speeds.

With the master clutch engaged, power is transmitted across the range transmission input shaft to the low range
drive gear. Power then flows to the low range clutch pack gear and across the range countershaft to the constant
mesh gear set, driving the pinion shaft.

Rae 6-12760 Issued 7-02

 6000-31

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Reverse No.1

DROP BOX

..
MFD CLUTCH
(SPRING ENGAGED)
RT98A049

Reverse No.2

DROP BOX

..
o Inactive Clutches
MFD CLUTCH t;"3
_ Pressurized Clutches
(SPRING ENGAGED) W
~ Non·Torque TransmiHing Parts
• Torque Transmitting Parts
RT98A064

RT9BA05O

Rac 6-12760 Issued 7·02

6000-32

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. Since the countershaft gears are in constant mesh with the output shaft gears, power flows
forward from the countershaft, to the even-speed drive gear (idler gear) , to the engaged reverse-speed clutch pack.
Power is then directed across the output shaft to the master clutch. The addition of an idler gear for third-reverse
causes the speed output shaft, and everything rearward of the pinion shaft, to reverse rotation in contrast to the
forward gear rotation. With the master clutch engaged, power is transmitted across the range transmission input
shaft to the medium range clutch pack . Power then flows to the medium-range driven gear on the range
countershaft, across to the constant mesh gear set driving the pinion shaft.

FOURTH REVERSE GEAR - As the operator selects fourth reverse speed , the odd-speed clutch is disengaged ,
and the even-speed clutch is engaged. Power then flows from the speed transmission input shaft, through the even
speed clutch, directly to the reverse-speed clutch . Since the countershaft is not used to transmit power in fourth
reverse, the direction of rotation provided to the speed output shaft is opposite that which occurs in the forward
speeds. Power flows through the range transmission in the same manner as third reverse.

NOTE: HIGH RANGE CLUTCH PACK IS NOT USED FOR REVERSE SPEEDS.

Rae 6-12760 1ssued 7-02

 6000-33

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Reverse No_ 3

DROP BOX
MASTER CLUTCH

SPEED
INPUT SHAFT
I"
I

MFD CLUTCH
(SPRING ENGAGED)
RT98A051

Reverse No.4

DROP BOX

D Inactive Clutches

IT] Pressurized Clutches

~ Non·Torque Transmitting Parts
• Torque Transm itting Parts
RT96A064

RT98A052

Rae 6-12760 Issued 7·02

6000-34

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. This is accomplished through the transmission controller. Power
then flows from the speed transmission input shaft creep speed drive gear through the creep-speed clutch, and
across the countershaft to the first-speed clutch drive gear. Power is then directed through the first speed constant
mesh gear set and the clutch pack, across the output shaft to the master clutch.

With the master clutch engaged, power is transmitted across the range transmission input shaft to the low-range
drive gear. Power then flows to the low-range clutch pack gear and across the range countershaft to the constant
mesh gear set. Power flow is delivered to the pinion shaft by this constant mesh gear set in all speeds.

SECOND CREEP GEAR - As the operator selects second 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 then the master
clutch. Power flow through the range transmission is the same for speeds first creep through third creep.

Rae 6-12760 Issued 7-02

 6000-35

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Creeper Gear No.1

DROP BOX
MASTER CLUTCH

MFD CLUTCH
(SPRING ENGAGED)
RT96A053

Creeper Gear No.2

DROP BOX

-
o Inactive Clutches
~~~~~~~AGED) m Pressurized Clutches
~ Non-Torque Transmitting Parts
• Torque Transmitting Parts
RT98A064

RT96A054

Rae 6·t2760 Issued 7-02

6000-36

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 .
Power flow through the range transmission is the same for speeds first creep through third creep.

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

W ith the master clutch engaged, power is transmitted across the range transmission input shaft to the medium-
ran ge clutch. Power then flows to the range countershaft driven gear, across the countershaft, to the constant
mesh gear set. Power flow is delivered to the pinion shaft by this constant mesh gear set in all speeds.

Rae 6-12760 Issued 7~02

 6000-37

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Creeper Gear No.3

DRDPBDX

..
MFD CLUTCH
(SPRING ENGAGED)
RT9BA055

Creeper Gear No.4

DRDPBDX

..
D Inactive Clutches
~~:;'~~~~AGED) m Pressurized Clulehes
~ Non·Torque TransmiHing Parts
• Torque Transmitting Parts
RT98A064

RT96A056

Rae 6-12760 Issued 7·02

6000-38

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 .
Power flow through the range transmission is the same for speeds fourth creep through sixth creep.

SIXTH CREEP GEAR - As the operator selects sixth creep speed, he simultaneously disengages the third-speed
clutch and engages the fifth-speed clutch. Power then flows from the speed transmission input shaft, through the
creep-speed clutch on the countershaft, to the fifth-speed clutch on the output Shaft, across to the master clutch .
Power flow through the range transmission is the same for speeds fourth creep through sixth creep.

NOTE: High range clutch pack is not used for the creeper speeds.

Rae 6-12760 Issued 7-02

 6000-39

MXMAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Creeper Gear No.5

DROP BOX

..
MFD CLUTCH
(SPRING ENGAGED)
RT9ElA057

Creeper Gear No.6

DROP BOX

..
D Inactive Clutches
MFD CLUTCH
(SPRING ENGAGED) rn Pressurized Clutches
~ Non-Torque Transmitting Parts
• Torque Transmitting Parts
RT""""",,
RT98A058

Rae 6·12760 Issued 7-02

6000-40

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. This is
accomplished through the transmission controller. Power then flows from the speed transmission input shaft
creeper speed drive gear, through the creeper speed clutch, to the counters haft. The countershaft drive gear
transmits power through the even drive gear (idler gear), through the engaged reverse clutch, to the output shaft.
The addition of an idler gear for reverse speed causes the speed output shaft, and everything rearward of the
pinion shaft, to reverse rotation compared to the forward gear rotation. Power is transmitted across the output shaft
and engaged master clutch, to the range input shaft. From the range input shaft, power is transmitted through the
low-range drive gear, low-range driven gear, and clutch, to the constant mesh gear set and pinion shaft.

CREEPER REVERSE SECOND GEAR (CR2) - As the operator selects creeper second-reverse speed, he
simultaneously disengages and locks out the odd/even speed clutch packs. He also engages the creep speed
clutch pack, the reverse clutch pack and medium clutch pack. Power then flows from the speed input shaft creeper
speed drive gear, through the creeper speed clutch, to the cou ntershafl. The countershaft drive gear transmits
power through the even-speed drive gear (idler gear), through the engaged reverse clutch, to the output shaft. The
addition of the idler gear for reverse speed causes the speed output shaft and every1hing rearward of the pinion
shaft to reverse rotation compared to the forward rotation. Power is transmitted across the output shaft and the
engaged master clutch to the range transmission input shaft. From the range input shaft, power is transmitted
through the medium-range clutch , the medium-range drive gear, to the medium-range driven gear on the
countershaft. The power is then transmitted across the countershaft to the constant mesh gear set and the pinion
shaft.

Rae 6-12760 Issued 7-02

 6000-41

MX MAGNUM
Powershift Transmission Clutch Layout with Pump Drive,
PTO, MFD, and Creeper Drive
Creeper Reverse Gear No_ 1

DROP BOX
MASTER CLUTCH

..
MFDCLUTCH
(SPRING ENGAGED)
RT98A059

Creeper Reverse Gear No_ 2

DROP BOX

HI

..
KEY~
Inactive Clutches
rn Pressurized Clutches
~ Non-Torque Transmitting Parts
• Torque Transmitting Parts

RT98A06O

Rae 6-12760 Issued 7-02

6000-42
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. PROPORTIONAL CURRENT CONTROL SOLENOID 10. CHECK VALVE

The transmission controller has to be run through the "Trans Setup" Procedure when ever a transmission
component is replaced: clutch pedal switch, inching valve, transmission controlier, or replacement of the master
clutch.

TRANS SETUP consists of: Cal Pedal - Used to calibrate the operating range of the clutch pedal.
Cal Valve - Used to calibrate the fill current of the master clutch and detect the
presence of the optional creeper transmission. The fill current is the
current required to just fill the clutch with oil without conducting torque
through the clutch.

Rae 6-12760 Issued 7-02

 6000-43

AH02F071

-
11\"'1
f ....
-"': · -·:~::
, .'··"j-.
REGULATED PRESSURE

INTERMEDIATE PRESSURE
TANK/SUMP PRESSURE

RT96F01 S

1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING

2. INCHING VALVE BODY 7. INNER MODULATOR SPRING
3. MODULATOR SPOOL 8. PISTON CENTER PIN
4. REGULATED PRESSURE SUPPLY 9. MODULATOR PISTON ASSEMBLY
5. PROPORTIONAL CURRENT CONTROL SOLENOID 10. CHECK VALVE

The inching valve is shown with the engine running and the inching pedal fully depressed. The position of the
inching pedal controls the current value supplied to the inching valve pee solenoid. When the inching pedal is fully
depressed there is no current supplied to the inching valve pee solenoid.

Rae 6-12760 Issued 7-02

6000-44

-.'1
RH02F072

REGULATED PRESSURE

INTERMEDIATE PRESSURE

t-:.':':.'
#
, .,'
.
,
·:1
• • ••
"
TANK/SUMP PRESSURE

AT98F015

1. PORTING TO MASTER CLUTCH 6. PRELOAD SPRING

2. INCHING VALVE BODY 7. INNER MODULATOR SPRING
3. MODULATOR SPOOL 8. PISTON CENTER PIN
4. REGULATED PRESSURE SUPPLY 9. MODULATOR PISTON ASSEMBLY
5. PROPORTIONAL CURRENT CONTROL SOLENOID 10. CHECK VALVE

As the inching pedal is let uP. the transmission controller sends a current signal to the inching valve pee solenoid .
The current value is based on the inching pedal position. The solenoid spool shifts. metering oil through the center
of the spool assembly down to the bottom of the modulator piston assembly.
As the pressure builds the modulator piston assembly begins to move uP. against the force of both the inner
modulator and preload springs. As the modulator piston assembly moves uP. the center pin of the modulator piston
assembly moves into the bore of the modulator spool. The modulator piston assembly does not directly shift the
modulator spool. The inner modulator spring force begins to shift the modulator spool.
As the modulator spool shifts upward it simultaneously blocks the master clutch return and opens the master clutch
supply to the inlet regulated supply. At the same time the inlet regulated supply is also ported through a cross
drilled and end drilled holes to the top of the modulator spool. The balance between the increasing inner modulator
spring force and pressure against the increasing clutch pressure at the top of the modulator spool causes the
master clutch pressure to gradually build.

Rae 6-12760 Issued 7· 02

 6000-45

-
RHQ2F073

REGULATED PRESSURE

1.1;~ INTERMEDIATE PRESSURE

r:·':,:.
". , .. , " "·:1
"
, 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. MODULATOR PISTON ASSEMBLY
5. PROPORTIONAL CURRENT CONTROL SOLENOID 10. CHECK VALVE

As the inching pedal is brought fully up the current supplied to the inching valve solenoid is at the maximum.

With the inching pedal fully up the modulator piston moves up and fully shifts the modulator spool. The modulator
spool is no longer being moved by the inner spring, but through direct contact from the ramp area on the modulator
piston assembly.

The modulator spool has now moved far enough to allow full regulated pressure from the valve inlet to be applied
to the master clutch .

Rae 6-12760 1ssued 7·02

6000-46

TRACTOR MONITOR - 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. The priority regulator valve maintains the regulated pressure circuit at 23 to 24
bar (335 to 345 PSI). The regulated pump flow supplies the PTOI Dill lock valve, transmission control valves and
brake valve. Both the remote and hitch valves are also supplied with pilot pressure.

Once these circuits are satisfied the excess regulated pump flow is directed through the oil coolers and joins up
with the charge pump flow at the downstream side of the main filter head.

The 27 GPM tandem gear pump is a fixed displacement pump, therefore the output flow will decrease as the
engine speed is lowered. At low engine speeds leaks in the regulated and transmission circuits are more
noticeable.
BACKGROUND INFORMATION:
The transmission controller monitors the pressure through the system pressure transducer. The manifold pressure
can be read from the display through the Trans View Menu screen.

NOTE: Start the engine and heat the transmission oil to 120°F (49°C).
- Turn the ignition switch to the OFF position. Be prepared to press and hold the PROG key on the Tractor Monitor
within the first 10 seconds after restarting the engine.

- Start and run the engine at low idle. Press and hold the PROG key
- The tractor monitor will emit a short beep and display INST SET MENU. Press the DECR key until the display
reads TRANS SET MENU.
- Next press the PROG key until the display reads TRANS VIEW. Continue to press the PROG key until the display
reads "PresS".

- The powershift system manifold pressure (in KPa) is now visible on the bottom of the display.
- Record pressure with the PTO and Dill Lock in the OFF position and the MFD switch in the ON position.

- Increase engine speed to 2000 RPM. Record the range powershift manifold pressure. Decrease engine speed.

• The "PresS" - Powershift System Manifold Pressure_ _ _ _ _ _kPa at 2000 RPM

A. If the pressure reading is less than 300 PSI (20.7 bar) go to the regulated pump flow test.
B. If the pressure reading is greater than 300 PSI (20.7 bar) go to the regulated system leakage test.
(Complete the regulated system leakage test before adjusting the regulated pressure).

NOTE: Transducer Pressure Range: 2300 to 2400 kPa (335 to 345 PSI) at 2000 RPM and 120'F (49'C). To convert kPa to
bar move the decimal place over two places to left, 2300 kPa equals 23.0 bar.
Fault codes will be generated if a problem is detected with the following components:
• System pressure transducer failure.
• Wire failed, or shorted between sensor and controller.
• Low regulated supply pressure to powershift valves.
• Low powershift manifold pressure due to leaking clutch.
• Wire failed, or shorted between powershift valve solenoid and controller.

Rae 6·12760 Issued 7-02

 6000-47
STEP 1 - Record Clutch Pressures in each Gear with Tractor Monitor
NOTE: Clutch pack leaks can be identified through the tractor monitor 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.

- Move the transmission control lever into "P" Park position .

- Turn the MFD switch to the ON position.

- Turn the ignition switch to the OFF position. Start and run the engine at low idle. Press and hold the PROG key.

- The tractor monitor will emit a short beep and display INST SET MENU. Press the DECR key until the display
reads TRANS SET MENU.
- Next press the PROG key until the display reads TRANS VIEW. Continue to press the PROG key until the display
reads PresS.

- Select 1st gear with the Gear selection switch.

Move the transmission control lever to forward. Release the inching pedal. Shift through the gears and record the
"PresS" valve manifold pressures below.

NOTE: Valve manifold pressures will momentarily drop and quickly recover pressure as each shift is completed.

GEAR 1 GEAR 7 GEAR 13

GEAR 2 GEAR 8 GEAR 14

GEAR 3 GEAR 9 GEAR 15

GEAR4 GEAR 10 GEAR 16

GEAR5 GEAR 11 GEAR 17

GEAR 6 GEAR 12 GEAR 18

Shift back to 1st gear and move the transmission control lever to reverse. Shift through the reverse speeds and
record the pressures.

REVERSE1 _____________

REVERSE 2 _____________

REVERSE 3 __-----------

REVERSE 4 _____________

The "PresS" system pressure will be noticeably lower in the following gears if ttiere is significant clutch leakage:

Low pressure for Speeds Rl , R2, R3 and R4 --------------------- Indicates Reverse Clutch Leakage.

Low pressure for Speeds I , 2, 7, 8, 13 and 14 ---------------------- Indicates 1st Speed Clutch Leakage.

Rae 6-12760 Issued 7-02

6000-48
Low pressure for Speeds 3, 4, 9, 10,15 and 16-----------------lndicates 3rd Speed Clutch Leakage.

Low pressure for Speeds 5, 6,11,12, 17 and 18 -------------------Indicates 5th Speed Clutch Leakage.

Low pressure for Speeds 1, 3, 5, 7, 9, 11 , 13, 15, 17, R1 and R3 ---------------- Indicates Odd Clutch Leakage.

Low pressure for Speeds 2, 4, 6, 8, 10, 12, 14, 16, 18, R2 and R4 ----------------------Indicates Even Clutch Leakage.

Low pressure for Speeds 1, 2, 3, 4, 5, 6, R1 and R2 -------------------------------- Indicates Low Range Clutch Leakage.

Low pressure for Speeds 7, 8, 9, 10, 11 , 12, R3 and R4 ---------------- Indicates Mid Range Clutch Leakage.

Low pressure for Speeds 13, 14, 15, 16, 17 and 18----------------------lndicates High Range Clutch Leakage.

Low pressure in all creep gears -----------------------------------------------------1ndicates Creep Clutch Leakage.

Rae 6· 12760 Issued 7-02

 6000-49

MASTER CLUTCH PRESSURE CHECK

RH98F161

1. DIAGNOSTIC TEST PORT 2. PUMP DRIVE GEAR HOUSING

The master clutch pressure diagnostic test port is located on the right hand side of the transmission below the
pump drive gear housing.

Test Fitting and Tool Requirements:

• 400 PSI (28 bar) pressure gauge with extension hose long enough to reach into cab.

IMPORTANT: The tractor must be driven to perform this test. Perform this test in an open outdoor location free of
obstacles and people.

- Connect the gauge/extension hose to the diagnostic port.

- Turn the Differential Lock OFF.

- Place the transmission control lever in "P" Park. Start and run the tractor at low idle.

- Using the gear selection switch select gear number 1.

- Press and hold the inching pedal to the floor.

- Place the transmission control lever in forward.

Rae 6-12760 Issued 7-02

6000-50
- As the inching pedal is slowly let up the gauge reading should gradually increase.

- Once the pedal is fully up and the tractor is moving forward the gauge reading should be 335 to 345 PSI (23.0 to
24.0 bar).

A. If the master clutch pressure reading is low go to section BOot and perform the Regulated System
Pressure Test.
If the regulated pressure is also low (matches master clutch) continue with the procedure in section B001.
If the regulated pressure is within specification check for the following:
• Check for fault code in section 10003.
• 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 section 6009 for disassembly.
• Master clutch is leaking see transmission section 6001.

Rae 6-12760 Issued 7-02

 Section
6001

TRANSMISSION INPUT SHAFT AND DRIVE PLATE

CASE CORPORATION
<C> 2002 Case Corporation
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13850 Oelobef, 2002
6001-2

TABLE OF CONTENTS
SPECIAL TORQUES ................... ............................................................................................. .............•......... ... .... . 3
SPECIAL TOOLS ................................. .......................................................... ..................... ......................... ...... ..... 3
TRANSMISSION INPUT SHAFT AND DRIVE PLATE ............. ...... .. ........... ....... ..................................•••................ 4
Removal ...................... ............. .... ....................................................... ............................................................... 4
Installation ............. ........•....................... ...... ............. ................... .. .... .... ........................................... ..... ... .. ..... ..... 9

Rae 6·13850 Issued 10·02

 6001-3

SPECIAL TORQUES
Drive Shalt Yoke Bolt (MX210 and MX230) ................................. .............. ....................... 58 to 64 Nm (43 to 47 Ib It)
Drive Shalt Yoke Bolt (MX255 and MX285 .........•.......................... ...................... ... ...... 101 to 113 Nm (75 to 83 Ib It)
Drive Plate to Flywheel Bolts (All Models) .........•....... ................................................... 101 to 113 Nm (75 to 83 Ib It)

SPECIAL TOOLS

Cab Raising Bracket Kit CAS2577

Rae 6·13850 Issued 10-02

6001-4

TRANSMISSION INPUT SHAFT AND DRIVE PLATE

Removal STEP 4

STEP 1
Park the tractor on a hard level surface. Put the
transmission shift lever in PARK. Turn off the engine
and remove the key. Place blocks in front of and
behind the rear wheels.

STEP 2

Remove the two bolts (1) for the left lower fixed hood
panel. Disconnect the hose (2) for the rear window
washer, if equipped. Disconnect the main wiring
harness (3).

STEP 5

Remove the tilt hood and the fixed hood . Refer to

Section 9008 for the procedure.

STEP 3

Remove the passive terminator harness.

STEP 6

Remove the toolbox and battery cover. Disconnect

the negative (-) battery cable. Disconnect the positive
(+) battery cable.

Tag and disconnect the electrical plugs from the fuse

box.

Rae 6-13650 Issued 10-02

 6001-5

STEP 7 STEP 9

Remove the windshield washer reservoir electrical

connectors.

STEP 8

Remove the air cleaner outlet elbow at the clamp (1).

Properly support the air cleaner assembly and the
hood support. Remove the starter solenoid (2) and
the coolant reservoir (3). Remove the fixed hood
support bolts (4) from both sides of the tractor.
Remove the air cleaner and the hood support from
the tractor.

STEP 10

Loosen the clamp (1) at the turbo outlet pipe. Loosen

the hose clamp (2) and remove the aspirator tube
hose at the exhaust elbow. Loosen the lower clamp
(3) on the exhaust flex pipe.

Remove the turbo outlet pipe.

Rae 6-13850 Issued 10-02

6001-6
STEP 11
Remove the bolt (1). nut. and washer for the plastic
tube clamp that retains the oil cooler tubes to the left
hood support bracket. Remove the two flywheel
shield bracket attaching bolts (2). Remove the two
left fixed hood bracket bolts (3) and remove the
bracket.
STEP 12
Remove the left fan shield . Remove the oil cooler
supply line (1) at the left side of the radiator shroud .
Remove the oil cooler return line (2). Drain the
hydraulic fluid into a suitable container. Remove the
bolt (3) from the plastic tube clamp and remove the
top half of the clamp.
Rae 6-13850
STEP 13
Remove the nuts and washers from the front cab
mounts. Loosen the nuts on the rear cab mounts .
Refer to Section 9005 for the cab raising procedure.
Use CAS2577 Cab Raising Bracket Kit to raise th e
cab and remove the two hydraulic oil cooler lines .
Tag and remove the oil cooler lines from the tractor.
STEP 14
Remove the nut (1) from the stud on the flywhee l
shield and remove the hose bracket. Remove the
attaching nut (2) for the drive shaft shield. Remove
the two flywheel shield bracket attaching bolts (3).
Remove the two right fixed hood bracket bolts (4)
and remove the bracket.
Issued 10-02
 6001-7

STEP 15

Remove the bolt for the drive shaft shield bracket at Lift up on the drive shaft shield (1). Release the drive
the exhaust bracket. shaft shield from the stud (2) on the flywheel shield
(3). Slide the drive shaft shield towards the cab.
Move the hoses and wire harnesses out of the way.
STEP 16 Pull up on the flywheel shield and remove.

Remove the drive shaft shield bracket bolt (1) at the

left side of the firewall. Remove the nut (2) for the
plastic hose clamp on the steering lines.

Rae 6-13650 Issued 10-02

6001 -8

STEP 18 STEP 19
~--

ROO2H091 RD02H092

Move the drive shaft shield out of the way with all Remove the four rear universal joint attaching bolts
hoses and wire harnesses attached. Place identifying (1). Remove the two bolts (2) for the upper drive
ma rks on the engine end of the drive shaft for shaft containment plate. Remove the drive shaft.
reassembly. Remove the four front universal joint to
drive plate attaching bolts (1) . Remove the six bolts
a nd washers that attach the drive plate to the
flywheel (2) . Remove the drive plate by sliding it
towa rd the transmission.

Rae 6· 13850 Issued 10-02

 6001-9

Installation STEP 21
--
........
STEP 20

Install the transmission end of the driveshaft. Using

the procedure from the preceding step, install the
four rear universal joint attaching bolts (1) . Tighten
Install the drive plate. Slide the drive plate toward the the bolts to a torque of 58 to 64 Nm (43 to 47 Ib ft) for
engine. Install the six bolts (1) and washers that the MX210 and the MX230, 101 to 113 Nm (75 to 83
attach the drive plate to the flywheel. Tighten the Ib tt) for the MX255 and the MX285. Install and
bolts to a torque of 101 to 113 Nm (75 to 83 Ib ft). tighten the two bolts (2) for the upper drive shaft
Using the identifying marks made during containment plate.
disassembly, install the engine end of the drive shaft.
Install the four front universal joint to driveshaft
attaching bolts (2). Tighten the bolts to a torque of 58 STEP 22
to 64 Nm (43 to 47 Ib ft) for the MX21 0 and the
MX230, 101 to 113 Nm (75 to 83 Ib ft) for the MX255
and the MX285. Tighten the bolts in a crossing
pattern.

NOTE: Use a rubber mallet to lightly tap the outside

edge of the top bearing end cap to position it into the
keyway of the yoke. Do not use the bolts to pull the
bearing end caps into the yoke keyway

Install the flywheel shield (1). Position the drive shaft

shield over the flywheel shield stud (2) and install the
drive shaft shield (3). Position the hoses and wiring
harnesses.

Rae 6-13850
Issued 10-02
6001-10

STEP 23 STEP 25

Install the drive shaft shield bracket bolt (1) at the left
side of the firewall. Install the nut (2) for the plastic
hose clamp on the steering lines.
STEP 24
Install the drive shaft shield attaching nut (1) on the
flywheel shield stUd . Install the hose bracket and
attaching nut (2). Install the engine ground strap
along with the right fixed hood bracket and the
mounting bolts (3) . Install the two flywheel sh ield
bracket attaching bolts (4) .

STEP 26

Install the bolt for the drive shaft shield bracket at the
exhaust bracket.

Install new O-rings on the oil cooler line fittings.

Install the oil cooler lines at the chassis under the
firewal l. Lower the cab. Refer to Section 9005 for the
cab lowering procedure. Tighten the rear cab mount
nuts and install the front cab mount washers a nd
nuts. Torque the cab mount nuts by following th e
procedure in Section 9005.

Rae 6- 13850 Issued 10-02

 6001-11

STEP 27 STEP 29

Install new O-rings at the oil cooler line fittings. Install Position the turbo outlet pipe on the tractor.
the oil cooler return line (1) at the left side of the
radiator shroud. Install the oil cooler supply line (2).
Install the top half of the plastic tube clamp and STEP 30
tighten the bolt (3). Install the left fan shield. Check
the hydraulic fluid level.

STEP 28

Install the left fixed hood bracket and tighten the bolts
(1). Install the two flywheel shield bracket attaching
bolts (2). Install the bolt (3), the plastic tube retaining
clamp, the washer, and the nut for the oil cooler
tubes.

Properly support the air cleaner and the hood

support and lower on the tractor chassis. Install the
hood support bolts (1) on both sides of the tractor.
Install the air cleaner elbow and tighten the clamp
(2). Install the coolant reservoir (3) and the starter
solenoid (4).

Rae 6-13850 Issued 10~02

6001-12

STEP 31 STEP 33
;---

Connect the electrical plugs on the fuse box.

STEP 34

Install the clamp (1) at the turbo outlet pipe. Install

the aspirator tube hose at the exhaust elbow and
tighten the clamp (2). Tighten the lower clamp (3) on
the exhaust flex pipe. Install the passive terminator harness.

STEP 32 STEP 35

Install the windshield washer reservoir electrical Connect the main wiring harness (1). Connect the
connectors. hose (2) for the rear window washer, if equipped .
Install the two bolts (3) for the left lower fixed hood
panel.

Rae 6-13850 Issued 10-02

 6001-13

STEP 36 STEP 37

Install the positive (+) battery cable . Install the Install the tilt hood and the fixed hood . Refer to
negative (-) battery cable. Install the battery cover Section 9008 for the procedure.
and the tool box.

STEP 38
Make sure the transm ission shift lever is in Park.
Start the engine and check for leaks. Check the
hydraulic fluid level. Add fluid as needed. Turn the
engine off and remove the key. Remove the blocks in
front of and behind the rear wheels.

Rae 6·13850 Issued 10-02

 Section
6002

INPUT DROP BOX

Case, LlC
700 State Street
© 2003 Case, LLC
Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 7-86552 April,2003
6002·2

TABLE OF CONTENTS
SPECIAL TOOLS ................................................................................ ...... .................................................... .......... 3

SPEC IAL TORQUES ................................ .......... ........................... ........... .. .......... .............. ..................................... 3

INPUT DROP BOX ................................................................................... ................. ...................... ........................ 4

Removal ...................... ....................................................................................... ................................ .................. 4

DISASSEMBLY ....................... ............................................ ........ ..... ..................... ................. ....... ...... .. .................. 6
Input Gear Removal .......... ..................... .................... ........................... ..... ..... ............. ......................... ............... 6
Output Gear As sembly Removal ............. ............. ...................................................... .... ..................................... 9
Idler Gear Removal ............................ .............. .... .......... ........ .... .................................................. ...................... 10
Input Drop Box Assembly .... ....... .......... ........... .... .............................................................................. ..... ..... ...... 12
Idler Gear Installation ............................... ............. ............................................................................................. 15
Output Gear Installation .................... ................................................ .... ................... .......................................... 18
Input Gear Installation ...... ...................................... ...... .. .. ...... ............................................................. ....... .... .... 20
Tubing Installation ..... ...................... .......................................................... .............. ......... .... .. .............. .............. 22

Rae 7·86552 Issued 04·03

 6002-3

SPECIAL TOOLS

,,(, (, ('lThIiJ}JD
©=
-_~(L(U(J.'
__ '.L(LJU)~I.J,.I
J)J 1)) . .~. ~J/~I~I;I;:

®@ Spacer CAS2635-5
CAS26355

CAS26351

Tools CAS2635-1

CAS2635-2 CAS26356

H-block with forcing screw and shaft protector

CAS2635-6 CAS2635-6

CAS2635-3
Bolts CAS2635-3

CAS2635-4

Bolts CAS2535-4

SPECIAL TORQUES
Cover Plate Bolts ........................................... ......................................... ....... .. ................. 51 to 57 Nm (3B to 421b It)
Output Gear Retaining Bolts ........................................................................... .................. 51 to 57 Nm (3B to 42 Ib It)
Input Gear Retaining Bolts ............................ ................................................................... 51 to 57 Nm (3B to 42 Ib It)
Input Drop Box Bolts:
M20 x 280/B.9 ........................................•............................................•••........... .. 250 to 428 Nm (184 to 316 Ib It)
M20 x 110110.9 ...........................................................•........ ......... ...........•••••..... . 486 to 4BO Nm (317 to 35B Ib It)
M16 x 70/B.B........................ ................... ............................. .................. ••. .......... .. 234 to 260 Nm (173 to 192 Ib It)
Input Yoke Center Bolt... .......................... ........................................................ ......... 430 to 486 Nm (145 to 166 Ib It)

Rae 7-86552 1ssued 04-03

6002-4

INPUT DROP BOX

Removal STEP 3

NOTE: Before removing the drop box from the

speed transmission, split the power train between the
engine frame and the drop box (see Section 6003,
Engine Frame and Drop Box Split). The drop box
cannot be removed from the speed transmission until
the drop box is split from the engine frame.

STEP 1

11-21

Remove the MFD output shaft bearing cage, output

shaft and yoke.

Remove the drop box and the speed transmission

from the power train.

STEP 2

Remove the four bolts that attach the MFD output

shaft bearing cage to the front of the drop box.

NOTE: If the tractor does not have a mechanical

front drive, remove only the bottom two bolts and
washers.

Rae 7·86552 Issued 04-03

 6002-5

STEP 4 STEP 5

"-27
Remove the drop box.

NOTE: The drop box was removed from the speed

transmission housing in this section for photographic
purposes. The drop box can be serviced without
removal, if desired
Remove the drop box.

11·25

Pry drop box from speed transmission as follows:

1. Remove two M20 (1) bolts with washers from the
front of the drop box.
2. Remove two M16 bolts (2) with washers from the
back side of the speed housing at the top.
3. Insert two pry bars between the drop box and
speed transmission.

IMPORTANT: DO NOT REMOVE any locating pins.

Rae 7-86552 Issued 04-03

6002-6

DISASSEMBLY

STEP 6 Input Gear Removal

STEP 8

11·31

On back of drop box, remove the lubrication tube (1).

Move the drop box to clean location and place it on
its rear side. 23-2
Insert a small block between a yoke and the side of
the drop box. Loosen the center bolt. Do not remove
STEP 7 the bolt at this time.

STEP 9

18-21

Remove the tubing from front of the drop box.

19-24

Remove the three bolts that attach the input gear

bearing cage to the drop box .

Rac 7-86552 Issued 04-03

 6002-7

STEP 10 STEP 12

'9-30
Remove input gear assembly and shims. Remove O-ring from yoke.

IMPORTANT: Take care not to damage the rear

bearing during removal. When removing the cage, STEP 13
the gear will drop. The weight of the gear assembly
might allow the rear bearing to hit the idler gear and
result in damage to the bearing.

STEP 11

Remove yoke from input gear subassembly.

STEP 14

Remove the bolt, washer and shim pack.

NOTE: Keep the shims with the washer as it is

removed.

Lift input bearing cage from input gear.

Rae 7-86552 Issued 04·03

6002-8

STEP 15 STEP 18

60-31 21·5

Remove O-ring from input gear bearing cage. Remove the bearing cup from the input bearing cage.

STEP 16 STEP 19

60-2. 79-14

Remove shims from input gear bearing cage. Remove the input gear rear bearing cup from th e
drop box housing.
NOTE: Keep the shims with the bearing cage.

STEP 20
STEP 17

61·25 Remove the input gear bearings.

Remove oil seal.

Rae 7-86552 Issued 04-03

 6002-9

Output Gear Assembly Removal STEP 23

STEP 21

2().8

Remove the bearing cup from the output gear

bearing cage.
'''5
Remove the output gear bearing cage. Remove the
O-ring from the cage. Remove the shims. STEP 24

NOTE: Keep the shims with the bearing cage as it is

removed.

STEP 22

79-17R

Remove the output gear rear bearing cup from the

drop box housing.

STEP 25
19-12

Remove the output gear assembly. Remove the

splined output shaft.

IMPORTANT: Take caution to prevent damage to

the rear bearing when removing the gear. The weight
of the assembly might allow the rear bearing to hit
the idler gear.

NOTE: The coupler on the end of the output shaft

should have been removed when the drop box was
split from the speed transmission. If not, make sure
the coupler does not fall when the output shaft is
removed.
Remove the output gear bearing cones.

Rae 7-86552 Issued 04-03

6002-10

Idler Gear Removal STEP 28

STEP 26

Remove the O-ring from the idler gear pin.

Remove the cover plate for the idler gear. STEP 29

STEP 27

9-23

Use tools CAS2635-1 and CAS2635-2 and remove

the idler pin.
62·23
Remove the adjusting shims from the front end of the
idler gear. STEP 30

NOTE: Keep the shims with the front cover as it is

removed.

66-2
Remove the idler gear and bearings through the
input gear hole.

Rae 7-86552 Issued 04·03

 6002-11

STEP 31 STEP 32

Remove the bearing cones from the idler gear.

o
Remove the two snap rings from the idler gear.
Remove the bearing cups from the idler gear.

Rae 7·86552 Issued 04·03

6002-12

Input Drop Box Assembly

RT98A013

Rae 7-86552 Issued 04·03

 6002-13

1. HOUSING ASSEMBLY 26. RETAINING RING 49. BOLT

2. PIN 27. BEARING CONE 50. GASKET
3. PIN 28. BEARING CUP 51. BOLT
4. GEAR 29. SHAFT 52. TUBE
ASSEMBLY
5. INPUT GEAR BEARING CONE 30. PIN 53. BOLT
6. CUP BEARING 31. PLUG 54. LOCK WASHER
7. CONE BEARING 32. a-RING 55. UNION
8. CUP BEARING 33. SHIM 56. a-RING
9. SHIM 34. PLATE 57. a-RING
10. CAGE 35. BOLT 60. COVER WITHOUT MFD
11. a-RING 40. GEAR 61. BOLT
12. BOLT 41. SHAFT 62. BOLT
ASSEMBLY
13. OIL SEAL 42. ROLL PIN 63. WASHER
14. YOKE 43. SETSCREW 70. CAP
15. a-RING 44. BEARING CONE 71. TUBE
16. SHIM 45. BEARING CUP 72. a-RING
17. SPECIAL WASHER 46. SHIM 73. BOLT
18. BOLT 47. CAGE
25. IDLER GEAR 48. a-RING

STEP 33 STEP 34
. ''''

22-17 22-26

Press rear bearing cone (#28682) onto the input Press the front bearing cone (#387A) onto the input
gear. Press on the inner race only to prevent damage gear_Press on the inner bearing race only to prevent
to the cage. damage to the cage.

NOTE: The front and rear bearings are different. NOTE: The front and rear bearings are different.

Rae 7-86552 Issued 04-03

6002-14

STEP 35 STEP 38

22-5 61535

Press two bearings onto the output gear. Press the input gear rear bearing cup (#28622) into
the housing.
NOTE: Bearings are the same.
NOTE: The front and rear bearing cups are different.

STEP 36
STEP 39

61-20

Press the input shaft seal into the cage. 20-9

Press the bearing cup into the output gear bearing

cage.
STEP 37
STEP 40

21-11

Press the front bearing cup (#382A) into the input

gear cage. 6262
Press the output gear bearing cup into the housing.
NOTE: Front and rear bearing cups are different.

Rae 7-86552 Issued 04-03

 6002-15

Idler Gear Installation STEP 43

NOTE: During a complete overhaul of the drop box,

the bearing end play settings are made in this
sequence:
1. Idler gear
2. Output gear
3. Input gear
Sometimes it may not be practical to follow through
with the complete sequence. If only one unit such as
the input gear is to be repaired, make sure that the
idler gear and output gear are not damaged or have
66-2
heavy wear.
Insert the bearing cones in the idler gear and insert
the gear through the input gear hole. Slide the idler
STEP 41 gear into place.

STEP 44

o 60-3

Place the two snap rings in the grooves in the ID of

the idler gear.
. 3-8
Set up the press (H-block with forcing screw and
STEP 42 shaft protector CAS2635-6) as shown. Use bolts
CAS2635-4 and spacer CAS2635-5 to secure the
press. Put a bearing spacer between the idler shaft
and the press to prevent damage to the end of the
shaft . Press the shaft into the idler gear bearing
cones . Make sure the idler shaft is fully seated .
Remove the press and retaining bolts.

IMPORTANT: Do not strike the press because

bearing damage may result.

Insert the bearing cup into one side of the idler gear
(larger ID side to the outside). Insert the second
bearing cup into the opposite side of the idler gear.
Make sure that both bearing cups are completely
seated against the snap rings.

Rae 7·86552 Issued 04-03

6002-16
STEP 45
79-32
Insert two full thread bolts, CAS2635-4, into the idler
gear cover bolt holes. Lightly tighten both bolts
against the front of the idler gear to hold it in place as
the shaft is pulled a slight amount. Install idler pin
removal tool CAS2635-2 in place.
STEP 46
Use tools CAS2635-1 and CAS2635-2 to pull the
idler shaft a slight amount to reduce the rolling torque
of the idler gear. Turn the threaded rod until the gear
rotates freely. Remove the idler gear puller tool and
full thread bolts.
Rae 7-86552
STEP 47
Insert the input gear into the housing. Do not install
the bearing cage. Make sure the input gear meshes
properly with the idler gear.
STEP 48
62-32
Press the idler gear shaft in while rotating the input
gear slightly with a torque wrench to check the
resistance to rolling torque. Continue pressing until
the input gear rolling torque measures from 0.1 to 0.9
Nm (1 to 8 Ib inch).
Issued 04·03
 6002-17

STEP 49 STEP 51
-~~

62-34 62-30
Reduce the pressing force to just secure the shaft in Install the O-ring on the top of the idler gear shaft.
position. Using a depth micrometer, measure the
distance from the machined surface of the drop box
to the top of the idler shaft. Record this measurement STEP 52
for determining the shim pack thickness.

STEP 50

.. - Place the shims on top of the idler gear shaft.

~- STEP 53
63-1

Place the idler shaft shims on a machined surface.

Using the same depth micrometer, measure the
distance through the center hole. Select a shim pack
with the thickness determined in Step 49 to within
0.025 mm (0.001 inch).

62·19
Install the cover plate. Tighten the bolts to a torque of
51 to 57 Nm (38 to 42 Ib ft) .

Rae 7-86552 Issued 04-03

6002-18
Output Gear Installation
STEP 54
64-32
Insert the output gear so that the internal splines are
toward the front. Make sure the bearing is not
damaged from contact with the idler gear. Insert the
bearing cage.
NOTE: Do not install the a -ring or shims at this time.
STEP 55
"'5
In sert three bolts through the flange of the output
gear cage into the drop box. While rotating the output
gear, torque each retaining bolt. Tighten the bolts in
sequence in three increments of increasing torque
until the bolts are each torqued to 6.8 Nm (60 Ib
inch).
Rae 7·86552
STEP 56
Measure the gap between the bearing cage and the
housing at each bolt. Record the measurements. The
total difference between readings must not exceed
0.20 mm (0.008 inch) .
STEP 57
Average the measurements recorded in Step 56 to
the nearest 0.025 mm (0.001 inch) . To this average,
add 0 .254 mm (0 .010 inch ). This is the required
dimension thickness.
Example:
Measurement #1 .............. ..... 1.143 mm (0.045 inch)
Measurement #2 ........... .... .... 1.168 mm (0.046 inch)
Measurement #3 ................... 1.118 mm (0.044 inch)
Total. ............... ........................ 3.429 mm (0.135 inch)
Average of all 3 ....... ................ 1.143 mm (0.045 inch)
Additional shims to add .......... 0.254 mm (0.010 inch)
Total thickness required ...... .... 1.397 mm (0.055 inch)
NOTE: Finalize these '10tal thickness required" only
after finding "average of all 3 " shim thickness above.
STEP 58
Select the shim pack that will result in the total
thickness calculated in Step 57 to within 0.025 mm
(0.001 inch).
Issued 04·03
 6002-19

STEP 59 STEP 61

65·14
Place the shims on the bearing cage. Place the 0- Install a dial indicator and measure the output gear
ring on the output gear bearing cage. end play to confirm that the proper shim pack was
selected . The end play must be between .025 to
0.125 mm (0.001 to 0.005 inch) . Add or subtract from
STEP 60 the shim pack to obtain the correct end play.

STEP 62

Install the output gear bearing cage, shims and 0-

ring. Insert the three retaining bolts and tighten to a
torque of 51 to 57 Nm (38 to 42 Ib It). 66- "
Check to make sure the setscrew is in the end of the
output shalt.

STEP 63

66-' 8
Check to make sure the roll pin is in the output shaft.

Rae 7·86552 Issued 04-03

6002-20
Input Gear Installation
STEP 64
Carefully install the input gear. Make sure the gear
bearing is not damaged from contact with the idler
gear. Install the bearing cage and three bolts.
NOTE: Do not install the O-ring or shims at this time.
STEP 65
Wh ile rotating the input gear, torque each retaining
bolt. Tighten the bolts in 3 increments until the bolts
are each torqued to 5.6 Nm (50 Ib inch).
If the drop box has not been removed, the output
gea r, cage , and shims must be removed to allow
input gear rotation.
Rae 7·86552
STEP 66
-=-_..-"""IIIiI_
63-14
Measure the gap between the bearing cage and the
machined surface of the input gear bearing cage to
the machined surface of the drop box at each bolt.
Record the measurements . The total difference
between readings must not exceed 0.20 mm (0 .008
inch) .
STEP 67
Average the measurements recorded in Step 66 to
the nearest 0.025 mm (0.001 inch). To this average,
add 0.10 mm (0 .004 inch ). This is the required
thickness dimension.
Example:
Measurement #1 ................... 1.143 mm (0.045 inch)
Measurement #2 ............. ...... 1.168 mm (0.046 inch)
Measurement #3 ................... 1.118 mm (0.044 inch)
TotaL ....................................... 3.429 mm (0.135 inch)
Average of all 3 .... .............. ...... 1.143mm (0.045 inch)
Additional shims to add ............ 0.10 mm (0.004 inch)
Total thickness required ...... 1.2430 mm (0.0049 inch)
STEP 68
Select the shim pack that will result in the thickness
calculated in Step 67 to within 0.025 mm (0.00 1
inch).
Issued 04-03
 6002-21

STEP 69 STEP 72

64-8
Install the required shims. Place the O-ring on the Place the yoke on the input gear.
input gear bearing cage.

STEP 73
STEP 70
---..-

64-5
Install the input gear bearing cage, shims and O-ring.
Insert the three retaining bolts and torque them to 51
to 57 Nm (38 to 42 Ib It).
64-20
Place a depth micrometer across the face of the
yoke . Measure the distance to the end of the input
shaft. Select the shim pack that would result in an
end play for the yoke of 0.01 to 0.10 mm (0.0005 to
0.004 inch) . Install the shims, washer and bolt.

STEP 71
STEP 74

64-2

Install a dial indicator and measure the input gear 64-23

end play to confirm that the proper shim pack was Torque the bolt to 252 to 280 Nm (186 to 207 Ib It).
selected. The end play must be between 0.04 to 0.08
mm (0.0015 to 0.003 inch).

Rae 7-86552 Issued 04-03

6002-22

STEP 75 STEP 77

64-26 11-33

Set up a dial indicator as shown. Measure the end Install the lubrication tube on the rear of the drop box.
play for the yoke on the input shaft. The end play Install the output shalt and coupling. Tighten the tube
must be between 0.01 to 0.10 mm (0.0005 to 0.004 nut to a torque of 12 to 16 Nm (9 to 12 Ib It).
inch). If not, add or subtract from the shim pack as
needed.
STEP 78
Tubing Installation

STEP 76

Pos ition the drop box onto the speed housing as

follows:
1. Move the drop box to the speed housing.
2. Install two guide pins in the speed housing .
Install the lubrication tube on the forward face of the Install the gasket.
drop box.
3. Slide the drop box over the guide pins.
4. Turn the input yoke to align the coupling to the
speed input shalt.
5. Install and tighten the bolts to the following
torques:
M20 x 280/8.9 ......... 250 to 428 Nm (184 to 316 Ib It)
M20 x 110/10.9 ........430 to 486 Nm (317 to 358 Ib It)
M16 x 70/8.8 ................... 234 to 260 (173 to 192 Ib It)

Rae 7·86552 Issued 04-03

 6002·23

STEP 79 STEP 80
"I......WF1

11 ·21 11-19

Install a new a ·ring on the bearing cage. Install the
MFD output shalt, MFD output shalt bearing cage
and yoke.
IMPORTANT: The MFD output shaft must be
installed through a needle bearing in the speed
housing rear wall. Be careful not to damage the
needle bearing. Rotate the shaft to engage splines in
the MFD clutch hub.
Install the four bolts that attach the MFD output gear
bearing cage to the bottom of the drop box. Tighten
the bolts to a torque of 375 to 415 Nm (277 to 358 Ib
It).
NOTE: If the tractor does not have a mechanical
front drive, install the two bolts, two washers and
cover.

Rae 7·86552 Issued 04-03

 6002·24

Rae 7·86552
Issued 04-03
 Section
6003

ENGINE FRAME AND DROP BOX SPLIT

Case, LLC
© 2003 Case, LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 7-86561 April,2003
6003-2

TABLE OF CONTENTS
SPECIAL TORQUES ................... ......... ..................... .......... ............... ................................ ..................................... 3
SPECIAL TOOLS ....... .... ............................. ...... .... ................................................ ............................................... 3

ENGINE FRAME AND DROP BOX SPLIT .................................................................................................. ............ 4

Removal ...................................................... ....... ..... ............................................................................................. 4
Installation ..... ................................. ....................... ....... ................... .... ................................................................. 7

Rae 7-86561 Issued 4-03

 6003-3

SPECIAL TORQUES
Bolts attaching Engine Frame to Drop Box.. ........................... ............. ..................... 375 to 485 Nm (277 to 358 Ib tt)
Engine Side Rail to Speed Transmission Retaining Bolts ........................................ 430 to 486 Nm (317 to 358 Ib tt)
Drive Shatt Yoke Bolts
MX255 /285 ..... .............................•........................... ............................. .. ................. 101 to 113 Nm (75 to 83 Ib tt)
MX21 0/230 .... ....................... ....... ....... ...... ............ ......... ....... .. ••.. ... .................. .......... .. . 58 to 64 Nm (43 to 47 Ib tt)
Drive Plate to Flywheel Bolts ....................... ........ ................................................... ..... 101 to 113 Nm (75 to 83 Ib tt).

SPECIAL TOOLS
1. Tractor Splitting Kit CAS17-526, including: 3. 4 WD Support Bracket CAS1 0852-1
A. Base CAS3009A-1 4. Hydraulic Jack CAS10855 (4 required)
B. Adaptor Kit CAS30029
5. Tractor Splitting Stand (rear) CAS10853
or
6. Alignment Studs CAS1995A
2. Tractor Splitting Stand (front) CAS10852

..
.....,
ENGINE TURN OYER TOOl

CASl690

e
ca

SUI'I'ORT ASIUIBlY
'7-521-5
175264A

17527

ADAmR PLATES
17-142-10

171421C

ATTACHING BRACE
17-6f1..1'

17526A
1752614

Rae 7-86561 Issued 4-03

r
6003-4

ENGINE FRAME AND DROP BOX SPLIT

Removal STEP 4

STEP 1
1. Park the tractor on hard , level ground.
2. Apply the parking brake and put the shifting lever
in PARK.
3. Lower the rear three-point hitch and front hitch (if
equipped).
4. Stop the engine and remove the key.
5. Put blocks in front of and behind the rear wheels.

STEP 2 For tractors equipped with mechanical front drive

(MFD), disconnect the MFD drive shaft at the yoke
on the drop box. See Section 6016, MFD Drive Shaft
for procedure.

STEP 5
Evacuate the A/C system. See Section 9020 , Air
Conditioning Component Service for procedure.
Remove the AlC lines from the compressor.

IMPORTANT: It is recommended that the system be

ROO2H091
See Section 6001 , Transmission Input Shaft and
Drive Plate, and follow the procedure to remove the
Input Drive shaft.
STEP 3
In addition, disconnect the following:
1. Electrical harness from the
compressor and sending units.
starter,
2. Heater hoses from the engine to the cab.
3. Steering supply and return lines for steering
cylinders.
4. Injection pump fuel supply and return lines.
evacuated and the hoses disconnected, leaving the
compressor and condenser in place.
WARNING : NEVER touch liquid refrigerant
~ because even a drop on your skin will cause
ll.l. severe and painful frostbite. Always wear
protective gloves. SMO
AlC A WARNING: ALWA YS wear safety goggles
when working with liquid refrigerant. Liquid
refrigerant in eyes could cause blindness.
STEP 6
See Section 9005 , Cab Raise / Removal and
Installation and raise the cab.

Drain any fluids, such as lubricant or antifreeze

where necessary.
Make a note of routing of all tubes, hoses , and
electrical harnesses.

Rae 7-86561 Issued 4-03


STEP 7
",.,
Set up the front splitting stand CAS17-526 as follows:
1. Lay the track under the engine in the proper
position.
2. Place the trolley on the track.
STEP 8
Position the stand components as follows:
1. Mount the adapter plates (one on each side) at
the end of the engine frame with two bolts each.
2. Position the threaded rods on the trolley under
the holes in the jacking plate.
3. Position an appropriate jack under the speed
transmission housing.
Rae 7-86561
6003-5
STEP 9
Raise the T-bar on the trolley to insert the threaded
rods through the holes in the adapter plate. Adjust
the jacking nuts on the threaded rods and the jack
under the speed transmission just enough to support
the weight of the tractor.
STEP 10
..,......---,
7·10
Split the drop box from the engine frame as follows:
1. Loosen the four bolts (two on each side) that
attach the engine frame to the drop box.
NOTE: Do not loosen the two bolts at the bottom at
this time.
IMPORTANT : Check that all tubes , hoses,
harnesses, and cables are removed.
2. Slightly loosen the two bolts on the bottom of the
engine frame and drop box.
3. Observe if the joint between the engine frame
and drop box splits unevenly, indicating an
uneven distribution of weight.
4. If necessary, further adjust the position of the
splitting stand to redistribute the weight correctly.
5. Remove the last of the 10 bolts.
6. Carefully separate the engine frame from the
drop box.
Issued 4-03
6003-6

STEP 11 Installation
Alter the engine frame and drop box have been split,
the drop box can be removed from the speed
transmission for service . See Section 6002 , Input
STEP 12
Drop Box. Install the drop box onto the speed transmission. See
Section 6002, Input Drop Box for installation
IMPORTANT: The initial split in the area of the procedure.
engine frame, drop box, and speed transmission
cannot be made between the drop box and the
speed transmission. The drop box must be split from STEP 13
the engine frame first because some bolts go through
the engine frame, drop box, and tap into the speed
housing.

7·10

Attach the engine frame to the drop box as follows:

1. Carefully push the engine toward the drop box.

NOTE: Make sure the alignment dowels in the drop

box fit into the mating holes in the ends of the engine
frame.
2. Install and evenly tighten two bolts, one on each
side in the mid position. Use these two bolts as
jacking bolts to draw the drop box and engine
frame close together.
3. Install the remaining eight bolts as follows:
A. Evenly tighten all 10 bolts.
B. Tighten the bolts in a criss-cross pattern
from side to side to a torque of 375 to 485
Nm (277 to 358 Ib It).

Rae 7·86561 Issued 4-03

 6003-7

STEP 14 STEP 17

Release the weight of the tractor from the front
splitting stand . Remove the adapter plate, the front
splitting stand and the jack from under the speed
transmission.
ROO2H09 1
See Section 6001, Transmission Input Shaft and
Drive Plate, and follow the procedure to install the
Input Drive shaft.

STEP 18
STEP 15
Connect the following:
1. Electrical harness to the starter, AlC compressor
and sending units.
2. Heater hoses from the engine to the cab.
3. Steering supply and return lines for steering
cylinders.
4. Injection pump fuel supply and return lines.
Add fluids, such as lubricant or antifreeze as
required.

STEP 19
If equipped , connect the MFD drive shaft . See
Start the tractor and check for leaks. Check all fluid
Section 6016, MFD Drive Shaft for procedure.
levels. Add as required . .

STEP 16
Connect the AIC lines to the compressor and
•
recharge the AIC system. See Section 9020 , Air
Conditioning Component Service for procedure. .' , .
WARNING : NEVER touch liquid refrigerant
A. because even a drop on your skin will cause
ili severe and painful frostbite. Always wear
protective gloves. SMO

WARNING : ALWAYS wear safety goggles

& •
when working with liquid refrigerant. Liquid
refrigerant in eyes could cause blindness.
••

Rae 7-86561 Issued 4-03

 Section
6005

SPEED TO RANGE TRANSMISSION SPLIT

MX Series Tractors

CASE CORPORATION
«:1 2002 Case Corporation
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13250 September, 2002
6005-2

TABLE OF CONTENTS
SPECIAL TOOLS ................................ ..... .............................. ............................... .. ... ............................. .............. .. 3

SPECIAL TORQUES .................................... ................ .... ........... ..... .............................. ... .. ............. ....................... 3

SPEED TO RANGE TRANSMISSION SPLIT ................................ .. .......................... ............................................. 4

Removal ................................................................................................................................. .............................. 4
Installation .................................. .. ... ............... ............................. .. ....................................................................... 7

Rae 6-13250 Issued 9·02 Printed in U.S.A

 6005-3

SPECIAL TOOLS

0507TLSA
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 BRIDGE 17-526·7
7. SUPPORT ASSEMBLY 17-526-5

SPECIAL TORQUES
Speed to Range Transmission Bolts
20mm ............................................................................................................... 232 to 262 Nm (171 to 193 Ib tt)
20mm X 80mm (3.15 in) ...... .. .................. ........................................................ 220 to 250 Nm (162 to 184 Ib tt)
24mm .......................................................................................................... ..... 430 to 486 Nm (317 to 358 Ib tt)

Rae 6·13250 Issued 9·02

6005-4

SPEED TO RANGE TRANSMISSION SPLIT

Removal
/
STEP 1 STEP 2

91517

Prepare for removal as follows : Drain the transmission fluids from the range, speed,
and rear frame. Drain fluid into clean drain pans.
1. Park the tractor on a hard, level surface.
2. Put the shift control lever in PARK. NOTE : The transmission capacity is approximately
172 liters (45 gallons)
3. Fully lower the rear three-point hitch.
4. Stop the engine and remove the key.
5. Put blocks behind and in front of the rear wheels.
6. See Section 9008 for hood removal information
and remove the hood.
7. See Section 9005 for cab removal information
and remove the cab.
8. See Section 300 1 for fuel tank removal
information and remove the fuel tanks.
9. See Section 6016 for MFD drive shaft removal
information and remove the MFD drive shaft.

Rae 6- 13250 Issued 9-02

 6005-5

STEP 3 STEP 4

RD02C 165

Disconnect th e wire harness from the speed

powershift valve solenoids.

STEP 5

Position the front splitting stand 17-526A (1) and

attach the adapter plates (2) on both sides.
Position the rear housing handler 17-527 (3) and
adjust it to support the rear frame and range
transmission without lifting up on them. Remove the clamp bar (1) over the hydraulic lines on
Be sure that the transmission is as level as possible top of the speed transmission. Tag and remove the
and that the front wheels are as straight as possible. lines.
This will aid in shaft alignment on assembly.
STEP 6
NOTE: The exhaust stack does not have to be
removed for this split, but removal does simplify the
task.

NOTE : Rear wheels removed for photographic

purposes.

NOTE: Tag and identify all lines before removing

them throughout this procedure.

If equipped , disconnect the true ground speed radar

from the wire harness and remove the radar and
mounting bracket from the speed transmission
housing.

Rae 6-13250 Issued 9·02

6005-6

STEP 7 STEP 9

1. STEERING SENSING 4. REGULATED PRESSURE Remove the 10 bolts attaching the speed
AND SUPPLY LINES SUPPLY LINE
2. REGULATED SUPPLY 5. OIL COOLER RETURN
transmission to the range transmission and install a
JUMPER TUBE LINE guide stud on each side.
3. MFD/DIFF LOCK SUPPLY 6. PARK LOCK RELEASE
LINE SUPPLY LINE
STEP 10
Disconnect these lines from the top of the
transmission

STEP 8

Move the speed and range transmissions apart a few

inches. Check to be sure no lines are connected
across the split. Push on the front wheels and
continue to move the speed and range transmissions
apart.
1. ODD EVEN VALVE 3. OIL COOLER SUPPLY
RETURN LINE LINE
2. FILTER TEMP SENDING 4. STEERING RETURN LINE
WIRE

Remove these lines from the hydraulic filter head .

Disconnect the filter temperature sender wire.
Move the transmission wire harness back out of the
way.

Rae 6-13250 Issued 9-02

 6005-7

Installation

STEP 11 STEP 12

Install and partially tighten the 10 bolts.

STEP 13

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). Install a new gasket onto the range
housing. Push on the front wheels to move the
transmissions together. The thrre shaft splines must
align and engage. It may be necessary to rotate the
drive shaft yoke end of the MFD shaft (2), rotate the
engine crankshaft dampener (not shown) and to o
remove the side cover plate and rotate the gear (3) to
align all the shaft splines.
2 'Y""-----'''-'>.ll--
BOLTPAT4

1 .............................. 220 to 250 Nm (162 to 184lb ft)

80 mm (3.15 in.) long bolt
2 .............................. 232 to 262 Nm (171 to 193 Ib ft)
3 .............................. 430 to 486 Nm (317 to 358 Ib ft)
Tighten the bolts according to the torque values
shown above.

IMPORTANT: Failure to properly torque the bolts

could lead to failure of the bolts and housings.

Rae 6-13250 Issued 9-02

6005-8

STEP 14 STEP 16

1. ODD EVEN VALVE 3. OIL COOLER SUPPLY If equipped, install the true ground speed radar on to
RETURN LINE LINE
2. FILTER TEMP SENDING 4. STEERING RETURN LINE
the transmission housing and connect to the wire
WIRE harness.

Move the transmission wire harness into position

over the speed transmission housing.
STEP 17
Connect filter temp erature sender wire to the
hydraulic filter head. Connect the hydraulic lines to
the filter head.

STEP 15

Connect the removed tagged lines. Position the lines

in the retaining bracket and install the clamp bar (1).

STEP 18

1. STEERING SENSING 4. REGULATED PRESSURE

AND SUPPLY LINES SUPPLY LINE
2. REGULATED SUPPLY 5. OIL COOLER RETURN
JUMPER TUBE LINE
3. MFD/DIFF LOCK SUPPLY 6. PARK LOCK RELEASE
LINE SUPPLY LINE

Connect these lines on the top of the transmission

A002C165

Connect the wire harness to the speed powershift

valve solenoids.

Rae 6-13250 Issued 9·02

 6005-9

STEP 19 STEP 21

ROO2Cl64

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.
4. Install the hood. See Hood Removal information.
5. Install transmission fluid.
.. "- ;::-- ~- 6. Install transmission fluid.
RD02Cl63
Remove the rear handler and front splitting stand. 7. Remove the blocks from the wheels.

STEP 20 STEP 22
When tractor assembly is complete, run the tractor
and check for hydraulic leaks.
Check the fluid level in the transmission and add as
required.

Install the plugs for range , speed, and final drive

transmission housings.

Rae 6·13250 Issued 9-02

6005-10

Rae 6-13250 Issued 9-02

 Section
6006

SPEED TRANSMISSION

© 2002 Case Corporation

Printed in U.S.A.
6-13490 September, 2002
6006-2

TABLE OF CONTENTS
PICTORIAL INDEX - SPEED TRANSMISSION ................... ........................................ ........................................... 3

SPECIFICATIONS ....................... ............................ ... ......................................................................... .................... 4

SPECIAL TORQUES .......................................................................... .............. .......... ........... .... ..................... ......... 4

TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR .. ............................................... ................... .... 4

SPECIAL TOOLS ... ......... ..................... ....................................................................................... ........... .............. ... 5

SPEED TRANSMISSION WITH CREEP OPTION .................. .... .................. .............................. ............................ 6
Countershaft, Input Shaft. And Output Shaft Removal
For Transmissions With Creep Option ......................... .......................... .............................................................. 7
Countershaft, Input Shaft, and Output Shaft Removal for Transmissions without Creep .................................... 8
Disassembling the Counters haft with Creeper Speed Clutch ............ .................................................................. 9
Disassembling the Countershaft with the Creeper Speed Clutch ............................ ....................................... ..... 9
Alternative Method for Snap Ring Removal ......... ....................... ............................................ .................... ..... 12

ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH ....................................................... 13

Countershaft with Creep ........................ ................................................... ....................................................... 21
Disassembly and Assembly of Countershaft without Creep ..................... ....................................................... 22
Disassembling the Speed Input Shaft ................... ...................................... ....................................................... 23
Speed Input Shaft Assembly .................... ........... ......................... .......................................... ... .... ..................... 29
Assembly of the Speed Input Shaft ... .......... ......... .......... ... ...................... ........................................................... 30
Speed Input Shaft ................ ............................................................................................................................ 40
Disassembling the Speed Output Shaft .................... .. ........... .... ......... ................ ............................................ ... 41
Disassembling the Speed Output Shaft ..................... ............ ................ ............................................................ 41
Speed Output Shaft Assembly ...................................................................................... ......... .......................... 48
Cross-Section View of Output Shaft ........ ............... ......................................................................................... .. 66
Air Check for Speed Transmission Clutch Piston Operation ............................ ...........................•.................... 67
Countershaft, Input Shaft, and Output Shaft Installation - Exploded View ...................... ............................•...... 69
Bearing Removal and Replacement .................................................................................................................. 70

TRANSMISS ION ASSEMBLY WITH CREEP OPTION ............................ ......................................................... ... 73

Shafts in Speed Transmission ............. ......... .... .. ... ..... .................................... .......................... ......................... 74

TRANSMISS ION ASSEMBLY WITHOUT CREEP OPTION ................................................................................. 75

Setting the End Play of the Speed Transmission Countershaft,
Input Shaft, and Output Shaft .................................................................................. .......................................... 76
 6006-3

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 SH AFT CLUTCH 10. 3RD SPEED CLUTCH
3. REVERSE SPEED CLUTCH 6. COUNTERSHAFT 8. EVEN SPEED CLUTCH
6006-4

SPECIFICATIONS
End Play for Installed Speed Transmission Counters haft,
Input Shaft and Output Shaft ................... ................................................ 0.03 to 0.13 mm (0.0012 to 0.0051 inch)
Clutch Pack Oil Leakage .............................. ......... ................. ............. ..................... 0.5 Umin (0.13 gpm) Maximum

SPECIAL TORQUES
Mounting Bolts for Front Bearing Support Cover on
Speed Transmission Housing ...................................................................................... 94 to 106 Nm (69 to 78 Ib ft)
Mounting Bolts for Rear Bearing Cages on
Speed Transmission Housing ........................................................................................ 54 to 61 Nm (40 to 45 Ib ft)
Mounting Bolts for Speed Transmission Housing
Through Speed Housing Front Flange into Drop Box
16 mm (grade 8.8, plain) ....... ........................................................ ......... ............... 234 to 260 Nm (173 to 192 Ib ft)
Through Speed Housing Rear Flange into Range Housing
16 mm (grade 10.9, plated) ................................................................................... 220 to 250 Nm (162 to 185 Ib ft)
16 mm (grade 8.8, plain) ........................................... ....... .................................... 232 to 262 Nm (171 to 193 Ib ft)
20 mm (grade 10.9, plated) ....... ................................... ......................... ............... 430 to 486 Nm (317 to 3591b ft)

TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR

Problem Probable Cause

Tractor moves in reverse when shifted into 5th, 6th The Reverse/5th clutch hub is installed backward on
11th and 12th gear. shaft.

Odd gears are even and even gears are odd. The odd/even clutch pack is installed backward.
 6006-5

SPECIAL TOOLS

T98826
Compression Sleeve with Notch CAS1903-3 (first used
1. Mounting Plate 17-52-14 on Page 10).
2. Mounting Brackets 17-52-16 (set of two)
3. Engine Mounting Stand CAS10431

CASl 903-4
Centering Sleeve CAS1903-4 (first used on Page 52) .

CASl9031
Compression Plate with 6 Tangs and 2 Capscrews
CAS1903-1 (first used on Page 12).

CASl903-5
Compression Sleeve CAS 1903-5 (first used on Page
CAS 1903-2
37) .
Compression Plate CAS 1903-2 (first used on Page
12).
6006-6

SPEED TRANSMISSION WITH CREEP OPTION

STEP 3

886LO
, . INPUT SHAFT
2. OUTPUT SHAFT
3. COUNTERSHAFT 886LO
Remove any remaining seal material from the bolt hole
Remove the mounting bolts from the front bearing threads. Install two bolts in the bearing support cover at
support cover. the 1 and 7 o ' clock position (front view shown ) .
Tighten bolts only finger-tight.
STEP 2
NOTE: Use- Steps 4 through 6 for transmission
equipped with the creep option. Use Steps 8 through
11 for transmissions without the creep option.

STEP 4

.. 51L91

Make support blocks as follows:

1. Use suitable material to make two support blocks
that will hold at least 400 Ib (181 kg) .
2. One block must be 14 inch H x 10 inch L x 2-3/4
886LOP
inch W.
Use prybars under the two lift areas in the front bearing
support cover and loosen the cover. 3. The other block must be 14 inch H x 4-1 /2 inch L x
2-1 /4W.
NOTE: Cover is shown without creep option. Prybars
must be in same lift areas for covers with or without
creep option.
 6006-7

Countershaft, Input Shaft, And Output Shaft Removal

For Transmissions With Creep Option
STEP 5 STEP 6

18·11

Remove housing as follows:

1. Connect a chain to the rear of the speed housing
(shown with cab mounting bracket attached).
2. Use a suitable hoist to remove the housing from
the engine stand.
3. Raise the housing up enough to put the support
blocks in position under the bearing support cover
as shown above.
4. Slowly lower the transmission housing until the
bearing support cover is fully seated on the support
blocks.
18·14
Slowly raise the transmission housing leaving the
NOTE: Be sure the blocks are in the correct position
bearing support cover and three shaft assemblies on
on the support cover.
the support blocks.
5. Reach under the housing and remove the two
remaining support cover retaining bolts that were STEP 7
tightened only finger tight.

'8-2
Remove the mounting bolts from the three bearing
cages. Remove the bearing cages and shims.

NOTE : Keep the shims together with the bearing cage

as the cages are removed.
6006-8

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 stand,
turn the housing so the cover is in the upright STEP 11
position.
2. Remove the mounting bolts from the front bearing
support.
3. Loosen and raise the transmission housing cover
using prybars under the two lift areas.

STEP 9

Remove input shaft.

Place strap around input shaft. Raise input shaft and

remove countershaft.
 6006-9

Disassembling the Countershaft with Creeper Speed Clutch

STEP 12 STEP 14

Remove the two seal rings from the shaft. Remove the caged needle bearing.

STEP 13 STEP 15

T95238 A11511

Use a hydraulic press to remove the front bearing cone Remove t he rear needle thrust bearing and the two
and the creeper driven gear. bearing thrust washers.

NOTE: The front needle thrust bearing and two

bearing thrust washers wi/l come off with the front
bearing cone.
6006-10

STEP 16 STEP 18

Remove snap ring as follows: Remove the snap ring.

1. Install the compression sleeve CAS1903-3 with the
notch over the piston return Belleville washers (see STEP 19
the Special Tools page in this section).
2. The opening in the special tool must be over the
ends of the snap ring.
3. Compress the Belleville washers with a hydraulic
press and remove the snap ring.

NOTE: See Steps 27 through 30 for an alternative

method for removing the snap ring.

STEP 17

Al'515
Use a hydraulic press to move the shaft through the
clutch plate carrier, spacer and the (2nd-4th-6th) speed
driven gear.

STEP 20

Remove the Belleville washers.

Al0871

Remove the snap ring from inside the clutch plate

carrier.
 6006-11

STEP 21 STEP 24

4().33 T95256

Remove the backing plate. friction plates. separator Turn the shaft over and use a hydraulic press to
plates and reaction plate (thicker than separator plate) remove the rear bearing cone (1 st-2nd) speed driver
from the clutch carrier. gear and steel ball.

STEP 22 STEP 25
--.....,........

T95251 T95267

Remove the spacer. Remove the snap ring .

STEP 23

T95252

Remove the (2nd-4th-6th) speed driven gear and steel

ball.
6006-12

STEP 26 STEP 28

PRESS

T95546

Install the compression plate (CAS 1903-1) with the

two cap screws and six tangs inside the clutch carrier.
OBR01
1. COUNTERSHAFT 3. 1ST·3RD·5TH DRIVEN
Th e tangs on the plate must engage the snap ring
GEAR groove inside the carrier.
2. 3RD·4TH DRIVER GEAR 4. SUPPORT
STEP 29
Turn the sh aft over and use a hydraulic press to
remove the (3rd-4th) speed driver gear and the (1 st·
3rd-5th) speed driven gear. Remove the two steel
balls.

Alternative Method for Snap Ring 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.

STEP 27
T95547
~-
Compress the Belleville washers by tightening the cap
screws in the tool.

STEP 30

T95545
Install the compression plate (CAS 1903-2) over the
piston return Belleville washers. The counterbore of the
plate must go over the Belleville washers.

T95548

Remove the snap ring.

 6006-13

ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH

rJ~~

8 ~~ ~
~ ~~
/~~ ®: I

~~~~~ ~4 !
~~- 11 ,:

(~~ ~
I "",,'
__ X@~~
..... 0°
_:
--
\
,
v
21

39L94
1. FRONT BEARING CONE 11 . PISTON RETURN BELLEVILLE WASHERS (13) 21. 2ND-4TH-6TH SPEED DRIVEN GEAR
2. NEEDLE BEARING 12. CLUTCH PISTON 22. SLOTTED SPRING PIN
3. CREEPER DRIVEN GEAR 13. SNAP RING 23. STEEL BALL
4. THRUST WASHERS 14. SNAP RING 24. COUNTERSHAFT
5. NEEDLE THRUST BEARING 15. O-RING 25. 1ST-3RD-5TH SPEED DRIVEN GEAR
6. SNAP RING 16. PISTON OD RING 26. 3RD-4TH SPEED DRIVER GEAR
7. BACKING PLATE 17. PISTON ID RING 27. 1ST-2ND SPEED DRIVER GEAR
8. SEPARATOR PLATE 18. O-RING 28. REAR BEARING CONE
9. FRICTION PLATE 19. CLUTCH PLATE CARRIER
10. REACTION PLATE 20. SPACER

NOTE: If any elutcD pack is disassembled, new friction plates must be installed.
6006-14

STEP 31 STEP 32

A22751

DIMENSION

1. 1ST-2ND DRIVER
GEAR
2. REAR BEARING CONE
3. 3RD STEEL BALL
4. 2ND STEEL BALL
66L94
5. 3RD-4TH DRIVER GEAR
6. 1ST STEEL BALL
7. 1ST-3RD-5TH DRIVEN
GEAR

Install steel balls as follows:

389L7
1. SLOTTED SPRING PIN
2. PLUG
3. DOWEL PIN
DIMENSION A - 3 mm (0.118 inch)
Install countershaft components as follows:
1. Install slotted pin (1) and press flush with shaft 00.
2. Install the plug (2) and press in place as shown; 3
mm (0.11 8 in .) beyond the face of the shaft.
3. Install the dowel pin (3) and press in flush as
shown.
4. Be sure the dowel pin, plug and the slotted spring
pin for the countershaft are in place.
5. Make sure that all the oil passages in the shaft are
open. See the illustration above.
1. Apply petroleum jelly to the first steel ball (6) and
install ball into hole in shaft for (1 st-3rd-Sth) driven
gear (7).
2. Heat the (1 st-3rd-Sth) speed driven gear in a
bearing oven for 3 to 4 hours at a temperature of
350 to 370 0 F (177 to 1870 C).
WARNING: Always wear heat protective
*-
Lll
gloves to prevent burning your hands when
handling heated parts.
SM121A
NOTE: Do not heat the gear beyond a temperature of
375" F(19(f' C).
3. Install the gear over the shaft, engaging the ball
and seat against the shaft shoulder.
4. Apply petroleum jelly to the second steel ball (4)
and install into the shaft hole for (3rd-4th) speed
driver gear.
 6006-15
5. Heat the (3rd-4th) speed drive gear (5) in a bearing STEP 34
oven for 3 to 4 hours at a temperature of 350 to
370° F (177-18JOC).

NOTE: Do not heat the gear beyond a temperature of

375 o f (190' C).
6. Install the gear (5) over the shaft. engaging the ball
and seat against the (1 st-3rd-5th) speed driven
gear.
7. Install the snap ring. The flat side of the snap ring
must face away from the gear.
8. Apply petroleum jelly to the third steel ball (3) and
install into the shaft hole for (1 st-2nd) speed driver
A22753
gear.
Apply petroleum jelly to the steel ball and install in the
9. Heat the (1 st-2nd) speed driver gear (1) in a shaft hole.
bearing oven for 3 to 4 hours at a temperature of
350 to 370°F (177 to 187° C). STEP 35
NOTE: Do not heat the gear beyond a temperature of
375" F (190' C).
10. Install the gear (1) over the shaft. engaging the ball
and seat against the shaft shoulder.

STEP 33

Heat the (2nd-4th-6th) speed driven gear in a bearing

oven for 3 to 4 hours at a temperature of 350° to 370°F
(177° to 187°C).

NOTE: Do not heat the gear beyond a temperature of

375°F (190°C).
A11504

Install the bearing cone over the shaft with the larger WARNING: Always wear heat protective
00 end of the bearing seated against the gear. Press ".. gloves to prevent burning your hands when
the bearing on the inner race to properly seat the Loll handling heated parts.
bearing on the shaft. SM121A
6006-16
STEP 36

40-35
Install the spacer.
Remove and replace teflon ring and a-ring as follows:
STEP 37 1. Replace the teflon ring and the a-ring on the
carrier and piston .
2. Install the a-ring in the groove. Install the teflon
ring over the a-ring as shown below.

T952n
Hit the clutc h plate carrier against a wood block to
remove the clutch piston .

STEP 38

1. PISTON
2. TEFLON RING
3. O-RING

STEP 39

T95278

T95280
 6006-17

STEP 42

Al0876
41 ·3
Install a new friction plate.
Apply petroleum jelly to the teflon rings.

NOTE: Dip all friction plates in clean transmission

STEP 40 fluid.

STEP 43

Al0873
Install the clutch piston into the carrier with the flat side
of the piston facing down. Push the piston into the
Al08n
carrier by hand.
Install a separator plate. Install the remaining seven
new friction plates and six separator plates, alternating
STEP 41 the plates.

STEP 44

A10875
Install the reaction plate (thicker than separator plate).
Al0878
NOTE: The reaction plate is similar to a separator
plate except that it is thicker. Install the backing plate. The flat side of the plate must
be facing down.
6006-18
STEP 45 STEP 48

Install the snap ring.

STEP 46

7ela

Install the first piston-return Belleville washer. The

concave side of the washer must be facing down.

STEP 49

___ ~l'

AAl1505

Put the carrier assembly in a press. Align the oil hole in

the carrier with the oil gallery hole in the shafl. Press
the shaft into the carrier until fully seated.

NOTE: Be sure the oil holes in the shaft and carrier

are aligned before proceeding.

STEP 47

A11509

Install the remaining Belleville washers as follows:

1. Install the second Belleville washer. The concave
side of the washer must be facing up.
2. Install the remaining eleven Belleville washers,
alternating the position of the washers until the last
washer is installe . with the concave side facing
down.

Install the carrier retaining snap ring.

 6006-19

STEP 50 STEP 51

Install the needle thrust bearing and the two bearing

thrust washers. The needle thrust bearing must be
between the two bearing thrust washers.

STEP 52

DIMENSION

T95295

Install a new seal ring on the creeper driven gear.

STEP 53
389L7
1. SLOTIED SPRING PIN
2. PLUG
3. DOWEL
DIMENSION A - O.11SINCH (3 mm)

Install snap ring as follows:

1. Install the snap ring on the shaft.
2. Align the opening on the snap ring with the slotted
spring pin in the shaft (see drawing above).
3. Install the compression sleeve CAS1903-3 with the
notch over the shaft.
T95296
4. Use a hydraulic press to compress the Belleville
washers. Align the friction plate teeth. Install the creeper driven
gear into the clutch carrier assembly. Slight oscillation
5. Install the snap ring in the groove. of the gear will help with the installation. The splined
hub of the gear must engage all the friction plates.
6006-20

STEP 54 STEP 57

Install the caged needle bearing. The top of the needle
bearing cage will be aligned with the top of the gear
hub when all the friction plates are engaged on the
hub.
STEP 55
Install two new seal rings on the rear of the shaft.
STEP 58
Disassemble and assemble the countershaft using the
illustrations provided. For disassembly. follow Steps
23 to 26. For assembly. follow Steps 32 to 36.

A11513

Install the needle thrust bearing and the two bearing

thrust washers . The needle thrust bearing must be
between the two bearing thrust washers.

STEP 56
""""-

A11 5 14

Install the bearing cone with the larger 00 bearing end

facing down. Press the bearing on the inner race to
properly seat the bearing on the shaft.
 6006-21
Counters haft with Creep

SSl 94A
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. COUNTERSHAFT 8. EVEN SPEED CLUTCH
6006-22
Disassembly and Assembly of Countershaft without Creep

, ~ ~ ~./"
~ /
./ CD
........... "// 5

,,
~
' ~~
o
,/
/~

91194
1. 1ST-3RD-5TH DRIVEN GEAR 6. FRONT BEARING CONE
2. 3RD-4TH SPEED DRIVER GEAR 7. SNAP RING
3. 1ST-2ND SPEED DRIVER GEAR 8. 2ND-4TH-6TH SPEED DRIVEN GEAR
4. REAR BEARING CONE 9. GEAR DETENT BALLS (4)
5. SNAP RING 10. COUNTERSHAFT

1 2 3

4
1. 1ST-2ND SPEED DRIVER GEAR
2. 3RD-4TH SPEED DRIVER GEAR
5
87L94
3. 2ND-4TH-6TH SPEED DRIVEN GEAR 5. 1ST.lRD-5TH SPEED DRIVEN
GEAR
4. REAR BEARING CONE 6. FR9 NT BEARING CONE
 6006-23

Disassembling the Speed Input Shaft

STEP 59 STEP 62

Remove the five seal rings from the speed input shaft. Remove the two snap rings.

STEP 60 STEP 63

Use a bearing puller to remove the rear bearing cone. Remove the spacer.

STEP 61 STEP 64

T95307
Remove the spacer. Remove the two bearing thrust washers and the needle
thrust bearing.
6006-24
STEP 65

Remove the (1 st-3rd-5th) speed drive gear. Remove the snap ring .

STEP 66 STEP 69

Remove the caged needle bearing. Remove the backing plate.

STEP 67 STEP 70

T95310 T95313

Remove the two bearing thrust washers and the needle Remove the friction plates, separator plates and the
thrust bearing. reaction plate (thicker than separator plate) .
 6006-25
STEP 71 STEP 74

T95315

Use a bearing puller to remove the front bearing cone. Remove the snap ring.

STEP 72

89010 A11538

Non Creep Transmission Remove the two bearing thrust washers and the needle
thrust bearing .
Use a bearing puller to remove the gear and front
bearing cone.
STEP 76
STEP 73

T95319

Remove the (2nd-4th-6th) speed drive gear.

T95316

Use a bearing puller to remove the creeper gear, if

equipped.
6006-26

STEP 77

Remove the caged needle bearing. Remove the snap ring.

STEP 78 STEP 81

Remove the spacer. Remove the backing plate.

STEP 79 STEP 82

Remove the second caged needle bearing. Remove the friction plates, separator plates and the
reaction plate (thicker t~an separator plate).
 6006-27

STEP 83 STEP 86

T95327 T95332

Remove the two bearing thrust washers and the needle Remove the carrier retaining snap ring from each side
thrust bearing. of the clutch plate carrier.

STEP 84 STEP 87

\
( :
Install the compression sleeve CAS1903-3 with the
notch over the piston return Belleville washer. The
opening in the sleeve must be over the ends of the
snap ring . Compress the Belleville washers with a
hydraulic press and remove the snap ring from both
sides of the clutch plate carrier. 468172

.....
1. MARK ON FACE OF 2. MARK ON FRONT END
CARRIER OF SHAFT
STEP 85
~ Make an appropriate mark with scratch awl, prick
punch , etc ., on the front end of the carrier. Make a
similar mark on the same end of the shafl. Make sure
that these marks are aligned. These marks will be used
to align the carrier on the shaft during assembly.

NOTE: If a new part replaces an old part, make a mark

on the new part that is in the same position as the mark
for the old part.

T95331
Remove the piston retu rn Belleville washers from each
side of the clutch plate carrier.
6006-28

STEP 88

6006-30

Assembly of the Speed Input Shaft

STEP 89 STEP 91

396L7 T95337

1. SLOTIED SPRING PIN 2 . COILED SPRING PIN (4)

(2)

Install plugs, slotted spring pins, and coiled spring pins

as follows:
1. Install slotted spring pins (1) by pressing them in
flush with the shaft 00.
2. If non-creep, install the coiled spring pins (2) so
that it is pressed 1 mm below the shaft 00. If creep
option, install five pins (2) .
3. Be sure the plugs, slotted spring pins and the
coiled spring pins are in place.
4. Make sure that all the oil passages in the shaft are 40-3'
clean and open. See the illustration above. Replace the teflon ring and a-ring on the carrier and
piston. Install the a-ring in the grove. Install the teflon
STEP ~9~O __________________ ~
ring over the a -ring .

T95336

Hit the clutch plate carrier against a wood block to

remove the clutch piston from each side of the carrier.
 6006-31

STEP 92 STEP 94

T95280
\
468Ln
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).

NOTE: If a new part replaces an old part, make a mark

41 -3
on the new part that is in the same position as the mark
for the old part.
Apply petroleum jelly to the teflon rings

STEP 93 STEP 95

Install the shaft on the carrier as follows:

Install the snap ring on the shaft in the third groove
from the front to retain the rear side of the clutch plate
carrier.
1. Align the mark on the front end of the shaft with the
mark on the face of the clutch plate carrier before
pressing the shaft through the carrier. Aligning the
marks will align the oil holes in the shaft with the oil
holes in the carrier.
2. Press the front end of the shaft through the carrier
until the carrier is seated against the snap ring.
6006-32
3. Check to be sure that all the oil holes in the shaft
and carrier are aligned.

NOTE: Be sure marks are properly aligned for correct

timing.

STEP 96

T95341

Turn the shaft over and install the carrier retaining ring.

STEP 97 181.8

Install the first piston return Belleville washer. The

concave side of the washer must be facing down.

STEP 99

" 11519
Install a clutch piston into each side of the carrier. The
flat side of the piston must be down. Push the piston
into the carrier by hand.

Install the remaining Belleville washers as follows:

1. Install the second Belleville washer. The concave
side of the washer must be facing up.
2. Install the remaining eleven Belleville washers,
alternating the posilion of the washers until the last
washer with the concave side is facing down.
 6006-33
STEP 100 3. Install the Belleville washer compression sleeve
over the shaft and centering sleeve CAS 1903-5
and on top of the snap ring.

NOTE: The smaller 00 side of the sleeve must be

facing up.

STEP 102

A11523

Install the centering sleeve CAS 1903-4 over the shaft.

Install the compression sleeve CAS1903-3 with the

notch over the shaft. Use a hydraulic press to press
the sleeves down. The snap ring will be pushed into
position in the groove with the pin between the snap
ring ends. Verify that the snap ring is properly seated in
the groove.

STEP 103
1525
Install the snap ring as follows:
1. Install the snap ring over the centering sleeve.
2. Align the opening in the snap ring with the slotted
spring pin in the shaft, as shown in the illustration
below.

~--CD

Install the reaction plate (thicker separator plate) .

DETAILA-2
1. SNAP RING GAP
2. SNAP RING
3. SHAFTOD
4. SLOTTED SPRING PIN

"
6006-34

STEP 104 STEP 107

Install a new friction plate. Install the snap ring.

NOTE: Dip all friction plates in clean transmission STEP 108

fluid.

STEP 105

Install the two bearing thrust washers and the needle

Install a separator plate. Install the remaining six new
friction plates and five separator plates, alternating the
plates.
thrust bearing. The needle thrust bearing must be
between the two thrust washers.
STEP 109

STEP 106

1. SEAL

A11531 Install a new seal ring on the (2nd-4th-6th) speed drive

Install the backing plate. The flat side of the plate must gear at location shown by arrow. Align the friction plate
face down. teeth. Install the gear into the clutch pack. The splined
hub of the gear must be facing down.
 6006-35
STEP 110 STEP 113

A"534
Slight oscillation of the gear will help with the Install another caged needle bearing into the gear hub.
installation. The splined hub of the gear must engage
all the friction plates. NOTE: The top of the second needle bearing cage will
be aligned with the top of the gear hub when all the
STEP 111 friction plates are engaged with the splined hub of the
gear.

STEP 114

Install a caged needle bearing into the gear hub.

STEP 112 A11538

Install the two bearing thrust washers and the needle

thrust bearing. The needle thrust bearing must be
between the two bearing thrust washers.

Install a spacer into the gear hUb.

6006-36

STEP 115 STEP 11 8

If the transmission has the creep option , install the
snap ring against the bearing thrust washer_
STEP 116
A'1S16
Install the bearing conb on the shafl. The larger 00
end of the bearing cone must face down . Press the
bearing on the inner race to properly seat the bearing
on the shaft.

STEP 119

In stall the creeper speed gear (if equipped). The

longer hub of the gear must face down.
Turn the shaft over and install the thirteen piston return
STEP 117 Belleville washers as shown in Steps 98 and 99.

-
1. LONGER HUB

Press the creeper speed gear into position.

 6006-37
2. Use a hydraulic press to press the sleeve down.
The snap ring will be pushed into position in the
groove with the pin between the snap ring ends.
3. Verify that the snap ring is seated properly in the
groove.

STEP 123

DETAtLA
1. SNAP RING GAP 3. SHAFTOD
2. SNAP RING 4. SLOTIED SPRING PIN

Install a snap ring over the shaft. Align the opening in

the snap ring with the slotted pin in the shaft to allow for
flow of lubricant.

STEP 121
T953 13

Install the reaction plate, friction plates, and separator

plates as follows:
1. Install the reaction plate (thicker separator plate).
2. Install the seven new friction plates and six
separator plates, alternating the plates.

STEP 124

Install the Belleville washer compression sleeve

CAS1903-5 over the shaft and on top of the snap ring.
The smaller 00 side of the sleeve must be facing up.

STEP 122

Install the backing plate. The flat side of the plate must
face down.

Al l 542
Install snap ring as follows:
1. Install the compression sleeve CAS1903-3 with the
notch over the shaft.
6006-38

STEP 125

Install the snap ring. Slight oscillation of I he gear will help with the
installation. The I hub of the gear must engage
STEP 126 all the friction plates. I

STEP 129

Install the two bearing thrust washers and the needle

thrust bearing. The needle thrust bearing must be
between the two thrust washers. Install a caged needle bearing into the gear hub.

STEP 127 NOTE: The top of thJ needle bearing cage will be
aligned with the top of the gear hub when all the friction
plates are engaged wit1 the splined hub of the gear.

1. SEAL

Install a new seal ring on the (1 st-3rd-Sth speed) drive

gear. Align the friction plate teeth. Install the gear over
the shaft. The splined hub of the gear must be facing
down .
 6006-39
STEP 130 STEP 133

Install the two bearing thrust washers and the needle Install the second spacer.
thrust bearing.
STEP 134
NOTE: The needle thrust bearing must be between
the two bearing thrust washers.

STEP 131

A11517

Install the bearing cone on the shaft. The larger 00

end of the bearing must be facing down. Press the
bearing on the inner race to properly seat the bearing
on the shaft.
Install the first spacer.
STEP 135
STEP 132

T95300

Install five new seal rings on the end of the input shaft.
Install the two snap rings.
6006-40
Speed Input Shaft

\ CD
I
1. (lst-3rd-5th) SPEED DRIVE GEAR 4. CREEPER SPEED GEAR (IF EQUIPPED) . EVEN SPEED CLUTCH
385L7

2. CLUTCH PLATE CARRIER 5. FRONT BEARING CONE

r PACK
B. ODD SPEED CLUTCH PACK
3. (2 ND-4TH-STH) SPEED DRIVE S. INPUT SHAFT 9. REAR BEARING CONE
GEAR
 6006-29

Speed Input Shaft Assembly

1\ ,
:~(;)~ ,\,~
I /
I
I

,
I

93210
1. FRONT BEARING CONE 8. EVEN SPEED CLUTCH 15. THRUST WASHERS
2. CREEPER SPEED GEAR 9. ODD SPEED CLUTCH PACK 16. SPACERS
3. 2ND·4TH·6TH SPEED DRIVE GEAR 10. INPUT SHAFT 17. REAR BEARING CONE
4. CAGED NEEDLE BEARING 11 . PISTON RETURN BELLEVILLE WASHERS 18. SEALS
5. SPACER 12. 1ST-3RD-5TH SPEED DRIVE GEAR 19. SNAP RINGS
6. SEAL RING 13. CAGED NEEDLE BEARING
7. PISTON RETURN BELLEVILLE WASHERS 14. THRUST BEARING

NOTE: If any clutch pack is disassembled, new friction plates must be installed.
6006-30

Assembly of the Speed Input Shaft

STEP 89 STEP 91

396L7

1. SLOTTED SPRING PIN 2. COILED SPRING PIN (4)

(2)

Install plugs, slotted spring pins , and coiled spring pins

as follows:
1. Install slotted spring pins (1) by pressing them in
flush with the shaft OD.
2. If non-creep, install the coiled spring pins (2) so
that it is pressed 1 mm below the shaft OD. If creep
option, install five pins (2).
3. Be sure the plugs, slotted sp ring pins and the
coiled spring pins are in place.
4. Make sure that all the oil passages in the shaft are 40-35
clean and open. See the illustration above. Replace the teflon ring and O-ring on the carrier and
piston. Install the O-ring in the grove. Install the teflon
STEP 90 ring over the O-ring .
~--------------------~

T95336

Hit the clutch plate carrier against a wood block to

remove the clutch piston from each side of the carrier.
 6006-41

Disassembling the Speed Output Shaft

STEP 136 STEP 139

--
T95391
Remove the four seal rings. Remove the reverse driven gear.

STEP 1~ STEP 1~
--~r-~~--~--~

T95387 A 11638

Use a bearing puller to remove the front bearing cone Remove the caged needle bearing and nylon spacer.
and the reverse driven gear from the shaft.
STEP 141
STEP 138

A11555
T95369 Remove the two bearing thrust washers and the needle
Remove the two bearing thrust washers and the needle thrust bearing.
thrust bearing.
6006-42
STEP 142

A11556 T95407

Remove the snap ring from inside the clutch plate Remove the piston return Belleville washers.
carrier.
STEP 146
STEP 143

T95410

Remove the backing plate , friction plates, separator

plates, and reaction plate (thicker separator plate).

STEP 144

\
2
468172
Install the compression sleeve CAS1903-3 with the 1. MARK ON FACE OF 2. MARK ON FRONT END
notch over the piston return Belleville washers . The CARRIER OF SHAFT
opening in the sleeve must be over the ends of the
snap ring. Compress the Belleville washers with a
hydraulic press and remove the snap ring.
 6006-43
Remove the snap ring. Make a mark on the carrier STEP 149
face that will align with the mark on the end of the shaft.
These marks will be used to align the carrier on the
shaft during assembly.

NOTE: If a new part replaces an old part, make a mark

on the new part that is in the same position as the mark
for the old part.

STEP 147

Remove the backing plate, friction plates, separator

plates and reaction plate.

STEP 150

Remove the clutch plate carrier from the shaft.

STEP 148

Install the compression sleeve CAS1903-3 with the

notch over the piston return Belleville washers. The
opening in the sleeve must be over the ends of the
snap ring. Compress the Belleville washers with a
hydraulic press and remove the snap ring.

STEP 151
Remove the snap ring from the clutch plate carrier.
'560 ......
-...~---

T95425
Remove the piston return Belleville washers
6006-44

STEP 152 STEP 155

-~--"- T95432
Remove the snap ring. Remove the caged needle bearing.

STEP 153 STEP 156

Remove the two bearing thrust washers and the needle

th rust bearing. Remove the thrust washer.

STEP 154 STEP 157

T95431
Remove the (3rd-4th ~"O'CUJ
Remove the (5th-6th speed) driven gear.
 6006-45
STEP 158 STEP 161

T95435

Remove the thrust washer spacer. Remove the snap ring from inside the clutch plate
carrier.
STEP 159
STEP 162

Remove the caged needle bearing. Al1563

Remove the backing plate, friction plates and separator
STEP 160 plates.

T95437

Remove the two bearing thrust washers and the needle

thrust bearing.
6006-46

STEP 163 STEP 165

Al1566
Remove Belleville washers as follows: Remove the caged needle bearing and the two bearing
thrust washers and needle thrust bearing.
1. Install the compression sleeve with the notch
CAS1903-3 over the piston return Belleville
washers. The opening in the sleeve must be over STEP 166
the ends of the snap ring .
2. Compress the Belleville washers with a hydraulic
press and remove the snap ring.
3. Remove the Belleville washers.

STEP 164

T95460

Remove the snap ring from inside the clutch plate

carrier.

STEP 167

A11565

Turn the shaft over. Use a bearing puller to remove the

(1 st-2nd) driven gear, two bearing thrust washers,
needle thrust bearing and the rear bearing cone.

T95461

Remove the backing plat~, friction plates and separator

plates .
 6006-47
STEP 168

T95469

Install the compression sleeve CAS1903-3 with the

\ 2

notch over the piston return Belleville washers. The 468L72

opening in the sleeve must be over the ends of the
snap ring . Compress the Belleville washers with a
hydraulic press and remove the snap ring.
STEP 169
1. MARK ON CARRI ER FACE 2. MARK ON SHAFT FRONT
Remove snap ring. Make a rnark on carrier face that
will align with rnark on the end of shaft. This mark will
help align carrier on the shaft during assembly.

NOTE: If a new part replaces an old part, make a mark

on the new part that is in the same position as the mark
for the old part.

STEP 171

T95471

Remove the piston return Belleville washers.

STEP 170
T95416
Press the splined rear end of the shaft so the shaft
moves through the clutch plate carrier.

1"95474
6006-48
Speed Output Shaft Assembly

,, ,
v

931LO

NOTE: If any clutch pack is disassembled, new friction plates must be installed.
1. SPACEA 5. (5TH-6TH) SPEED DRIVEN 9. PISTON RETURN 13. 3RD SPEED CLUTCH PACK
GEAR BELLEVILLE WASHERS
2. AEVERSE SPEED DRIVEN 6. PISTON RETURN 10. (3RD-4TH) SPEED DRIVEN 14. 1ST SPEED CLUTCH PACK
GEAR BELLEVILLE WASHERS GEAR
3. FRONT BEARING CONE 7 . 5TH SPEED CLUTCH PACK 11 . PISTON RETURN 15. ( 1ST-2ND) SPEED DRIVEN
BELLEVILLE WASHERS GEAR
4. FIBER THRUST WASHER 8. REVERSE SPEED CLUTCH 12. OUTPUT SHAFT 16. PISTON RETURN BELLEVILLE
PACK WASHERS
 6006-49

STEP 172 STEP 174 __________________--.

T95337
435L7
Replace the teflon ring and a-ring on the piston and
1. COILED SPRING PIN (6)
2. PLUG (3)
carrier as follows:
3. SLOTTED SPRING (4)

Install dowel pins, slotted spring pins and the coiled

spring pins as follows:
1. Press coiled spring pin (1) 1 mm below the shaft
00.
2. Install the plug (2) flush to the surface, as shown.
3. Press the slotted spring pin (3) flush to the surface,
as shown.
4. Be sure the plugs, slotted spring pins and the
coiled spring pins are in place.
5. Make sure that all the oil passages in the shaft are
clean and open. 1. Install the a-ring in the groove.

STEP 173 2. Install the teflon ring over the a-ring.

STEP 175

Hit the clutch carrier against a wood block to remove

the clutch pistons. T95497
Install the snap ring into the third groove in the shaft,
down from the rear end of the shaft.
6006-50

STEP 176 STEP 177

T95496
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
shaft with the oil holes in the carrier.
3. Press the carrier down on the shaft until the carrier
433L7
is against the snap ring.
1. FRONT FACE OF CARRIER 4. Check to be sure that all the oil holes in the shaft
2. MARK and carrier are aligned.
3 . REAR END OF SHAFT

Before pressing the shaft through the clutch plate STEP 178
carrier, find the etch mark that was made in Step 170
on the rear end of the shaft and on the front face of the
rear clutch plate carrier.

NOTE: If a new part replaces an old part, make a mark

on the part that is in the same position as the mark for
the old part.

1. CARRIER RETAINING RING SLOT

Install the carrier retaining ring.

 6006-51

STEP 179 STEP 181

T95280
Install the first piston return Belleville washer. The
concave side of the washer must be facing down.

STEP 182

41-3

Apply petroleum jelly to the teflon rings.

STEP 180

7Bl8

Install the second Belleville washer. The concave side

of the washer must be facing up. Install the remaining
11 Belleville washers, alternating the position of the
"11568
washers until the last washer with the concave side is
Install a piston in each side of the clutch carrier with the facing down .
flat side toward the inside.
6006-52

STEP 183 3. Install the Belleville washer compression sleeve

CAS1903-5 over the shaft and centering sleeve.
The compression sleeve will rest on top of the snap
ring.

NOTE: The smaller 00 side of the sleeve must be

facing up.

STEP 185

Install the centering sleeve CAS1903-4 over the shaft.

STEP 184

Install the sleeves and snap ring as follows:

1. Install the compression sleeve with the notch over
the shaft.
2. Use a hydraulic press to press the sleeves down.
The snap ring will be pushed into position in the
groove with the pin between the snap ring ends.
3. Verify that the snap ring is properly seated in the
groove.

1-4---.....,CD STEP 186

OETAILA
1. SNAP RING GAP 3. SHAFTOD
2. SNAP RING 4. SLOTIED SPRING PIN

Install snap ring as follows:

Install a separator plate.
1. Install the snap ring over the centering sleeve.
2. Align the opening in the snap ring with the slotted
NOTE: 1st and 3rd clutch does not use a reaction
plate (thicker than separator plate).
spring pin in the shaft.
 6006-53
STEP 187 STEP 190

Install a new friction plate. Install the snap ring.

NOTE: Dip all friction plates in clean transmission STEP 191

fluid.

STEP 188

A1 1581

Install the needle thrust bearing and the two bearing

thrust washers. The needle thrust bearing must be
between the two bearing thrust washers.
Install the remaining 10 separator plates and 10 friction
plates. alternating the plates.

STEP 189

Install the backing plate. The flat side of the plate must
face down.
6006-54
STEP 192 STEP 194

A1 1582
1. SEAL
Install the two bearing thrust washers and the needle
Install 1st-2nd speed driven gear as follows: thrust bearing. The needle thrust bearing must be
between the two bearing thrust washers.
1. Install a new seal ring on the (1 st-2nd speed)
driven gear. STEP 195
2. Align the friction plate teeth. Install the gear into
the clutch pack. The splined hub of the gear must
be facing down.
3. Slight oscillation of the gear will help with the
installation. The splined hub of the gear must
engage all the friction plates.

STEP 193

Install the bearing on the shaft with larger 00 side of

the bearing cone facing down. Press the bearing on the
inner race to properly seat the bearing on the shaft.

Install a caged needle bearing into the gear hub.

 6006-55

STEP 196 STEP 199

Turn the shaft over and install the first piston return
Belleville washer.
NOTE: The concave side of the washer must be facing
down.
Install the snap ring as follows:
1. Install the snap ring over the shaft.
2. Align the opening in the snap ring with the slotted
spring pin in the shaft.

STEP 197

DETAILA
1. SNAP RING GAP 3. SHAFTOD
2 . SNAP RING 4. SLOTIED SPRING PIN

Install the second Belleville washer. 3. Install the Belleville washer compression sleeve
CAS1903-5 over the shaft and on top of the snap
NOTE: The concave side of the washer must be facing ring.
up.
NOTE: The smaller 00 side of the sleeve must be
STEP 198 facing up.

7818
Install the remaining eleven Belleville washers,
alternating the position of the washers until the last
washer with the concave side is facing down.
6006-56
STEP 200 STEP 202

Install the snap ring as follows: Install a new friction plate.

I . Install the compression sleeve CAS1903-3 with the
NOTE: Dip all friction plates in clean transmission
notch over the shaft.
fluid.
2. Use a hydraulic press to press the sleeves down.
The snap ring will be pushed into position in the STEP 203
groove.
3. Verify that the snap ring is seated properly in the
groove.

STEP 201

Install the remaining 8 separator plates and 8 friction

plates, alternating the plates.

STEP 204

Install a separator plate.

NOTE: 1st and 3rd clutch does not use a reaction

plate (thicker than separator plate).

A11S90

Install the backing plate.

NOTE: The flat side of the plate must face down.

 6006-57
STEP 205 1. Install a new seal ring on the (3rd - 4th speed)
driven gear.
2. Align the friction plate teeth. Install the gear into
the clutch pack. The splined hub of the gear must
be facing down.
3. Slight oscillation of the gear will help with the
installation.
4. The splined hub of the gear must engage all the
friction plates.

STEP 208

Install the snap ring.

STEP 206

A11603

Install the caged needle bearing.

STEP 209

A11601

Install the two bearing thrust washers and the needle

thrust bearing .

NOTE: The needle thrust bearing must be between

the two bearing thrust washers.

STEP 207

A11604

Install the spacer.

A11602
1. SEAL

Install the 3rd-4th speed driven gear as follows:

6006-58

STEP 210 STEP 213

A11605 T95430

Install the fiber thrust washer on the spacer ring. Install the two bearing thrust washers and the needle
thrust bearing.
STEP 211
NOTE: The needle thrust bearing must be between
the two bearing thrust washers.

STEP 214

Al'606
Install another caged needle bearing.

STEP 212

A11607
1. SEAL 1. SNAP RING GAP 3. SHAFTOD
2. SNAP RING 4. SLOTTED SPRING PIN

Install a new seal ring on the (5th-6th speed) gear.

Install the retaining ring for the piston return Belleville
Install the gear on the shaft.
washers on the shaft.
NOTE: The splined hub of the gear must be facing up.
NOTE: The gap in the snap ring must be centered
over the slotted spring pin in the shaft.
 6006-59

STEP 215 STEP 217

~.....,..-=""

, ~ .... --
T95425 T95499
Install the Belleville washer compression sleeve
CAS1903-5 on the shaft and over the piston return
Belleville washers.

NOTE: The smaller 00 end of the sleeve must be

facing up.

STEP 218
79LBR

Install Belleville washers as follows:

1. Install the first washer with the concave side facing
up.
2. Install the second washer with the concave side
facing down.
3. Install the remaining eleven washers, alternating
the position of the washers until the last washer
concave side is facing up.

STEP 216
~~
Install the snap ring as follows:
1. Install the compression sleeve CAS1903-3 with the
notch over the shaft.
2. Use a hydraulic press to press the sleeves down.
The snap ring will be pushed into position in the
groove.
3. Verify that the snap ring is seated properly in the
groove.
.-
T95424
Install the snap ring on the shaft and let the snap ring
lie on top of the last piston return Belleville washer that
was installed.
6006-60

STEP 219 STEP 222

T95418

Put the clutch pack retaining ring on top of the gear. Install a separator plate.

STEP 220 STEP 223

~-"-"'II!

T95416

Install the backing plate over the gear.
NOTE: The flat side of the place must be facing up.
STEP 221
Install the remaining six new friction plates and five
separator plates. alternating the plates.
STEP 224
!!IJ!ISII''IIIIIIIIII~~rn~

~~

T95420
T95417 Install the reaction plate (thicker separator plate) over
Install a new friction plate. the gear.

NOTE: Dip all friction plates in clean transmission

fluid.
 6006-61
STEP 225 STEP 227

43417
1. FRONT FACE OF CARRIER
2. MARK
3. FRONT FACE OF SHAFT

Before installing the front clutch plate carrier on the

shaft, find the mark made in Step 146 on the front face
'0-35 of the carrier and on the front end of the shaft.
Install the teflon and a-rings as follows:
1. Hit the clutch carrier against a wood block to STEP 228
remove the clutch pistons.
2. Replace the teflon ring and a-ring on the carrier
and piston.
3. Install the a-ring in the groove.
4. Install the teflon ring over the a-ring.

STEP 226

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.

NOTE: Aligning the marks will align the oil holes in the
A11609 shaft with the oil holes in the carrier.
Apply petroleum jelly to the teflon rings and install the
5th clutch piston into the carrier.
6006-62
3. Align the separator plate tabs with the slots in the STEP 231
carrier.
4. Use a press if necessary to carefully push the
carrier down on the shaft.
5. Check to be sure that the oil holes in the shaft and
carrier are aligned. Look through the oil hole in the
carrier and almost a full hole in the shaft should be
visible.

STEP 229

Install snap ring as follows:

1. Insert a tubular pressing tool that is smaller in
diameter than the larger ID of the compression
tool, but not so small that it goes through the hole
in the compression tool.
2. Use a hydraulic press to press the carrier snap ring
into the groove.
" 3. Verify that the snap ring is seated properly in the
- - - -- ~T95503
groove.
Install the carrier snap ring over the shaft.
STEP 232
STEP 230 '--'_ -"';""_l'""

A11610
Use a screwdriver to install the snap ring that was
Install the compression sleeve CAS1903-5 over the
installed on top of the gear (Step 219) , into the inside
shaft.
groove in the carrier. Air check the clutch using the
procedure in Step 252.
NOTE: The large 00 end of the sleeve must be up.
 6006-63

STEP 233 STEP 235

A11612 A116 14

Apply petroleum jelly to the teflon rings and install the

reverse clutch piston into the carrier with the flat side
facing down.

STEP 234

1. SNAP RING GAP 3. SHAFTOD

2. SNAP RING 4. SLOTTED SPRING PIN

Install snap ring and Belleville washer compression

sleeve as follows:
1. Install a centering sleeve CAS1903-4 over the
shaft.
2. Install the snap ring over the centering sleeve.
3. Align the opening in the snap ring with the slotted
spring pin in the shaft.

4. Install the Belleville washer compression sleeve

CAS1903-5 on top of the snap ring.
8218

NOTE: The reverse piston uses 11 piston return

Belleville washers.
Install Belleville washers as follows:
1. Install the first washer with the concave side facing
down.
2. Install the second washer with the concave side
facing up.
3. Install the remaining nine washers, alternating the
position of the washers until the last washer is
installed with the concave side is facing down.
6006-64

STEP 236 STEP 238

T95399
Install snap ring as follows: Install a new friction plate.
1. Install the compression sleeve CAS1903-3 with the
NOTE: Dip all friction plates in clean transmission
notch over the shaft.
fluid.
2. Use a hydraulic press to push the sleeves down.
The snap ring will be pushed into position in the STEP 239
groove with the pin between the snap ring ends.
3. Verify that the snap ring is seated properly in the
groove.

STEP 237

Install a separator plate. Install the remaining 6 new

friction plates and 5 separator plates , alternating the
plates and plates.

T95396
STEP 240
Install the reaction plate (thicker separator plate).

T95395

Install the backing plate. The flat side must be facing

down.
 6006-65
STEP 241 1. Install a new seal ring on the reverse speed driven
gear.
2. Alig n the friction plate teeth.
3. Install the reverse speed driven gear into the clutch
pack. The splined hub of the gear must be facing
down. Slight oscillation of the gear will help with
the installation.

NOTE: The splined hub of the gear must engage all

the friction plates.

STEP 244
T95393
Install the snap ring.

STEP 242

"-
A116l7

Install the spacer in the gear hub. Install the caged

needle bearing into the gear hub.

STEP 245
Install the needle thrust bearing and the two bearing
thrust washers.

NOTE: The needle thrust bearing must be between

the two bearing thrust washers.

STEP 243

Install the needle thrust bearing and the two bearing

thrust washers.

NOTE: The needle thrust bearing must be between

the two bearing thrust washers.

Al16l6
1. SEAL

Install the reverse speed driven gear as follows:

6006-66
STEP 246
A11552
Install the front bearing cone with the smaller OD end
of the bearing cone facing up. Press the bearing on the
inner race to properly seat the bearing on the shaft.
Cross-Section View of Output Shaft
1. 1ST SPEED CLUTCH PACK
2. 3RD SPEED CLUTCH PACK
3. 5TH SPEED CLUTCH PACK
4. REVERSE SPEED CLUTCH
PACK
5. OUTPUT SHAFT
6. FRONT BEARING CONE
7. REVERSE SPEED DRIVEN GEAR
STEP 247
T95386
Install four new seal rings on the shaft.
73194
8. FRONT CLUTCH PLATE
CARRIER
9 . (5TH-6TH) SPEED DRIVEN GEAR
10. (3RD·4TH) SPEED DRIVEN GEAR
11 . REAR CLUTCH PLATE CARRIER
12. (1ST-2ND) SPEED DRIVEN GEAR
13. REAR BEARING CONE

Air Check for Speed Transmission Clutch Piston Operation
STEP 248
1. CREEPER CLUTCH PLATES
Use an air gun to check the movement of the creeper
clutch piston, if equipped, as follows:
1. Install the tip of the air gun into the oil hole at the
rear end of the countershafl. The air pressure will
move the clutch plates on the creeper clutch.
2. Replace the seal rings on the piston if the clutch
plates do not move.
STEP 249
1. ODD CLUTCH PLATES
Check the odd gear clutch piston operation as follows:
1. Install the tip of the air gun into the hole in the third
groove from the rear of the input shaft.
2. The air pressure will move the clutch plates in the
odd gear clutch .
3. Replace the seal rings on the clutch piston if the
clutch plates do not move.
6006-67
STEP 250
;.;......;.....-- T95510A
1. EVEN CLUTCH PLATES
Check the even gear clutch piston operation as follows:
1. Install the tip of the air gun into the hole in the
fourth groove from the rear of the input shaft.
2. The air pressure will move the clutch plates in the
even gear clutch.
3. Replace the seal rings on the clutch piston if the
clutch plates do not move.
STEP 251
1. REVERSE CLUTCH PLATES
Check reverse gear drive clutch as follows:
1. Install the tip of the air gun into the oil hole in the
end of the output shaft. The air pressure will move
the clutch plates in the reverse gear drive clutch.
2. Replace the seal rings on the clutch piston if the
clutch plates do not move.
6006-68
STEP 252_ _ _~.."._ _ _ _ _....,.,..., STEP 254

T95514
1. 5TH CLUTCH PLATES 1. 3RD CLUTCH PLATES

Check 5th gear clutch piston operation as follows:
1. Install the tip of the air gun into the oil hole in the
first groove from the rear of the output shaft. The
air pressure will move the clutch plates in the 5th
gear clutch.
2. Replace the seals on the clutch piston if the clutch
plates do not move.
Check 3rd gear clutch piston operation as follows:
1. Install the tip of the air gun into the oil hole in the
third groove from the rear of the output shaft. The
air pressure will move the clutch plates in the 3rd
gear clutch.
2. Replace the seal rings on the clutch piston if the
clutch plates do not move.

STEP 253

1. 1ST CLUTCH PLATES

Check 1st gear clutch piston operation as follows:

1. Install the tip of the air gun into the oil hole in the
second groove from the rear of the output shaft.
The air pressure will move the clutch plates in the
1st gear clutch.
2. Replace the seals on the clutch piston if the clutch
plates do not move.
 6006-69

Countershaft, Input Shaft, and Output Shaft Installation - Exploded View

73L~AR

1. OUTPUT SHAFT REAR BEARING CAGE 9. SHIM

2. SHIM 10. COUNTERSHAFT REAR BEARING CAGE
3. BEARING CUP 11 . SHIM
4. OUTPUT SHAFT ASSEMBLY 12. BEARING CUP
5. INPUT SHAFT ASSEMBLY 13. MFD NEEDLE BEARING
6. BEARING CUPS 14. COUNTERSHAFT ASSEMBLY
7. FRONT BEARING CAGE (WITH CREEP SPEED) 15. FRONT BEARING CAGE (WITHOUT CREEP SPEED)
8. INPUT SHAFT REAR BEARING CAGE
6006-70

Bearing Removal and Replacement

STEP 255 STEP 257

A11623 A 1 162 1

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. Press a new bearing fully seated.
assembly into the housing until the bearing is flush with
the rear housing surface. STEP 258

STEP 256

Press the bearing cup out of the rear output shaft
bearing cage if the bearing cone on the output shaft
has been replaced.
T95462
Use a puller to remove the bearing cup from the rear
countershaft bearing cage if the bearing cone on the
counters haft has been replaced.
STEP 259

A11620

Press a new bearing cup into the cage until the cup is
fully seated .
 6006-71
STEP 260 STEP 262

41-12 CVR901

Use a bearing puller to remove the bearing cup from
the rear input shaft cage if the bearing cone on the
input shaft has been replaced.
STEP 261
1. BEARING CUP
Remove all foreign material from the rear surface of the
front bearing support cover. Use a puller to remove any
bearing cup from the support cover (input shaft bearing
cup shown) if the bearing cone of that set was
replaced.

NOTE: Support cover shown for creep option.

STEP 263

41-16

Press a new bearing cup into the cage until the cup is
fully seated.

Press the new cup into the bearing support until the
cup is fully seated.

NOTE: Replacement of bearing cups in non-creeper

bearing support cover is similar.
6006-72

STEP 264 STEP 265

23-14

Install the rear bearing shim packs that were removed Remove all foreign material from the speed
during disassembly. and the rear bearing cages. Do transmission housing front flange.
not fully tighten the bolts.

TRANSMISSION ASSEMBLY WITH CREEP OPTION
STEP 266
A11624
Put the bearing support cover on support blocks as
shown in Step 4 in this section. Apply petroleum jelly to
the seal rings. Install the three shaft assemblies in the
cover.
STEP 267
18-11
Connect a chain to the rear of the speed housing. Use
a suitable hoist and slowly and carefully lower the
housing over the shaft assemblies until the shaft
bearing cones are seated in the cups.
6006-73
STEP 268
8""-0
Install and tighten a bolt in the bearing support cover at
the 1 and 7 o'clock position. Install bearing support
cover as follows:
1. Mount the speed housing to the engine stand.
2. Turn the housing up right and install the remaining
bolts into the bearing support cover.
3. Tighten the bolts to a torque of 94 to 106 Nm (69 to
78 Ib ft) .
6006-74
Shafts in Speed Transmission

85L94

1. OUTPUT SHAFT ASSEMBLY

2. INPUT SHAFT ASSEMBLY
3. COUNTERS HAFT
ASSEMBLY

• (I':
 ';g
1: 6006-75

TRANSMISSION ASSEMBLY WITHOUT'CREEP OPTION

STEP 269 STEP 271

Install input shaft as follows: Install the countershalt as follows:

1. Mount the transmission housing in the engine 1. Raise the input shalt approximately 44 mm (1-3/4
stand. inch.
2. Apply petroleum jelly to the seal rings on the 2. Install the countershalt until the gears of the
shafts. counters halt are in mesh with the gears of the input
shalt.
3. Install the input shaft.
3. Lower both the countershalt and input shalt into
STEP 270 position.

STEP 272

Install the output shaft.

Install the bearing support cover and bolts. Tighten the

bolts to a torque of 94 to 106 Nm (69 to 78 Ib It).
6006-76

Setting the End Play of the Speed Transmission Countershaft,

Input Shaft, and Output Shaft
STEP 273 4. Tighten two opposite bolts, alternately, in three
increments until the bolts are tightened to a torque
of 5.6 Nm (50 Ib in).
5. To get a correct end play, rotate the shaft until the
bolts torques do not change.

STEP 275

SCH306

NOTE: End play of each shaft must be checked if any

of the following parts were replaced: shaft, rear bearing
cage, front bearing cage, bearing cups, and bearing
cones. This procedure is an adjustable bearing set-up
to provide an end play of O. 03 to O. 13 mm (0. 00 1 to
0.005 inch) for each shaft assembly Check one shaft
at a time for end play.
Remove the rear bearing cage and remove all the
shims.
STEP 274
Do the following:
1. Measure the shim gap clearance between the rear
bearing cage and the housing. Measure at two
locations next to the two bolts that were tightened.
2. Use a tapered feeler gauge.
3. If the difference between the two measurements is
0.254 mm (0.010 inch) or less, take an average of
the two readings to the nearest 0.025 mm (0.001
inch).
4. If the difference is greater than 0.25 mm (0.010
inch), loosen the two bolts and check for correct
bearing seating, burrs, or foreign material.
5. Do the procedure again until a range of 0.25 mm
(0.010 inch) or less is obtained. Take an average
of the two readings.

SCH307

Install a rear bearing cage (with no shims) for the

appropriate shaft (output shaft shown) as follows:
1. Install the rear bearing cage.
2. Install the bolts into the rear bearing cage. The
bolts must be loose.
3. Rotate the shaft a minimum of 12 revolutions while
tightening the bolts.

Ee·
 6006-77

STEP 276 STEP 278

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. Use a dial indicator to measure the end play.
3. Use a pry bar inside the speed transmission
Input Shaft without Creep Drive 0 .009 in . (0.229 mm)
housing to lift a gear on the shaft.
Input Shaft with Creep Drive ..... 0 .008 in. (0.203 mm)
Countershaft without Creep Drive ....... ..... .. .. 0.014 in. 4. The end play must be 0.001 to 0.005 inch (0.03 to
(0.356 mm) 0 .13 mm).
Countershaft with Creep Drive .. ................... 0.008 in.
5. Add or remove shims to get a correct reading.
(0.203 mm)
Output Shaft ............................. 0.014 in. (0.356 mm)
NOTE : Measure the end play of all three shafts
The result is the correct shim pack thickness. Select a following the procedure in Steps 273 through 278.
measured shim pack having a thickness within 0 .001 Check one shaft at a time.
inch (0.025 mm) of the desired value.

STEP 277

SCH310

Install the measured shim pack and the rear bearing

cage. Tighten the bolts to a torque of 54 to 61 Nm (40
to 45 Ib ft).
6006-78
 Section
6007

RANGE TRANSMISSION TO REAR FRAME SPLIT

MX Series Tractors

CASE CORPORATION
@2002 Case Corporation
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13270 September, 2002
6007-2

TABLE OF CONTENTS
SPECIAL TOOLS ............ ............................................................................... ....................................... .................. 3

SPECIAL TORQUES ....................................... .. ......................................... ....... ..................................... .... ............. 3

RANGE TRANSMISSION TO REAR FRAME SPLIT .................................................................... .......................... 4

Disassembly .............................................. .. ............................. .................. .................................. ........................ 4
Assembly ....................................................................... ................................. ...... ............ .... ..................... .......... 8

Rae 6-13270 Issued 9-02 Printed in U.S.A

 6007-3

SPECIAL TOOLS

0507TlSR

1. SPLITIING 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 60mm ......................... .................. .... ............. ................................................. 232 to 262 Nm (171 to 193 Ib 11)
M16 x 80mm .............................................. ................... ..............••............................ 220 to 250 Nm (162 to 184 Ib 11)
M16 x 110mm ................................................................................ ....................... .. .. 220 to 250 Nm (162 to 1841b 11)

Rae 6-13270 Issued 9-02 Printed in U .S.A.

E
6007-4

RANGE TRANSMISSION TO REAR FRAME SPLIT

Disassembly STEP 2

NOTE: Clean the entire transmission housing before

beginning this procedure.

STEP 1

Before starting the procedure, do the following:

1. Park the tractor on a hard, level surface.
2. Put the gear shift control lever in PARK.
3. Fully lower the rear three-point hitch:
4. Turn the engine off and remove the key.
ROO2Cl80
5. Put blocks behind and in front of the rear wheels.
Position the splitting stand 17-526A (1). adapter
6. See the cab removal information and remove the plates (2), and jack stands (3) as shown above.
cab.
Position rear housing handler 17-527 (4) and adjust it
7. See the fuel tank removal information and to support the rear frame without lifting up on it.
remove the fuel tank.
Be sure that the transmission is as level as possible
8. Drain the transmission fluid into a clean and the rear handler wheels are straight. This will aid
container. in shaft alignment on assembly.

NOTE: The transmission capacity is approximately NOTE: Rear wheels removed for photographic
172 liters (45 gallons). purposes.

Rae 6-13270 issued 9-02 Printed in U .S. A.

 6007-5

STEP 3 STEP 6

Remove the hitch position sensor cover. Disconnect the wire harness from the PTO (1) and
MFD (2) solenoids.

STEP 4
STEP 7

Disconnect the hitch position sensor connector.

Remove the two lines (1) from the trailer brake valve
(if equipped). Remove the two lines (2) from the
STEP 5 steering priority valve.

Disconnect the draft pin connector (1 - LH and RH

side) and the transmission sump temperature sender
connector (2).

Rae 6-13270 Issued 9· 02 Printed in U .S.A.

6007-6

STEP 8 STEP 11

Disconnect the remote auxiliary controller (1) from Remove the top bolts.
the wire harness. Move the remaining controllers and
wire harness (2) forward until the harness is on the
front side of the rear housing/range housing seam. STEP 12
ii5f-!!!lI'I"i'.':~

STEP 9
,....----.

Remove the five bolts on each side of the housing.

Install alignment dowels on each side.

Tag and remove the hydraulic lines from the remote NOTE: Two bolts on the bottom are removed from
valve. Cap all lines and fittings. the rear.

STEP 10

Remove the cover from the RH side of the range

transmission. Move the snap ring out of the groove
and forward on the shaft.

Issued 9-02 Printed in U .S .A.

 6007·7
STEP 13

Separate the rear housing from the range housing.

As the rear housing is moved rearward , move the
snap ring and gear forward on the shaft. There is
also a spacer between the snap ring and gear. Be
sure to capture the snap ring, spacer and gear before
they reach the end of the shaft.

NOTE: Be sure that the PTa input shaft (1) stays

with the rear housing.

Rae 6·13270 Issued 9·02 Printed in U.S.A.

6007-8

Assembly STEP 16

STEP 14

Using a bolt on both sides, draw the rear frame and

Clean off all old gasket material in the flange area.
Install alignment dowels and a new gasket. Move the
rear housing forward until the PTO shaft (1) and the
bevel pinion shaft (2) are started in the range
housing.
range transmission together evenly. Remove guide
studs when two bolts are drawn tight and replace
with the bolts.Check to be sure the snap ring is fully
seated in the shaft groove.
NOTE: It may be necessary to rotate the PTa output
shaft to align splines.

STEP 15 STEP 17

When the bevel pinion shaft is far enough into the Install the top bolts.
range housing, install the constant mesh gear (1),
spacer (2) and snap ring (3) onto the shaft. Continue
to move the rear housing forward while moving the
snap ring along the shaft until it is seated in the
groove in the shaft.

Rae 6-13270 Issued 9-02 Printed in U .S.A.

 6007-9
STEP 18 STEP 20

Install tube removed from the remote valve.

STEP 21

Tighten the bolts to the following torques:

M16 x 60mm ....... ..... 232 to 262 Nm (171 to 1931b It)
M16 x 80mm ............ 220 to 250 Nm (162 to 1841b It)
M16 x 110mm .......... 220 to 250 Nm (162 to 184 Ib It)

IMPORTANT: Failure to correctly tighten bolts could

lead to failure of the bolts and housing.

STEP 19

Move the wire harness (1) and controllers back in

position. Connect the remote auxiliary controller (2)
to the wire harness.

STEP 22

Remove all foreign material from the cover and cover

mounting flange. Apply a bead of Loctite Gasket
Eliminator 515 down the center of the flange and
around each bolt hole. Install the cover and seven
bolts. Tighten all bolts to a torque of 54 to 61 Nm (40
to 45 Ib It).

Install the two steering priority lines (1) and the two
lines (2) for the trailer brake valve (if equipped).

Rae 6-13270 Issued 9-02 Printed in

6007-10

STEP 23 STEP 26

Install the hitch position sensor cover and tighten the

Connect the wire harness to the MFD and PTO
bolts.
solenoids.

STEP 24 STEP 27

9 1817

If not already done, install all removed drain plugs in

Connect the draft pin connector (1 - LH and RH side)
the transmission.
and the transmission sump temperature sender
connector (2) to the wire harness.
STEP 28
STEP 25

Remove the rear handler, front splitting stand and

jack stands.
Connect the hitch position sensor to the wire
harness.

Rae 6·13270 Issued 9-02 Printed in U .S .A.

 6007-11

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.

Complete the installation as follows:

1. Install the fuel tanks. See Fuel Tank Removal
and Installation information.
2. Install the cab. See Cab Raise/Removal and
Installation information.
3. Fill the transmission with fluid.
4. Remove the blocks from the wheels.

Rae 6-13270 Issued 9-02 Printed in U.S.A.

6007·12

Rae 6·13270 Issued 9-02 Printed in U.S.A.

 Section
6008

RANGE TRANSMISSION

~ 2003 Case Corporation

Printed in U.S.A .
6-13501 April , 2003
6008-2

TABLE OF CONTENTS
SPECIFICATIONS ...................................................................................... .................. ........................ ....... ...... ...... 3

TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR ......... ....... .......... ........ ...... ............................... 3

SPECIAL TORQUES ........... ................. .. ............................. ................. ................................ ... ................................ 3

SPECIAL TOOLS ....................................................................................................•... ....... .....•...... ......................... 4

RANGE TRANSMISSION ..................................... ............................................ .... ............................................. ..... 5

Removing the Shaft Master Clutch ........................ .............................. ................................................................ 5
Removing the Input Shaft, Countershaft, and Mechanical Front Drive (MFD) Clutch Shaft .............. .... .............. 7
Disassembly of the Master Clutch .... ......... ............... ..... ...................................... .............................................. 12
Exploded View of the Master Clutch .................................................................................................................. 14
Assembly of the Master Clutch .................................................... ........ ............................. ................................. 15
Disassembly of the Range Transmission Input Shaft .................... .................. .................................................. 16
Exploded View of the Range Transmission Input Shaft ..................................................................................... 21
Assembly of the Range Transmission Input Shaft ............................................................................................. 22
Cross-Section of Input Shaft ........................................................................................... .... .............. ................. 33
Disassembly of the Range Transmission Countershaft ................................................. .......... .......................... 34
Exploded View of the Range Transmission Countershaft .................................................................................. 38
Assembly of the Range Transmission Countershaft .......................................................................................... 39
Disassembly of the Mechanical Front Drive (MFD) Hub and Input Shaft ........................ .................................. 47
Exploded View of MFD and Park/Emergency Brake .................. .......................................... ............................. 52
Assembly of the MFD Clutch ................................................................................................. .... ..................... ... 54
Assembly of the MFD Input Shaft ...................................................................................................................... 57
Air Check for Clutch Piston ................................................................................... ..... ...... ..... .. ....................... .... 61
Exploded View of the Range Transmission Countershaft, Input Shaft, and MFD Input Shaft ........................... 64
Installing the Range Transmission Countershaft, Input Shaft, and MFD Input Shaft into the Range Transmission
Housing ............... .................................... ....... .................... ................................................... .. ....................... .... 65

SETTING THE END PLAY OF THE RANGE TRANSMISSION

COUNTERSHAFT AND INPUT SHAFT ................. ............................... ................................................................ 72
Installing the Range Input Master Clutch ............ ............................ ................................................................... 74
 6008-3

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 Ib)
MFD Clutch Pack Oil Leakage ...................................... ...................... ...................... 0.40 Umin max (0.10 gpm max)
MFD Input Shaft Bearing End Play .................... ............................. ............. 0.025 to 0.100 mm (0.001 to 0.004 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)
Clutch Pack Oil Leakage .... ...................... ................................................................. 0.5 Umin (0.13 gpm) maximum

TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR

Problem Probable Cause

Tractor has three sets of 1st-6th gear shift speeds. MediumlHigh clutch pack is incorrectly indexed on the
shaft.

Tractor will not move after the Master clutch repair Master clutch pack is incorrectly indexed on the shaft.
(with the Master clutch pressure within specifications) .

Loss of Low range clutch pressure after repair (within Bearing on range countershaft not installed correctly
first 200 hours) . (the Belleville spring was not compressed during
Installation).

Check distributor hub and seal ring area for damage

when repairing.

SPECIAL TORQUES
Hex Socket Screw in Rear End of MFD Input Shaft (Apply Loctite 242 to Threads) ........ 16 to 19 Nm (12 to 14 Ib ft)
MFD Input Shaft Rear Gear Shield to Bearing Cage Mounting Bolts ............................... 27 to 31 Nm (20 to 22 Ib ft)
MFD Input Shaft Rear Bearing Cage to Range Housing Mounting Bolts ........ ................. 46 to 52 Nm (34 to 38 Ib ft)
Range Transmission Housing Front Bearing Support Cover Mounting Bolts ................. 90 to 107 Nm (66 to 79 Ib ft)
Range Transmission Housing to Rear Frame Mounting Bolts .... .............................. 232 to 262 Nm (171 to 194 Ib ft)
Range Transmission Access Cover Mounting Bolts ................ .. ....................................... 54 to 61 Nm (40 to 45 Ib ft)
Lubrication Manifold Mounting Bolts .. ............................... ........... .......................... .... ... .... 52 to 61 Nm (38 to 45 Ib ft)
Transmission Park Lock Assembly Mounting Bolts ................................................. .......... 52 to 61 Nm (38 to 45 Ib ft)
Hydraulic Pump Assembly Mounting Bolts ............................. ..................................•....... 52 to 61 Nm (38 to 45 Ib ft)

Rae 6-13501 Issued 4/03

6008-4

SPECIAL TOOLS

Cl903H5
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

Cl903H3
Compression Sleeve with notch CAS1903-3

Rae 6-13501 Issued 4/03

 6008-5

RANGE TRANSMISSION

Removing the Shaft Master Clutch

STEP 1 STEP 3

After completing Section 6005 , Speed to Range Remove feeder tubes.

Transmission Split, and Section 6007 Range
Transmission to Rear Frame Split, the range
transmission is ready for service. Mount the STEP 4
transmission on an engine stand CAS1 0431.

STEP 2

Remove the large, internal snap ring from the master

clutch.

12S9CUA4
Remove cover from oil feeder tubes.

Rae 6-13501 Issued 4/03

6008-6

STEP 5 STEP 8

Remove the clutch backing plates. Enlarged View:

STEP 6

1. ALIGNMENT MARK

Mark the master clutch for reassembly. Remove the

Remove the clutch hub. snap ring that fastens the master cl utch to the range
input shaft.
STEP 7
IMPORTANT: The master clutch must be aligned
properly with the input shaft.

STEP 9

Remove 9 friction plates and 9 separator plates.

Remove the master clutch carrier assembly.

including master clutch piston and return springs.

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 6008-7

Removing the Input Shaft, Countershaft, and Mechanical Front Drive (MFD)
Clutch Shaft

STEP 10 STEP 12

Remove the lubrication tube from the input shaft Remove the mounting bolts from the input shaft
bearing cage. bearing cage.

STEP 11
=="'"

Remove the master clutch carrier rear retaining ring Remove the input shaft bearing cage.
from the input shaft.

Rae 6-13501 Issued 4/03

6008-8

STEP 14 STEP 17

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.
shims will be used again during assembly.

STEP 18
STEP 15

Remove the mounting bolts from the front bearing

Remove the mounting bolts from the countershaft support cover.
bearing cage.

STEP 19
STEP 16

16527

Remove the front bearing support cover.

Remove the countershaft bearing cage and pump
drive gear assembly.

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 6008-9

STEP 20 STEP 22

17832

Remove the counters haft as follows: Remove the fou r screws from the MFD shield and
remove the shield.
1. Move the input shaft over to the side for
clearance.
2. A threaded rod with a washer slightly larger than STEP 23
the countershaft diameter may be used to lift the
shaft assembly.
3. Use a hoist to remove the countershafl.

STEP 21

Remove the MFD clutch assembly from the MFD

input shaft and drive gear.

Remove the input shaft.

Rae 6· 13501 Issued 4/03

6008-10

STEP 24 STEP 26

17S10
Remove the park brake release tube. Remove the Remove the fitting for the MFD clutch release
park brake cover. Two bolts fasten the cover to the pressure supply.
park brake housing and four bolts fasten the cover to
the range housing.
STEP 27
NOTE: There is a relief valve in this cover to prevent
excessive park brake pressure. Remove and service
only as necessary.

STEP 25

Remove the MFD clutch inlet tube.

STEP 28

Remove the park brake.

Remove the MFD lube supply tube from the rear of

the MFD input shaft.

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 6008-11

STEP 29 STEP 30
~:o-a

Remove the six mounting bolts for the MFD shaft Remove the MFD shaft assembly from the range
rear flange. transmission.

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6008-12

Disassembly of the Master Clutch

STEP 31 STEP 33
.....,.........-.,......,.

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.
STEP 34
STEP 32

Remove the piston from the clutch carrier.

Release the press and remove the spring retainer

plate.

Rae 6-13501 Issued 4/03

 6008-13

STEP 35 STEP 36

248L7

Check seals and replace if necessary as follows:
1. Inspect the seals (see arrows) on the master
clutch carrier.
2. If necessary, remove both the seals and the 0-
rings beneath them.
3. Replace the O-rings and seals.
4. Lightly lubricate with petroleum jelly.
Check the clutch springs with a spring compression
tester. The spr i ngs must have the following
specifications:
Free Length ................. ....... 35.82 mm (1.410 inches)
Compressed to 23.12 mm
(0.910 inch) ........... .......... ... ...... .... . 111 .25 N (25 Ib)
NOTE: Do not compress these springs beyond
23.12 mm (0.910 inch).

Rae 6-13501 Issued 4/03

6008-14 Clutch
.
Exploded View 0 f the Master

/"---.
/' I
/' I
/" I
/" I
/" I
/" I
I
}
/
/'
/'

,-
/'
r
(

/'
/'
/"
/"
/"
/'
/"
/"
/'

/'
/'
/"
/"
/"
/'
/"
/"
/'
/"
/'
/'
/'
/'

1----------~1. SEAL 31L94 A

9. SNAP RGI~~AINER
2. HUB 10. SPRIN
11 . SPRING
3. SEAL PLATE
4 BACKING
. SNAP RING 12. PISTO;H CARRIER
13. CLUT
5. SNAP RING 14. SEALS S
6. ON PLATE 15. 0·RING
7. FRICTRI ATOR PLATE
8. SEPA

Rae 6·13501 Issued 4/03

 6008-15

Assembly of the Master Clutch

STEP 37 STEP 39

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.
lubricated seals.

STEP 40
STEP 38
.....,.........-...,.........

Use a bridge and hydraulic press to compress the

Install the 16 springs. springs. Install the snap ring in the groove in the
clutch carrier.

NOTE: The assembly of the master clutch is

continued after the master clutch is installed onto the
range input shaft.

Rae 6-13501 Issued 4/03

6008-16

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
the four seal rings on the front of the shaft (1) , and pack assembly.
the one seal ring at the rear (2).

STEP 44
STEP 42

Al0871
T95697 Remove the snap ring from the clutch pack
Use a puller to remove the low range drive gear and assembly.
front bearing cone.
STEP 45

40833
Turn the assembly over and remove the friction ,
separator, and backing plates.

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 6008-17

STEP 46 STEP 49

T95714

Install the compression sleeve with the notch Remove the 13 piston return Belleville springs.
CAS1903-3 to remove the retaining ring for the
piston return Belleville washers.
STEP 50
STEP 47

Remove the snap ring for the Belleville springs.

Use a press to compres. the Belleville washers.

Move the snap ring out of the groove in the shaft. STEP 51

STEP 48

Remove the compression sleeve and the snap ring.

•

Rae 6·13501 Issued 4/03

6008-18

STEP 52 STEP 55

Remove the two bearing thrust washers and the Remove the thrust washer.
needle thrust bearing.

STEP 53

T957 19 Remove the thrust washer spacer ring.

Remove the medium range drive gear.

STEP 57
STEP 54 _ _--.....,...

T95720 Remove the high range drive gear.

Remove the caged needle bearing.

Rae 6-13501 Issued 4/03

 6008-19

STEP 58 2. Position the opening in the compression sleeve

~.:;;;:= over the ends of the snap ring.
3. Compress the Belleville washers with a press.
4. Remove the snap ring.

STEP 61

Remove the caged needle bearing.

STEP 59

Al0885
Remove the 13 piston return Belleville washers.

STEP 62
';"~ '" .:",

Remove the two bearing thrust washers and the

needle thrust bearing.

STEP 60

"0888
Use a puller to remove the rear bearing cone.

Remove the piston return Belleville washers as

follows:
1. Install a compression sleeve with the notch
CAS1903-3 over the piston return Belleville
washers for removing the snap ring.

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6008-20

STEP 63 STEP 65

Al0889 '0S33
Remove the snap ring and remove the high range Turn the assembly over and remove the friction and
clutch pack assembly from the shaft. separator plates.

STEP 64 STEP 66

1110671 Al0891

Remove the snap ring from the clutch pack Remove the snap ring.
assembly.

Exploded View of the Range Transmission Input Shaft

1. SHAFT ASSEMBLY 14. THRUST WASHER 31. FRICTION PLATE 44. SUPPORT
2. PLUG 18. THRUST BEARING 32. SEPARATOR PLATE 45. BOLT
3. COILED SPRING PIN 19. RETAINING RING 33. BACKING PLATE 46. RING
4. PIN 20. BELLEVILLE WASHER (13) 34. RETAINING RING 47. CAGE
5. RING 21. CARRIER 35. LOW RANGE GEAR 48. SHIM
9. THRUST WASHER 22. RING 36. BEARING CONE 49. BOLT
10. NEEDLE BEARING 23. RING 37. BEARING CUP
11 . MEDIUM RANGE GEAR 24. PISTON 38. RING
12. HIGH RANGE GEAR 25. RING 39. BEARING CONE
13. RING 26. RING 40. BEARING CUP

NOTE: When a clutch pack is disassembled, new friction plates must be installed.

Rae 6-13501 Issued 4/03

 6008-21

Exploded V·lew of the Range Transmiss·

_________ Ion Input Shaft

SCAB96B

Rae 6-1 3501 Issued 4103

6008-22

Assembly of the Range Transmission Input Shaft

STEP 67 STEP 68

T95747 A l0B91

Install the snap ring for the high range clutch plate
carrier into the second groove on the shaft.

STEP 69

1. SEALING PLUG AT END OF SHAFT

2. SLOTTED SPRING PIN FLUSH WITH SHAFT OD
3. COILED SPRING PINS AT 5 LOCATIONS MARKED "3"
4. 3 SEALING PLUGS AT END OF SHAFT T952n
Hit the high range clutch plate carrier against a
Inspect the sealing plugs, slotted spring pins, and the wooden block to remove the clutch piston.
spring pins in the input shaft. Make sure that the pins
are secure and all the oil passages in the shaft are
open. See illustration above.

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 6008-23

STEP 70 STEP 71

T952BO

40535 41$3

Install the teflon ring and O-ring as follows: Put petroleum jelly on the teflon rings.
1. Replace the teflon ring and O-ring from the
carrier (1) and piston (2). STEP 72
2. Install the O-ring in the groove.
3. Install the teflon ring over the O-ring .

A10873

Install the clutch piston into the carrier. The flat side
of the piston must face down. Push the piston into
the carrier by hand .

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6008-24

STEP 73 STEP 75
Repeat Steps 69 through 72 on the medium range
clutch plate carrier.

STEP 74
-~------..,...,.--

Al 0876
Install a new friction plate.

NOTE: Dip all friction plates in clean transmission

fluid.
Al0875
Install a separator plate.

Rae 6-13501 Issued 4/03

 6008-25

STEP 76 STEP 78

Al 06n Al 0879

Install a separator plate. Install the remaining 10 Install the clutch pack snap ring into the groove in the
friction plates and 9 separator plates, alternating the carrier.
plates.
NOTE: Do not assemble the medium range clutch
pack. It will be assembled on the shaft.
STEP 77

STEP 79

A1OB78

Install the backing plate. The flat side of the plate

must be facing down. Al0889
Install the high range clutch pack assembly as
shown.

NOTE: The oil gallery hole in the shaft must be

aligned with the hole in the carrier. Install the carrier
snap ring onto the shaft.

Rae 6-13501 Issued 4/03

 •
6008-26
•

STEP 80 STEP 82

701.8

NOTE : Thirteen Belleville washers arranged as

shown.

A10917

Install the bearing on the shaft with the larger 00

end of the bearing facing down . Press the bearing
into place to be sure that it is properly seated on the
shaft.

NOTE: Do not press on the bearing cage.

STEP 81

Install additional Belleville washers as follows:

1. Install a second Belleville washer. The concave
side of the washer must be facing up.
2. Install the remaining 11 Belleville washers,
alternating the position of the washers until the
last washer with the concave side is facing down.

"0666
Install the first piston return Belleville washer. The
concave side of the washer must be facing down.

Rae 6-13501 Issued 4/03

 6008-27

STEP 83 STEP 85

1. SPRING PIN 3. GAP Remove the two compression sleeves.

2. OPENING

Install Belleville washers as follows:

1. Install a snap ring over the shaft.
2. Align the gap between the ends of the snap ring
with the opening for the slotted spring pin as
shown.
3. With the compression tool without a notch
CAS1903-5 , install the Belleville washer
compression sleeve (smaller OD up) over the
shaft and on top of the snap ring .

STEP 84 RI NG GAP l

NOTE: Check to be sure that the snap ring is

properly seated in the groove on the shaft and that
the gap is over the spring pin.

STEP 86

Install the snap ring as follows:

1. Install the compression sleeve with the notch
CAS1903-3.
2. Use a hydraulic press to press the compression
sleeve down onto the shaft. Al0908

3. The snap ring will slip into position in the groove. Install the needle thrust bearing and two bearing
thrust washers. The needle bearing must be between
the two bearing thrust washers.

Rae 6-13501 Issued.

6008-28

STEP 87
.
STEP 90

Al0907
Align the gear teeth on all the friction plates. Install the caged needle bearing.

STEP 88
---,- - STEP 91

A 1()9()4

Install a new seal ring on the hub of the high range Install the thrust washer spacer ring.
drive gear.

STEP 92
STEP 89 ----=--"""

Install the thrust washer.

Install the high range drive gear. The teeth on the
gear hub align with the friction plates. Slight
oscillation of the drive gear will help with the
installation.

Rae 6·13501 Issued 4/03

 6008-29

STEP 93 STEP 96
_ r -----..;

Install the caged needle bearing. Install the snap ring for the bearing thrust washers
and needle thrust bearing. The ring goes into the
lowest of the three grooves in the shaft.
STEP 94

STEP 97

Install a new seal ring on the medium range drive

gear. Install the gear. The hub of the gear must be
facing up. Install the snap ring for the piston return Belleville
washers. This ring goes into the second groove down
on the shaft.
STEP 95

STEP 98

Install the two bearing thrust washers and the needle

thrust bearing. The needle thrust bearing must be
positioned between the two bearing thrust washers. Install the first piston return Belleville washer. The
concave side of the washer must be facing up.

Rae 6·13501 Issued 4/03

6008-30

STEP 99 STEP 101

79L8

NOTE: Thirteen Belleville washers arranged as

shown.

In stall the compression sleeve with the notch

CAS1903-3 over the shafl. Use a hydraulic press to
press the compression sleeves down. The snap ring
will slip into position in the groove.

STEP 102

T95716

Install the remaining Belleville washers as follows:

1. Install the second Belleville washer. The
concave side of the washer must be facing
down.
2. Install the remaining 11 Belleville washers,
alternating the position of the washers until the
last washer with the concave side is facing up.
Remove the compression sleeve. Check to make
sure the snap ring is properly seated in the groove on
STEP 100 the shaft.

STEP 103

Al0911

Install the retaining ring onto the shaft along with the
Belleville was her compressio n sleeve. Use tool
CAS1903-5. T95710

Install the clutch plate snap ring on top of the gear.

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 6008-31

STEP 104 STEP 106

T95709 T95708
Install the backing plate. The flat side of the plate Install a separator plate. Install the remaining 10
must be facing up. friction plates and 10 separator plates , alternating the
plates. Whenever the clutch pack has been
disassembled, new friction plates must be installed.
STEP 105

STEP 107

•
T95707

Install a friction plate.

A10915

NOTE: Dip all friction plates in clean transmission Install the medium range clutch plate carrier onto the
fluid. shaft , open end facing down. Align holes between
shaft and carrier. Carefully press the carrier on over
the friction and separator plates.

NOTE: The oil gallery hole in the shaft must be

aligned with the hole in the carrier.

Rae 6-13501 Issued 4tbs

6008-32

STEP 108 STEP 110

Turn the shaft assembly over and move the snap ring
into the groove in the carrier.
STEP 109
Al0920
Install the bearing cone with the larger outside
diameter (OD) side of the bearing cone facing down.
Press the bearing with approximately 22250 N (5000
Ib) of force to compress the Belleville washers and
properly seat the bearing.

NOTE: Do not press on bearing cage.

STEP 111

Install the low range drive gear.

A22361

Install four new seal rings on the front end of the

shaft and one new seal on the rear end of the shaft.

Rae 6-13501 Issued 4103

 6008-33

Cross-Section of Input Shaft

l1L94R2

1. REAR BEARING CONE 5. FRONT BEARING CONE

2. HIGH RANGE DRIVE GEAR 6. MEDIUM RANGE CLUTCH PLATE CARRIER
3. MEDIUM RANGE DRIVE GEAR 7. HIGH RANGE CLUTCH PLATE CARRIER
4. LOW RANGE DRIVE GEAR

l'
Rae 6-13501 Issued 4/03
,
6008-34

Disassembly of the Range Transmission Countershaft

STEP 112 STEP 115

T95748

Put the countershaft on a clean work bench . Remove the high range driven gear.

STEP 113 STEP 116

T95749

Use a puller to remove the constant mesh gear and Remove the medium range driven gear from the
the rear bearing cone. carrier.

STEP 114 STEP 117

T95750

Remove the gear spacer. Remove the snap ring for the medium range driven
gear.

Rae 6-13501 Issued 4/03

 6008-35

STEP 118 STEP 121

Al0926

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).

NOTE: Be careful not to let the shaft fall through.

STEP 122

STEP 119

Al0928

Turn the low range driven gear and clutch plate

.,092. carrier over and remove the snap ring.
Remove the front bearing cone and front bearing
cone spacer.
STEP 123

STEP 120

"0929
Carefully turn the assembly over and remove
Al0925 backing , friction, and separator plates.
Remove the two bearing thrust washers and the
needle thrust bearing .

; :,' .. .J!,
Rae 6-13501 Issued 4/03
6008-36

STEP 124 STEP .;.:

12:.;7_ _

T95771 T9sn4
Remove the caged needle bearing. Remove the two bearing thrust washers and the
needle thrust bearing.

STEP 125
STEP 128

Remove the bearing spacer. Al0939

Remove the snap ring as follows:

STEP 126 1. Install compression sleeve with the notch

CAS1903-3 over the shaft and on top of the
piston return Belleville washers.
2. Position the opening in the compression sleeve
over the ends of the snap ring.
3. Compress the Belleville washers with a press
and remove the snap ring.

Remove the caged needle bearing.

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 6008-37

STEP 129 STEP 130

Remove the two bearing thrust washers and the Remove the 13 piston return Belleville washers.
needle thrust bearing.

STEP 131

Use a puller to remove the roller bearing from the

rear end of the shaft.

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6008-38

Exploded View of the Range Transmission Countershaft

AB98B026

Rae 6-13501 Issued 4/03

 6008-39

1. COUNTERSHAFT 18. REAR BEARING CONE 34. BACKING PLATE

2. COILED SPRING PIN 19. REAR BEARING CUP 35. RETAINING RING
3. ROLLER BEARING 20. THRUST WASHER 36. RING
4. RETAINING RING 21 . THRUST BEARING 37. RING
5. BELLEVILLE WASHERS (13) 22. LOW RANGE DRIVEN GEAR 39. NEEDLE BEARING
8. THRUST WASHER 23. RING 40. SPACER
9. THRUST BEARING 24. RING 41 . SPACER
10. RETAINING RING 25. PISTON 42. FRONT BEARING CONE
11 . MEDIUM RANGE DRIVEN GEAR 26. RING 43. FRONT BEARING CUP
12. RING 27. RING 44. CAGE ASSEMBLY
13. HIGH RANGE DRIVEN GEAR 31 . REACTION PLATE 45. EXPANSION PLUG
14. SPACER 32. FRICTION PLATE (15) 47. BOLT
15. CONSTANT MESH GEAR 33. SEPARATOR PLATE (14) 50. SHIM

NOTE: When the clutch pack is disassembled, new friction discs must be installed.

Assembly of the Range Transmission Countershaft

STEP 132 STEP 133

A1 0937

\
~ ~ Ir
~
~
~
\ "- ~
[\,
20.64 mm
(0.81 INCH)
) "-
n \\
.-II ~ ~ t
"-
"- ~
[\,
498L7
"-
Replace the spring pins (1) in the countershaft, if
required. Make sure that all the oil passages in the DEPTH1

shaft are open (see arrows). Install bearing inside of shaft with the numbers on the
bearing facing outward. Press to a depth of 20.64
mm (0.81 inch) .

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6008-40

STEP 134 STEP 136

Install the first piston return Belleville washer with the Install the needle thrust bearing and the two bearing
concave side of the washer facing up. thrust washers. The needle bearing must be between
the two bearing thrust washers.

STEP 135
STEP 137

79L8

NOTE: Thirteen Belleville washers arranged as

shown.

Install the snap ring onto the shaft.

Install additional Belleville washers as follows:

1. Install the second Belleville washer with the
concave side facing down.
2. Install the remaining 11 Belleville washers,
alternating the position of the washers until the
last washer is installed with the concave side
facing up.

Rae 6- 13501 Issued 4/03

 6008-41

STEP 138 STEP 140

Al0939 T95752
Install the snap ring and Belleville washers as Install a new seal ring (1) on the medium range
follows: driven gear. Install the gear on the shaft.
1. Install the compression sleeve with the notch
CAS1903-3 over the shaft and snap ring (see STEP 141
Special Tools in this section) .
2. Position the opening in the compression sleeve
over the ends of the snap ring.
3. Compress Belleville washers with a hydraulic
press.
4. Install the snap ring in the groove.

STEP 139

Install the high range driven gear.

Install the snap ring for the medium range driven f

gear. t •
11, :..

•
•

Rae 6-13501 Issued 4/03

6008-42

STEP 142 STEP 144

T95774CR
Install the gear spacer. 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
STEP 143 washers.

STEP 145

Al0949
Install the constant mesh gear (1). Install the bearing
cone . The larger 00 side of the bearing cone must
be facing down. Press the bearing in place to be sure
the bearing is properly seated .
NOTE: 00 not press on the bearing cage.
40518
Remove the clutch piston from the clutch plate
carrier. If necessary, hit the low range driven gear
and clutch plate carrier against a wooden block to
remove the clutch piston .

•
•
•

Rae 6-13501 Issued 4/03

 6008-43

STEP 146 STEP 148

40524 40527
Install the clutch piston into the carrier. The flat side
of the piston must be down. Push the piston into the
carrier by hand.

STEP 149

40521

Remove the teflon ring (1) and a-ring (2) from the
carrier (3) and piston (4). Install the new a-ring in the
groove. Install the new teflon ring over the a-ring .

40529
STEP 147

-----t-

4153

Put petroleum jelly on the rings.

CTRINGS
1. TEFLON RING 2. CAST IRON RINGS

Install two new seal rings in each groove on the hub

of the gear.

Rae 6-13501 Issued 4/03

6008-44

STEP 150 STEP 152

Al0932 A'0934
Install the reaction plate (thicker separator plate). Install separator plates as follows:
1. Install a separator plate.
STEP 151 2. Install the remaining 14 friction plates and 13
separator plates, alternating the plates.

STEP 153

Install a new friction plate.

NOTE: Dip al/ friction plates in clean transmission

fluid. Al0935
Install the backing plate with the flat side of the plate
facing down.

Rae 6-13501 Issued 4103

 6008-45

STEP 154 STEP 156

A43T71C4

Install the snap ring into the groove on the carrier. Install a caged bearing spacer and caged bearing.

STEP 155 STEP 157

T95785A2
Install the low range driven gear and clutch pack Install the needle thrust bearing and the two bearing
assembly onto the shaft. The gear end of the carrier thrust washers. The needle bearing must be between
must be facing up. The teeth on the medium gear the two bearing thrust washers.
hub align with the friction plate teeth. Slight
oscillation of the low range driven gear will help with
the installation. Be sure the hub passes through all
the friction plates.

Rae 6·13501 Issued 4/0'3 ."

6008-46

STEP 158 STEP 159

... Al0943 Al0945

Install the bearing spacer. Install the front bearing cone so that the larger 00
side of the bearing cone is facing down. Press the
bearing in place to be sure the bearing is properly
seated.

NOTE: Be sure the tool used to press the bearing

does not contact the end of the shaft. Do not press
on the bearing cage.

Rae 6-13501 Issued 4/03

 6008-47

Disassembly of the Mechanical Front Drive (MFD) Hub and Input Shaft

STEP 160 STEP 162

A222n
Remove the snap ring as follows: Remove the spring retainer.
1. Place the notched compression sleeve CAS2602
over the spring retainer. STEP 163
2. Use a suitable hydraulic press to compress the
Belleville springs just far eno ugh to move the
snap ring out of the groove.
3. Slowly relieve the press.
4. Remove the compression sleeve.

STEP 161

A22280
Remove the Belleville springs.

STEP 164

A2227.
Remove the snap ring.

A2228'
Turn the clutch carrier assembly over and remove
the retaining ring from the clutch hub.

Rae 6-13501 Issued 4/03

6008-48

STEP 165 STEP 167

A22283 A22289

Remove the clutch backing plate. Remove the backing plate.

STEP 166 STEP 168

A22284 A22290

Remove the 16 friction plates and 15 separator Turn the hub assembly over and remove the clutch
plates. piston from the hub.

NOTE: For Model 2101230, remove 13 friction and

12 separator plates.

NOTE: Once the friction plates are removed from

the hub, the plates must not be reused. Install all new
friction plates for the assembly.

Rae 6-13501 Issued 4/03

 6008-49

STEP 169 STEP 170

A22291
Remove the two clutch hub-to-piston sealing rings
(1) and the a-rings from the hub assembly. Install
new a-rings. Install new sealing rings over a-ring
seals. ~
/I lLt'.
z:; z:
:z:
C
r=
vV
? I
A/
:z
z
z

?7~/ ~/A
A

1
p:
? ~
lit
7

~
/
1 ~
.508 mm
/
~
(0.020 INCH)

-
V /
V /
./ ~

10L94

Inspect the hub oil seal and the inner and outer
needle bearings (2). If replacement is necessary, use
an appropriate puller to remove seal and bearings.
Press the new inner bearing (3), outer bearing , and
oil seal into the hUb. The oil seal and larger bearing
must be flush as shown above (1). The inner bearing
must be recessed 0.508 mm (0.020 inch).

Rae 6·13501 Issued 4/03

6008-50

STEP 171 STEP 172

A22330

Remove the plastic shield from the MFD shaft
assembly. Remove the fiber washer (1) if it remained
on the end of the shafl.
Inspect the MFD gear/shaft assembly.
1. Do not disassemble the MFD gear/shaft
assembly unless the bearings need to be
replaced.
2. If the bearings are to be replaced, first press the
bearing onto the shaft to relieve the load on the
snap ring.
3. Remove the snap ring.

Rae 6-13501 Issued 4/03

 6008-51

STEP 173 STEP 175

Remove the washer.

STEP 174

111L94R

Install three 12 mm (1 /2 inch) dia. approximately

102 mm (4 inch) long pins (A) through the holes in
the base of the shaft. Use a press to carefully press
A22333
the bearing off the shaft.
Remove the shims. Disassemble the gear/shaft assembly as follows:
1. Place the gear/shaft assembly (1) into a press
(8 ).
2. Press the clutch shaft (2) out of the gear
assembly.
3. Use an appropriate puller to remove the bearing
cone (3) from the clutch shaft.
4. Remove the bearing races from the gear
assembly.

Rae 6·13501 Issued 4/03

6008-52

Exploded View of MFD and Park/Emergency Brake

1. SHAFT WIO MFD 19. SHIELD 42. BACKING PLATE
2. SHAFT WI MFD 20. SEAL RING 43. BRAKE DISC
3. BOLT 23. a-RING 44. SEPARATOR PLATE
4. ADAPTER 24. COVER 45. PISTON
5. O·RING 25. BALL 46. O.RING
6. TUBE 26. PLUG 47. SEAL RING
10. SHIELD 27. O·RING 46. SEAL RING
11 . BOLT 26. SPRING 49. O.RING
12. BEARING CONE 29. BOLT 50. BELLEVILLE WASHER
13. BEARING CUP 30. BOLT 51. BACKING PLATE
14. GEAR 31 . WASHER 52. RETAINING RING
15. SNAP RING 32. SPECIAL BOLT 55. SHIELD WIO MFD
16. SHIM 33. a-RING 56. PLUG
17. WASHER 40. CARRIER 57. SHIELD WI MFD
16. RETAINING RING 41. RETAINING RING 56. BOLT

Rae 6-1350 1 Issued 4/03

Rae 6-13501 Issued 4/03
6008-54

Assembly of the MFD Clutch

NOTE: Be sure parts are free of all contaminants.
Once the MFD shaft is assembled, it cannot be
disassembled without damaging the bearing cones.

STEP 176

COADTIE 4

7. Set preload as follows:

A. Tie a cord approximately meter (3 feet)
long around one of the hub webs.
B. Wrap the remainder of the cord around the
outside of the hub.
C. Use a spring scale to pull on the cord in a
straight line from the gear.
O. As the bearing cone is being pressed onto
the shaft rotate the gear until a rolling torque
of 2 .1 to 3.2 Nm ( 18 to 28 Ib inch) is
obtained.
m94
Install the bearings and metal shield as follows:
1. Install two snap rings into the grooves in the
MFO gear.
2. Press a bearing race, cupped side out, into each
side of MFO gear. Be sure the races are seated
against retaining rings.
3. Fasten the new metal shield onto the clutch shaft
with three bolts.
4. Use a press to install the inboard bearing cone,
larger 00 of the cone down, onto the clutch
shaft.
5. Install the MFO gear assembly onto the shaft.
6. Place the outboard bearing cone, smaller 00 of
the cone down, onto the clutch shaft assembly.

Rae 6- 13501 Issued 4/03

 6008-55

STEP 177 STEP 179

Obtain dimension for shim pack as follows: Install the spacer.

1. Install the spacer and the snap ring into the
groove. STEP 180
2. Use feeler gauges to measure the gap between
the snap ring and the spacer at positions 180·
apart.
3. If the difference in the two measurements is 0.05
mm (0.002 inches) or less, take the average of
these two measurements and subtract 0.12 mm
(0.004 inch). This is the dimension for the shim
pack.
4. Remove the snap ring and spacer.

STEP 178
Install the snap ring.

A22333

Install the shim pack as determined in the previous

step.

Rae 6-13501 Issued 4/03

6008-56

STEP 181 STEP 182

Check for end playas follows:

1. Place a dial indicator near the center of the shaft.
2. Carefully pry up between the MFD gear and
shaft.
3. The end play must range from 0.051 to 0.127
mm (0.002 to 0.005 inch).
4. If the end play does not fall within 0.051 to 0.127
mm (0.002 to 0.005 inch), select a different shim
to obtain a proper reading.
5. If shims are installed, check the end play again .

l11l94 STEP 183

Install three 12 mm (112 inch) dia. pins approximately
102 mm (4 inches) long , through the holes in the
base of the shaft. Use a press to carefully backseat
the bearing up against the snap ring.

A22330
Install the rear shield assembly with the three
screws.

Rae 6-13501 Issued 4/03

 6008-57

Assembly of the MFD Input Shaft STEP 186

STEP 184

AA2229'
Install the two clutch hub-to-piston sealing rings (1)
and a-ring seals. Install the sealing rings over the 0-
A22358 rings.
Lubricate the MFD clutch shaft seals with petroleum
jelly.
STEP 187
NOTE: Be sure to install the fiber thrust washer (1)
on the end of the shaft.

STEP 185

A22293

Lubricate the hub assembly seals with petroleum

jelly.
•
3 1>"--11+
.508 mm
(0.020 INCH)

101..94

On MFD hub assembly. inspect hub oil seal and the

inner and outer needle bearings (2). Make sure that
the oil seal and larger bearing are flush as shown
above (1) . The inner bearing (3) must be recessed
0.508 mm (0.020 inch).

Rae 6-13501 ~ tssued 4/03

6008-58

STEP 188 STEP 190

A22290 .22266
Carefully install the clutch actuator over the hub Install a new friction plate.
assembly.

STEP 191
STEP 189

A22289
Apply a thin bead of Loctite 680 on the outside edge
of the brake piston . Install the clutch backing plate
into the clutch piston , flat side up.
A22287
Install a separator plate.
For 210/230 models, install the remaining 12 friction
plates and 11 separator plates, alternating between
friction and separator plates.
For 255/285 models, install the remaining 15 friction
plates and 14 separator plates, alternating between
friction plates and separator plates.

Rae 6-13501 Issued 4/03

 6008-59

STEP 192 STEP 194

=., A22351

Install the clutch backing plate, flat side down, on top Install the hub assembly into the gear/carrier to align
of the last friction plate. the separator plate tabs. Once the separator plate
tabs are aligned, carefully remove the hub assembly.

STEP 193
STEP 195

A22282

Install the snap ring into the groove in the hub "227.
assembly. Without moving the separator plates, place the hub
assembly in a hydraulic press . Install a Belleville
spring concave side up and a second concave side
down. Install the next two pairs of Belleville springs in
the same way.
For 255/285 models, install a third pair of springs in
the same way.

Rae 6-13501 Issued 4/03

6008-60

STEP 196 STEP 198

Install the spring retainer, flat side down. Install compression sleeve CAS2602 over the spring
retainer. Carefully compress the Belleville springs
with the hydraulic press and install the snap ring in
STEP 197 the groove. Make sure the snap ring is seated in the
groove.

STEP 199
-='""

A22276

Install the snap ring.

Install the MFD gear assembly to check for proper

tab alignment. If there is interference between the
MFD gear and the separator plate tabs, repeat Steps
194 through 198, and align tabs carefully.

Rae 6-13501 Issued 4/03

 6008-61

Air Check for Clutch Piston STEP 201

NOTE: The clutch piston will typically move up to 3

mm (1/8 inch).

NOTE: Steps 200,201 , and 202 are procedures for

air check for the clutch piston.

STEP 200

T95940
Check the low range clutch (1) as follows:
1. Install the front bearing cage over the front of the
range transmission countershaft.
2. Insert the tip of the air gun into the cage port. The
air pressure will move the clutch plates in the low
range clutch .

T95936
Replace the seal rings on the clutch piston if the
Perform the following test: clutch plates do not move.

1. Use an air gun to check the movement of the

clutch piston in the range transmission input STEP 202
shaft. This will determine if the piston seals were
damaged during assembly.
2. The clutch piston will move the clutch plates if
the seals on the piston are good.
3. Install the tip of an air gun into the oil hole in the
third groove of the shaft. The air pressure will
move the clutch plates in the high range clutch.
4. If the clutch plates do not move, check to see if
the pressure hole in the clutch carrier aligns with
the pressure supply hole in the shaft.
5. Replace clutch piston seal rings if damaged
A22360
during assembly.
Install the tip of the air gun into the MFD clutch shaft
6. Install the tip of the air gun into the oil hole in the assembly. The air pressure will not release the spring
first groove of the shaft. The air pressure will pressure off the clutch plates. Check for air leakage
move the clutch plates in the medium range from the MFD assembly.
clutch.

Rae 6-13501 Issued 4/03

M
6008-62

STEP 203 STEP 206

Install six mounting bolts lor the rear bearing cage.
Tighten to a torque 01 52 to 61 Nm (38 to 45 Ib It).
STEP 204
Install the MFD lube tube at shaft end and to litting in
the top 01 the range housing.
16S36
Install two park brake carrier retaining bolts. Install 0-
rings on MFD clutch inlet tube and slide in place in
Irame and MFD input shaft assembly.
STEP 207

STEP 205

17510

Install O-ring in housing . Install access plate and

secure with lour bolts.

STEP 208
Install park/emergency brake through the open end
01 the range transmission. Install park brake release tube.

Rae 6-13501 Issued 4/03

 6008-63

STEP 209 STEP 210

17532

Position MFD brake housing for bolt-up. Install the MFD shield and secure with four bolts.

Rae 6·13501 Issued 4/03

6008-64

Exploded View of the Range Transmission Countershaft, Input Shaft, and

MFD In Shaft

29L94R
1. SHIMS 7. FRONT BEARING CUP 13. PLUG
2. FRONT BEARING CUP 8. SHIM 14. HEATER
3. INPUT SHAFT BEARING CAGE 9. FRONT BEARING SUPPORT COVER 15. COVER
4. HYDRAULIC PUMP DRIVE GEAR 10. COVER 16. NEEDLE BEARING
5. ROLLER BEARING 11 . RANGE TRANSMISSION HOUSING 17. PLUG
6. COUNTERS HAFT BEARING CAGE 12. BEVEL PINION CONSTANT MESH GEAR

Rae 6-13501 Issued 4/03

 6008-65

Installing the Range Transmission Countershaft, Input Shaft, and MFD Input
Shaft into the Range Transmission Housing

STEP 211 STEP 213

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. Drive are seated against the housing shoulder.
a new bearing cage into the bore. The bearing cage
must be centered in the bore.
STEP 214

STEP 212

•
40510

Use a puller to remove the bearing cup from the

T95612 range transmission input shaft bearing cage.
Use a puller to remove the rear bearing cups from
the range transmission housing.

/'

Rae 6-13501 Issued 4/03

6008-66

STEP 215 STEP 217

41 519 T95883A

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. the range transmission countershaft bearing cage .
Move the snap ring out of the groove that is in the
bearing cage.
STEP 216

STEP 218

40513

Install a new seal ring on the input shaft bearing

cage.
Remove the hydraulic pump drive gear.

STEP 219

T95885R

Use a puller to remove the bearing cup from the

range transmission countershaft bearing cage.

Rae 6-13501 Issued 4/03

 6008-67

STEP 220 STEP 223

T95886A
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 224
STEP 221

T....' Install the gear retaining snap ring inside the gear
Remove the snap ring from inside the hydraulic and over the hub. The flat side of the snap ring must
pump drive gear. be facing down.

STEP 222 STEP 225

T95688 T95891R

Drive the roller bearing out of the gear. The gear Press a new ball bearing inside the gear until the
retaining snap ring from Step 217 will come out with roller bearing seats against the gear housing.
the roller bearing. " ,

Rae 6- 13501 Issued 4/03

6008-68

STEP 226 STEP 229

17535
Install the bearing snap ring . Install the MFD input shaft assembly as follows:
1. Carefully install the MFD input shaft assembly
STEP 227 into the range housing .
2. Tilt the gear end of the shaft to clear the inner
section of the housing wall and install the MFD
shaft end into the bore in the range housing.
3. Line up the shaft pressure inlet hole with the oi l
inlet tube hole in the range casting.
4. The exposed section of the MFD gear must be at
the top.

NOTE: The MFD clutch hub assembly can be

installed separately after the shaft/carrier assembly is
installed. Use care not to damage seals.
T95884A
Install the gear on the countershaft bearing cage. STEP 230

STEP 228

Install the six mounting bolts. Tighten bolts to a

torque of 52 to 61 Nm (38 to 45 Ib ft). Install the MFD
T95883R
lube fitting.
Reach through the opening in the gear and install the
snap ring into the groove in the bearing cage.

Rae 6-13501 Issued 4/03


_.....
STEP 231
Install the MFD lube tube at the shaft end and to
fitting in top of range casting .
STEP 232
Install a new a-ring on each end of the oil inlet tube.
Apply petroleum jelly to the a-rings. Install the oil
inlet tube for the MFD input shaft bearing cage
through the range housing and into the clutch shaft
assembly.
Rae 6-13501
I
6008-69
STEP 233
Install the park brake assembly.
NOTE : See Section 7004, Parking Brake, for service
information.
STEP 234
Install a-ring in park brake housing.
1. Install two M10 x 70 mm long bolts in access
plate to fasten park brake housing to access
plate. Torque bolts to 51 to 57 Nm (38 to 42 Ib It).
2. Install four M10 x 30 Nm long bolts in cover.
Torque to 51 to 57 Nm (38 to 42 Ib It).
NOTE: Make sure that the park brake relief valve
components are installed on the inside of the cover.
Issued 4/03
6008-70

STEP 235 STEP 238

Install the MFD clutch assembly into the emergency/ Apply petroleum jelly to the seal ring on the rear end
park brake housing. of the range transmission input shaft. Install the
range transmission input shaft into the housing.
Make sure that the rear bearing cone is resting in the
STEP 236 bearing cup.

STEP 239

1754

Install the MFD shield and secure with four bolts.

Torque four bolts to 10 to 12 Nm (8 to 9 Ib It).

Tilt the range input shalt over to the side and install
STEP 237 the range transmission countershalt.

16534
Install two new O-rings on the MFD inlet fitting. Install
the MFD straight fitting.

Rae 6-13501 Issued 4/03

 6008-71

STEP 240 STEP 243

Apply petroleum jelly to the seal rings on the Install the countershalt front bearing cage. Install the
countershalt low range driven gear. Install the front mounting bolts to a torque of 54 to 61 Nm (40 to 45 Ib
bearing support cover. Tap the support cover down It).
over the dowel pins in the range housing .

STEP 244
STEP 241

16$2'
Apply petroleum jelly to the four seal rings on the
Install and tighten the support cover bolts to a torque
front end of the input shalt. Place the original shims
of 90 to 107 Nm (66 to 79 Ib ft).
over the range input shalt.

STEP 242
STEP 245

16$21 .

Place the original shims over the end of the range

transmission countershalt. Install the range input shalt front bearing cage. Install
• the mounting bolts to a torque of 54 to 61 Nm (40 to
45 Ib )I).
,. •
Rae 6·13501 Issued 4103
6008-72

SETTING THE END PLAY OF THE RANGE TRANSMISSION

COUNTERSHAFT AND INPUT SHAFT

STEP 246 STEP 247

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.

Install the snap ring on the input shaft that positions

the master clutch.

STEP 248

Install the lubrication tube to the input shaft bearing

Rotate the shaft a minimum of 12 revolutions. Use a cage.
dial ind icator to measure the end play. Use a prybar " .
inside the range transmission housing to lift a gear ,
on the shaft. The end play must be 0.025 to 0.127 • , "
mm (0.001 to 0.005 inches) for the input shaft (2) and
0.013 to 0.102 mm (0.0005 to 0.004 inches) for the
countershaft (1).
If the end play is not within 0.025 to 0.127 mm (0.001
to 0.005 inches) for the input shaft, add or remove
shims to get a correct reading.
If the end play for the countershaft is not within 0.013
to 0.102 mm (0.0005 to 0.004 inches), add or remove
•shims to get a correct reading.

NOTE: Check one shaft at a time.

Rae 6-13501 Issued 4/03

! ,
 6008-73

STEP 249 STEP 250

Install a new O-ring onto the transmission speed
sensor and install the sensor into the top of the range
housing.
Apply petroleum jelly to the seal ring on the input
shaft front bearing cage. Align the master clutch fill
hole with the range transmission input shaft fill hole.
Align the marks made before removal in Step 8.
Install the master clutch on the range transmission
input shaft.

NOTE: The master clutch carrier assembly must be

indexed correctly on the input shaft.

Rae 6-13501 Issued 4/03

6008-74

Installing the Range Input Master Clutch

STEP 251 STEP 253

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. Install the hub
input shaft according to the mark made in Step 8. assembly onto the master clutch carrier.

STEP 252

Install a new seal ring into the hub assembly. Install a separator plate into the master clutch.
Lubricate the seal ring with petroleum jelly.

Issued 4/03
Rae 6-13501
-.
; ""\..,
 6008-75

STEP 255 STEP 257

A22305CR A22297CR

Install a new friction plate into the master clutch. Install the snap ring into the master clutch carrier.
Install the remaining eight separator plates and eight
friction plates. alternating the plates.
STEP 258
NOTE: Dip all friction plates in clean transmission
fluid before installation.

STEP 256

Install feeder tubes.

STEP 259
A22298CR

Install the clutch backing plate.

12S9CUR4

Attach oil protection cover.

Rae 6-13501 Issued 4/03

6008-76

Rae 6-13501 Issued 4/03

 Section
6009

TRANSMISSION CONTROL VALVES

AND INCHING VALVE

CASE, LLC
C> 2003 Case , LLC
700 State Street Printed In U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13751 September, 2002 (Revised April, 2003)
6009-2

TABLE OF CONTENTS
SPECIAL TORQUES ................ .......... .................................... .... ......... .... ................................................................ 3

POWERSH IFTTRANSMISSION CONTROL VALVES .. .. .. ......... ....... .............. ....................................................... 3

TRANSMISS ION CONTROL VALVE CONFIGURATION ............... ....... .. ..... .......................................................... 4

Figure 1 - Transmission Control Valve with Four Solenoids ............ ...... ......................... .. ................................. 5
Figure 2 - Transmission Control Valve with Four Solenoids ..... ............................................. ............................ 6
Figure 3 - Transmission Control Valve with Three Solenoids and Plug ............................................................. 7
Figure 4 - Transmission Control Valve with Three Solenoids and Plug ........................................................ .. ... B
Figure 5 - Transmission Control Valve with Two Solenoids. Check Valve and Plug ................. ........................ 9
Figure 6 - Transmission Control Valve with Three Solenoids and Check Valve .................... ...... ............... ..... 10
Valve Removal ................... .......................................... .. .......................... ................................................... ....... 11
Disassembly ............................ ................. .......................... ...................................................................... .. .. .. .... 12
Assembly ... .............. ............................................................................. ............... .............. ............................. ... 13
Valve Installation ...... ................ .................................................. ........ ................................................. ............... 14

INCHING VALVE ...................................................................................... ...................... ....................................... 15

Removal ............................... ... .......... ................................................................................... .............................. 15
Disassembly ............................................................................... .................... ............... ........ ............................. 16
Assembly ...... ........... ................ .. ..................... .................. ............. .................... .......... .............................. ........ 1B
Installation ..... ...... ... ..................... ........................................ .... ...................... ..................................................... 20
Inching Valve Cross Section ........................................................ ... ............ ..................................... ............. ... 21

Rae 6-13751 Issued 9-021 Revised 4-03

 6009-3

SPECIAL TORQUES
Transmission Control Valves
Plug, M 18 .............. ...................................................................................................... 19 to 25 Nm (14 to 18 Ib It)
Plug , M 27 ........................................•••..................•............................................... ....... 34 to 54 Nm (25 to 40 Ib It)
Pressure Sensor ............. ....................... ............... •. ........... .......................................... 19 to 25 Nm (14 to 18 Ib It)
Solenoid Cartridge ................................. ............ .......................................................... 19 to 25 Nm (14 to 18 Ib It)
Solenoid Nut ............................................................. .................................. ...................... 5.5 to 8 Nm (4 to 6 Ib It)
Inching Valve
Hex Head Mounting Bolt ............................................................ .................................. 50 to 60 Nm (37 to 14 Ib It)
Plugs ................ .............. .... .. ........ ...................................... .......................................... 34 to 54 Nm (25 to 40 Ib It)
Solenoid Cartridge ..................... .... ....... ......................................................................... 12 to 18 Nm (9 to 13 Ib It)
Solenoid Nut.. ................. .......................... .................................. ..................................... ..... 5 to 8 Nm (4 to 6 Ib It)

POWERSHIFT TRANSMISSION CONTROL VALVES

There is one basic transmission control valve that
can be configured for three d ifferent applications :
Speed Transmission Control Valve (1), Odd-Even
Transmission Control Valve (2), and Rang e
Transmission Control Valve (3) . The function of this
basic valves is determined by its location on the
transmission , how it is connected hydraulically and
number of solenoids.
The odd even and range valve can be removed alter
raising the cab See Section 9005 , Cab Raise!
Removal and Installation for information. The speed
valve can be removed without removing the fuel tank,
but if equipped with the large tank, removing the fuel
tank will make access easier. See Section 3001, Fuel
Tank for procedure.

1. SPEED TRANSMISSION CONTROL VALVE 3. RANGE TRANSMI SSION CONTROL VALVE

2. ODD-EVEN TRANSMISSION CONTROL VALVE

Rae 6-13751 Issued 9-02 1 Revised 4-03

6009-4

TRANSMISSION CONTROL VALVE CONFIGURATION

This chart matches transmission valve configuration with tractor options controlled by those valves (Figures 1
through 6).

SPEED QQQ-E~Et:,I RAt:,lGE

IBAt:,ISMISSIQt:,I IBAt:,ISMISSIQt:,I IBAt:,ISMISSIQt:,I
IBAt:,ISMISSIQt:,I QPIIQt:,IS QQt:,IIBQL ~AL.~E QQt:,IIBQL ~AL.\lE QQt:,ITBQL ~AL.~E

NAO WITHOUT MFDIWITHOUT CREEP FIGURE 1 FIGURE 4 FIGURE 3

NAO WITHOUT MFDIWITH CREEP FIGURE 1 FIGURE 2 FIGURE 3

NAO WITH MFDIWITHOUT CREEP FIGURE 1 FIGURE 4 FIGURE 2

NAO WITH MFDIWITH CREEP FIGURE 1 FIGURE 2 FIGURE 2

EURO WITH MFDIWITHOUT CREEP FIGURE 1 FIGURES FIGURE 2

EURO WITH MFDIWITH CREEP FIGURE 1 FIGURE 6 FIGURE 2

NOTE: Before removing any components, thoroughly clean the valve body and the area on the transmission
housing adjacent to the valve body to eliminate any contamination.

,
Rae 6-13751 Issued 9-02 1 Revised 4-03
 6009-5

Figure 1 - Transmission Control Valve with Four Solenoids

This type of control valve is used with these • Speed control valve for all tractor configurations.
transmission configurations:

1. VALVE BODY 5. COVER PLATE

2. PWM SOLENOID 6. PLUG
3. O_ RINGS 7. MOUNTING BOLT
4. GASKET 8. PRESSURE SENSOR (SPEED VALVE ONLY)

Rae 6-13751 Issued 9-02 1 Revised 4-03

6009-6

Figure 2 - Transmission Control Valve with Four Solenoids

This type of control valve is used with these • Range control valve with MFD.
transmission configurations:
• Odd - Even control valve with NA park and creep.

1. VALVE BODY
,
6. PLUG
AI02E099

2. PWM SOLENOID 7. MOUNTING BOLT

3. O-RINGS 8. SOLENOID
4 . GASKET 9. SOLENOID CARTRIDGE
5. COVER PLATE

Rae 6-13751 Issued 9·02 1 Revised 4-03

 6009-7

Figure 3 - Transmission Control Valve with Three Solenoids and Plug

This type of control valve is used with t hese • Range control valve without MFD.
transmission configurations:

RI02E096
1. VALVE BODY 5. COVER PLATE
2. PWM SOLENOID 6. PLUG
3. O·RINGS 7. MOUNTING BOLT
4. GASKET

Rae 6-13751 Issued 9-02 1 Revised 4-03

6009-8

Figure 4 - Transmission Control Valve with Three Solenoids and Plug

This type of control valve is used with these • Odd-even control valve with NA park without
transmission configurations: creep.

RI02E097

1. VALVE BODY 6. PLUG

2. PWM SOLENOID 7. MOUNTING BOLT
3. O-RINGS 8. SOLENOID
4. GASKET 9. SOLENOID CARTRIDG
5. COVER PLATE

Rae &13751 Issued 9-02 I Revised 4-03

 6009-9

Figure 5 - Transmission Control Valve with Two Solenoids, Check Valve and Plug

This type of control valve is used with this • Odd-even control valve with Euro park without
transmission configuration: creep.

, ~000(y/
\

~
0°0 ~

o
rJP~
RI02E095
1. VALVE BODY 6. PLUG
2. PWM SOLENOID 7. MOUNTING BOLT
3. O-RINGS 8. CHECK VALVE
4. GASKET 9. BALL
5. COVER PLATE

Rae 6-13751 Issued 9· 02/ Revised 4·03

6009-10

Figure 6 - Transmission Control Valve with Three Solenoids and Check Valve

This type of control valve is used with this • Odd-even control valve with Euro park with creep.
transmission configuration:

RI02E098
1. VALVE BODY 6. PLUG
2. PWM SOLENOID 7. MOUNTING BOLT
3. O-RINGS 8. CHECK VALVE
4. GASKET 9. BALL
5. COVER PLATE

Rae 6-13751 Issued 9·021 Revised 4-03

 6009-11

Valve Removal
NOTE: Before removing any components, STEP 3
thoroughly clean the valve body and the area on the
transmission housing adjacent to the valve body to
eliminate any contamination.

STEP 1

Remove the odd-even transmission control valve as

follows:
1. Tag and disconnect the park lock and if
equipped , the MFD tubes (1). Tag and
disconnect the regulated pressure tubes (2).
1. SPEED TRANSMISSION CONTROL VALVE
2. ODD· EVEN TRANSMISSION CONTROL VALVE
2. Tag and disconnect the solenoid wires (3).
3. RANGE TRANSMISSION CONTROL VALVE
3. Remove the mounting bolts (4) and remove the
valve and gasket. Discard the gasket.
To gain access to the speed transmission control
valve, remove the fuel tank. See Section 3001, Fuel
STEP 4
Tank for procedure. For access to the odd-even and
range transmission control valves, raise or remove
the cab. See Section 9005, Cab Raise/Removal and
Installation.

STEP 2

Remove the range transmission control valve as

follows:
1. Tag and remove the regulated supply tube (1).
2. Tag and disconnect the wire harness from the
solenoid (2).
Remove speed transmission control valve as follows: 3. Remove the mounting bolts (3), valve body, and
1. Tag the wire harness connectors to the solenoids gasket. Discard the gasket.
and pressure sensor (1) and disconnect.
2. Remove the valve supply tube (2).
3. Remove the valve retaining bolts, valve body,
and gasket. Discard the gasket.

Rae 6-13751 Issued 9-02 1 Revised 4-03

6009-12

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.

STEP 5

RD02E223

Remove the solenoid cover plate. Remove the

solenoid assembly and discard the O-rings.

STEP 8
Repeat for the remaining solenoids.

RD02E221

Place the valve on a clean surface.

STEP 6

RD02E222

Remove the park lock solenoid nut and coil and

cartridge. Remove and discard the O-rings.

Rae 6-13751 Issued 9-021 Revised 4-03

 6009-13

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.

STEP 9

Install new a-rings on the cartridge . Install the

cartridge into the valve body. Tighten to a torque of
19 to 25 Nm (14 to 18 Ib It). Install new a-rings on
the coil and install the coil onto the cartridge. Tighten
the retaining nut to a torque of 6 to 8 Nm (4 to 6 Ib It).
Install a new a-ring on the plug . Install the plug to a
torque of 34 to 54 Nm (25 to 40 Ib It).

ROO2E223
Install new a-rings on the solenoidl Install the
solenoid into the valve body. Repeat for the
remaining solenoids. Install the cover plate and
retaining bolts. Tighten the bolts to a torque of 6 to 8
Nm (4 to 6 Ib It).

Rae 6-13751 Issued 9·02 1 Revised 4-03

6009-14

Valve Installation

STEP 11 STEP 13

ROO2E274
Install the range transmission control valve as
follows:
1. Install a new gasket and the valve.
2. Tighten the MB socket head mounting bolt (3) to
a torque of 27 to 32 Nm (20 to 24 Ib It).
3. Connect the wire harness to the solenoids (2).
4. Connect the regulated supply tube (1).
Install the speed transmission valve as follows:
1. Install a new gasket and the valve.
2. Tighten the MB socket head mounting bolts to a
torque of 27 to 32 Nm (20 to 24 Ib It).
3. Connect the wiring harness to the pressure
sensor and solenoids (1) .
4. Connect the supply tube (2).

STEP 12

Install the odd-even transmissio n control valve as

follows:
1. Install a new gasket and the valve.
2. Tighten the MB socket head mounting bolts (4) to
a torque of 27 to 32 Nm (20 to 24 Ib It).
3. Connect the wire harness to the solenoids (2) .
4. Connect the regulated pressure tube (2) .
Connect the park lock and if equipped, the MFD
tubes (1).

Rae 6-1 3751 Issued 9-02 I Revised 4-03

 6009-15

INCHING VALVE

Removal

STEP 14 STEP 15

The inching valve (1) is located under the range
transmission valve (2). Raise or remove the cab for
access to the valves See Section 9005 , Cab Raise!
Removal and Installation.
Remove the inching valve as follows:
1. Tag and remove the regulated supply tube (1).
2. Tag and disconnect the wire harness from the
range valve solenoids(2).
3. Remove the mounting bolts (4), range valve, and
gasket. Discard the gasket.
4. Tag and remove the hydraulic tubes from the
inching valve.
5. Disconnect the wire harness from the inching
valve solenoid.
6. Remove four attaching bolts for the inching valve.
7. Remove the inching valve and mounting gasket.
Discard the gasket.

Rae 6-13751 Issued 9~021 Revised 4-03

6009-16

Disassembly

STEP 16
- -...."., .. STEP 18

56·34 57· 10
Place the inchi ng 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
assembly. 57·13
Remove plug .

Rae 6-13751 Issued 9-02 / Revised 4-03

 6009-17

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

Rae 6-13751 Issued 9·02 I Revised 4·03

l
6009-18

Assembly

RT98COO2
1. VALVE BODY 9. O-RING 24. SLEEVE
2 . M18 PLUG 11 . O-RING 25. BALL
3. O-RING 12. O-RING 26. SPRING
4. M27 PLUG 13. O-RING 27. SPRING
5. O-RING 20. M14 PLUG 28. M14 PLUG
6. CARTRIDGE 21 . O-RING 29. O-RING
7. COIL 22. SPOOL 35. GASKET
8. NUT 23. MODULATOR PISTON 36. SOCKET BOLT

Rae 6-13751 Issued 9·02 / Revised 4·03

 6009-19

STEP 22 STEP 25

' 4-33 57· 19

Install the inching modulator spool assembly and Install a new a -ring on plug. Install plug in valve body
spring. and tighten to a torque of 34 to 54 Nm (25 to 40 Ib tt).

STEP 23 STEP 26

57·25 .57·16
Install a new a-ring on plug. Install plug. Tighten the Install a new a-ring on plug. Install plug in valve body
plug to a torque of 34 to 54 Nm (25 to 40 Ib tt) . and tighten to a torque of 34 to 54 Nm (25 to 40 Ib tt).

STEP 24 STEP 27

56-34 57-28
Install a new a-ring on the plug. Install plug. Tighten Install new a-rings on the solenoid cartridge.
the plug to a torque of 34 to 54 Nm (25 to 40 Ib tt).

Rae 6-13751 Issued 9·02 / Revised 4-03

6009-20

STEP 28 Installation

STEP 31

57·10

Install the solenoid cartridge and tighten to a torque

to 12 to 18 Nm (9 to 131b It).

Install the inching valve and range transmission

STEP 29 control valve as follows:
1. Install a new inching valve gasket on top of the
range transmission. Install the inching valve and
four retaining bolts. Tighten the bolts to a torque
of 50 to 60 Nm (37 to 44 Ib It).
2. Install a new gasket on top of the inching valve
and install the range transmission control valve.
Install the M8 socket head bolts(4) and tighten to ,..
a torque of 27 to 32 Nm (20 to 24 Ib It).
3. Connect the Hydraulic tubes to the inching valve.
4. Connect the wire harness to the inching valve
solenoid.
57-6

Instal new O-rings on both ends of coil. Install over 5. Connect the wire harness to the range valve
the solenoid cartridge. Make sure the connector on solenoids (2).
the coil is facing outward . 6. Connect the regulated supply tube (1) to the
range valve.
STEP 30
STEP 32
Install or lower the cab as shown in Section 9005 ,
Cab Raise/Removal and Installation.

57·5
Install the nut and tighten to a torque to 5 to 8 Nm (4
to 6 Ib It).

Rae 6-13761 Issued 9-02 I Revised 4-03

 6009-21

Inching Valve Cross Section

302171 AA WMF
1. VALVE BODY 7. SPRING
2. PLUG B. SPRING
3. SOLENOID 9. PLUG
4. INCHING SPOOL 10. INCHING MODULATOR SPOOL ASSEMBLY
5. BALL 11 . MODULATOR ASSEMBLY PISTON
6. RETAINING SLEEVE 12. PLUG

Rae 6- 13751 Issued 9-02 1 Revised 4-03

 6009-22

Rae 6-13751 Issued 9-021 Revised 4-03

 MX Magnum - Service Manual
Book 4 - Table of Contents

Section
Description
Number
Rear Frame 6011
Hydraulic Pump Drive 6012
Mechanical Front Drive MFD Control System
6013
How it Works
Differential Lock Control System
6014
How it Works
MFD Clutch And Output Shaft Removal Without Tractor Split 6015
MFD Drive Shaft 6016
Limited Slip MFD Differential 6017
Locking MFD Differential 6018
Rear Axle and Planetaries 6019
Power Take Off Control System How it Works 6020
MFD Planetary Hub, Steering Knuckle, and Axle Drive Shaft 6022
Suspension MFD Axle 6023
Suspended MFD Axle System
How It Works and Troubleshooting
6024
Brake Valve 7001
Brake Cylinders 7002
Park Brake 7004
Trailer Brake System
How It Works
7005

•
,I

•
Rae 6-14231 C> 2003
- --~
Issued 10-02 1 Revised 4-
 MX Magnum
MX210, MX230, MX255, MX285

R ~31 ©2003
2
Issued 10-02 I Revised 4-03
 Section
6011

REAR FRAME

CASE CORPORATION It> 2002 Case Corporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. 6·13440 September, 2002 .
6011-2

TABLE OF CONTENTS
SPECIFICATIONS .......................................... ...................................... ........................................... ..... ................... 3

SPECIAL TORQUES .......................................... ... ................... ...... ......................................................................... 3

SPECIAL TOOLS .............................................. :..................... ............. .......... ... ..... .. ............... ................................ 3

DIFFERENTIAL REMOVAL ......................................................................................................................... .... .. ..... 4

Removal ... .. .. ........................................................ .................................................................................. ....... ....... 4

DIFFERENTIAL DISASSEMBLY ...................... ..... ................................................................................................ 11

PINION SHAFT ................................................................................... .................................................. ... ....... ...... 16

Removal and Disassembly .. ................................... ....................... .................................................................... 16
Assembly and Installation ........................................................................ ...................................................... .... 19

DIFFERENTIAL ASSEMBLY ......................... ............................................................................. .. ......................... 28

DIFFER ENTIAL INSTALLATION .... .................................................................................. .......... ...... ............ ........ 33

ADJUSTING THE DIFFERENTIAL PRELOAD ......... .. ...................................... ..... .................. .............. .......... ... .. 40

ADJUSTING THE RING AND PINION BACKLASH .......... ....................... ............................................................. 42

BEVEL PINION AND GEAR TOOTH CONTACT CHECK .................................................................................... 43

Printed in U .S.A
 6011-3

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 Ib inch)
Differential Bearing Rolling Torque (Used) ................ .... ..... ..... .. ............................ 2.25 to 3.95 Nm (20 to 35 Ib 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)

SPECIAL TORQU ES
Right-Hand (RH) Retainer (Initial) ...................... ..... ....... ........................................ ..................... 11 Nm (100 Ib inch)
Bearing Retainer (Final Phosphate Coated with Oiled Threads) ........ ........ ....... ....... 235 to 260 Nm (173 to 195 Ib It)
Pinion Shaft Assembly Mounting Bolts .............................................................. ..... 101.7 to 112.5 Nm (75 to 831b ft)

SPECIAL TOOLS

cas1952

Differential Lifting Tool CAS1952

S04l7
Pinion Seming Tool CAS1902-1

' - - - - - - - - - - - - - - - - CASl902·2

Rolling Torque Adapter, CAS1902-2

Rae 6-13440 Issued 9~02

~
!
6011-4

DIFFERENTIAL REMOVAL

Removal 5. Remote valve return line.

6. Regulated supply to PTa valve.
STEP 1 7. Difflock supply tube.

Prepare to remove the differential as follows:

STEP 6
1. Start the tractor and lower the hitch.
2. Turn the tractor OFF and remove the key. Disconnect the hydraulic lines to the hitch lift
cylinders.

STEP 2 NOTE: If the pinion shaft must be serviced, the

power train must be split between the range housing
Remove the cab (refer to Cab Removal in this and the rear frame. Refer to Range Transmission to
manual). Rear Frame Split in this manual for procedures.

STEP 3 STEP 7
Remove the axle shafts and planetaries (refer to
Rear Axle and Planetaries in this manual) . If
necessary, remove the brake cylinders (refer to Brake
Cylinders in this manual).

26s21b

Remove the hex head bolt and nut from the locking
flag plate where the vertical lifting link is attached to
the rock shaft.

NOTE: Refer to Tractor Hitch in this manual for

details.

Remove the drain plug from the bottom of the rear STEP 8
ame housing. Drain the oil from the housing into a
!luitable container.

TEP 5
efer to Hydraulic Systems and Troubleshooting in
I is manual and remove the following:
1. Supply line from PFC piston pump to remote
valve.
;2. Signal line to compensator.
S. PTO lube supply.
4. Bevel gear lube tube.
Lift up on the locking flag plate to remove it.

~c 6-13440 Issued 9-02

 6011-5

STEP 9 STEP 11

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).
through 11 for the other vertical lifting link.

NOTE: Be prepared for the sudden drop in the STEP 12

vertical lifting link as the pin is driven out.

STEP 10

35·24
Secure the rockshaft assembly as follows:
1. Attach a chain hoist to the top of the rocks haft
assembly.
27s12b

Remove the hydraulic lines to the hitch lift cylinder as 2. Place enough tension on the chains to support
follows: the assembly without adding a lifting force.
1. Be prepared to catch hydraulic fluid as the
hydraulic system is opened.
2. Remove the hydraulic line from the top of the
hitch lift cylinder and then from the bottom of the
hitch lift cylinder (both sides).

Rae 6-13440 Issued 9-02

6011-6

STEP 13 STEP 15

Remove the two bolts that attach the rocks haft Remove pin and free the upper end of the hitch lift
sensor shield to the hitch support C-bracket. cylinder.

NOTE: Be sure to remove hitch position sensor

(potentiometer) prior to removing the hitch lift STEP 16
cylinders. If the cylinders are removed first, there
may be excessive travel of the rockshaft, which would
damage the sensor.

STEP 14

Remove the bolt, locking flag plate pin and free the
lower end of the hitch lift cylinder. Remove th e
cylinder.

STEP 17
Remove the nut from the link assembly.

Hold the left nut on the tie rod and turn the right side
nut (shown).

Rae 6-13440 Issued 9-02

 6011-7

STEP 18 STEP 20

35-30
Remove the position sensor bracket. Remove the split ring retainers from both ends of the
rockshaft.

STEP 19

Remove the split ring washer. Remove the tie rod

through the opposite end from which the washer and
retainer were removed. " tires are on tractor, the tie
rod may be disassembled by sliding tie rod through
the chain support hole in the disc. Position the
wheels as necessary.
Use a long piece of wood to reach through the
rocks haft and contact the rocker pin. Tap the piece of
wood to dislodge the rockshaft pin. Use care not to
damage the seal or bushing.

STEP 22

Remove the rockshaft pin.

Rae 6·13440 Issued 9-02

E
6011-8

STEP 23 STEP 26

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

material. STEP 27

STEP 24

Remove the rear frame cover and the PTO clutch

assembly (refer to PTO Assembly, Single and Dual
Speeds in this manual).
Remove the bolts that attach the cover and rear cab
bracket to the rear frame.
STEP 28
STEP 25

Remove the differential lube line from the rear frame.

Remove the rear frame top cover and set aside. NOTE: Bevel pinion must be removed from rear
frame housing before proceeding.

Rae 6-13440 Issued 9-02

 6011-9

STEP 29

Install the differential lifting tool , CAS-1952, on the Remove the LH bearing retainer shims from the rear
differential. Connect a hoist to the differential lifting fram e and tag for location.
tool and put tension on the hoist chain or strap.

STEP 30
,; -
~

T98187

Remove the RH bearing retainerfrom the housing.

Remove the left-hand bearing retainer from the rear
frame.

Rae 6-13440 Issued goO?

 6011-10

STEP 33
STEP 34

Remove the right-hand bearing retainer shims from T98204

the housing and tag for location. Remove and set up the differential assembly as
follows:

1. Remove the differential assembly from the rear

frame.

2. Place the differential assembly on a clean

workbench with the ring gear facing up.
3. Support the assembly on a wood block(s) to
provide clearance for bolt removal.

1 6·13440
Issued 9-02
 6011-11

DIFFERENTIAL DISASSEMBLY

STEP 35 STEP 37

t98146 S8-28A

Remove and discard the 12 ring gear mounting bolts. Remove the thrust washer from the cover.
Remove the ring gear. Remove the differentia l
housing seal rings.
STEP 38
NOTE : Attach the differential case to the cover using
a nut and bolt. Carefully turn the assembly over.
Remove the nut and bolt.

STEP 36

Remove the differential lock separator and friction

plates from the housing.

STEP 39

Remove the differential cover from the housing.

Remove the bevel lock side gear and six dowel pins
from the housing.

Rae 6-13440 Issued 9-02

6011-12

STEP 40 STEP 43

T98156 R96159

Apply compressed air to the differential lock piston Insert an MB bolt into the short pinion shaft hole.
supply port to break the piston loose.

STEP 44
STEP 41

T98160

Remove each short pinion shaft from the housing .

Remove the piston from the housing.

STEP 45
STEP 42

Remove the short spacers from the housing.

emove the short pinion shaft retaini ng bolts from
e housing.

ac 6·13440 Issued 9-02

 6011-13

STEP 46 STEP 49

Remove the short shaft pinion gears from the Remove the long spacer from the housing .
housing. Remove the thrust ring and needle bearings
from both short shaft pinion gears.
STEP 50

STEP 47

T98166
Remove the long pinion shaft gears from the
housing. Remove the thrust ring and needle bearings
Remove the thrust washers from the housing. from both long shaft pinion gears.

STEP 48 STEP 51

T98167

Remove the long shaft from the housing. Remove the thrust washers from the housing.

Rae 6-13440 Issued 9-02

,
 60 11 -14

STEP 52 STEP 54

...

T98168
T98183
Remove the bevel side gear from the housing.
Remove the bearing cup from the housing .

STEP 53 STEP 55

88-19A
Remove the thrust washer from the housing.
Remove the bearing cup from the differential cover.

ae 6-13440
Issued 9·02
 6011-15

STEP 56 STEP 58

T98174

Remove the oil seal from each bearing retainer. Remove the seal ring and the bearing cone from the
left hand bearing retainer.

STEP 57

Remove the seal ring and the bearing cone from the
right hand bearing retainer.

Rac ·S·13440 Issued 9-02

6011-16

PINION SHAFT

Removal and Di sassembly

STEP 59 STEP 62
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

Remove the shims from the bearing cage. Use a

micrometer to measure all the shims and record the
shim pack size.

STEP 63

Remove the pinion shaft bearing cage mounting

bolts.

STEP 61

T95915
Remove the front pinion shaft snap ring . Press on the
bearing cone race if it blocks removal of the snap
ring.

Install two aligning dowels through the bearing cage

and into the rear frame. Remove the pinion shaft
assembly from the rear frame.

Rae 6-13440 Issued 9-02

 6011-17

STEP 64 STEP 67

T95921

Mount pinion shaft in a press with pinion gear facing Remove the front bearing cup from the bearing cage.
down. Position support plates under bearing carrier.

STEP 68
STEP 65

T95925

Remove the inner snap ring from the bearing cage.

Press the pinion shaft and bearings out of the
bearing cage.
STEP 69
NOTE: Make sure that the rear bearing (against the
gear) will clear the press.

STEP 66

T95923

Remove the rear bearing cup from the bearing cage.

Press the bearing cone from the pinion shaft.

Rae 6·13440
6011- 18

STEP 70

T95919

Be sure the hole in the button of the pinion shaft is

open.

ac 6·13440 Issued 9-02

 6011-19

Assembl y and Installation

/'
( ~

"" ~
"@
12

23817
1. RING GEAR
2. CUP
3. PLUG
PINION SHAFT 8. BEARING CAGE
4. BEARINGC~~H HOLE 9. SNAP RING -
s. BEARING CUP E

'"'" "~ "~".

10. SPACER-
6. SNAP RING 11 . CONSTANT M

:! ~~~::~~
NO ' '"'" " ""

TE: All parts marked with' remam

. in th CONE
CUP
e range transmission.

Rae 6·13440 Issued 9·02

6011-20

STEP 71 STEP 74

195924a 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

Install the rear snap ring in the bearing cage groove. Install the bearing cage over the shaft and bearing.

STEP 73 STEP 76
.................

T95922
Press the front bearing cup into the bearing cage
until seated against the snap ring.
Press the front bearing on the pinion shaft and into
the bearing cup as you turn the bearing cage to help
seat the bearing.
•

Rae 6-13440 Issued 9-02

"
 6011-21

STEP 77 STEP,...;...
78;_ _

Measure the distance from the bearing cone to the

front of the snap ring groove using feeler gauges.

Select a snap ring with a thickness between 0.05 mm

(0 .002 inch) less than your measurement to 0.007
mm (0.003 inch) more than your measurement. If
more than one ring can be used , install the thicker
ring in the pinion shaft groove.

Rae 6-13440 Issued 9-02

6011 ·22
STEP 79
Backseat the front bearing on the snap ring with
10000 to 15 000 Ib of force . Check the end play
again. The end play must be from 0.013 to 0.102 mm
(0.0005 to 0.004 inch). If the end play is incorrect,
install the correct size snap ring (larger or smaller) to
obtain the correct end play.
It may be necessary to make calcu lations to
determine the force to use with your ram. See "How
to Determine Ram Pressure" below.
1060L9
Determine pinion shaft bearing end playas follows:
6-13440
1. Mount the bearing cage in a vise.
2. Attach a dial indicator on the bearing cage so
that it indicates from the end of the pinion shaft.
3. Measu re the end play by pushing on the shaft
with 50 to 100 Ib of force.
4. Record the indicator reading while slightly
oscillating the shaft.
5. Repeat the procedure in the opposite direction.
The difference between the two readings is the pinion
shaft bearing end play.
How To Determine Ram Pressure
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.
EXAMPLE: Find the effective area of twin rams, each
ram having a piston diameter of 1.5 inch.
The formula for the effective area is :
Effective area = (d2 + d2) x 0.7854
d = diameter of each ram (1.5 inch)
d2 = d x d or 1.5 x 1.5 = 2.25 sq inch for each ram
Effective area = (2 .25 + 2.25) x 0.7854 = 3.574 sq
inch
EXAMPLE: Find the pressure gauge reading for the
specified minimum and maximum Ib ft force rising a
ram with 3.528 sq inch effective area.
Minimum pressure gauge
reading (PSI) = 2090 Ib - 591 PSI
3.534 sq inch
Maximum pressure gauge
reading (PSI) = 2610 Ib - 738 PSI
Issued 9-02
 6011-23

STEP 80 STEP 81

106119

Determine correct dimension as follows: Install the pinion shaft assembly without any shims.
Install and tighten retaining bolts to a torque of 102 to
1. The reference number etched on the end of the
113 Nm (75 to 831b It).
pinion shaft is a + or - adjustment in hundredths
of a mm.
2. Add or subtract the reference number from the STEP 82
standard nominal dimension of 33:92 mm. This
will,provide the desired dimension in mm.
3. To convert the desired dimension to inches,
multiply by 0.03937.
Example:
33.92 mm Standard Dimension
+0 22 mm Reference
, 34.14 mm Desired Dimensien.
I
34.14 x 0.03937 = 1.344 inches

Install the pinion shaft depth setting tool CAS1902-1

into the differential bearing retainer bores so the bar
is centered on the pinion shaft.

Rae 6-13440 Issued 9-02

6011·24

Differentia
· I Assembly

ac 6-13440 Issued 9-02

 6011-25

1. SHIM 29. COVER

2. HOUSING 30. WASHER
3. PIN 31. BOLT
4. RING 32. CONE BEARING
7. GEAR 33. CUP BEARING
8. GEAR 34. RETAINER
10. THRUST WASHER 35. PIN
11 . THRUST WASHER 36. SEAL
12. WASHER 40. RING
13. SHAFT 41. RETAINER
14. SHAFT 43. PIN
15. BOLT 44. SEAL
19. SPACER 45. RING
20. SPACER 46. BOLT
21 . NEEDLE BEARING 50. PISTON
22. RING 55. PLATE
23. CONE BEARING 56. PLATE
25. CUP BEARING 57. TUBE
58. O-RING

Rae 6- 13440 Issued 9·02

•
6011-26

STEP 83 STEP 85

3
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 Ibs forward loading on the pinion
the alignment dowels.
shaft to remove all bearing end play.
2. Measu re from the face of the pinion shaft to the
face of the depth setting tool bar in millimeters. STEP 86
This is your measured dimension.
3. Subtract this measurement from the desired
dimension calculated in Step 80.
Example:

34.14 mm Desired Dimension

-33 82 mm Measured Dimension
0.32 mm Shim Pack Size
-.
4. Shims are available in the following sizes:
0.003, 0.004, 0.005 and 0.012 inches (0.076 ,
0.10, 0.13, and 0.30 mm).

Select the correct shim pack, determined in Step 83,

within 0.03 mm (0.001 inch) . Install the shims over
the alignment dowels.

R"mClv" the pinion shaft assembly from the housing.

c 6-13440 Issued 9-02

 6011-27

STEP 87 STEP 88

,
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 63 Ib ft) to
each bolt.

Rae 6·13440 Issued 9-0:

6011-28

DIFFERENTIAL ASSEMBLY

STEP 89 STEP 91

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

39717

Install the oil seals into the bearing retainers. The

Irstall the seal rings on both the RH and LH retainer.
Make sure the ends of the ring lock together.
rubber lip faces the outside of the retainer. The seal
must be recessed below the retainer face (1) 0.8 ·mm
(0.032 inch) .
STEP 92

Install a new O-ring lubricated with petroluem jelly on

the pinion shaft lubrication tube.

R 6-13440 Issued 9-02

\
 6011-29

STEP 93 STEP 96

T98209 --------------~
T;~l~
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 T98167

Install the bearing cup into the housing until seated Apply petroleum jelly to the four thrust washers.
against the housing. Install two washers for the long pinion shaft so the
tabs (1) enter the cavities (2) in the housing. The long
shaft does not use locking bolts.
STEP 95

STEP 98

88-19A

Install the smaller thrust washer into the differential

housing so the washer tabs enter the cavities in the T9820

housing. Apply ·petroleum jelly to the inside of the four pinior

gears. Install 28 needle bearings in each gear.

Issued 9-0
Rae 6·13440
6011-30

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.

STEP 100
STEP 103

T98166

Install the two pinion gears for the long shaft into the
housing against the thrust washers.
STEP 101
Install the remaining two thrust washers into the
housing so that the washer tabs enter the cavities in
the housing .
STEP 104

stall the long spacer into the housing cavity.

T98162

Install the two remaining pinon gears into the housing

against the thrust washers.

c 6·13440 Issued 9-02

 6011-31

STEP 105
.. STEP 108

T98 161

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

T98160 Install the six dowel pins into the housing.

Install the two short pinion shafts (small end first) into
the housing bores, through the short spacers and
into the hole in the long spacer and long pinion shafl. STEP 110
Keep the locking bolt hole of the short shaft aligned
with the bolt hole in the housing.

STEP 107

Install the locking side gear into the housing so that

the teeth mesh with the pinion gears.

T96155

Install the short pinion shaft locking bolts through the

housing into the shafts.

Rae 6-13440 Issued 9-02

6011-32

STEP 111 STEP 114 •

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.

112 STEP 115

T961 52 BS-28AO

one friction plate in the housing so it will mesh Apply grease to the larger thrust washer and install
the locking side gear. the washer on the cover so the tabs enter the cover
cavities.

STEP 113

~ ternate the separator and friction plates untiIT;~5~

have a total of three friction plates and four separator
p\ptes in the housing .

I
J 6·13440 Issued 9-02
 6011-33

DIFFERENTIAL INSTALLATION

STEP 116 STEP 117

Install the seal rings on the housing . Make sure the

ends of the rings are locked together.

STEP 118

Install the differential cover on the housing.

T98148

Place the ring gear on the differential housing. Install

12 new ring gear bolts and torque to 310 Nm (230 Ib
tt ).

STEP 119

T98204

Install the differential lifting tool onto the differential.

Rae 6· 13440 Issued 9-02

 6011-34

STEP 120 STEP 121

T98214
Install the differential into the rear frame with the ring Install two aligning dowels in each bearing retainer
gear to the left-hand side. mounting surface of the rear frame.

IMPORTANT: The pinion shaft must not be

assembled into the housing. STEP 122

Install shims as follows:

1. If no changes were made with the differential

Rae 6·13440
Issued 9-02
 6011-35

STEP 123 With a 3-point sling and hoist, lift the rocks haft
casting into place.

STEP 126

Install bearing retainers as follows:

1. Align the lube passage on the rear frame
housing with the lube passage in the bearing 35·18

retainer (shown). Th e rockshaft pins must be clean and free of oil,

grease, antiseize compound, etc. Orient pin with
2. Install the bearing retainers on the rear frame
bearing surface outboard. Insert a rockshaft pin. Use
housing.
a wooden block to tap the pin until it is seated in
3. Gradually and evenly torque the retainer place. Insert the other rockshaft pin.
mounting bolts to 235 to 260 Nm (173 to 192 Ib
It).
STEP 127 _ _-=-
NOTE: If the differential bearings were changed, the
backlash on the ring and pinion must be set. See
Adjusting the Ring and Pinion Backlash in this
section.

STEP 124
Install the Dill Lock supply line, Dill Lube line, rear
frame cover, and PTO assemblies that were
removed. Install rear frame top cover.

STEP 125
-.- Insert new split washer retainers at the ends of both
rockshaft pins.

Rae 6-13440 Issued 9·02

6011-36

STEP 128 STEP 130

Install the tie rod as follows: Install the nut that attaches the position locator
bracket to the end of the tie rod. Tighten to a torque
1. Place one washer and retainer in place on the
of 490 to 555 Nm (362 to 410 Ib ft) . The nut on the
end tie rod with the nut.
opposite end of the tie rod will need to be held with a
2. Insert the end of the tie rod without the washer wrench to achieve torque.
and retainer through the centers of the rockshaft
pins.
STEP 131
3. Attach the split rings washer and retainer to the
end projecting through the rockshaft pin.

STEP 129

Install the two bolts that attach the rockshaft sensor

shield to the hitch support arm. Tighten to a torque of
62 to 60 Nm (46 to 59 Ib ft).

NOTE: Refer to Tractor Hitch in this manual for

ttach the position sensor bracket.
details about adjusting the hitch support system.

ac 6-13440 Issued 9-02

 6011-37

STEP 132 STEP 134

Install the nut for the rockshaft sensor link assembly.
Torque to 18 to 23 Nm (14 to 17 Ib tt) .
STEP 133
Insert the top cylinder pin as follows:
1. Pin must be clean and free of oil, grease, anti-
seize.
2. Adjust the vertical position of the rockshatt, if
necessary to align holes in cylinder rod and
rockshaft.
3. Insert the top cylinder pin through the holes
(groove to inside).

STEP 135

Install the hitch litt cylinder as follows:

1. Pins must be clean and free of dirt, grease, oil
and anti-seize compound, etc.
2. Position a hitch litt cylinder into place. Insert the
bottom cylinder pin (groove outside) through the
mounting bracket and cylinder. ,....
3. Attach the locking flag plate. Install the locki ng flag plate. Install the bolt and
tighten to a torque of 82 to 106 Nm (60 to 70 Ib tt).
4. Tighten bolt to a torque of 82 to 106 Nm (60 to 78
Ib tt).

Rae 6-13440 Issued 9~ 02

6011-38

STEP 136 STEP 138

27s12b 26s24b

Connect the hydraulic lines to the top and bottom of Insert the slotted end of a locking flag plate into the
the hitch cyli nder. Repeat for the other hitch lift groove on the inside of the hitch swivel pin.
cylinder.

STEP 139
STEP 137

Install the hex-head bolt and tighten it to a torque of

Install the vertical lift links as follows: 82 to 106 Nm (60 to 78 Ib ft). Repeat for the other
vertical lifting link.
1. Pin must be clean and free of oil, grease, anti-
seize.
NOTE: Refer to Tractor Hitch in this manual for
2. Refer to the view in Step 10 if necessary to details about orienting the links in the three-point
assemble the vertical lift link for proper hitch if they were removed.
orientation of swivels and flags.
3. Place a hitch swivel pir (groove to outside) part- STEP 140
way through the outside hole in the rockshaft
arm. When the rockshaft is fully assembled, calibrate the
hitch (see Hitch Controller Calibration and Fault
4. Lift the link into position by aligning the swivel pin
Codes in this manual for the procedure) .
with the hole in the swivel.
5. Push the swivel pin through the lift link into the
inner ear of the rockshaft arm.

Rae 6-13440 Issued 9-02

 6011-39

STEP 141 STEP 144

Install the axle shafts and planetaries on the tractor.

STEP 145

Connect the range transmission and the rear frame

together (refer to Range Transmission to Differential
Split in this manual).

STEP 146
Install the fuel tank on the tractor.

Install and tighten the rear frame drain plug in the

STEP 147
housing.
After filling the transmission, operate the tractor for a
STEP 142 few minutes. Shut down and check' the transmission
flu id level.
Install the drawbar on the tractor and secure with the
pin. Torque the pivot pin retaining bolt to 125 to 150
STEP 148
Nm (93 to 112 Ib ft). Refer to Tractor Hitch in this
manual for details. If not already performed , calibrate the hitch (see
Hitch Controller Calibration and Fault Codes in this
STEP 143 manual) .

Install the brake cylinders onto the tractor.

Rae 6·13440 Issued 9-02

6011-40

ADJUSTING THE DIFFERENTIAL PRELOAD

NOTE: When the differential bearings or housing are Install the LH bearing retainer assembly on the rear
replaced, the bearing preload must be adjusted. Irame without shims.

STEP 149 STEP 151

Install the differential assembly into the rear frame
without the ring gear when the pinion assembly is in
place or with the ring gear when the pinion assembly
is removed. If no adjustment is necessary, go to Step
156 lor the differential rolling torque check.
Tighten the three retainer mounting bolts to a torque
01235 to 260 Nm (173 to 192 Ib It).
STEP 152

STEP 150

Install the RH bearing retainer assembly on the rear

Irame without shims.

6·13440 Issued 9-02

 6011-41

STEP 153 STEP 155

• - - -->'"<'I
.- ~

Tighten the three bearing retainer bolts while rotating
the differential to seat the bearings. Torque the bolts
equally and evenly in steps of 2.8 Nm (25 Ib inch)
steps, until 11 Nm (100 Ib inch) of torque is reached
on each bolt.
STEP 154
Use a depth micrometer to measure from the RH
bearing retainer face to the rear frame through the
three equally spaced holes. Average the three
measurements and record the dimension.
NOTE: If any two readings vary by more than 0.254
mm (0.010 inch), loosen the bolts and check for
proper seat, burrs, or foreign material. Repeat the
procedure until the desired range is obtained.

Obtain the rolling torque as follows:

1. Install the rolling torque adapter into the
differential assembly.
2. Loosen the RH carrier" bolts evenly until they are
finger-tight.
3. Tighten the RH carrier bolts equally and evenly
until a rolling torque of 5 Nm (45 Ib inch) is
reached.

NOTE: Do not tighten beyond this point.

Rae 6-13440
6011-42
t
ADJUSTING THE RING AND PINION BACKLASH

STEP 156 2. Tighte the bearing carrier bolts to a torque of 255

to 260 Nm (130 to 144 Ib ft) while rotating the
differential.
3. The rolling torque of the differential must be 4.5
to 8.0 Nm (40 to 70 Ib inch) for new bearings and
2 to 4 Nm (20 to 35 Ib inch) for old bearings
(used for more than 200 hours) . The desired
settings are in the upper half of the ranges.
,
4. To increase the rolling· torque, remove
approximately 0.05 mm (0.002 inch) of shim
material from the right-hand bearing retainer.
5. To decrease the rolling ·'! orque, add
approximately 0.05 mm (0.002 inch) of shim
material to the right-hand bearing carrier.

STEP 158

If the differential was installed without the ring gear,

remove the differential assembly from the rear frame
and complete Steps 117 to 122 to install the ring
gear.

If the pinion assembly is not installed, refer to Pinion

Shaft Assembly and Installation in this section to
install the pinion. Then proceed with the following
steps.

ltoo"""m;,,,' required shim pack thickness as follows: STEP 159

1. Measure the thickness of the RH bearing retainer
at the machined surfaces (1).
2. Subtract this dimension from the average
dimension obtained when measuring the retainer
face to the rear frame (Step 154).
3. The difference is the required shim pack
thickness.
4. Split the shim pack equally between the two
bearing retainers.

TEP 157 RR98C045

Install the seal rings on both the LH and RH bearing

Install bearing carriers as follows: retainer. Make sure the ends of the ring lock
together.
1. After installing the new shim pack, or the original
shim pack, install the bearing carriers.

6-13440 Issued 9-02

 6011-43

BEVEL PINION AND GEAR TOOTH CONTACT CHECK

STEP 160 STEP 161

r-":;l
Put Prussian Blue or red lead onto the convex side of
the gear teeth. Turn the pinion several revolutions in
the forward (clockwise) direction. while applying a
braking force on the gear. to determine the contact
pattern. See the contact patterns in the following
illustrations.

NOTE: The contact pattern of the gear teeth that are

Adjust the ring and pinion backlash as follows:
1. Mount a dial indicator on the rear frame.
2. Position the dial indicator so that it contacts one
tooth on the ring gear. Do not move the pinion
gear.
3. Rotate the ring gear in either the forward or
reverse direction to achieve full contact with the
pinion gear.
shown are approximate shapes. The gear tooth
contact patterns can change from the illustrations.
Any shape or pattern (L -type. band. C-type. triangle.
etc.) is acceptable if it is tapering off from toe to heel
and falls into the contact area shown. The tooth
contact pattern can change in a used gear set
because of wear of the parts. Try to get a contact
pattern that is similiar to the illustrations to get the
best results.

IMPORTANT: Pinion shaft must be held in place so

it will not move.
4. Zero the dial indicator.
5. Rotate the ring gear in the opposite direction to 61'-6
achieve full contact with the pinion gear in the
Correct Tooth ContaCt Pattern
opposite direction.
Correct adjustment is made when the pattern of the
IMPORTANT: Pinion shaft must be held in place so tooth contact area (both horizontal anc~ vertical) is as
it will not move. shown.
6. Record the dial indicator reading.
7. The dial indicator reading is the ring and pinion
gear backlash . The backlash must be between
0.179 to 0.279 mm (0.007 to 0.11 inch).
8. To adjust the ring and pinion gear backlash .
move shims from one side of the differential to
the other. Moving a 0.254 mm (0.0 10 inch) shim
from one side to the other will change the
backlash approximately 0.169 mm (0.0067 inch).
6&.6

Pattern A
The pinion is out too far. Remove approximately 0.10
mm (0.005 inch) of shim material that was installed in
Step 75.

Rae 6·13440 Issued 9-02

(
6011-44

:-~0

247LO

Pattern B 244LO
1. RING/BEVEL GEAR 3. BEVEL GEAR
The pinion is in too far. Add approximately 0.10 mm 2. BEVEL PINION 4. BEVEL PINION IN TO
(0 .005 inch) of shim material under the pinion IN TO CORRECT CORRECT PATTERN B
PATTERN A
bearing cage.
Adjust the backlash to specifications. See Step 159
before checking contact pattern again.

ac 6·13440 Issued 9-02

e '
 6011-45

,,,
IT'-~ ~
, ,
.. ' :-. -.-. '

LL-

RH98C093
1. DIFFERENTIAL LOCK ASSEMBLY 3. DRIVE PINION SHAFT
2. RING GEAR 4. DIFFERENTIAL ASSEMBLY

Rae 6-13440 1_9-02

 6011-46

Ractl3440 Issued 9-02

 Section
6012

HYDRAULIC PUMP DRIVE

CASE CORPORATION © 2002 Case Corporation

700 Slate Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6· 13350 October, 2002
6012-2

TABLE OF CONTENTS
SPECIAL TORQUES ............. ..... ...... .. ...... ... ........................... .... .. .. ... ... .. .... ........ .................. ... ......... .. ...... .. ... .. ...... .. 4

SPEC IFICATIONS ... ... .. .. .. ...... ....... .. ....... ....................... ... ................ ......... .......................... ........ ... .................. ....... 4

PUMP DRIVE .. .......... ........................................... .... .................. .. ............... .. ... .. ....... ................................... ..... ...... 4
Removal ................... .. .. ...... ............. .......... ...... .. .. ............ ............... ...... .... .. .... ........... .. .... ...... .... .. ......................... 4
Disassembly .....................................................................................•.. ................................................. ................ 5
Assembly ....... .. ................ .. ................. .. ......... .. .... ......................................... .................................... ................... 8
Installation ................. .. ..... .. ....... ................ ... .............. ..................................... .................................. ............... .. 13 •

ac 6·13350 Issued 10-02

 6012-3

SPECIAL TORQU ES
Bearing Cage Bolt ........................... ............. ........ ................................................. ........... 55 to 60 Nm (41 to 44 Ib tt)
Hydraulic Drive Pump Assembly Mounting Bolts ..... .......................................•................. 52 to 61 Nm (38 to 45 Ib tt)

SPECIFICATIONS
Driven Gear Shaft End Play ........ ........................ ... ... .. ...... ........... ... .............. ... 0.026 to 0.1 mm (0.001 to 0.004 inch)

PUMP DRIVE
Removal
STEP 1 STEP 3

Use identification tags to mark the hydraulic lines. Remove the two mounting bolts (1) from the
Cap the lines and open fittings. Remove the charge hydraulic line support bracket.
pump and filter (1) . Refer to Section 8006 in this
manual. Remove the transmission filter with base (2)
and the hydraulic PFC piston pump (3) from the
hydraulic pump drive (4). Refer to Section 8007 in
this manual for transmission filter base and PFC
piston pump removal.

NOTE: Provide open access to the pump drive by

blocking the front wheels and properly supporting the
rear axle. Loosen the six wheel bushing bolts and
move the wheel outward on the axle.

STEP 2

Remove the two longer top mounting bolts and the

six shorter bolts from the pump drive mountin!l
flange. Remove the pump drive assembly.

Remove the three hydraulic line clamps (1) on top of

the hydraulic line support bracket.

Rae 6-13350 Issued 10-02

6012-4

Disassembly

STEP 5 STEP 8

RP98B083 AP98B049
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

AP98B053 T94753
Remove the bearing cup from the bearing cage. Remove the idler gear bolt and washer from the
pump drive housing.
STEP 7
STEP 10

A
RP96B048
emove the shims from the pump drive housing. T94764

Install a slide hammer on the idler gear shaft.

ac 6-13350 Issued 10-02

 6012-5

STEP 11 STEP 13

T94752 T94750

Remove the idler gear shaft from the pump drive Drive one of the bearings from the idler gear. Discard
housing. the bearing.

STEP 12 STEP 14

T94751 T94749

Remove the idler gear assembly from the pump drive Remove the spacer from the idler gear.
housing.

Rae 6-13350 Issued 10-02

 6012-6

STEP 15 STEP 17

T94748
RP96B051
Press the other bearing from the idler gear. Discard Remove the front and rear bearing cone from the
the bearing. driven gear shaft using a bearing puller or a press
and collet.
STEP 16

T94747
Remove the two snap rings from the idler gear.

ac 6-13350 Issued 10-02

 6012-7

Assembly

SCRH98A5

2. IDLER SHA~ HOUSING

1. PUMP DR IV 7. BEARING CUP
8.
9 BEARING CONE
3. BEARING . DRIVEN GEAR
4. SPACER 10. SHIM
~. RETAINING RING 11 . O-RING
. IDLER GEAR 12. BEARING CAGE

Rae 6-13350 Issued 10-02

60 12-8

STEP 18 STEP 21

RP9SB051 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. Install a new spacer if damaged or worn.
shaft shoulder.

STEP 22
STEP 19

T94750
T94747 Press the other new bearing into the idler gear until it
Install the two snap ring s into the grooves of the idler rests solidly against the snap ring.
gear.

STEP 23
STEP 20

T94751

T94748 Install the idler gear assembly into the pump d rive
ress a new bearing into the idler gear until it rests housing.
olidly against the snap ring .

ac 6-13350 Issued 10-02

 6012-9

STEP 24 STEP 26

T94752

Install the idler gear shaft through the pump drive U si ng the identifying marks made during
housing and the idler gear. disassembly, install the drive gear assembly into the
pump drive housing.

STEP 25
STEP 27

T94753

Install the idler shaft retaining bolt and the flat washer AA98C026

through the idler shaft and into the pump drive Install the bearing cage as follows:
housing. 1. Install the bearing cage on the pump drive
housing without shims or O-rings.
2_ Install two opposite bolts, rotate the shaft, and
alternately, in two increments , tighten the
bearing cage bolts to a torque of 3.4 Nm (30 Ib
in).
3. Turn the shaft while tightening the bolts to help
seat the bearings.
Check all bolt torques. Tighten again if necessary.

Rae 6-13350 Issued 10·02

6012-10

STEP 28 STEP 30

RR98BOO3 AP06B052

Determine required shim pack size as follows: Lubricate a new O-ring with petroleum jelly. Install
the O-ring on the bearing cage.
1. Measure the gap between the bearing cage and
the pump drive housing at each bolt.
2. If the difference between the measurement at the STEP 31
two bolt areas is greater than 0.254 mm (0.010
inch), check for proper bearing seating, burrs, or
foreign matter.
3. Repeat the steps until the required difference,
less than 0.254 mm (0.010 inch), is obtained .
4. Take the average measurement. Add 0.13 mm
(0.005 inch) to the measurement. This is the
shim pack size needed.

STEP 29
.....
RP96B048

Install the shim pack, determined in Step 28, on the

bearing cage mounting surface of the pump drive
housing .

STEP 32

RP98S083
Remove the bearing cage from the pump drive
housing.

Install the bearing cage on the pump drive housing.

ac 6- 13350 Issued 10-02

 6012-11

STEP 33 STEP 34

RR98BOO5 RR98BOO4

Tighten the bearing cage bolts to a torque of 55 to 60
Nm(41 to 44 Ibft).
If necessary, adjust shim pack to obtain correct end
playas 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.
3. Set the dial face to zero.
4. Move the drive gear shaft in and out of the
housing as you observe the dial indicator. End
play must be 0.025 to 0.1 mm (0.001 to 0.004
inch).

If needed , adjust the shim pack to get the correct end

play.

Rae 6-13350 Issued 10-02

 6012-12
Installation
STEP 35
ItA,PPIV a continuous bead of Loctite ® 515 Sealant,
mm (3/16 inch) wide to the mounting surface of
pump drive housing and around the bolt holes.
I the hydraulic pump drive assembly on the
Itra n~rTliis,~icln.
Install the mounting bolts and tighten to
torque of 52 to 61 Nm (38 to 45 Ib It).
II the two hydraulic line support bracket
mn"'nl-rnn bolts (1).
STEP 38
With the hydraulic pump drive (1) installed on the
transmission, install the hydraulic PFC pump (2) and
the transmission filter and base (3) . Refer to Section
8007 in this manual. Install the charge pump and
filter (4). Refer to Section 8006 in this manual. When
installing the charge pump, it will be necessary to
loosen the clamps on the rubber charge pump
suction hose and pry up on the hose to provide
needed clearance for the suction flange O-ring .
STEP 39
Connect the hydraulic lines . Install the three
hydrau lic line clamps (1) on top of the hydraulic line
support bracket.
STEP 40
Move the rear wheel inward on the axle . Apply
anti seize to the bushing bolts . Tighten the bushing
bolts to a torque of 300 to 350 Nm (220 to 260 Ib ft).
Remove the axle support equipment and the front
wheel blocks. Check the hydraulic fluid level in the
tractor and add fluid as needed.
Issued 10-02
 Section
6013

MECHANICAL FRONT DRIVE

MFD CONTROL SYSTEM

How It Works

CASE CORPORATION Cl 2002 Case Corporation

700 State Street Pri nted in U.S.A.
Racine, WI 53404 U.S.A. Rae 6·j2770 J uly, 2002
6013-2

TABLE OF CONTENTS
MFD ................................................................. ............................ ............................................................................ 3

ELECTRONIC MFD CONTROL ..................................... .... ....................... ....... .................. ...... .... ........................... 5

MFD CONTROL MODES .. ......... ..... ........... .......... .... ........................ ................ ....................................................... 7

MFD FUNCTIONAL TESTS .... ....... .. ........................ .. ................. ............. ....... ...... ........... .... ... ....... .. .......... ..... ....... . 9
MFD Valve .. ......... ...... ... .. ....... ....... .... ..... ..... ..... ...... ... ............... ... ............ .... ............ ..... ... .. .................. ........ .... ... 10
Solenoid Ca rtridge Valve .... ............... ............... ...... .... ...................... ...... ................................ .... ................ ....... 10

MFD CLUTCH DI SENGAGED ........................... .... .. .......................... ........... .... .... ......... ..... ............ .. ..... ............... 11

TROUBLESHOOTING .................. ......... ....... .... .. ......... .... .................. ............ .... ...................... ..... .. ....... ... ............ 12
MFD Clutch Engaged ................. ..................... ......... ......... ....... ...... .. ...................................... .... ................ ....... . 14

TROUBLESf-jOOTING ......... ... ............... ....... .... ................... ....... ............... ........................ ............................... .... 15

WARNING .. ... .. .... .... .......... ........ .... ....... ......... ......... .................................... ............................ ........ ........ ............... 17

ac 6-12770 Issued 7-02

 6013-3

MFD
General Description - The Mechanical Front wheel Drive (MFD) consists of the of the MFD axle, a drive shaft,
MFD clutch, MFD control valve, MFD control switch, brake pedal switches, true ground speed circuit, hitch position
circuit, transmission speed circuit, and electronic control modules (through the Data Bus) . Because the MFD is
electronically controlled automatic operation is possible.

The MFD solenoid valve is mounted externally on top of the range transmission (front coil 01 range powershift
manifold) . The control valve is supplied with regulated circuit pressure from the priority/ regulator valve. This
pressurized supply is directed to the MFD clutch for disengagement purposes. If the MFD clutch is activated
(solenoid not activated) the valve drains the pressurized supply from the MFD clutch allowing four (4) Belleville
springs to activate the MFD clutch.

The PTa controller supplies current to the MFD valve to operate the MFD clutch based on commands from the
operator (MFD switch). Signals supplied to the controller from the brake pedal switches, true ground speed circuit,
hitch position control system, and transmission speed signal circuit provide for automatic operation.

Diagnosing control system faults is accomplished by reading appropriate faults codes through the instrument
cluster display or with the service tool. Refer to fault code section for a complete list of fault codes related to the
PTa, MFD, and Differential Lock system.

IMPORTANT: To activate the MFD clutch pack, the solenoid valve is de-energized. The clutch pack is applied
mechanically by means of Belleville springs.

WARNING
These tractors are equipped with a spring applied mechanical front wheel drive (MFD) clutch and a limited slip
differential. Even with the engaging switch in the OFF position the MFD clutch can propel both front wheels if any of
the .following conditions exist.

1. The engine is shut off (regulated supply pressure will drain).

2. The engine is stopped when the rear wheels are still coasting).
3. Any interruption in the clutch operating regulated pressure (hydraulically released clutch).
4. Any interruption in the electrical control power (coil energized to releas e clutch).
5. Both brakes are applied (automatic MFD operation) .

For these reasons the following service procedures must be utilized:

Before rotating the rear wheels of an MFD equipped tractor (when using engine power with the rear wheels raised
off the ground) one of the following must be done to prevent accidental tractor movement.

• Jack up and support both front wheels completely off the ground .
• Disconnect the front wheel drive shaft (transmission end).

Observing one 01 these options will insure that engagement of the MFD clutch will not result in tractor movement.

Rae 6-12770 Issued 7-02

.2
6013-4

RI02E066
1. MFD SOLENOID 2. POWERSHIFT VALVE RANGE

Rae 6-12770 Issued 7-02

 6013-5

ELECTRONIC MFD CONTROL

General Description - The MFD consists of the of the MFD axle, a drive shaft, MFD clutch , MFD control valve,
MFD control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission speed
circuit, and electronic control modules (through the Data Bus). Because the MFD is electronically controlled
automatic operation is possible.

All MFD operator commands are sent to the Arm Rest Control Module (hard wired to the Arm Rest Control
Module), then relayed to the PTO controller via the Data Bus. Transmission speed and true ground speed signals
are sent (hard wired) to the instrument Cluster Unit (ICU) then relayed to the PTO controller. Diagnostic and
programming information are communicated between the PTO controller and the Instrument Control Unit (IC U) by
way of the Data Bus.

Operating Modes - The MFD system operates in one of three (3) modes based on operator commands and the
signals received from the other tractor systems.

OFF (O) ISO Symbol

Manual MFD Control (MFD Symbol)
Automatic MFD Control (A)

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! !
6013-6

RH02G333

1. MECHANICAL FRONT DRIVE (MFD) SWITCH

ac 6-12770 Issued 7·02

 6013-7

MFD CONTROL MODES

OFF - When the MFD switch is placed in the OFF position , the MFD clutch will be deactivated (coil energized)
unless both brakes are applied. The MFD clutch is applied as both brake pedals are applied to allow four wheel
braking.

Manual MFD Control (ON) - When the MFD switch is placed in the ON position the
MFD will be activated (solenoid deactivated) at all times.

IMPORTANT: To activate the MFD clutch pack, the solenoid valve is de-energized. The clutch pack is applied
mechanically by means of Belleville springs.

Automatic MFD Control - When the MFD switch is placed in the Automatic position
the MFD will be activated (solenoid deactivated) unless the following conditions are
applicable.

1. Operating with the hitch position control lever down and the hitch is raised with the UP/DOWN switch (End of
Row Feature deactivates MFD).
2. One of the brake pedals is depressed and slip is below 15%.
3. Ground speed is in excess of 10 MPH and slip is below 15%.

NOTE: If the MFD disengages due to ground speed it will automatically re-engage when ground speed decreases
below 8 MPH. To operate the MFD at speeds in excess of 10 MPH, place the switch in the ON position.

Rae 6·12770 Issued 7·02

6013-8

ENGINE
SPEED

~
KEY PTO CONTROL MODULE ENGINE

I SWITCH

' W'1fCIO

OFFtON OFFt OFF

.ON
~~I '"
_, S",,"CH . ~ ON

,
PTO
CONTROL
ENGINE
SPEED

[5
. ARMREST
CONTROL
TRANSMISSION

MODULE
PTO
PTO
CLUTCH
VALVE
I-- CLUTCH

PTO SHAFT
SPEED SENSOR
I
INST.
CONTROL
MODULE PTO SHAFT
SIZE ~ENSOR

D P
A T PTOSHAFT_
T 0
A

B
'CAN
- , TRANSCEIVER
MICRO
CONTROLLER
I I S
H
'-- L\otPLEMEN
BRAKE
U ~ LIGHTS
A
S F
T

BRAKE TRACTOR
LIGHT BRAKE
RELAY LIGHTS

LH BRAKE RANGE TRANSMISSION HOUSING

PEDAL
SWITCH
MFDIDIFF LOCK MFD MFD
CONTROL VALVE CLUTCH

RH BRAKE
PEDAL
SWITCH REAR FRAME HOUSING

DIFF LOC
VALVE
-- DIFF LOC
CLUTCH

~
CLEAN GROUND
RI9BG145

ac 6-12770 Issued 7-02

 6013-9

MFD FUNCTIONAL TESTS

Switch Position MFD Engaged/ MFD Operation Description

Disengaged

Disengaged Except: When both brake pedals are pressed .

Engaged Operator will feel engagement as switch is cycled .

Check operational indicator.

Disengaged Hitch is UP with UP/DOWN switch. Position lever in

down position.

Except: Both brake pedals are pressed.

Except: When slip is above 15%.

Engaged Hitch DOWN with UP/DOWN switch. Position lever

in down position.

Except: When speed is in excess of 10 MPH.

Except: When one brake is pressed and slip is

below 15%.

Engaged Hitch UP with UPIDOWN switch. Position lever in

UP position .

Except : When speed is above 10 MPH. MFD

reapplies if speed is decreases below 8 MPH.

Except: When one brake is pressed and slip is

below 15%.

IMPORTANT: Hitch position and wheel slip will also influence MFO operation when tractor is in motion.

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.....
6013-10

RI02E0B6

1. MFD SOLENOID 3. MID CLUTCH SOLENOID

2. LOW CLUTCH SOLENOID 4. HIGH CLUTCH SOLENOID

MFD Valve
The MFD valve is a closed center valve and is contained as a part of the range transmission powershift valve
manifold. Oil is supplied to the MFD valve from the regulated pressure circuit. The valve is mounted on top of the
range transmission .

Solenoid Cartridge Valve

The solenoid is controlled by an armrest mounted rocker switch. The armrest controller communicates (via Data
Bus) with the PTO controller, supplying current to deactivate the MFD clutch, based on commands from the
operator (MFD switch) and signals supplied to it from the brake pedal switches, true ground speed circuit, hitch
position control system , and transmission speed signal circuit. The MFD is a spring engaged and hydraulic
disengage type clutch. . .
Rae 6-12770 Issued 7·02
 6013-11

TROUBLESHOOTING
Problem - MFD clutch will not disengage

1. Check for PTO fault codes. (MFD 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 .

2. Place the MFD switch in the OFF position. Check the tractor monitor for the MFD icon in the instrumentation
display.
A. If the MFD icon is not displayed , this is an indication the electrical control circuit is functioning correctly.
Go to step 4.
B. If the MFD icon is displayed , this in an indication the electrical control circuit is not functioning correctly.
Check fault codes, controller, and data bus function .

3. Place the MFD switch in the OFF position. Check for 12 VDC at MFD valve coil.
A. If 12 VDC is available to the coil, the electrical circuit is functioning properly.
B. If 12 VDC is not found, troubleshoot the MFD electrical circuit.
1 . Check wires 540A Rand 175D (BK) (ground).
2. Check all connections for excessive resistance.

Place the MFD switch in the manual ON position. Check for 12 VDC at MFD valve coil.
C. If 12 VDC is not available to the coil, the electrical circuit is functioning properly.
D. If 12 VDC is found, troubleshoot the MFD electrical circuit.
3. Check wires 540A (R) and175D (BK) (ground).
4. Check all connections for excessive resistance.

4. Turn the ignition switch to the OFF position. Be prepared to press and hold the PROG key on the Tractor
Monitor within the first 10 seconds after restarting the engine.

- Start and run the engine at low idle. Press and hold the PROG key
- The tractor monitor will emit a short beep and display INST SET MENU. Press the DECR key until the display
reads TRANS SET MENU.
- Next press the PROG key until the display reads TRANS VIEW. Continue to press the PROG key until the display
reads "PresS".

- The powershift system manifold pressure (in KPa) is now visible on the bottom of the display.

NOTE: Start the engine and heat the transmission oil to 120°F (49°C).

5. While viewing the display, deactivate the MFD. The display pressure should dip, then recover to normal
regulated pressure. If the pressure dips, but does not recover there is a leak in the MFD circuit. Repeat this
check several times.
A. Inspect the MFD valve cartridge for leaking seals.
B. Inspect the MFD clutch for leaking seals.

6. Check and repair the MFD clutch as needed.

Rae 6· 12770 Issued 7-02

6013-12

TROUBLESHOOTING
Problem - MFD will not engage

1. Check for PTO fault codes. (MFD 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.

2. Place the MFD switch in the ON position . Check tractor monitor for MFD icon in the instrumentation display.
A. If the MFD icon is displayed, this is an indication the electrical control circuit is functioning correctly. Go to
Step 4.
B. If the MFD icon is not displayed, this is an indication the electrical control ci rcuit is not functioning
correctly. Check fault codes, controller and data bus function.

3. Place the MFD switch in the ON position. Check for 12 VDC at MFD valve coil.
A. If 12 VDC is not available to the coil, the electrical circuit is functioning properly.
B. If 12 VDC found, troubleshoot the MFD electrical circuit.
1. Check wires 540A (R) and 175D (BK) ground.
2. Check all connections for excessive resistance

Place the MFD switch in the OFF position. Check for 12 VDC at MFD valve coil.
C. If 12 VDC is available to the coil, the electrical circuit is functioning properly.
D. If 12 VDC is not found, troubleshoot the MFD electrical circuit.
3. Check wires 540A (R) and 175D (BK) ground.
4. Check all connections for excessive resistance.

4. Check and repair the MFD clutch as needed .

Rae 6-12770 Issued 7-02

 6013-13

WA RNIN G
These tractors are equipped with a spring applied mechanical front wheel drive (MFD) clutch and a limited slip
differential. Even with the engaging switch in the OFF position the MFD clutch can propel both front wheels if any of
the following conditions exist.

1. The engine is shut off (regulated supply pressure will drain).

2. The engine is stopped when the rear wheels are still coasting).
3. Any interruption in the clutch operating regulated pressure (hydraulically released clutch).
4. Any interruption in the electrical control power (coil energized to release clutch).
5. Both brakes are applied (automatic MFD operation) .

For these reasons the following service procedures must be utilized:

Before rotating the rear wheels of an MFD equipped tractor (when using engine power with the rear wheels raised
off the ground) one of the following must be done to prevent accidental tractor movement.

• Jaqk up and support both front wheels completely off the ground .
• Disconnect the front wheel drive shaft (transmission end).

Observing one of these options will insure that engagement of the MFD clutch will not result in tractor movement.

Rae 6·12770 Issued 7-02

L
6013-14

Rae 6-12770 Issued 7-02

 Section
6014

DIFFERENTIAL LOCK CONTROL SYSTEM

How It Works

CASE CORPORATION © 2002 Case Corporation

. 700 State Street Pri nted in U.S.A.
Racine, WI 53404 U.S.A. Rae 6- 12780 J uly, 2002
6014-2

TABLE OF CONTENTS
DIFFERENTIAL LOCK ............. ............................................... ......... .... ................................. ....... ... ............ .... .. ...... 3

ELECTRONIC DIFFERENTIAL LOCK CONTROL ............... ...... ........... ..... .................................. ....... ................... 5

DIFFERENTIAL LOCK CONTROL MODES ........... ..... ........... ........ ....... ..... .............. .............................................. 7

DIFFERENTIAL LOCK CONTROL ................... ............................................................ ........................................... B

DIFFERENTIAL LOCK FUNCTIONAL TESTS .......................................................................... .......... ................ .... 9

Differential Lock Valve ...... ..... ... ..... .. ... ....................... ............................................................ .. .......... .. ............ .. 10
Solenoid Cartridge Valve ... .......... .... ..... ........ ..... .. ...... .... .. .... ........... ....... ......................................... .... ... ......... ... 10
Differential Lock Clutch Disengaged .. ................ ..... ... .. ........................................................ ................... ........... 11

TROUBLESHOOTING ............ ..................... ......... ..... ..... .......................................... .. ... ....................................... 12

Differential Lock Engaged .................... ... .............. .............. ............. .................................. ........................ ........ 14

TROUBLESHOOTIN G ... .................. ..................... ...... .. ............................. ................ .............. ............................. 15

PTOIDIFFER ENTIAL LOCK VALVE CIRCUIT ...... ................... ...... ................ ......... .............................................. 16

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 6014-3

DIFFERENTIAL LOCK
General Description - The Diflerential Lock consists of the diflerential lock piston, differential lock control valve,
diflerential lock control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission
speed circuit, and electronic control modules (through the Data Bus). Because the diflerentiallock is electronically
controlled automatic operation is possible.

The PTO/Diflerential Lock valve is mounted externally on top of the rear frame transrnission housing. The control
valve is supplied with regulated circuit pressure from the priority/ regulator valve. This pressurized supply is
directed to the diflerential lock piston for engagement. " the diflerential lock is activated , pressurized oil from the
regulated supply circuit is ported to the differential lock piston in the differential carrier housing . As the piston
extends friction discs and separator plates are locked together. The separator plates are pinned to the diflerential
carrier, while the friction plates are splined to the left diflerential side gear. When the differential lock is applied, the
clutch pack locks causing the left side gear to rotate with the dilferential carrier. This eliminates all differential
action, causing power to be transmitted equally through both rear axles.

The PTO controller supplies current to the differential lock valve to activate the clutch based on commands from
the operator (Diflerential Lock switch) and signals supplied to it from the brake pedal switches, true ground speed
circuit, hitch position control system, and transmission speed signal circuit.

Diagnosing control system faults is accomplished by reading appropriate faults codes through the instrument
cluster display or the service tool. Reier to PTO system fault code section 01 this manual for a complete list of fault
codes related to the PTO, MFD, and Differential Lock system.

Rae 6-12780 Issued 7-02

6014-4

AI02E086
1. PTOfDlFF LOCK VALVE 2. DIFF LOCK CLUTCH SOLENOID

Rae 6-12780 Issued 7-02

 6014-5

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). Because the differential lock is electronically
controlled, automatic operation is possible.

All differential lock operator commands are sent to the Arm Rest Control Module then relayed to the PTa controller
via the Data Bus. Transmission speed and true ground speed signals are sent to the instrument Cluster Unit (ICU)
then relayed to the PTa controller. Diagnostic and programming information are communicated between the PTa
controller and the Instrument Control Unit (ICU) by way of the Data Bus.

Operational Modes - The differential lock system operates in one of two (2) modes based on operator commands
and the signals received from the other tractor systems.

OFF (see NOTE below)

ON (Differential Symbol)
Automatic Differential Lock Control (A)

NOTE: It is not possible to disengage the differential lock with the switch control. Pushing either brake pedal will
deactivate the differential lock.

Rae 6·12780 Issued 7-02

6014-6

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RH02G333

1. DIFFERENTIAL LOCK SWITCH

Rae 6-12780 Issued 7-02

 6014-7

DIFFERENTIAL LOCK CONTROL MODES

ON (Differential Symbol) - When the dilferentiallock 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.

NOTE: It is not possible to disengage the differential lock with the switch control. Pushing
either brake pedal will deactivate the differential lock.

The differential lock switch has three (3) positions. The mid switch position is OFF when the differential lock is
deactivated. The same switch position is ON when the differential lock is activated manually.

Automatic Differential Lock Control - When the differential lock switch is placed in the
Automatic position (A symbol) the differential lock will be activated (differential symbol will be
illuminated on the tractor monitor) unless the following conditions are applicable.

1. Operating with the hitch position control lever down and the hitch is raised with the UP/DOWN switch (End of
Row Feature deactivates differential lock).

2. One of the brake pedals is depressed and slip is below 15%.

3. Ground speed is in excess of 10 MPH and slip is below 15%.

NOTE: If the differential lock automatically disengages when ground speed exceeds 10 MPH. The differential lock
will not automatically engage when ground speed decreases. To reactivate the differential lock after speed
decreases (below 8 MPH), place the switch in the AUTO position and return the switch to the middle position.

Rae 6-12780 Issued 7·02

601 4-8

DIFFERENTIAL LOCK CONTROL

•

TRUE GROUND ENGINE

SPEED SENSOR I
, + /

INST.
CONTROL
MODULE
I lC"- TRANSMI~.

TRANSMISSION /
SPEED SENSOR

~
KEY PTO CONTROL MODULE
I SWITCH

PTO
ON
~" ~
' WI1CH ' WlTeH IWIT
'ro. .:!J
CONTROL

OFF/ON OFF/ OFF

tON .~

ARMREST
CONTROL
MODULE

I CAN
0' TRANSCEIVER
MICRO
CONTROLLER
I
IMPLEMEN
r - BRAKE
LIGHTS

MFDIDIFF LOCK BRAKE TRACTOR

CONTROL LIGHT BRAKE
RELAY LIGHTS

o LH BRAKE RANGE TRANSMISSION HOUSING

A PEDAL
T SWITCH
A MFD MFD
VALVE CLUTCH
B
U
S RH BRAKE
PEDAL
SWITCH
REAR FRAME HOUSING

DIFF LOCK DIFF LOCK

VALVE CLUTCH

+
CLEAN GROUND
AI98G1 46

Rae 6·1 2780 Issued 7-02

 6014-9

DIFFERENTIAL LOCK FUNCTIONAL TESTS

IMPORTANT: Hitch position and wheel slip will influence differential lock operation when tractor is in motion.

Switch Position Engaged/ Operational Comments

Disengaged

ON Engaged The differential Lock icon will illuminate.

If one (or both) brake pedals is pushed the

differential lock light will go out and the differential
lock will be deactivated.

AUTO Disengaged As hitch raises and reaches upper 30% of travel.

(lever down/switch.

NOTE: If slippage is above 15% the differential lock

will engage (or stay engaged).

Disengaged As travel speed exceeds 10 MPH.

NOTE: If slippage is above 15% the differential lock

will engage (or stay engaged).

Disengaged As one or both brakes is applied. Differential lock will

re-engage if both brake pedals are released .

Engaged As hitch lowers below upper 30% of travel. (lever

down/switch down)

Engaged Brakes not applied.

IMPORTANT: Hitch position and wheel slip will influence differential lock operation when tractor is in motion.

Rae 6·12780 Issued 7-02

6014-10

Rt02E087
1. PTOIDIFF 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. The differential lock clutch supply flow is
distributed internally (no external tubing) to the clutch . The valve is mounted on the top of the rear frame
transmission housing . The following components of the PTO valve are involved in the differential lock system.

Solenoid Cartridge Valve

The solenoid is controlled by an armrest mounted rocker switch. The armrest controller communicates (via the
Data Bus) with the PTO controller. The PTO controller supplies current to the differential lock valve to activate the
differential lock clutch based on commands from the operator (differential lock switch) and signals supplied to it
from the brake pedal switches, true ground speed circuit, hitch position control system, and transmission speed
signal circuit. The differential lock is a hydraulically applied clutch.

Rae 6-12780 Issued 7-02

 6014-11

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. As the piston retracts, oil will be ported to the transmission housing
and the differential lock clutch will disengage

NOTE: It is not possible to disengage the differential lock with the switch control. Pushing either brake pedal will
deactivate the differential lock.

The differential lock switch has three (3) positions. The mid switch position is OFF when the differential lock is
deactivated. The same switch position is ON when the differential lock is activated manually.

RT98A024

1. PTO SOLENOID 3. TO DIFF LOCK CLUTCH (PORTED THROUGH BACK OF

VALVE)
2. REGULATED SUPPLY PASSAGE (THROUGH TOP OF 4. DIFF LOCK SOLENOID
VALVE BODY)

Rae 6-12780 Issued 7-02

6014-12

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.

2. Push either brake pedal switch to deactivate the differential lock. Check the tractor monitor for the differential
lock icon in the instrumentation display.
A. If the differential lock icon is not displayed, this is an indication the electrical control circuit is functioning
correctly. Go to step 4.
B. If the differential lock icon is displayed , this in an indication the electrical control circuit is not functioning
correctly. Check fault codes, controller, and data bus function .

3. Activate the differential lock with the manual switch position. Check for 12 VDC at differential lock valve coil.
A. If 12 VDC is available to the coil, the differential lock electrical circuit is functioning properly.
B. If 12 VDC is not found, troubleshoot the differential lock electrical circuit.
1. Check wires 530A (R) and 175E (BK) ground.
2. Check all connections for excessive resistance.

Apply the brakes, this will deactivate the differential lock. Check for 12 VDC at differential lock valve coil.
C. If 12 VDC is available to the coil, the differential lock electrical circuit is not functioning properly.
1. Check left and right brake switches.
D. If 12 VDC is not found the differential lock electrical circuit is functioning properly.

4. Turn the ignition switch to the OFF position. Be prepared to press and hold the PROG key on the Tractor
Monitor within the first 10 seconds after restarting the engine.

- Start and run the engine at low idle. Press and hold the PROG key
- The tractor monitor will emit a short beep and display INST SET MENU. Press the DECR key until the display
reads TRANS SET MENU.
- Next press the PROG key until the display reads TRANS VIEW. Continue to press the PROG key until the display
reads "PresS".

- The powershift system manifold pressure (in KPa) is now visible on the bottom of the display.

NOTE: Start the engine and heat the transmission oil to 120' F (49' C).

5. While viewing the display, activate the Differential Lock. The display pressure should dip, then recover to
normal regulated pressure. If the pressure dips, but does not recover there is a leak in the Differential Lock
circuit. Repeat this check several times.

6.
A. Inspect the differential lock valve cartridge for leaking seals.
B. Inspect the differential lock slip ring teflon seals.
C. Inspect the differential lock piston o-ring.

7. Check and repair the differential lock clutch as needed.

Rae 6-12780 Issued 7-02

 6014-13

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. The clutch pack
locks causing the left side gear to rotate with the differential carrier, eliminating differential action.

DIFFERENTIAL LOCK
ASSEMBLY

RH98H056

Rae 6-12780 Issued 7-02

 6014-14

TROUBLESHOOTING
Problem - Differential lock will not disengage

1 . Check for PTa fault codes.

A. If fault codes are found, follow procedures outlined in PTa system fault code troubleshooting in this
section.

2. Place the differential lock switch in the ON position. Check the tractor monitor for the differential lock icon in the
instrumentation display.
A. If the differential lock icon is displayed, this is an indication the electrical control circuit is functioning
correctly. Go to step 4.
B. If the differential lock icon is not displayed, this in an indication the electrical control circuit is not
functioning correctly. Check fault codes, controller, and data bus function.

3. Place the differential lock switch in the ON position . Check for 12 VDC at differential lock valve coil.
A. If 12 VDC is available to the coil, the differential lock electrical circuit is functioning properly.
B. If 12 VDC is not found, troubleshoot the differential lock electrical circuit.
1. Check wires 530A (R) and 175E(BK) ground.
2. Check all connections for excessive resistance.

Apply the brakes, this will deactivate the differential lock. Check for 12 VDC at differential lock valve coil.
C. If 12 VDC is available to the coil, the differential lock electrical circuit is not functioning properly.
1. Check left and right brake switches.
D. If 12 VDC is not found the differential lock electrical circuit is functioning properly.

4. Check and repair the differential lock clutch as needed .

Rae 6-12780 Issued 7-02

I,
 6014-15

PTO/DIFFERENTIAL LOCK VALVE CIRCUIT

PTa CLUTCH
PISTON

r '- DIFFERENTIAL
LOCK PISTON

PTa
CLUTCH
LUBE r-~-----------------

,--- -- -- - -- - --- -- - -- - --

(
IPTO
:SOLENOID
I
I DIFF LOCK
: SOLENOID
I
I
- - ~

BEVEL
PIN
REGULATED LUBE
SUPPLY

RH02A059

NOTE: Refer to Differential Lock electrical schematic diagram _

Rae 6-12780 Issued 7·02

! '
 6014-16

This page left blank intentionally

c 6-12780
Issued 7-02
 Section
6015

MFD CLUTCH AND OUTPUT SHAFT REMOVAL

WITHOUT TRACTOR SPLIT

CASE CORPORATION co 2002 Case Corporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6·13980 October, 2002
6015-2

TABLE OF CONTENTS
SPECIAL TORQUES ...... ....... .......... ..... .. ..... ........ ..... ............. ....................... ... ... ............... .... ... .............. .... .... .. .... ... 3
MFD CLUTCH AND OUTPUT SHAFT REMOVAL WITHOUT TRACTOR SPLIT ...... ........ ......... ........ ................ ... 4
MFD Output Shaft Removal ... ......... ....... ...... ... ..... ............................ ................................................... .. ............... 4
MFD Output Shaft Disassembly ............. ................ ......... ........ ............................... ............ ................. .... ....... .... 5
MFD Output Shaft Assembly ........ .......... .... ............... ............. ........ ........................ ............ ............. .... ................ 9
MFD Clutch Removal .... ........... ......... .............. ........ ................................ ............. ............ ................ .... ... ........... 14
MFD Clutch Installation ....... ............. ......................................................... ................. ..... ........ ................... ........ 16

ac 6· 13980 Issued 10-02

 6015-3

SPECIAL TORQUES
Park/Emergency Brake Shield Bolt ..................................................... ...................... 10.4 to 11.6 Nm (7.7 to 8.6 Ib It)
Suction Screen Base to Transmission Boll... ........... ............ .......................................... ... 54 to 61 Nm (40 to 45 Ib It)
Suction Hose Flange Bolt ................................... ....... ............................. .......................... 54 to 61 Nm (40 to 45 Ib It)
MFD Output Shalt Yoke Retaining Boll... ...... .......... ................... ......... ...................... 252 to 280 Nm (186 to 206 Ib It)
MFD Output Shalt Bearing Cage Bolt .... ................................................ ....... ..... ... ... 375 to 485 Nm (276 to 358 Ib It)
MFD Drive Shalt Retaining Bolts .................................................... ............................... ... 58 to 64 Nm (43 to 47 Ib It)

Rae 6· 13980 Issued 10-02

6015-4

MFD CLUTCH AND OUTPUT SHAFT REMOVAL WITHOUT TRACTOR SPLIT

MFD Output Shaft Removal STEP 3

STEP 1

Park the tractor on a hard, level surface . Put the

transmission shift lever in PARK. Turn off the engine
and remove the key. Place blocks in front of and
behind the rear wheels.

NOTE: The following procedures must be performed

to access the MFD clutch for servicing.

STEP 2

Mark the position of the sleeve on the drive shaft

protector. Remove the drive shaft protector pins (1).
Slide the drive shaft p rotector toward the
transmission . Properly support the drive shafl. Refer
to Section 6016 MFD Drive Shaft Removal for the
procedure. Remove the four bolts (2) from the pinion
yoke, and the transmission yoke. Remove the drive
shaft protector and the drive shaft.

NOTE: Suspended MFD axle shown. The procedure

will be similar for all MFD axles.

Remove the plug and drain the transmission oil from

he speed transmission into a suitable, clean
ontainer.

ac 6·13980 Issued 10-02

 6015-5
STEP 4 MFD Output Shaft Disassembly

STEP 6

11519

Remove four bolts and four washers on the output

shaft bearing cage.
l06AS4

NOTE: The drop box is shown removed from the Place the MFD output shaft in a vise and remove the
tractor chassis for photographic purposes. yoke retaining bolt.

STEP 5 STEP 7

106RS7

Remove MFD shaft and bearing cage from drop box. Re move the yoke retaining bolt washer and the
shim(s) .
NOTE: Steps 5 through 32 are for the replacement
of the au/put shaft bearings, cage, or yoke. NOTE: Keep the shims with the yoke.

Rae 6-13980 Issued 10-02

 6015-6
STEP 8 STEP 11

108RS 10
Remove and discard the O-ring. Remove the internal retaining ring.

STEP 9 STEP 12

Remove the yoke from the output shaft spline. Remove the bearing spacer.

STEP 10

Remove and discard the oil seal.

Rae 6-13980
Issued 10-02
 6015-7

STEP 13 STEP 15

Remove the shim (s). The bearing spacer is shown

with two shims. 2940CUPl

Remove the rear bearing cup from the bearing cage,

NOTE: Keep the shim(s) with the bearing cage.
as shown in drawing above.

STEP 14
STEP 16

Remove the bearing cage as follows:

Press the front bearing cone from the output shaft.
1. Rest the bottom of the drive shaft on a wooden
block.
STEP 17
2. Hold the bearing cage.
3. Tap downward on the ears of the bearing cage in
a crossing pattern.
4. Remove the front bearing cup.
5. Remove the bearing cage.

Remove the external retaining ring .

Rae 6-13980 Issued 10-02

 6015-8

STEP 18 STEP 19

Press the rear bearing cone from output shaft. Remove and discard the O-ring from bearing cage.

Rae 6-13980
Issued 10-02
 6015-9

MFD Output Shaft Assembly

1. SEAL 8. BEARING SPACER

2. YOKE 9. a-RING
3. WASHER 10. SHIMS
4. BOLT 11 . EXTERNAL RETAINING RING
5. SHIMS 12. BEARING CONE
6. a-RING 13. BEARING CUP
7. INTERNAL RETAINING RING 14. BEARING CAGE

Rae 6-13980 Issued 10-02

!J
6015-10
STEP 20 STEP 23

109AS16

Lubricate a new O-ring with Case HY- TRAN ® Install a new front bearing cone on the output shaft.
ULTRA oil. Install the O-ring into the groove on the Press the front bearing cone against the external
bearing cage. retaining ring .

STEP 21 STEP 24

Install a new rear bearing cone just below the

external retaining ring groove. 294OCUP2
Press a new rear bearing cup into the bearing cage.
STEP 22

stall a new external retaining ring and press the

ar bearing cone against the retaining ring.

ac 6-13980 Issued 10-02

 6015-11
STEP 25 STEP 26

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 . Install the bolt into the end of the
output shafl. Measure the rolling torque of the
output shaft. The reading obtained must be 1.5
to 2.2 Nm (13 to 191b in).
4. Measure the distance from the bearing cup face
to the top edge of the internal retaining ring
groove in the bearing cage. Subtract 0.27 mm 2940SEAT

(0.011 inch) for bearing end play. 1. MFD OUTPUT SHAFT

5. This will be the total shim, spacer, and internal
retaining ring dimension required. Select shims
that, with the spacer and the internal retaining
ring , will equal the dimension to within 0.25 mm
(0.010 inch). Refer to Step 14 to remove the front
bearing cup from the bearing cage . Install the
shims and the spacer.
2. BEARING CAGE
Install the internal retaining ring. Hold the bearing
cage and press on the shaft end to seat the bearing
cup until the internal retaining ring is seated tightly to
the top edge of the internal retaining ring groove.

Rac 6·13980 Issued 10-02

 6015-12

STEP 27 STEP 29

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
(0.001 to 0.006 inch), remove the output shaft from
108RS11
the bearing cage and repeat Steps 25 and 26 to
Lubricate a new O-ring with Case HY- TRAN ®
obtain the proper measurement.
ULTRA oil. Install the O-ring into the yoke.

STEP 28

Lubricate the inner diameter of the MFD output shaft

seal with clean Case HY-TRAN ® ULTRA oil. Install
the oil seal. The seal must be installed 8.5 mm (0.335
inch) below the surface of the bearing cage.

Rae 6·13980
Issued 10-02
 6015-13

STEP 31 STEP 33

Place the MFD output shalt in a vise and install the

yoke retaining boll. Apply a torque of 252 to 280 Nm
(186 to 206 Ib It) to the boll.

NOTE: Do not install the output shaft if the MFD

YOKESHJM clutch is to be serviced. Refer to MFD Clutch
Measure from the end of output shalt to the surtace Removal in this section.
of yoke. Select a shim combination to obtain a
distance of 0 to 0.1 mm (0 to 0.004 inch) .
STEP 34
STEP 32

Proceed to the next step il the MFD clutch needs to

108RS7
Install the shims and the yoke retaining bolt washer.
be serviced. If the MFD clutch does not need to be
serviced, install the MFD output shalt into the needle
bearing in the rear wall of the transmission speed
housing and into the MFD clutch hub splines in the
range transmissio n. Install the four output shaft
bearing cage retaining bolts. Tighten the bolts to a
torque of 375 to 485 Nm (276 to 358 Ib It).

IMPORTANT: The rear of the shaft engages a

needle bearing in the rear wall of the transmission
speed housing. Use care not to dislodge the bearing.

Rae 6·13980 Issued 10-02

 6015-14

MFD Clutch Removal STEP 36

STEP 35

Remove the suction screen and O-ring . Discard the

O-ring.

STEP 37

Remove the hydraulic filter (1) from the charge pump

base. Drain the hydraulic oil into a clean container. Remove the shroud and housing gasket. Discard the
Remove the hydraulic line (2) from the suction gasket.
screen to the filter head. Loosen the hose clamps (3)
on the rubber charge pump suction hose. Remove
the two suction hose flange bolts (4). Remove the six STEP 38
bolts (5) attaching the suction screen base to the
side of the range transmission housing. Remove the
suction screen base. Use care when removing the
base so as not to damage the plastic pin on the
·suction screen shroud. Remove the O-ring on the
suction hose flange and discard.

1754
Remove four bolts from the park brake front shield.

Rae 6- 13980 Issued 10-02

 6015-15

STEP 39 STEP 41

1757

Remove and set aside the park brake shield inside of
the housing of the range transmission.
NOTE: Because of the size of the shield, it cannot
be removed through the access opening in the range
transmission housing.
Remove the MFD clutch.
NOTE: The park brake is removed only after a split
between the range and speed transmissions (see
Section 6005, Speed to Range Transmission Split).

STEP 42
STEP 40

17523

Remove the MFD clutch pack through the access

Pry out on the belleville springs to begin the removal opening in the range transmission housing.
of the MFD clutch.
NOTE: Further access to the internal components
requires a tractor split.

STEP 43
Service the MFD clutch according to the procedures
contained in Section 6008, Range Transmission.

Rae 6-13980 Issued 10-02

6015-16

MFD Clutch Installation STEP 47

STEP 44

Install the MFD output shaft and bearing cage into

the housing.
17523

Install the MFD clutch pack into the range IMPORTANT: The output shaft engages a needle
transmission housing. bearing in the rear wall of the speed transmission
housing. Be careful not to dislodge the bearing.
STEP 45
STEP 48

17520

Position the MFD, clutch over the shaft inside the

11519
park lock carrier.
Install the MFD output shalt into the needle bearing
STEP 46 in the rear wall of the speed housing. Engage the
MFD output shalt with the MFD hub spline. Install the
four bolts through the output shalt bearing cage and
the drop box. Tighten the four bolts to a torque of 375
to 485 Nm (276 to 358 Ib It).

17$4

Install the four bolts into the park brake shield.

Tighten to a torque of 10.4 to 11 .6 Nm (7.7 to 8.6 Ib
It).

Rae 6·13980 Issued 10-02

 6015-17

STEP 49 STEP 51

Install a new range transmission access opening

gasket and the shroud.

STEP 50

Install a new O-ring and the suction screen. Install
the suction screen over the plastic pin (1) on the
shroud.
ROO2H1Bl
Lubricate and install a new O-ring on the suction
hose flange. Install and loosely tighten the six bolts
(1 ) attaching the suction screen base to the side of
the range transmission. Pry up on the suction hose to
provide needed clearance for the suction flange 0-
ring . Use care not to damage the new O-ring. Tighten
the six bolts (1 ) to a torque of 54 to 61 Nm (40 to 45
Ib ft) . Tighten the suction hose flange bolts (2) to a
torque of 54 to 61 Nm (40 to 45 Ib It). Tighten the
suction hose clamps (3). Install a new O-ring on the
fitting on the suction screen base, and tighten the
fitting (4). Install a new hydraulic filter (5).

Rae 6-13980 Issued 10-02

6015-18
STEP 52
Install the MFD drive shaft and the drive shaft
protector. Refer to Section 6016 MFD Drive Shaft
Installation for the procedure. Properly support the
drive shaft. Tighten the drive shaft retaining bolts (1)
to a torque of 58 to 64 Nm (43 to 47 Ib ft). Install the
drive shaft protector pins (2), using the position
marks on the drive shaft protector made during
disassembly.
NOTE: Suspended MFD axle shown. The procedure
will be similar for all MFD axles.
Rae 6-13980
STEP 53
Replace the transmission drain plug and fill the
transmission with Case HYTRAN ® ULTRA oil.
STEP 54
Check for oil leaks. Make sure the transmission shift
lever is in Park. Remove the blocks in front of and
behind the rear wheels. Start the tractor and check
the operation of the MFD suspended axle and the
transmission . Check the hydraulic oil level. Turn the
engine off and remove the key.
Issued 10-02
 Section
6016

MFD DRIVE SHAFT

CASE CORPORATION C> 2002 Case Corporation

700 State Street Printed in U.s.A.
Racine, WI 53404 U.S.A. Rae 6-13930 OCtober, 2002

! '
6016-2

TABLE OF CONTENTS
SPECIFICATIONS .............................. .... ...... ........ ................. ................ ...........................••............••....................... 3
SPECIAL TORQUES .......... .. .. ....... ...... .................... ..................... .... ............................................................... ........ 3
SPECIAL TOOLS ................................................. ...... ......................................................... ............... ..................... 3
MFD DRIVE SHAFT ............ ...... ..................•••...............••..............•.................................•....................................... 4
Removal ................................ .......... .... ................................. .................. .... ........ ........ ................... ....... .......... ...... 4
MFD Standard Axle ............. ................. .•••. ................ ......... ............................. .................... .......................... ..... 4
Suspended MFD Axle ..............••..................... ........ .•• .. .. .............. ..... ...... ................................•..................•... .... 6
Installation .................... ............................•....... ... .......... ................. .. ......... .. ••. ...... ................................................ 7
MFD Standard Axle .. ........................................... ..... .. ... .............. ...... ...... ..•........ ................................................ 7
Suspended MFD Axle ............................•............... ........ ............. ...... ........•........... ......... .............. ..........••.......... 9

ac 6·13930 Issued 10-02

 601 6-3

SPECIFICATIONS
Limited Slip Additive Capaci ty (If Required) ....................................................................... 0.473 Liter (1.0 U.S. Pint)
MFD Axle Capacity (Standard and Suspended 10 Bolt) ................................................. 12.3 Liters (13 U.S. Quarts)
MFD Axle Capacity (Standard and Suspended 12 Bolt) .............................................. 11 .7 Liters (12.4 U.S. Quarts)
MFD Axle Lubricant... .............................. ... ... ... .... ..... .. ...................... Case 135 H EP Gear Lubricant, SAE 85W-140
Limited Slip Additive (If Equipped) ... ................... ...... ............................... ..... ... ...... ........ Limited Slip Additive B91246
Transmission/Hydraulic System Capacity ..................... ..........•. ... .........••............ .... ........... 172 Liters (45 .5 U.S. Gal. )
Transmission/Hydraulic System Oil Type ...................................... .............. ........................ Case HY-TRAN ® ULTRA

SPECIAL TORQUES
Drive Shaft Retaining Bolts ............ ....... ......................... ......................... ....................... ... 58 to 64 Nm (43 to 47 Ib tt)
Transmission Yoke Retaining Boll... ........................... .. ............. ................ .. ... .......... . 252 to 280 Nm (186 to 2061b ft)
MFD Axle Pinion Nut ............................. ........................................ ........................... 326 to 406 Nm (240 to 300 Ib tt)

SPECIAL TOOLS

AD02H229 RI02H02£

CAS1899 or FNH0041 0 PINION SEAL INSTALLER CAS1716-3, or CNH299077, or FNH00072 HANDLE

RD02H230

CAS2596 YOKE DUST SHIELD INSTALLER

Rae 6- 13930 Issued 10-02

6016-4

MFD DRIVE SHAFT

Removal STEP 3

MFD Standard Axle

RD02H097

Mark the alignment of the pinion yoke and universal

Park the tractor on a hard , level surface . Put the
transmission shift lever in PARK. Turn off the engine
a nd remove the key. Place blocks in front of and
behind the rear wheels.
STEP 2
joint for reassembly. Support the drive shaft and
remove the four drive shaft to pinion yoke retaining
bolts. Remove the drive shaft at the front axle. Check
the universal joint for damage or wear. Replace , if
necessary, by removing the four universal joint to
drive shaft retaining bolts. Drain the oil from the MFD
standard axle. Make alignment marks on the pinion
yoke and differential housing. Remove and discard
the pinion yoke nut. Remove the pinion washer.
Remove and inspect the MFD pinion yoke and
deflector for damage or wear. Replace the pinion
yoke and deflector if necessary. Remove the MFD
pinion seal with a puller. Refer to Section 6018 MFD
Differential-Pinion Disassembly for the removal
procedure.

RD02H096

Mark the position of the sleeve on the drive shaft

protector. Remove the plastic drive shaft protector
pin and discard. Slide the drive shaft sleeve toward
the transmission .

Rae 6· ' 3930 Issued 10-02


STEP 4
Mark the alignment of the transmission yoke and the
universal joint for assembly. Slide the drive shaft
protector (1) from the MFD drive shaft. Support the
drive shaft and remove the four drive shaft to
transmission yoke retaining bolts (2). Remove the
MFD drive shaft. Note the position of the directional
arrow decal on the drive shaft. Check the universal
joint for damage or wear. Replace, if necessary, by
removing the four universal joint to drive shaft
retaining bolts.
STEP 5
ROO2H191
Place the drive shaft (1) on V blocks (2). Position a
dial indicator (3), attached to a magnetic base, on the
outside diameter of the drive shaft. Turn the drive
shaft one complete turn to check for straightness.
Replace the drive shaft, if necessary.
Rae 6-13930
6016-5
STEP 6
Remove the plug and drain the transmission oil from
the speed transmission into a suitable, clean
container.
STEP 7
Place alignment marks on the transmission yoke and
the bearing cage (1). Remove the transmission yoke
retaining bolt (2) and the retaining washer (3).
Remove the shims and a-ring. Remove the
transmission yoke with deflector and inspect for
damage or wear. Replace the transmission yoke, if
necessary. Use a puller to remove the yoke seal from
the bearing cage. Refer to Section 6015,
Disassembly of MFD Output Shaft for the procedure.
NOTE : The transmission yoke seal can be replaced
without MFD output shaft removal.
Issued 10·02
6016-6

Suspended MFD Axle STEP 10

NOTE: The drive shaft removal procedure for the

suspended MFD axle is the same as the standard
MFD axle, except for the following steps.

STEP 8

Slide the drive shaft protector from the drive shaft .

STEP 11

ROO2Hl66

Mark the position of the sleeve on the drive shaft

protector. Remove the drive shaft protector pin. Slide
the drive shaft protector toward the transmission.

STEP 9

Install the drive shaft. Hand tighten two of the drive

shaft to pinion yoke retaining bolts to hold the drive
shaft in place.

STEP 12

Support the drive shaft. Remove the four drive shaft

to pinion yoke retaining bolts.

Use a long extension to remove the four drive shaft

to transmission yoke retaining bolts. Remove the
suspended MFD drive shaft.

ac 6- 13930 Issued 10-02

 6016-7

Installation STEP 14

MFD Standard Axle

STEP 13

Install the speed transmission drain plug and fill the

transmission.

STEP 15
Install a new oil seal in the transmission bearing cage
(1). The seal must be installed 8.5mm (0 .335 inch)
below the surface of the bearing cage. Lubricate the
inner diameter of the seal with clean Case HY-TRAN
® ULTRA oil. Use a suitable seal installer to install
the seal. Use the alignment marks from the
disassembly procedure to install the transmission
yoke. Install the a-ring, shims, retaining washer (2),
and the bolt (3). Refer to Section 6015 , Assembly of
MFD Output Shaft for the procedure. Tighten the bolt
to a torque of 252 to 280 Nm (186 to 206 Ib ft).

Properly support the drive shaft. Check the position

of the di rectional arrow decal on the drive shaft. Use
the alignment marks from the disassembly procedure
to position the universal joint on the transmission
yoke. Install the four drive shaft to transmission yoke
retaining bolts (1). Tighten the bolts to a torque of 58
to 64 Nm (43 to 47 Ib ft). Slide the drive shaft
protector (2) on the MFD drive shaft.

NOTE: When installing the drive shaft, make sure

the mating surfaces of the drive shaft universal joint
and yoke are free of paint, burrs, and chips. Use a
rubber mallet to lightly tap the outside edge of the top
bearing end cap to position it into the keyway of the
yoke. Do not use the bolts to pull the bearing end
caps into the yoke keyway

Rae 6·13930 Issued 10·02

6016-8

STEP 16 STEP 17

AD02H097
Lubricate the inner diameter of a new pinion seal with Slide the drive shaft protector sleeve toward the MFD
Case 135 H EP Gear Lubricant. Install the seal using standard axle. Use the position marks made during
CAS1899 Pinion Seal Installer. If a new yoke dust disassembly to install a new drive shaft protector pin.
shield is required, use CAS2596 Yoke Dust Shield
Installer with CAS1716-3 Handle to install the shield.
Refer to Section 6018 MFD Differential-Pinion STEP 18
Assembly for the procedure. Use the alignment
marks made during disassembly to install the pinion
yoke into the differential housing. Install the pinion
washer and a new pinion nut. Tighten the nut to a
torque of 326 to 406 Nm (240 to 300 Ib ft). Properly
support the drive shaft. Position the universal joint on
the pinion yoke using the alignment marks made
during disassembly. Install the four drive shaft to
pinion yoke retaining bolts. Tighten the bolts to a
torque of 58 to 64 Nm (43 to 47 Ib ft). Install and
tighten the MFD axle drain plug. Remove the MFD
axle level plug. Fill the axle to the proper level with
Case 135 H EP Gear Lubricant, and 891246 Limited
Slip Additive, if equipped. Refer to specifications in
this section for the capacity of the specific MFD axle. Check for oil leaks. Make sure the transmission shift
lever is in PARK. Remove the blocks in front of and
behind the rear wheels. Start the tractor and check
the operation of the MFD standard axle. Turn the
engine off and remove the key.

Rae 6· 13930 Issued 10-02

 6016·9

Suspended MFD Axle STEP 21

NOTE: The drive shaft installation procedure for the

suspended MFD front axle is the same as the MFD
front axle, except for the following steps.

STEP 19

Remove the two hand tightened bolts at the pinion

yoke. Install the drive shalt protector.

STEP 22

Properly support the MFD drive shaft. Hand tighten

two of the drive shalt to pinion yoke retaining bolts to
hold the drive shalt in place.

STEP 20

Support the MFD drive shaft. Push the drive shaft

protector sleeve toward the transmission. Tighten the
four drive shalt to pinion yoke bolts to a torque of 58
to 64 Nm (43 to 47 Ib It).

Use a long extension to install the four drive shaft to

transmission yoke retaining bolts. Tighten the bolts to
a torque of 58 to 64 Nm (43 to 47 Ib It).

Rae 6·13930 Issued 10-02

6016-10

STEP 23 STEP 24

Using the position marks made on the drive shaft
pro tector and sleeve, install a new drive shaft
protector pin .
Check for oil leaks. Make sure the transmission shift
lever is in PARK. Remove the blocks in front of and
behind the rear wheels. Start the tractor and check
the operation of the MFD suspended axle and the
transmission. Check the hydraulic oil level. Turn the
engine off and remove the key.

ac 6- 13930 1ssued 10· 02

 Section
6017

LIMITED SLIP MFD DIFFERENTIAL

Case, LlC <C> 2003 Case, LLC

100 State Street Printed in U.S.A.
Raci~. WI 53404 U.S.A. Rac 7-94201 March, 2003
6017-2

TABLE OF CONTENTS
SPECIFI CATIONS ............... ............................... ............................................. ........... ......... ... ................................. 2
SPECIAL TORQUES ........... .............................. .......... ................. ................... .. ...•.. ...........•.................•.... .............. 2
SPECIAL TOOLS .................. ............................... ................. ........ .... .....•....... ......•......... ............... ..... ..................... 2
DIFFERENTIAL CARRIER ASSEMBLY REMOVAL ............ ............•.•.............. .............................................. ........ 3
DIFFERENTIAL DISASSEMBLY ....................... ............... .. .... ...... .... ••. ............ ............ ........................ .. .................. 4
Pinion Disassembly ......... ........ ............ ..............• .............................•... .......... ... ............................. ..... .................. 8
DIFFERENTIAL ASSEMBLY ............................•••. ........ ...................... _•................... ..... .....•........ ... ..•... .............. .... 11
DI FFERE NTIAL CARRIER ASSEMBLY ............ ........................... ...... .. .... ..... ................ ..... .. .................. .............. 15
Pinion Position and Assembly .................................................... ...... ........... ........................... ............. ..... .......... 15
Shim Pack Thicknes s Chart ...........•.... ........•..... ........................•............... ........................ .......••..... .. .. .... ••. ..... . 16
Setting The Pinion Depth ............................................ .............. ......................... ... ................. .......... ............ ...... 17
Adjusting Bearing Preload ..... ... ..... .... ......... ........ ..... .............. .......................................................... ................ .. 20
DIFFERENTIAL INSTALLATION .............................. .. ...... ...... ... ................ ........................................................... 22
Checking Backlash .......... ..... ............................. .... ..................•........................... .......... .......... ........ .... ............ .. 23
Ring Gear and Pinion Tooth Pattern Interpretation .... .............. ........... .................. .... ............................. ............ 25
Installation of Carrier As sembly to Axle Housing ....... ........... ............. ..... .................•.. ... .... ........ .... ..... .......... ..... 27

SPECIFICATIONS
Pinion Shah Rolling Torque (Preload) ......................................................................................... .... 2.26 to 5.65 Nm (20 to 50 Ib Inch)
Differential Assembly Rolling Torque (without input seal) .................................. .................................. 2.83 to 5.65 Nm (25 to 50 Ib h)
Differential Ring Gear Backlash
10 Stud Wheel End Axle .......................................................................... ....................... 0.1 27 to 0.254 mm (0.005 to 0. 010 inch)
12 Stud Wheel End Axle ................................................................... ................ ........... ... 0. 127 to 0.203 mm (0.005 to 0.008 inch)

SPECIAL TORQUES
Differential Adjusting Ring .................................................................................................................. 85 to 115 Ib ft (11 5 to 156 Nm)
Differential Adjusting Ring Clip Bolts ....................................................................................................... .. 27 to 40 Nm (20 to 30 Ib h)
Differential Bearing Cap Bolls ........................................................................................................... 244 to 271 Nm (180 to 200 Ib h)
Differential Front Ring Gear Bolts ...................................................................................................... 163 to 190 Nm (120 to 140 Ib h)
Differential Housing Bolts .................................................................................................................... 122 to 135 Nm (90 to 100 Ib h)
Differential Pinion Shaft Nut .............................................................................................................. 325 to 406 Nm (240 to 300 Ib It)

SPECIAL TOOLS
CAS-1898 Pinion Setting Tool Kit
CAS-1898-9 Side Bearing Adjusting Wrench
CAS-1899 Pinion Shah Oil Seal Driver
CAS-2596 Yoke Dust Sh ield Installer
CAS-1716-3 Handle

ac 7-94201 Issued 03-03

 6017-3

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 in Section
6022 , MFD Planetary Hub, Steering Knuckle and
Axle Drive Shaft).

NOTE: Do not alter the tie rod adjustment.

STEP 2

Support the differential carrier with a chain or lift

strap and hoist. Carefully pry the differential carrier
from the axle housing. When lifting the carrier
assembly out of the axle assembly, make certain the
carrier does not hit the axle housing .

STEP 4
Remove the differential carrier from the axle housing
and mount it in a suitable holding fixture.

A hose clamp bracket is located on a lower carrier

housing bolt (1) . Note the location before bolt
removal.
Remove the bolts and washers that hold the
differential carrier to the axle housing (21 mm
socket).

Rae 7-94201 Issued 03-03

 6017-4

DIFFERENTIAL DISASSEMBLY

STEP 5 STEP 8
~--- ...

Mark the bearing cap and differential housing for

reassembly.

STEP 6

Remove the bearing caps and adjusting rings.

STEP 9

Remove the bolts , washers and ring clips from the

bearing caps. (13 mm socket or wrench).

STEP 7

Lift and remove the differential assembly from the

carrier. Remove the differential bearing cups from
the bearing cones. Note which side each cup
originates from.

IRe!mClVe bearing cap retaining bolts and washer. (24

or 15/1.6. inch socket).

Issued 03·03
 6017-5

STEP 10 STEP 12

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. Do not nick or mark for reassembly.
otherwise damage the ring gear teeth . Remove ring
gear screws and discard them. New ring gear screws
will be installed during reassembly. (13/16 inch STEP 13
socket) .

WARNING : Gear teeth may have sharp

~ edges. When handling gear, use care to
avoid personal injury. M687

STEP 11

RA98K017

Place shop towels over and between th.e vise jaws.

This will prevent possible damage to the axle shaft.
Place one of the axle shafts into the vise with the
spline end extending approximately 76 .2 mm (3
inches) above the vise. This will be used as a holding
device for disassembly and assembly of the
differential housing.
AR96K013

After removing screws , tap the ring gear with a

rawhide or plastic hammer to separate the gear from
the housing half.

Rae 7·94201 Issued 03~ 03

 6017-6

STEP 14 STEP 17

RR99K229
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.
STEP 15
--....,............

Install a split collet and remove the bearing cone

from the differential housing half.
Remove the dished disc.
STEP 16
STEP 19

Remove the differential housing half. RA99K234

Remove the side gear.

Rae 7·94201
Issued 03-03
 6017-7

STEP 20 STEP 23

RR98K025 RA99K238

Remove the pinion mate cross shaft, pinion mates Remove the d ished 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.

STEP 24

RA99K236

Separate the pinion mate cross shaft , the pinion

mate gears and thrust washers.
RR9BK031

In stall a split collet and remove the bearing cone

STEP 22 from the differential gear housing half.

AA99K237

Remove the side gear.

Rae 7 -94201 Issued 03-03

I•
6017·8

Pinion Disassembly

STEP 25 STEP 27

AA98K021 AR98K012

Hold end yoke or flange with tool simi lar to the one
shown, and remove nut and washer. Discard nut as
new one must be used at reassembly. (1 ·5/16 inch
socket) .
If a new yoke dust shield is required , use CAS·2596
Yoke Dust Shield Installer with CAS·1716·3 Handle
STEP 28

STEP 26

T98483 RR98K019

Remove the pinion by tapping with a rawhide

Remove end yoke. If yoke or flange shows wear in
hammer. Support the pinion to prevent it from falling
the seal contract area, if should be replaced
and being damaged.

A 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. The shims are to be
collected and kept together since they will used later
in reassembly. Do not damage the shims. If the
shims are damaged, replace with new ones: shims
are available in thicknesses of 0.003 inch, 0.005
inch, 0.010 inch and 0.030 inch.

NOTE: If ring gear and/or pinion shaft needs to be

replaced, ring gear and pinion shaft must be replaced
as matched set.

ac 7·94201 Issued 03-03

 6017-9

STEP 29 STEP 32
...,..--- -- -

RR98K020

Remove the pinion seal with a puller as shown.
DISCARD SEAL. Replace with new seal during
reassembly. Also, remove bearing cone and outer
pinion oil slinger.
STEP 30
Remove the inner bearing cup.
NOTE: Shims are located between the bearing cup
and carrier bore. If shims are bent or nicked, they
should be replaced at time of assembly. Wire the
stacks together and measure each. If a stack is
replaced, replace with the same thickness.

STEP 33

T98492

Remove the spacer from the pinion shaft as shown.

STEP 31 Remove inner bearing adjustment shims.

I'

T98490

Remove pinion adjustment shims from the pinion

shaft,

Rae 7-94201 Issued 03·03

6017-10
STEP 34
Turn nose of carrier down. Remove ou ter pinion
bearing cup as shown. Locate driver on back edge
cup; drive cup out of carrier if necessary.
NOTE: Do not damage the carrier bore.
ac 7-94201
STEP 35
RA96K036
Instal l a split collet and press the bearing cone off of
the pinion shaft.
WARNING: Do not allow the shaft to fall. It
can strike legs or feet and may cause serious
""
~ injury. Gear teeth may have sharp edges.
Use care when handling to avoid injury. M688
NOTE: It is recommended that whenever bearings
are removed, they are to be replaced with new ones
(regardless of hours).
NOTE: If replacement of a damaged bearing cup or
cone is necessary, the cup and cone must be
replaced as a set.
Issued 03-03
 6017-11

DIFFERENTIAL ASSEMBLY

o 2 4

cD '.

Rt03BOO4

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. DIFFERENTIAL RING GEAR 12. DIFFERENTIAL CASE SCREW
6. DISHED DISC 13. ADJUSTING RING
7. FRICTION DISCS 14. THRUST WASHER

STEP 36 STEP ;3,;7_ _

RR96K033
Apply friction modifier (891246) to all the disc and
Press bearing cone on each trunnion of eac h
plate friction surfaces.
differentia) case half.
NOTE: Make sure the discs and plates are kept in
the same order as disassembly.

Rae 7-94201 Issued 03·03

6017-12

STEP 38 STEP 40

RI03B005 RA99K237

Be sure the plates are arranged for installation as Apply grease to the shoulder of the side gear, then
follows: install the side gear in dished disc in the flanged
housing half.
3 Plates (in board side)
1 Discs
STEP 41
1 Plate
1 Disc
1 Plate
1 Disc
1 Plate
1 Disc
1 Plate
1 Disc

STEP 39
Lubricate the pinion mate gear ID's. Install the pinion
mate gears and thrust washers.

NOTE: Make sure the shafts are installed in the

same order as disassembly. Refer to the alignment
marks made prior to disassembly.

STEP 42

RR99K238

nstall the plate/ disc stack into the differential

ousing. Install the dished disc into the differential
ousing. The convex side of the disc must be up so
he ID of the disc makes contact with the side gear
at is installed next.

RR99K234

Place the side gear on top of the pinion gears.

ac 7·94201 Issued 03·03

 6017-13

STEP 43

RI03BOO5

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
1 Discs
1 Plate
1 Disc
1 Plate
1 Disc
1 Plate
1 Disc
1 Plate
1 Disc
RA99K231

Apply friction modifier (B91246) to all the discs and

plate friction surfaces.
NOTE: Make sure the discs and plates are kept in
the same order as disassembly.

Rae 7·94201 Issued 03-03

r
6017-14

STEP 46 STEP 47
--~~

AR99Km
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. Tighten the ring gear bolts
the in board side. to a torque of 163 to 190 Nm (120 to 140 Ib It). (Use a
13/ 16 inch socket).
Assemble the differential case halves. Make sure the
marks line up on the case halves . Refer to the
NOTE: Make sure the discs and plates are kept in
alignment marks made prior to disassembly. Install
the same order as disassembly.
eight (8) new differential case screws. Tighten to a
torque of 122 to 135 Nm (90 to 100 Ib It).

ac 7·94201 Issued 03-03

 6017-15

DIFFERENTIAL CARRIER ASS EM BLY

RH9BK105
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. NUT 9. BEARING CUP 12. OIL SEAL
13. BEARING CAP

Pinion Position and Assembly NOTE: On the pinion there is etched either a zero
(0), or plus (+) or minus (-) number. This indicates
the best running position for each gear set. The
STEP 48 dimension is set by shimming behind the inner pinion
bearing cup.

T98512

Verify that the numbers on the ring gear and pinion

gears match. Use the following char t as a guide
when determining shim pack thickness and setting
pinion distance.

Rae 7-94201 Issued 03-03

6017-16

Shim Pack Thickness Chart

•
Old New Pinion Marking
Pinion
Marking -4 -3 -2 -1 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

Shim Thickness To Add Or Remove

Rae 7-94201 Issued 03-03

 6017-17

Setting The Pinion Depth STEP 52

STEP 49
---

T98517

Install Aligning Disc CAS-1898-5 and the Gauge Disc

CAS-1898-3.
Install the outer bearing cup.

STEP 50

T98518

Install Gauge Block CAS-1898-4 and finger tighten to

hold the gauge assembly and bearing cones in
The pinion depth setting tool, CAS-1898 , must be
position.
assembled into the differential as shown above.
Follow Steps 60 through 64 to assemble tool to
differential housing. STEP 54

STEP 51

T98519

Install the Tube CAS-1898-6 .

T98516

Install the Handle CAS-1898-1 and Threaded Shaft

CAS-1898-2 into the carrier housing.

Rae 7-94201 Issued 03-03

6017-18
STEP 55
- - -, - - 'Mi-
"-"lIi
Install the bearing caps and cap bolts. Tighten the
bolts to a torque of 244 to 271 Nm (180 to 200 Ib ft)
(Use a 24 mm socket).
STEP 56
Position Gauge Block CAS-1898-4 under Tube CAS-
1898-6. Use a feeler gauge and measu re the
distance between the tube and the b lock . This
dimension is the shim thickness needed . provided
pinion shaft has not "+" or "-" marking n the button
7·94201
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 "-' marking. add the amount
shown to the measurement taken in Step 65. The
sum will be your shim pack thickness.
NOTE : The "+" and "-" markings on the pinion shaft
are given in thousandths of an inch. Shims are
available in thicknesses of 0.076 mm (0.003 inch).
0.127 mm (0.005 inch). 0.25 mm (0.0 10 inch).
Acceptable tolerance is 0.050 mm (+/-0.002 inch) of
number etched on pinion shaft (total shim
calculation).
STEP 58
Remove the depth setting tool CAS-1898 from the
carrier housing.
STEP 59
If necessary to adjust pinion position. remove the
inner bearing cup.
Issued 03-03
 6017-19

STEP 60 STEP 62

Install the proper amount of shims. Assemble inner bearing cone on pinion. Drive
bearing onto pinion using suitable press.

STEP 61

Install the inner bearing cup.

Rae 7-94201 Issued 03~03

6017-20

Adjusting Bearing Preload

STEP 63 STEP 66

\ J

I
,-

T98610

Inslalilhe pinion into the carrier. Install a shim pack Using an inch pound torque wrench, measure the
- ..
T98531

of 0.070 inch on the pinion shaft. rolling torque needed to turn the pinion shaft. The
torque must be 2.26 to 5.65 Nm (20 to 50 Ib inch). If
the torque is correct continue to Step 76. If torque is
STEP 64 not correct, do the following:
NOTE: Typically a change of 0.001 inch will change
rolling torque 151b inch.
1. To increase the torque adjust the 0.070 inch
shim pack to remove a small amount of
thickness. For example , replace a 0.015 inch
shim with a 0.014 inch shim. Repeat torque
check procedure.
2. To decrease the torque adjust the shim pack to
add a small amount of thickness. For example ,
replace a 0.014 inch shim with a 0.015 inch shim .
Repeat torque check procedure.
T98528

Use the Companion Flange Installer CAS-l B9B-B to NOTE: Shim kits contain the following size shims:
push the yoke onto the shaft. 0.010 inch, 0.014 inch, 0.015 inch, 0.016 inch, 0.018
inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch
and 0.030 inch.
STEP 65

T98530

Torque the pinion nut to 326 to 406 Nm (240 to 300

Ib ft)(I-5/16 inch socket) .

Rae 7-94201 Issued 03-03

 6017-21

STEP 67 STEP 69
~

RA9BK043 T9B534

Remove nut and end yoke. Apply Loctite 515 to the Use tool CAS-2596 and install a new dust shield
housing face and to the outer diameter of oil seal. (slinger) on the input yoke . Make sure sealing
surface for oil seal is in good condition.

STEP 68
STEP 70

RR98K044
Use the Pinion Seal Installer CAS-1899 to install a
new pinion shaft oil seal. Install the seal with the lip
towards the pinion shaft.
T98530
Tighten the pinion nut to a torque of 326 to 406 Nm
(240 to 300 Ib ft ) (1-5/16 inch socket) .

Rae 7-94201 Issued 03-03

 6017-22
DIFFERENTIAL INSTALLATION
STEP 71
Install ring gear and differential assembly with
bearing cups into carrier housing.
IMPORTANT: Care should be used when installing
ring gear and differential into carrier housing so
damage to ring gear, pinion bearings, or bearing bore
does not occur.
STEP 72
2. ADJUSTING RING
Inl,,<t;,11 adjusting rings in place. Thread in adjusting
until all slack is removed between bearing cups
Ir .....T·"': Adjusting rings must be installed with side of
having the deeper recess facing the bearing.
Il lnistcllled opposite, the adjusting ring would clamp
IlalJaiiost the bearing cage restricting movement.
7-94201
STEP 73
"".....,..-----,
Be sure bearing cups are seated on bearing cones,
then install differential bearing caps. Install bearing
cap bolts (finger tight only) so adjusting nut can still
be turned. (Do not torque cap bolts to specifications).
NOTE: Make sure the "match marked" bearing cap
and "match marked" leg of the carrier are aligned.
STEP 74
1. DIAL INDICATOR 2. ADJUSTING RING
Position a dial indicator on the housing lip and index
indicator dial to back face of the ring gear. Zero the
indicator.
Turn adjusting ring on the backside (flange side) of
the ring gear in until the indicator stops moving. (Ring
gear is moved into mesh with pinion) .
Issued 03-03

STEP 75
Next, tighten the adjustment ring on the tooth side
(bottom side) of the ring gear in until the bearing cup
is seated.
Use the Side Bearing Adjusting Wrench CAS-1898-9
to tighten the right hand and left hand rings to 115 to
129 Nm (85 to 95 Ib tt).
Rae 7·94201
6017-23
Checking Backlash
STEP 76
Position dial indicator on lip of differential housing
and indicate to side of one tooth on ring gear.
Move ring gear as far as it will go in one direction
before it moves the pinion.
"0" the dial on the indicator face.
Move the ring gear in the opposite direction until it
contacts the pinion gear and observe the dial face.
The reading should be 0.127 to 0.254 mm (0 .005 to
0.010 inch) (for 10 stud wheel end axle) , or 0.127
mm to 0.203 mm (0.005 to 0.008 inch) (for 12 stud
wheel end axle). Check the backlash at three
different locations around the gear. There should be
no more than 0.06 mm (0.003 inch) variation
between readings.
A reading larger than 0.008 to 0.010 inch is corrected
by moving ring gear closer to pinion . A reading
smaller than 0.005 inch is corrected by moving the
ring gear away from the pinion. Move the ring gear by
loosening on adjusting ring and then tightening the
opposite adjusting ring the same amount. Both
adjusting rings must be moved the same amount.
Issued 03~03
 6017-24

STEP 77
STEP 79

When backlash is adjusted properly, rotating torque T98561

at the pinion shaft should be 5 to 10 Ib inch higher Tighten all 01 the bearing cap bolts to a torque 01 240
than the torque you had when setting pinion shaft to 270 Nm (180 to 200 Ib It).
bearing preload.

STEP 78

T98560
the adjusting ring clips, one on each adjusting
Tighten adjusting ring clip bolts to a torque 0127
40 Nm (20 to 30 Ib It).

c 7-94201
Issued 03-03
 6017-25

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.
using gauges that verify the dimension from the
center line to the differential carrier (center line of the
ring gear) to the face of the pinion (button).

This surface (button) is not used on all new gears for

verifying the pinion position . The service tools will be
used to establish the proper amount of shims
required prior to installing the pinion gear. The final
pinion position will be verified by using the GEAR
CONTACT PATTERN METHOD, as described here.

Ring Gear and Pinion Tooth Contact Pattern

ITOp·LAND

h---
, ~~~~~~~~~r~-~ 2. Rotate the ring gear one complete revolution in
both directions.

Pattern Interpretation (Ring Gear))

TOE
\ I ,_ _ LENGTHWISE
---T
HEEL
BEARING
ARC
INormal or desirable patterr
The forward pattern should b
X- _L' - ______ 1I __ centered on the tooth, bl
slightly toward the toe. Ther
should be some clearanc
ROOT between the pattern and th
AH96K l07
top of the tooth.
The toe of the gear tooth is the portion of the tooth
Backlash correct. Thinne
surface at the end towards the center. The heel of
pinion bearing cup positio
the gear tooth is the portion of the tooth surface at
shim required.
the outer end . The top land of a gear tooth is the
surface of the top of the tooth. Every gear has a
characteristic pattern. The illustrations show typical Backlash correct. Thicke
patterns only, and explains how patterns shift as gear pinion bearing cup positio
location is changed. When making pinion position shim required.
changes, shims should be changed in the range of
0.05 mm (0.002 inch) to 0.10 mm (0.004 inch) until
correct pattern has been obtained.
~ IPinion position shim correc
~ Decrease backlash.
Pinion position shim correct.
When a change in backlash is required , backlash Increase backlash.

~~
should be changed approximately 1-112 times the
amount needed to bring the gears into specification.
For example, if the backlash needed to be changed
!FORWARD REVERSE
by 0.10 mm (0 .004 inch), the adjusting rings should DIRECTION DIRECTIO
PATTERN PATTERN
be moved so that the backlash changes by 0.15 mm
(0.006 inch) as a starting pOint. The actual amount of
backlash change obtained will vary depending upon
the ratio and gear size once everything is tightened
to specification.

High backlash is corrected by moving the ring gear

closer to the pinion . Low backlash is corrected by
. moving the ring gear away from the pinion.

Rac 7-94201 Issued 03-03

6017-26

Pattern Movements Summarized

RR96K054

3. A thicker pinion position shim with the backlash

constant moves the pinion closer to the ring
gear.
Forward Pattern moves deeper on the tooth
(flank contact) and slightly toward the toe.
Reverse Pattern moves deeper on the tooth and
toward the heel.

1. Decreasing backlash moves the ring gear closer

to the pinion .
Forward Pattern (convex side of ring gear)
moves lower and towards the toe.
Reverse Pattern (concave side of ring gear)
moves lower and towards the toe.
4. A thinner pinion position shim with the backlash
constant moves the pinion away from the ring
gear.
Forward Pattern moves toward the top of the
tooth (face contact) and toward the heel.
Reverse Pattern moves toward the top of the
tooth and slightly toward the toe.

2. Increasing backlash moves the ring gear away

from the pinion.
Forward Pattern moves slightly higher and
toward heel.
Reverse Pattern moves higher and toward heel.

Rae 7-94201 Issued 03-03

 6017-27

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

T98567

Apply Loctite 515 Gasket Eliminator to the axle

housing mounting flange and around the outside of
each bolt hole.

Install the carrier assembly into the axle housing .

Coat all bolt threads with Loctite 271 prior to
installation. Install the hose clamp on the lower bolt
(1 ) from where it was removed . Install washers and
bolts and tighten to a torque of 135 to 155 Nm (100 to
1151b tt).

STEP 83
Assemble axle shafts and wheel end components,
following procedures shown in Section 6022.

STEP 84
Clean drain plugs and install in carrier housing and
planetaries. Fill with the lubricant specified in the
operators manual to the proper levels.
Inspect wheel ends and housing for oil leaks. Take
immediate corrective action w hen oil leaks are
detected.

Rae 7-94201 Issued 03-03

! f
 6017-28

ac 7-94201
Issued 03-03
 Section
6018

LOCKING MFD DIFFERENTIAL

MX Series Tractor

CASE, llC <C> 2002 Case, llC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-14051 October, 2002
60 18-2

TABLE OF CONTENTS
TABLE OF CONTENTS ........•••........ .... .. .................................................... ...... .............. ....... ......... ....... •.. ... ..... ....... 2
SPECIFICATIONS ................................... .................................................•........................................... ................... 3
SPECIAL TORQUES ......... ............ ............................. ... ..... .......... .. ...... ...... ... .. .. ... .•............ .. ......... .......••........ .. .. ..... 3
SPECIAL TOOLS ............... ..... .. .. ...... ...................................................................................... ........ ........................ 3
REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY ............................ .............................. ......... 4
REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING .................................................. 5
DISASSEMBLY OF THE DIFFERENTIAL ............ ....... ...... .. ......... ................... ... ..... .. .. .. .... •. .. .... .. ...... ........... .......... 7
PINION DISASSEMBLY ...... .................................................................................................................................... 8
ASSEMBLY OF THE DIFFERENTIAL ..............••.............. .............. .. ....................... .. .. .. ..... ..... ........... ........... ....... 11
DIFFERENTIAL CARRIER ASSEMBLY ....... ..... ........ .....................................................................•..................... 14
Pinion Position and Assembly .........................................•..............••••..........................................•• .................... 14
Shim Pack Thickness Chart ........ .. .... ... .. .......... .. .............................•............................................•... ........... ....... 15
SETTING THE PINION DEPTH ............. ......... .•.................. ..... .. ...... •••... ......... .. ..................... .........•. .................... 16
ADJUSTING BEARING PRELOAD .................. .. ......... .... ..... ............. •••... ..... .. ............ .. ............. ... ...•..................... 18
DIFFERENTIAL INSTALLATION ............................... .............. ............................... .. .. .................•. ........ ............ 20
Checking Backlash .......................... ... ........ ............. .. ............. ..... .. .... ...... .. .............. ...................................... .... 22
Ring Gear and Pinion Tooth Pattern Interpretation ...... ... ...... .. ..... ...... ...... ......................................... .. ............... 23
Installation of Carrier Assembly to Axle Housing ....... .................................. ...................................... ...... .......... 25

Rae 6·14051 Issued 10-02

 6018-3

SPECIFICATIONS
P',nion Shaft Rolling Torque (Preload) ............................................................................................. 2.26 to 5.65 Nm (20 to 50 Ib Inch)
Differential Assembly Rolling Torque (without input seal) ................................................................... 2.83 to 5.65 Nm (25 to 50 Ib It)
Differential Ring Gear Backlash
10 Stud Wheel End Axle .................................................................................................. 0.127 to 0.254 mm (0.005 to 0.010 inch)
12 Stud Wheel End Axle .................................................................................................. 0.127 to 0.203 mm (0.005 to 0.008 inch)

SPECIAL TORQUES
Differential Adjusting Ring .................................................................................................................... 74.6 to 88 Nm (55 to 651b h)
Differential Adjusting Ring Clip Bolts ...................................................... ................................................... 27 to 40 Nm (20 to 30 Ib h)
Differential Bearing Cap Bolts ..................... .......................................................................................240 to 270 Nm (180 to 200 Ib h)
Differential Front Ring Gear Bolts ...................................................................................................... 163 to 190 Nm (120 to 140 Ib h)
Differential Housing Bolts .................................................................................................................... 122 to 135 Nm (90 to 100 Ib h)
Differential Pinion Shalt Nut... .. .. .. .................. .................................................................................... 325 to 406 Nm (240 to 300 Ib h)
Seal Retainer Socket Head Screws .............. .............................................................................. .... .... 4.0 to 4.6 Nm (36 to 40 Ib inch)

SPECIAL TOOLS
CAS-1898 Pinion Setting Tool Kit CAS-2596 Yoke Dust Shield Installer
CAS-1898-9 Side Bearing Adjusting Wrench CAS-1716-3 Handle
CAS-1899 Pinion Shah Oil Seal Driver 380000808 Differential Locknut Wrench

Rae 6-14051 Issued 10· 02

 6018-4

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
(refer to information in Section 6022, MFD Planetary
Hub, Steering Knuckle and Axle Drive Shaft).

STEP 2
Remove the front axle from the tractor.

NOTE: Do not alter the tie rod adjustment. Support the differential carrier with a chain or lift
strap and hoist. Carefully pry the differential carrier
STEP 3 from the axle housing. When lifting the carrier
assembly out of the axle assembly, make certain the
carrier does not hit the axle housing.

STEP 5
Remove the differential carrier from the axle housing
and mount it in a suitable holding fixture.

liR"ml,vA the differential lock supply and return hoses.

emove the bolts and washers that hold the
ifferential carrier to the axle housing (21 mm

6- 14051 Issued 10-02

 6018-5

REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING

STEP 6 STEP 8

RD02Hl84
Remove the three socket head screws from the seal
retainer. (3 mm allen wrench) .

STEP 9

Mark the bearing caps and differential housing for

reassembly.

ROO2Hl86
STEP 7 Remove the seal retainer.

STEP 10

ROO2Hl 84

Remove the bolt and washer locking the adjusting

nut in place. RD02H187

Remove bearing cap retaining bolts and washers

then remove bearing cap. (24 mm or 15/ 16 inch
socket) .

Issued 10-02
Rae 6-14051
 6018-6

STEP 11 STEP 14

ROO2H1B8
Remove the adjusting ring, piston rings and bearing Remove the adjusting ring .
cup. Keep the parts for this side together.

STEP 15
STEP 12

Remove the differential from the carrier.

Remove the bolt, washer and ring clip from the
bearing cap.
STEP 16
STEP 13

AD02H191
Remove the bearing cup and diff case seal.
emove the bolts, washers and bearing cap from the
ther side.

ac 6·14051
Issued 10-02
 6018-7

DISASSEMBLY OF THE DIFFERENTIAL

STEP 17 STEP 20

RD02Hl92 AD02H195

Mark the housing halves for reassembly. Remove the clutch driver and diff gear

STEP 18 STEP 21

AD02H193 RD02Hl96

Remove the socket head screws and washers. (6 Remove the pinon mate cross shaft , pinon mates
mm allen wrench). (pinon gears) and thrust washers.

STEP 19 STEP 22

RD02Hl94 AR99K236

Remove the flange half case from the clutch housing Separate the pinion mate cross shaft , pinion mate
and cap half case. gears and thrust washers.

Rae 6-14051 Issued 10-02

j
6018-8

STEP 23 PINION DISASSEMBLY

STEP 25

ROO2JOOS
Remove the pressure plates and friction plates.
RR9BK021

NOTE: Make sure the friction and pressure plates
are kept in the same order for reassembly.
STEP 24
Hold end yoke or flange with tool similar to the one
shown, and remove nut and washer. Discard nut as
new one must be used at reassembly. (1-5 /16 inch
socket).
STEP 26

ROO2Hl99 T98463

Remove end yoke . If yoke or flange shows wear in

the seal contact area, it should be replaced.

STEP 27

RD02H232

Remove the bearing cone from the flange half case

and cap half case if replacement is required.
RA98K0 12

If a new yoke dust shield is required, use CAS-2596

Yoke Dust Shield Installer with CAS-1716-3 Handle.

Rae 6- 14051 Issued 10-02

 6016-9

STEP 28 STEP 30

AR96K01 9 T98492

Remove the p i nion by t a pping with a rawhide Remove the spacer from the pinion shaft as shown.
hammer. Support the pinion to prevent it from fall ing
and being damaged.
STEP 31
WARNING: Gear teeth may have sharp
~ edges. Wh en 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. The shims are to be
collected and kept together since they will be used
later in reassembly. Do not damage the shims. If the
•
shims are damaged, replace with new ones: shims
are available in thicknesses of 0.003 inch, 0.005
Remove pinion adjustment shims from the pinion
inch, 0.010 inch and 0.030 inch.
shaft.
NOTE: If ring gear and/or pinion shaft needs to be
replaced, ring gear and pinion shaft must be replaced STEP 32
as matched set. ......- - --
STEP 29

Remove the inner bearing cup.

RA98K 020
NOTE: Shims are located between the bearing cup
and carrier bore. If shims are bent or nicked, they
Remove the pinion seal with a puller as shown .
should be replaced at time of assembly. Wire the
DISCARD SEAL. Replace with new seal during
stacks together and measure each. If a stack is
reassembly. Also, remove bearing cone and outer
replaced, replace with the same thickness.
pinion oil slinger.

Rae 6·1405 1 Issued 10-02

6018-10

STEP 33 STEP 35

RA9BK036

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. Gear teeth may have sharp edges.
Use care when handling to avoid injury.M6SS

NOTE: It is recommended tha t whenever bearings

are removed, they are to be replaced with new ones
(regardless of hours).

NOTE: If replacement of a damaged bearing cup or

cone is necessary, the cup and cone must be
replaced as a set.

Turn nose of carrier down. Remove outer pinion

bearing cup as shown. Locate driver on back edge
cup; drive cup out of carrier if necessary.

NOTE: Do not damage the carrier bore.

Rae 6-1 405 1 Issued 10-02

 6018-11

A102K063

1. CAP HALF CASE 7. FRICTION PLATES (1 3) 13. DlFF CROSS SHAFT

2. RING SEAL 8. CLUTCH DRIVER 14. DIFF SIDE GEAR
3. SEAL RING 9. DIFFERENTIAL GEAR 15. DIFF GEAR THRUST WASHER
4. CLUTCH PISTON 10. CLUTCH HOUSING 16. FLANGE HALF CASE
5. DIFF GEAR THRUST WASHER 11. DIFF THRUST WASHE (4) 17. WASHERS (20)
6. DIFF PRESSURE PLATES (14) 12. DIFF PINION GEAR (4) 18. SOCKET HEAD SCREWS (20)

STEP 36 STEP 37

AOO2H200 RD02JOO5

Press bearing cone on each trunnion of each Apply friction modifier (891246) to all the disc and
differential case half (if they were removed). plate friction surlaces.

NOTE: Make sure the discs and plates are kept in

the same order as disassembly.

Issued 10-02
 6018-12

STEP 38
STEP 40

RD02JOO3
Install the thrust washer into the flange half case.
RD02JOO8
Apply grease to the shoulder of the side gear, then Place the diff gear and clutch driver on top of the
install side gear into the flange half case. pinion gears

STEP 39
STEP 41

RD02JOO4
ubricate the pinion mate gear ID's. Install the pinion
ate gears, thrust washers and cross shaft into the RD02JOO9
ange half case. Place the clutch housing onto the flange half case.

OTE: Make sure the cross shaft is installed in the

ame order as disassembly Refer to the alignment STEP 42
arks.

Rl02K084
Arrange the plates for installation as follows:
1 plate, 1 disc, 1 plate, 1 disc, 1 plate, 1 disc, 1 plate,
3 discs, 5 plates, 3 discs, 1 plate, 1 disc, 1 plate, 1
disc, 1 plate, 1 disc, 1 plate, 1 disc, 1 plate.

6-14051
Issued 10-02
 6018·13

STEP 43 STEP 44

ROO2J006 ROO2Hl92

ROO2H202 ROO2H192

Install the plate/disc stack into the clutch housing.
NOTE: You may have to install the plates and discs
into the clutch housing one at a time.
Assemble the cap half case to the clutch housing and
flange half case. Make sure the marks line up on the
case halves. Refer to the alignment marks made
prior to disassembly. Install 20 socket head screws
and washers. Tighten to a torque of 122 to 135 Nm
(90 to 100 Ib It).

STEP 45

ROO2H197

Install the differential ring gear to the flange half case

(if it was removed). Install new ring gear bolts .
Tighten the ring gear bolts to a torque of 163 to 190
Nm (120 to 140 Ib It). (Use a 13/16 inch socket).

Rae 6·14051 Issued 10-02

! !
6018-14

DIFFERENTIAL CARRIER ASSEMBLY

(j)

~
~ ~

9 0 "@

AH02J027
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. NUT 9. BEARING CUP 12. OIL SEAL
13. BEARING CAP

Pinion Position and Assembly

STEP 47 NOTE : On the pinion there is etched either a zero

(0), or plus (+) or minus (-) number. This indicates
the best running position for each gear set. The
dimension is set by shimming behind the inner pinion
bearing cup.

T98512

Verify that the numbers on the ring gear and pinion

gears match. Use the following chart as a guide
when determining shim pack thickness and setting
pinion distance.

Issued 10-02
 6018-15

Shim Pack Th ickness Chart

Old New Pinion Marking
Pinion
Marking -4 -3 -2 -1 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0·005 -0.006

-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

Shim Thickness To Add Or Remove

Rae 6·14051 Issued 10·02

6018-16

SETTING THE PINION DEPTH

STEP 48 STEP 51

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 .
Follow Steps 50 through 54 to assemble tool to
differential housing.
STEP 50
Install Gauge Block CAS-1898-4 and finger tighten to
hold the gauge assembly and bearing cones in
position.
STEP 53

.-
T98516

Install the Handle CAS-1898-1 and Threaded Shaft T98519

CAS-1898-2 into the carrier housing.
Install the Tube CAS-1898-6.

Rae 6·14051 Issued 10-02

 6018-17

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 Ib It)
(Use a 24 mm socket).

STEP 55 ---"";';'~T96489
If necessary to adjust pinion position, remove the
inner bearing cup.

STEP 59

Position Gauge Block CAS-1898-4 under Tube CAS-

1898-6. Use a feeler gauge and measure the
distance between the tube and the block. This
dimension is the shim thickness needed, provided
the pinion shalt has not "+" or"-" marking n the button
end. Install the proper amount of shims.

STEP 56
If the pinion shaft has a "+" marking, subtract the
amount shown from the measurement taken in Step
55. The remainder is your shim pack thickness.
If the pinion shaft has a "-' marking , add the amount
shown to the measurement taken in Step 55. The
sum will be your shim pack thickness.

NOTE: The "+ " and "-" markings on the pinion shaft
are given in thousandths of an inch. Shims are
available in thicknesses of 0.076 mm (0.003 inch),
0.127 mm {0.005 inch}, 0.25 mm (0.010 inch).
Acceptable tolerance is 0.050 mm {+/ -0.002 inch} of
number etched on pinion shaft {total shim
calculation}.

Rae 6-14051 Issued 10-02

6018-18

STEP 60 STEP 61

RR9BK037

Install the inner bearing cup. Assemble inner bearing cone on pinion. Drive
bearing onto pinion using suitable press.

ADJUSTING BEARING PRELOAD

STEP 62 STEP 64

\ ./ ,
,,

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 shalt. Ib It) (1-5/16 inch socket).

STEP 63

T98528

Use the Companion Flange Installer CAS-1898-8 to

push the yoke onto the shalt.

Rae 6-14051 Issued 10-02

 6018-19

STEP 65 STEP 67

RA96K044

Using an inch pound torq ue wrench , measure the Use the Pinion Seal Installer CAS· 1899 to install a
rolling torque needed to turn the pinion shaft. The new pinion shalt oil seal. Install the seal with the lip
torque must be 2.26 to 4.5 Nm (20 to 40 Ib inch). If towards the pinion shalt.
the torque is correct continue to Step 66. If torque is
not correct, do the following:
NOTE: Typically a change of 0.001 inch will change
rolling torque 15 Ib inch.
1. To increase the torque adjust the 0.070 inch
shim p a ck to remove a small amount of
thickness. Fo r examp le, replace a 0.015 inch
shim with a 0.014 inch shim. Repeat torque
check procedure.
2. To decrease the torque adjust the shim pack to
add a small amount of thickness. For example,
replace a 0.014 inch shim with a 0.015 inch shim.
Repeat torque check procedure.
T98534
Use tool CAS·2596 and install a new dust shield
NOTE: Shim kits contain the following size shims:
(sl inger) on the input yoke. Make sure sealing
0.010 inch, 0.014 inch, 0.015 inch, 0.016 inch, 0.018
surface for oil seal is in good condition.
inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch
and 0.030 inch.

STEP 66

T98530

Tighten the pinion nut to a torque of 326 to 406 Nm

(240 to 300 Ib It) (1·5116 inch socket) .
RR96K043

Remove nut and end yoke. Apply Loctite 515 to the

housing face and to the outer diameter of oil seal.

Rae 6-14051 Issued 10-02

jl
6018-20
DIFFERENTIAL INSTALLATION
STEP 68
Install ring gear and differential assembly with
bearing cups into carrier housing.
IMPORTANT: Care should be used when installing
ring gear and differential into carrier housing so
damage to ring gear, pinion bearings, or bearing bore
does not occur.
STEP 69
1. BEARING CUP 2. ADJUSTING RING
Install adjusting rings in place. Thread in adjusting
rings until all slack is removed between bearing cups
and bearings.
NOTE: Adjusting rings must be installed with side of
nut having the deeper recess facing the bearing.
Installed opposite, the adjusting ring would clamp
against the bearing cage restricting movement.
NOTE: Right hand adjusting ring shown.
6-14051
STEP 70
Be sure bearing cups are seated on bearing cones,
then install differential bearing caps. Install bearing
cap bolts (finger tight only) so adjusting nut can still
be turned. (Do not torque cap bolts to specifications).
NOTE: Make sure the "match marked" bearing cap
and "match marked" leg of the carrier are aligned.
STEP 71
1. DIAL INDICATOR 2. ADJUSTING RING
Position a dial indicator on the housing lip and index
indicator dial to back face of the ring gear. Zero the
indicator.
Mesh ring gear and pinion to zero backlash by
loosening adjusting nut (A) (not shown) and
tightening adjusting nut (B). (Ring gear is moved into
mesh with pinion) .
Issued 10-02
 6018-21

STEP 72

Position dial indicator (1) on lip of differential housing

and indicate to side of one tooth on ring gear.
Loosen adjusting nut (8) until backlash is
approximately 0.127 mm (0.005 inch). Continue
loosening adjusting nut (8) until adjusting ring cap
bolt, washer and clip can be installed. Torque bolt to
27 to 40 Nm (20 to 30 Ib It). Tighten all of the bearing
cap bolts to a torque of 240 to 270 Nm (180 to 200 Ib
It).
Tighten adjusting nut (A) to a torque of 75 to 88 Nm
(55 to 65 Ib It) (with the differential locknut wrench
tool). Which will result in a bearing preload of 1.13 to
2.26 Nm (10 to 20 Ib inch). (When measured through
7 •
RD02J025 the pinion will read 2.5 to 5 Ib inch more than the
original pinion torque setting).
Install the bolt and washer for adjusting nut (A) and
torque to 27 to 40 Nm (20 to 30 Ib It) . Advance to
next hole if required.
Final backlash to be 0.076 to 0.3 mm (0.003 to 0.012
inch) (0.127 to 0.2 mm[0.005 to 0.008 inch]
preferred) .

Rae 6·14051 Issued 10-02

601 8-22

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 Ib inch) .

Checking Backlash
STEP 74 STEP 75

When backlash is adjusted properly, rotating torque

Position dial indicator on lip 01 differential housing
at the pinion shalt should be 2.5 to 5 Ib inch higher
and indicate to side 01 one tooth on ring gear.
than the torque you had when setting pinion shaft
Move ring gear as lar as it will go in one direction bearing preload.
before it moves the pinion.
"0" the dial on the indicator lace.
Move the ring gear in the opposite direction until it
contacts the pinion gear and observe the dial lace.
The reading should be 0.127 to 0.254 mm (0.005 to
0.010 inch) (lor 10 stud wheel end axle) , or 0.127
mm to 0.203 mm (0.005 to 0.008 inch) (lor 12 stud
wh e el end axle). Check the backlash at three
different locations around the gear. There should be
no more than 0.06 mm (0 .003 inch) variation
between readings.
A reading larger than 0.008 to 0.010 inch is corrected
by moving ring gear closer to pinion . A reading
smaller than 0.005 inch is corrected by moving the
ring gear away lrom the pinion. Move the ring gear by
loosening on adjusting ring and then tightening the
opposite adjusting ring the same amount. Both
adjusting ring s must be moved the same amount.

flac 6- 14051 Issued 10· 02

 6018-23

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.
using gauges that verify the dimension from the
center line to the differential carrier (center line of the
ring gear) to the face of the pinion (button).

This surface (button) is not used on all new gears for

verifying the pinion position. The service tools will be
used to establish the proper amount of shims
required prior to installing the pinion gear. The final
pinion position will be verified by using the GEAR
CONTACT PATTERN METHOD, as described here.

Ring Gear and Pinion Tooth Contact Pattern

PROFILE RD02J026
TOP LAND
2. Rotate the ring gear one complete revolution in
------ - T- both directions.
/
LENGTHWISE Pattern Interpretation (Ring Gear)
BEARING
HEEL ARC
_ L ________ i _
/ ~CD~
ROOT
RH96K1 07

The toe of the gear tooth is the portion of the tooth

~®~
~0~
surface at the end towards the center. The heel of the
gear tooth is the portion of the tooth surface at the
outer end. The top land of a gear tooth is the surface
of the top of the tooth. Every gear has a
characteristic pattern. The illustrations show typical
patterns only, and explains how patterns shift as gear
location is changed. When making pinion position
~0~
~ ~
changes, shims should be changed in the range of FORWARD REVERSE
0.05 mm (0.002 inch) to 0.10 mm (0.004 inch) until DIRECTION
PATTERN
f5\
\V
DIRECTION
PATTERN
correct pattern has been obtained.
RH96Kl 08

When a change in backlash is required, backlash
should be changed approximately 1-1 /2 times the
amount needed to bring the gears into specification.
For example, if the backlash needed to be changed
by 0.10 mm (0.004 inch) , the adjusting rings should
be moved so that the backlash changes by 0.15 mm
(0.006 inch) as a starting point. The actual amount of
backlash change obtained will vary depending upon
the ratio and gear size once everything is tightened
to specification .
High backlash is corrected by moving the ring gear
close r to the pinion. Low backlash is corrected by
moving the ring gear away from the pinion.
1. Normal or desirable pattern. The forward pattern
shou ld be centered on the tooth, but slightly
toward the toe. There should be some clearance
between the pattern and the top of the tooth.
2. Backlash correct. Thinner pinion bearing cup
position shim required.
3. Backlash correct. Thicker pinion bearing cup
position shim required.
4. Pinion position shim correct. Decrease backlash.
5. Pinion position shim correct. Increase backlash.

Rae 6-14051 Issued 10-02

6018-24

Pattern Movements Summarized

-.

RA98K054

3. A thicker pinion position shim with the backlash

constant moves the pinion closer to the ring gear.
Forward Pattern moves deeper on the tooth
(flank contact) and slightly toward the toe.
Reverse Pattern moves deeper on the tooth and
toward the heel. .

1. Decreasing backlash moves the ring gear closer

to the pinion.
Forward Pattern (convex side of ring gear)
moves lower and towards the toe.
Reverse Pattern (concave side of ring gear)
moves lower and towards the toe.
4. A thinner pinion position shim with the backlash
constant moves the pinion away from the ring
gear.
Forward Pattern moves toward the top of the
tooth (face contact) and toward the heel.
Reverse Pattern moves toward the top of the
tooth and slightly toward the toe.

2. Increasing backlash moves the ring gear away

from the pinion.
Forward Pattern moves slightly higher and
toward heel.
Re.verse Pattern moves higher and toward heel.

Rae 6·1 405 1 Issued 10-02

 6018-25

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

AD02J029

Apply Loctite 515 Gasket Eliminator to the axle

housing mounting flange and around the outside of
each bolt hole.

ROO2KOO2
Install the differential lock supply and return hoses.
Install the carrier assembly into the axle housing .
Coat all bolt threads with Loctite 271 prior to
installation. Install washers and bolts and tighten to a
torque of 135 to 155 Nm (100 to 115 Ib It).

STEP 79
Assemble axle shafts and wheel end components ,
following procedures shown in Section 6022 , MFD
Planetary Hub, Steering Knuckle and Axle Drive
Shalt).

STEP 80
Clean drain plugs and install in carrier housing and
planetaries . Fill with the lubricant specified in the
operators manual to the proper levels.
Inspect wheel ends and housing for oil leaks. Take
immediate corrective action when oil leaks are
detected.

Rae 6- 14051 Issued 10-02

 6018-26

Rae 6-14051
Issued 10-02
 Section
6019

REAR AXLE AND PLANETARIES

MX Series Tractors

CASE CORPORATION ~ 2002 Case Corporation

. 700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13470 October, 2002

, I
 6019-2

TABLE OF CONTENTS
SP ECIAL TOOLS ...................... ..... ........ ..... ............ ........ ...................................... ....... .... .. .......... ........................... 3

SPECIAL TORQUES ............. ............................ .. ............ .. ..... .............................................. ..... ........ ...................... 5

SPECIFICATIONS .. ............ ................... ............ ........... ........... ................. .............................. .................. .......... ..... 5

GENERAL INFORMATION ................ .................. ........... .............................. .................... ...................................... 5

Cleaning .............. ............. .. ...... .. ........ .............................. ..... .............. .................... ........................ ................... .. 5
Inspection ................... ... .... ................................ ............. .......... ................................................. ...................... ..... 5
Gears .......... ..................................................... ........ ................ ................................. ....... ............. ... ........ ............ 5
Oil Seals, O-rings And Gaskets ............. ........... ..... .... .................................... .................. ..... ............................... 5
Bearings ............... ... ............ .......... ................ ..... ...... ................................ ............................................................ 5

REAR AXLE ........... ... ................................. ................... ............................. ............... .............................................. 6

Removal ....... ......... ... ...... .............. ... ..................... ............. ................. .................................. ................................ 6

AXLE HOUSING DISASSEMBLY ..... ..... ... ................... ...................... ... ... ............................................................... 9

PLANETARY DISASSEMBLY ................ ......... .... ........ ...... ............. ..... ................................................................. . 11

DIFFERENTIAL CARRIER SEAL REPLACEMENT ......... ... .............. .. ..................................... ............................. 13

PLANETARY ASSEMBLY ..... .................. ......... ................................................................................................ ..... 14

AXLE HOUSING ASSEMBLY ...................... ................................................................ ...... .............. ...... .... .......... . 17
4-lnch Axle ................. .................. .... ..... ........................................................................................................... 18
4-lnch Heavy Duty Axle .. ...... ... .. ... ........... ........... ....... ......................................... .............................................. 18
4.5-lnch Axle .................................................................................................................................................... 19
4-lnch Standard Axle ......... .. ........ ................................ ............... ........ ...... ... ... ........ ...... .................................... 20
4-lnch Heavy Duty Axle ....... ........ ................. ............... ... .. ...... ....... .... ........... .......... ....... ........ ... ............ ............ 20
4.5-lnch Axle ..................... .............................. ................. .. ............... ....... ......................................... ............ ... 20
For All Axles ...................... ......................................... ....... ................................................................... ... ......... 21

I How To Determine Ram Pressure ......................................................................................................................... 22

XLE INSTALLATION ................................ ............................................................. .......... .................................... 25

XLE SEAL WEAR SLEEVE INSTALLATION (4- Inch Axle Only) .............................. ...... ....... ............................ 29

ac 7· 86720 Isissued 10-02 Printed in U.S.A

 60 19·3

SPECIAL TOOLS

Ii
I I

RH02Dl22 RH02D124

Rear Housing Handler 17-527 Brake Disc Alignment Toll 89-581-5

-----------n
R~ CAS2EIO I

Pushing Bridge 89-525-18 Alignment Guide Pins (studs) CAS2601

Rae 6· 13470 Issued 10-02

6019-4

40017
Puller Set with 30-Ton Ram CAS10030

T82109
T82107
Bushing Bearing And Seal Driver Set CAS 10387 Universal Driver Set (3-1116 Inch To 4-1/2 Inch
Tool Organizer Board CAS10390 Diameter) CAS10389

T821 08
Universal Driver Set (1/2 Inch To 4-1/2 Inch
Diameter) CAS10388

ac 6·13470 Issued 10-02

 6019-5

SPECIAL TORQUES
Axle Mounting Bolts ...... ................................. ........................................................... 232 to 262 Nm (171 to 1931b It)

SPECIFICATIONS
Axle Rolling Torque Without Outer Seal
Set Torque 3-1 /2 inch Axle ................ .... .... .... .. .... ...........•. ............ .••....... 200 to 240 Ib in (22.6 to 27.1 Nm )
4 inch Axle ...... ...... ... .... ..... .. ... ... .. .. .... ..... ..... .. •.. ............ .............. 250 to 300 Ib in (28.2 33 .9 Nm)
Final Torque With New Bearings 3-1/2 inch Axle .... .....•... ...... .. .....•......... 100 to 170 Ib in (11.3 to 19.2 Nm)
4 inch Axle .... ....... .. .. .. .. ....... .. ............. .. .... .... ... ...... .......... .. .. .. . 140 to 210 Ib in (15.8 to 23.7 Nm)
Final Torque With Used Bearings 3-1 /2 inch Axle .......... •.......... .....•. ... ........... 50 to 85 Ib in (5.6 to 9.6 Nm)
4 inch Axle ... ... ........... .. ... ......... ... ................. .•• ....... .. .... ... ... ....... 70 to 105 Ib in (7 .9 to 11.8 Nm)

GENERAL INFORMATION
WARNING : THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY
4'-
MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULL Y
~ READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY
OF PERSONAL INJURY OR DEATH. N171B

Cleaning
Before any service work is done, steam clean the
complete outside surface of the housing.
NOTE: Do not use caustic soda for steam cleaning.
Bearings
Check bearings for smooth action . If a bearing has a
loose fit or rough action , replace the bearing.
If necessary, wash bearings with clean solvent and
permit to air dry.

Clean all metal parts , except bearings , in mineral NOTE: DO NOT DRY WITH COMPRESSED AIR.
spirits or by steam cleaning.
Lubricate bearings alter cleaning to prevent rust.
Alter cleaning , dry and lubricate all parts . Clean oil
passages with compressed air.

Inspection .& WARNING: Always wear heat protecti ve

gloves to prevent burning your hands when
handling heated parts. SM121A
Visually inspect all parts when disassembled.

Replace all parts that have wear or damage. The

replacement of parts as necessary will prevent early
failure.

Gears
Check all gears for wear and damage.

Replace worn or damaged gears.

Oil Seals, O-rings And Gaskets

Always install new oil seals, a-rings and gaskets. Put
oil or petroleum jelly on seals and a-rings.

Rae 6-13470 Issued 10-02

6019-6

REAR AXLE

Removal

STEP 1 STEP 2

13523

Move the rear housing handler CAS17-527 into

position under the tractor.

STEP 3

91510

Drain the rear axle as follows:

1. Put a container under the transmission housing .
2. Remove the drain plug and drain the fluid from
the transmission housing.
3. Remove the drain plug from under the axle
housings and remove the fluid .
13529
Raise the front lift of the rear housing handler. Turn
the rear threaded rods until the rear frame is
supported .

NOTE: The transmission holds approximately 174

liters (46 gallons) of oil.

I ac6-13470 Issued 10-02

 6019-7

STEP 4 STEP 7

Remove the wheel and tire assemblies from both Install a lift strap at the axle balance point . Put
axles. tension on the lift strap. Remove the remaining bolts
and remove the axle.

STEP 5 NOTE: It will be necessary to break loose the axle

flange sealant by hitting the axle end with a soft
faced mallet.

STEP 8

RD020148

Remove the axle bolts that retain the draft pin wiring
tub bracket (1) and the hitch cylinder hose bracket
(2). Move the brackets out of the way.

T97973

STEP 6 Remove the ring gear from the axle housing.

o
STEP 9

t
\.

Remove a bolt from front and rear of the axle housing

and install a guide dowel in each bolt location .

Remove the retaining ring from the axle shaft.

Issued 10-02

! «
6019-8

STEP 10 STEP 11

197975

Use a sling and hoist to remove the planetary Remove the sun gear from the brake discs. Clean
assembly from the axle. and inspect for heavy wear or damage. Replace if
necessary.

Be 6- 13470 1ssued 10-02

 6019-9

AXLE HOUSING DISASSEMBLY

STEP .-:.:
12 = --_ STEP 14
I ----~------~---~

o
Rembve 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
retaining ring before removing retaining ring from STEP 15
shaft.

STEP 13

- "'- - .:eAIF T97984

Install a pulling bridge and a 3D-ton ram on the axle

housing. Press the axle assembly out of the axle
housing.

Remove the thrust ring from the axle shafl.

STEP 16

T97985

Remove the seal and , if equipped, the wear sleeve,

from the axle shaft.

Issued 10-02
 6019-10

STEP 17 STEP 19

T97986
T97991
Use a puller to remove the bearing from the axle Use a puller to remove the bushing from the axle
shaft. shaft.

STEP 18 NOTE : Remove the O-ring from the inside diameter

of the bushing on 115 mm (4.5 in.) diameter axle.

STEP 20

T97988
Remove and discard the O-ring used on 4-in. axles
from the axle bushing.
T97994
Use a puller to remove the inner bearing cup from the
axle housing.

STEP 21
r-~"

T97997
Use a puller to remove the outer bearing cup from
the axle housing.

ae 6-13470
Issued 10-02
 6019-11

PLANETARY DISASSEMBLY

STEP 22 STEP 24

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.
original location in the gear carrier.
STEP 25
STEP 23

Remove the planetary gear and bearing assembly

Drive the roll pin into the planet gear shaft. from the gear carrier.

Rae 6-13470 Issued 10-02

 6019-12

STEP 26 STEP 27

RD98C193
Remove the thrust washer and needle bearings from
one side of the planet gear.
R098C194
Remove the thrust ring. Turn the planet gear over
and remove the other thrust washer and needle
bearings.

STEP 28
Repeat Steps 22 through 27 for the other planet gear
assemblies.

Rae 6-13470
Issued 10-02
 6019-13

DIFFERENTIAL CARRIER SEAL REPLACEMENT

STEP 29 STEP 30

~
T9602.

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.

Rae 6-13470 Issued 10-02

! ..
6019-14

PLANETARY ASSEMBLY

L----------
1
1.
. lr~~;
ST WASHER
~~~~LE BEARING
6 THRUST WASHER
1071941\

2. ETGEAR 7: ROLL PIN AR CARRIER

~EARING
LANETGE
3. PLAN RING
~~~~~~ BEARING
:: SHAFT
:

I
Rae 6-13470 Issued 10·02
 6019-15

STEP 31 STEP 33

R098C0194

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. Make sure that the assemblies are installed
side . Turn the planet gear around and install the in their original locations.
thrust ring . Install the remaining needle bearings
lubricated with petroleum jelly. NOTE: Three-gear planetary shown.
Models 210, 230 and 255 will have two rows of 29
bearings in each gear. STEP 34
Model 285 will have two rows of 33 bearings in each
gear.

STEP 32

T98002

Align the holes in the bearing shaft with the roll pin
hole in the planetary gear carrier.

Install the thrust washer on both sides of the planet

gear.

Rae 6·13470 Issued 10·02

 6019-16

STEP 35 STEP 36

T98001
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.
planet gear carrier.

STEP 37
Repeat the procedure for the other planet gears in
the remaining planetary assembly.

ae 6-13470
Issued 10-02
 6019-17

AXLE HOUSING ASSEMBLY

108194
1. RETAINING RING 8. AXLE HOUSING 15. SEAL
2. PLANETARY 9. BEARING CONE 16. OIL SEAL, IF EQUIPPED
ASSEMBLY
3. RETAINING RING 10. BEARING CUP 17 WEAR SLEEVE, IF EQUIPPED
4. THRUST RING 11 . O-RING 18' OIL SEAL, IF EQUIPPED
5. SHIMS 12. AXLE BUSHING 19: WEAR SLEEVE, IF EQUIPPED
6. BEARING CONE 13. AXLE WEAR INSERT
7. BEARING CUP 14. AXLE SHAFT

Rae 6-13470 Issued 10-02

I,
6019-18

STEP 38 STEP 40

T97967 T97968

Install the retaining ring in the groove of the sun gear

shaft.

4-lnch Axle

STEP 39
~--------------------,

I
115RING

Lubricate a new a-ring (1) with transmission fluid or

~ ~
petroleum jelly and install in the groove of the axle
bushing (2) .

I 4-lnch Heavy Duty Axle

i
399L7
STEP 41
Press the bushing (1) onto the axle shaft with 89000
N (20 000 Ib) force so that it is seated tightly on the
shoulder.

4BSHG

Press the axle bushing (1) onto the axle shaft with
222500 N (50,000 Ib) force so that it is seated tightly
on the sho ulder. Lub ricate a new a-ring (2) with
transmission fluid or petroleum jelly and install in the
groove chamfer of the axle bushing.

Issued 10-02
 6019-19

4.5-lnch Axle STEP 45

jI IJ
L ______.:::=:::::::=__ - ====::::::.. - 115BSHG
Put antiseize compound on the 00 of the inner
T97995

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.
bushing (2). Press the axle bushing with O-ring
installed on the axle shaft with 89000 N (20000 Ib)
force so that it is seated tightly on the shoulder. STEP_4
~6~ ___________________

STEP 43
I ?
I ~q?
q;::::~~ A:

'-----...:=-- - - - - - - - - - - -
1. RAM 3. AXLE HOUSING
J
37610

2. SPACER 4. AXLE SHAFT

Press the outer axle bearing on the axle shaft so it is
tig ht against the bushing. Install the axle shaft assembly as follows:
1. Install the axle shaft assembly in the axle
STEP 44 housing.
2. Apply a light coat of oil to the bearing cone 10
and position the bearing on the axle shaft.
3. Install the proper spacer over the inner bearing
cone.
4. Position a 30-ton ram over the spacer and install
an M20 threaded rod through the ram and into
the axle end.
5. Secure in position with a washer and nut.

"...
T9_
Put anti seize compound on the 00 of the outer
bearing cup. Use a driver to install the bearing cup in
the axle housing until the cup is seated.

Rae 6-13470 Issued 10-02

6019-20
4-lnch Standard Axle
STEP 47
- --. .:.
Press the inner bearing onto the axle shaft with about
93450 N (21000 Ib) force while oscillating and
rotating the axle until a rolling torque of 28 to 34 Nm
(250 to 300 Ib in) is obtained. The torque may be
checked with a torque wrench on the nut installed on
the threaded rod.
NOTE: It may be necessary to make calculations to
determine the force to use with your ram. See How
To Determine Ram Pressure on page 23.
c 6-13470
4-lnch Heavy Duty Axle
STEP 48
T_2
Press the inner bearing onto the axle shaft with about
282500 (50000 Ib) force while oscillating and rotating
the axle until the bearing preload stops rotation.
NOTE: It may be necessary to make calculations to
determine the force to use with your ram. See How
To Determine Ram Pressure on page 23.
4.S-lnch Axle
STEP 49
Press the inner bearing onto the axle shaft with about
111250 (25000 Ib) force while oscillating and rotating
the axle until a rolling torque of 33 to 47 Nm (290 to
420 Ib in) is obtained . The torque may be checked
with a torque wrench on the nut installed on the
threaded rod.
NOTE: It may be necessary to make calculations to
determine the force to use with your ram. See How
To Determine Ram Pressure on page 23.
Issued 10·02
 • 6019-21

For All Axles STEP 51

STEP 50
I

37510

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.
4. Select a shim pack whose total height when
combined with the thrust ring and retaining ring is
equal to the distance obtained in step 3.
5. Install the shim pack, thrust ring, and retaining
ring on the axle. Be sure the thickest shim is next 1. RAM 3. AXLE HOUSING
2. BRIDGE 4. AXLES
to the bearing .
6. Be sure the retaining ring is fully seated in the Install the pushing bridge and a 30-ton ram onto the
groove. axle assembly. Back press the 4-inch axle 75,650 N
(17,000 Ibs). Back press the 4.5-inch axle 97,900 N
(22,000 Ibs). Check to assure the snap ring is tight in
the groove and will not rotate.

NOTE: It may be necessary to make calculations to

determine the force to use with your ram. See How
To Determine Ram Pressure on page 23.

Rae 6-13470 Issued 10-02

6019-22 •

HOW TO DETERMINE RAM PRESSURE

STEP 52 STEP 53
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.

Example: Find the effective area of twin rams .

each ram having a piston diameter of 1.5 inch .

The formula for the effective area is:

Effective Area = (2d + 2d) x 0.7B54

Check the axle assembly roll ing torque. T he final
d = diameter of each ram (1 .5 inch) specifications should be as follows:

.2d = d x d or 1.5 x 1.5 = 2.25 sq in for each ram
Effective Area = (2 .25 + 2.25) x 0.7B54 = 3.534
sq in.
EXAMPLE: Find the press ure gauge reading for the
specified minimum and maximum Ib force using a
ram with 3.534 sq in effective area .
The formula for the pressure gauge reading is:
force in Ib
reading (psi) =
effective area
98. 114 inch (4-lnch Dia) Standard Axle
New Beari ngs ... 15.8 to 23.7 Nm (140 to 210 Ib in )
Used Bea rings .... .. 7.9 to 11 .9 Nm (70 to 105 Ib in )
98 & 120 Inch (4-lnch Dia) Heavy Duty Axles
New Bearings .... 1B.O to 2B.0 Nm (160 to 250 Ib in)
Used Bea rings .... .. 9.0 to 14.0 Nm (BO to 125 Ib in)
120, Inch (4-112-lnch Dia) Axle
New Bearings .... 22.6 to 38.4Nm (200 to 340 Ib in)
Used Bea rings .. 11.3 to 19.2 Nm (100 to 170 Ib in)

NOTE: The rolling torque can be adjusted by adding

17000lb or subtracting shims. Changing the shim pack
Pressure Gauge Reading = =4B10psi
3.534 thickness by 0.025 mm (0.001 inch) will change the
rolling torque approximately 2 .3 Nm (20 Ib in) for the
21000lb 4-inch axle and 2.8 Nm (25 Ib in) for the 4-112-inch
Pressure Gauge Reading = ~3T."'53"'4'--- = 5942 psi
axle. Repeat Steps 57 through 64 until the axle
rolling torque is within specifications.
22000lb •
Pressure Gauge Reading = ~3""."'53'T4"--- = 6225 psi

ac 6-13470 Issued 10-02

 • 6019-23

STEP 54 STEP 57

197975 198015

Put the planetary in place on the inner axle shaft

(three planetary gears shown).

STEP 55

2SOl7

4 Inch Axle

Install the planetary assembly retaining ring in the

groove on the axle shaft.

STEP 56

- -- ;
' ...
' 5SEAL

4-112 Inch Axle

Fill the inner two grooves of the axle seal
approximately half full with 251 H EP Lithiam grease
512LO
(1 ).
1. NYLON WEAR INSERT 1. AXLE END

Install a new nylon wear insert in the axle.

/
Rae 6-13470
6019-24

STEP 58 STEP 60

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. The edge of the seal must be flush with
the axle housing.
STEP 61
Repeat Steps 50 through 71 for the remaining axle if
being serviced.
IMPORTANT: Use flat bar (not shown) between
driver and seal to install seal flush with housing.

NOTE: Do not apply Loctite 515 to seal 00 on the 4-

112-inch ax/e.

STEP 59

1- - - - - - - - - - - - - - - - - c210l0
Remove any foreign material from the ring gear. Put
a bead of Loctite 515 gasket eliminator (1) on the
axle side of the ring gear.

Rae 6-13470 Issued 10-02

 6019-25

AXLE INSTALLATION

STEP 62 STEP 64

87513 67519

Use a brake aligning tool to align the teeth of the Remove the brake aligning tool from the brake discs.
brake discs.

STEP 65
STEP 63

92$5
87515 If removed, install the guide pins in the rear frame.
Install the sun gear shaft through the brake discs and Apply Loctite 515 gasket eliminator on the mounting
into the rear frame. surface in the rear frame.

NOTE : If equipped, make sure the locator button is

installed on the RH sun gear shaft. STEP 66

Use a lift strap and hoist to move the axle assembly

into position.

Rae 6-13470 Issued 10-02

6019-26

STEP 67 STEP 69

Use a suitable tool and rotate the axle until the sun Move the draft pin wiring tube bracket (1) and hitch
and planet gears engage. cylinder hose bracket (2) into position. Install the
remaining axle bolts.

STEP 68

Tighten the axle housing mounting bolts to a torque

of 232 to 262 Nm (171 to 193 Ib It).
Install a few axle housing mounting bolts and tighten
unti l the axle housing contacts the rear housing
flange. Remove the aligning dowels.

ac 6-13470 Issued 10-02

 6019-27

STEP 70 STEP 71
Remove the re ar housing handler from the tractor.

STEP 72
Fill the transmission with fluid. See the Operators
Manual for the correct fluid type. Run the tractor and
check the fluid level. Add as necessary.

Install the wheel and tire assemblies on the rear

axles.

Rae 6-13470 Issued 10·02

6019-28

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

6-13470 Issued 10-02

 6019-29

AXLE SEAL WEAR SLEEVE INSTALLATION (4- Inch Axle Only)

STEP 73 STEP 75

93528
Remove the old seal from the axle housing. Clean the axle bushing of any foreign material and
remove any sc ratches . Make sure that the axle
bearing is not contaminated.
STEP 74

STEP 76

Remove the old wear sleeve. if equipped. Check

wear sleeve dimensions. If a thick sleeve was
installed. a puller may be required to remove the Clean the 00 of the axle and the 10 of the new wear
sleeve. sleeve with Loctite safety solvent.

Rae 6-13470 Issued 10-02

6019-30

STEP 77 STEP 79

94526
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 ° to 204°C (375° to 400°F) .
STEP 78

A WARNING: Always wear heat protective

gloves to prevent burning your hands when
handling heated parts. SM121A

2. Install the sleeve onto the axle bushing with the

OD chamfer to the outside. The wear sleeve
must just touch or be no more t han 0.51 mm
(0.020 inch) away from the axle bearing.

NOTE: If the wear sleeve is driven onto the axle

bushing, make sure that the sleeve does not touch
and preload the axle bearing.
94514

Apply Loctite 609 to the OD of the axle bushing.

Rae 6-13470 Issued 10-02

 6019-31

STEP 80 STEP 81

T98015 9453<

Apply Loctite 515 gasket eliminator to the 00 of the

axle shaft.

STEP 82

'SOl'
Fill the inner two grooves of the axle seal
approximately half full with 251 H EP Lithiam grease
(1 ).
9553
Start the axle seal over the axle and into the axle
housing. The edge of the seal must be flush with the
axle housing.

IMPORTANT: Place a flat bar (not shown) between

the drive and seal to install the seal flush with the
axle housing.

Rae 6·13470 Issued 10-02

 6019-32

Rae 6-13470 Issued 10-02

 Section
6020

POWER TAKE OFF CONTROL SYSTEM

How it Works

CASE CORPORATION C 2002 Case Corporation

700 State Street Printed in U.S.A.
, Racine, WI 53404 U.S.A. Rae 6·12790 July, 2002
6020·2

TABLE OF CONTENTS
POWER TAKE OFF ................. ........................... .... ............................ ................................................................ .... 3

ELECTRONIC PTO CONTROL .. ..................................... ....................................................................................... 5

PTO SYSTEM CONTROL .............................................. ......................................................................................... 8

PTO CONTROL MODES ................... ..........................................................................................................••......... 9

PTO Valve Oil Supply ........ ..... .. ....... ....................... .......................... ................................. ........ ...... ... ................... 12
PTO Proportional Current Control Solenoid Cartridge Valve .......... ........ ................... •....................................... 12
PTO Clutch Disengaged ............ ..... .... ........... .... ...... ..... ........ ..... ....... .............. ............ ........................ .............. . 12

PTO/D IFFERENTIAL LOCK VALVE ....................... ... ....•............. ....... ........... ........... ............................................ 13

TROUBLESHOOTING ........ ......... ......................................................... .. ............... ........ ....... .. ..... .. ..... ... ........... .... 14

PTO ELECTRICAL CIRCUIT ...................................................................... .... ............................... .. .. .......... ......... 15

PTO Clutch Engaged .............. ..... ......... ...... .................. ........................................... .............................................. 16

TROUBLESHOOTING .......................................................................................................................................... 17

DUAL SPEED 540/1000 RPM PTO .................................................... .................... ............ ... .... ... .... ...... .............. 23
1 3/4 INCH 1000 RPM OUTPUT SHAFT ......................................... .....................................•............................ 23

1 3/8 Inch 540 RPM Output Shaft .... ........ ... ........... ...... .......... ........ ............ .................................................... ..... ... 24

SINGLE SPEED 1000 RPM PTO ....................... ............................... ...................... ............ ....... ........................ ... 25
1 3/4 Inch 1000 Rpm Output Shaft .................. ... ........................ ............................................................... .... .. .. 25

Rae 6· 12790 Issued 7-02

 6020-3

POWER TAKE OFF

General Description - The PTa system consists of the of the PTa control switch, engine RPM speed circuit, PTa
shaft speed circuit, dual speed sensor, PTa control valve, PTa clutch , PTa control module, arm rest control
module, and Instrument cluster unit, (through the Data Bus).

The PTa valve is mounted externally on top of the rear frame transmission housing. The control valve is supplied
with regulated circuit pressure from the priority regulator valve. This pressurized supply is directed to the PTa
clutch for engagement purposes. If the PTa is activated, the valve ports the pressurized supply to the PTa clutch.

The PTa control module is located under the SMV cover at the back of the cab. The PTa controller supplies
current to the PTa valve solenoid to activate the PTa clutch based on commands from the operator (PTa switch)
and signals supplied to it from the PTa shaft speed sensor during modulation and operation.

Diagnosing system faults is accomplished by reading appropriate faults codes through the tractor monitor display
or with the service tool. Refer to fault code section for a complete list of fault codes related to the PTa, MFD, and
Differential Lock system.
NOTE: In addition to the components listed above the transmission speed circuit, true ground speed sensor, brake
pedal switches, MFD switch , differential lock switch, and electronic hitch control module are used in the control of
the MFD and differential lock. These components are discussed later in this manual.

1. PTO/DIFF LOCK VALVE

2. PTO CLUTCH SOLENOID
3. DIFF LOCK CLUTCH SOLENOID

Rae 6-12790 Issued 7-02

6020-4

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 modu le,
and instrument control unit, (through the Data Bus).

PTO Control Sw it ch - This switch provides the operator interface with the PTO system . The PTO switch has a
yellow cover for easy identification. To activate the PTO, pull the switch rearward and lift at the same time. To stop
the PTO, move the top of the control switch rearward and down.

NOTE: PTa OFF operator commands (open circuit) are sent to the Arm Rest Control Module (PTO OFF switch is
hard wired to the Arm Rest Control Module), then relayed to the PTa controller via the Data Bus.

PTO ON operator commands (B+, contact closed) are sent to the PTO controller directly (PTO ON switch is hard
wired to the PTO Control Module).

If both switch contact signals are present at the same time the PTO control module deactivates the PTO valve and
declares a sW.itch circuit fault.

Engine RPM Speed Circuit - Engine RPM is used by the PTO controller as a source of information to control
clutch engagement and modulation (clutch engagement rate) and to monitor clutch slip percentage. This allows
smooth engagement , and stops PTO operation if the clutch slips at an excessive rate . The engine RPM is
calculated by the PTO controller using a signal from the alternator (W terminal).

PTO Shaft Speed Circuit - PTO shaft speed is used in conjunction with engine RPM by the PTO controller to
control clutch modulation (clutch engagement rate) and to monitor clutch slip percentage. This allows smooth
engagement and stops PTO operation if the clutch slips at an excessive rate. The PTO shaft speed is calculated by
the PTO controller from a sensor signal located in the top cover of the rear frame transmission housing.

Dual Speed Sensor - If the tractor is equipped with a dual speed PTO, the dual speed sensor is used by the PTO
controller to determine the PTO shaft speed. This sensor is located on the PTO output shaft bearing support of
dual speed PTO units.

PTO Control Valve - The PTO/differential lock control valve directs regulated supply circuit oil to/from the PTO
cl utch, based on operator commands and information gathered by the PTO controller. This valve also controls the
amount of lubrication oil which is directed to the PTO clutch. Increased lubrication oil is supplied to the PTO clutch
whenever the clutch is engaging or totally engaged .

PTO Clutch - The PTO clutch is a hydraulically actuated multiple disc wet clutch located at the back of the rear
frame transmission housing. Access to the PTO clutch can be gained by removing the hitch upper link mounting
plate. When the PTO switch is activated hydraulic pressure is applied to the PTO clutch piston from the control
valve. Thi s pressure locks the discs together. The PTO clutch has the necessary capacity and lubrication to
provide for modulated engagements of typical PTO powered implements.

Rae 6-'2790 Issued 7-02

 6020-5

@
5t!t
~ F<I t~
~
.,~\~
~

•
_.
0

~
@ F<I .~ f!J~

5_
--
- ~

G
©
0
.&

AT97MOO5
1. PTO CONTROL SWITCH

Rac 6·12790 Issued 7-02

 =
6020-6

PTO Control Module - The PTa 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. The PTa controller communicates with other control
units via the Data Bus to monitor PTO clutch slip, and control modulation .

The control module incorporates a green status light which is visible to the technician. The status light flashes at a
rate of 1 cycle per second to indicate the module is operating correctly.

PTO System Fault Codes - PTO system fault codes are stored in the non-volatile memory (memory is maintained
even if the battery is disconnected) of the PTa control module for various control system faults. The engine hours
at which the fault occurred is available though the Electronic Service Tool (EST) and stored with the associated
code. A maximum of ten (10) fault codes can be stored in each controller at any time and may be retrieved in
sequence with the last code stored as the first code retrieved . PTO control system codes are displayed on the
tractor instrumentation. Refer to fault code section of this manual for complete listing of PTO fault codes.

Arm Rest Control Module - MFD and differential lock operator commands are sent to the arm rest control module
then relayed to the PTO controller via the Data Bus. The arm rest controller provides control switch position
information to the PTO controller for these functions. The PTO OFF signal is also provided to the PTO controller
from the arm rest control module. The PTO ON operator command signal is hard wired directly to the PTO
controller.

Instrument Control Unit (Tractor Monitor) PTO control system information is sent to the tractor monitor and
relayed to the PTO controller. Operator, diagnostic and programming information are communicated between the
PTa controller and the tractor instrumentation by way of the Data Bus. The tractor monitor displays lighted icons
and messages to notify the operator what PTO systems are activated.

Operational Modes - The PTO control system operates in one of four (4) modes based on operator commands
and the signals received from the other tractor systems.

Fill Mode
Modulation Mode
Ramp Mode
ON

In addition to the sequential electrical modes of operation listed above, the PTO control module conducts a
hardware reset and built in test (BIT), and transmits PTO controller status and data on the Data Bus within a
specific time frame to insure proper operation after start up.

Rae 6-12790 Issued 7·02

 6020-7

PTO SYSTEM CONTROL

ENGINE
SPEED

I
~
PTO CONTROL MODULE ENGINE
KEY
, SWITCH ALTERNATOR

ENGINE
-
SPEED
fW

~" I~~F ~
IWITCH

OFF/ON OFF/ OFF

a WIT aWIT
. !:]'
ON
PTO -
ON j CONTROL

TRANSMISSION
ARMREST
A. -" CONTROL
~ ~
MODULE
PTO
CLUTCH
VALVE - PTO
CLUTCH

PTO SHAFT
SPEED SENSOR
I
INST.
CONTROL
~
PTO SHAFT
MODULE
SIZE SINSOR

D
A PTOSHAFT~
T
A .ICAN
ITRANSCEIVER MICRO
CONTROLLER
I '--~ "'PlEMENT
B BRAKE
U LIGHTS
S

BRAKE TRACTOR
LIGHT BRAKE
RELAY LIGHTS

LH BRAKE RANGE TRANSMISSION HOUSING

PEDAL
SWITCH
MFD MFD
MFD/DIFF LOCK VALVE CLUTCH
CONTROL

RH BRAKE
PEDAL
SWITCH REAR FRAME HOUSING

~tFLOCK
ALVE - DIFFLOO
CLUTCH

~
CLEAN GROUND

Rae 6-12790 Issued 7-02

 6020-8
PTO CONTROL MODES
FF - When the PTO switch is placed in the OFF position, the PTa clutch will be deactivated. The PTa switch OFF signal i~
rected to the armrest controller and communicated to the PTa control module through the Data Bus.

OTE: PTa switch aN signal is directed to the PTa control module directly (hard wired to PTa controller).

II Mode - The PTO switch ON signal is hard wired to the PTa controller. When the PTa switch is place in the ON position
e PTa will begin the FILL mode of operation. The fill mode of operation is the length of time the PTa circuit is activated,
t there is no shaft speed . When shaft clutch shaft speed is detected the PTa enters the modulation mode of operation.

dulation Mode - As the PTa shaft begins to rotate the PTa is placed in the Modulation mode of operation . During the
dulation mode amperage to the PTa valve coil is increased gradually to control the slip rate of the PTa output shafl.
rrent supplied to the PTa proportional current control solenoid is increased until the PTO clutch is filled.

pmp Mode - Ramp mode begins at the completion of the modulation mode. The PTa controller increases the current
J pplied to the PTa proportional control solenoid at a constant rate until target coil current is reached. Target coil current will
~ large enough to saturate the solenoid coil. At the end of the ramp mode the control module activates PTa excessive slip
tection.

L ck Up - PTa lock up occurs when the PTa clutch slips 2% or less for a period of 100 milliseconds.

OTE: If the PTa does not lock up within a period of 6 seconds from the time of activation, the control module will shut off
a rrent supply to the PTa proportional current control solenoid output and flash the PTa output lamp. An excessive slip fault
c~de will be stored in the controller memory. The operator may try to re-initiate the sequence by turning the PTa switch from
to aFF to aN again.

PTa SOLENOID
COIL CURRENT

- 1.2 AMP

Ii TO SPEED
DETECTED
I IPTO CLUTCH
LOCK·UP
I

o FULL MODE MODULATION MODE RAMP MODE

• • • • • •

AI98G 150

ac 6- 12790 Issued 7-02

 6020-9

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. Slip is greater than 3% for 100 milliseconds continuously and then increases to more than 15% for 10
milliseconds continuously.

If the control module detects excessive slip, it will shut off current supply to the PTO proportional current control
solenoid output and flash the PTO output lamp. An excessive slip fault code will be stored in the controller memory.
The operator may try to re-initiate the sequence by turning the PTO switch from ON to OFF to ON again.

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

Rae 6-12790 Issued 7-02

6020-10

ENGINE
SPEED

ISWITCH
~
PTO CONTROL MODULE ENGINE
KEY
ALTERNATOR

ENGINE
SPEED
W

~'F 'ro
- , SWITCH swrr~ON
SWITCH

OFF/ON OFF/ OFF

ON j
PTO
CONTROL
-
A

v
~

......
ARMREST
CONTROL
MODULE
TRANSMISSION

PTO
I
CLUTCH f-- PTO
VALVE CLUTCH

PTO SHAFT
SPEED SENSOR
INST.
CONTROL
MODULE PTO SHAFT
SIZE S'[NSOR

D
A PTOSHAFT_
T
A ICAN
• ITRANSCEIVER MICRO II '-- t./IPLEMENT
CONTROLLER
B
U
r--- LIGHTS
BRAKE
S

BRAKE TRACTOR
LIGHT BRAKE
RELAY LIGHTS

LH BRAKE RANGE TRANSMISSION HOUSING

PEDAL
SWITCH
MFD MFD
MFD/DIFF LOCK VALVE CLUTCH
CONTROL

RH BRAKE
PEDAL
SWITCH REAR FRAME HOUSING

~~FF LOCI
ALVE - DIFF LOCI
CLUTCH

Jl.
CLEAN GROUND

RI01J013

ae 6-12790 Issued 7-02

 6020-11

PTO Valve Oil Supply

The PTa/differential lock valve is a closed center valve supplying regulated circuit pressure to the PTa and
differential lock control circuits. Regulated circui t oil is supplied to the PTa valve through the priority/regulator
valve. Pressure is regulated to approximately 335 to 345 PSI and can be adjusted if required.

PTO Proportional Current Control Solenoid Cartridge Valve

The PTa solenoid is controlled by an arm rest mounted switch. The switch communicates directly with the PTa
controller (PTa switch is hard wire to PTa controller) to supply current to the PTa solenoid cartridge valve. The
valve supplies regulated pressure to the PTa clutch based on commands from the operator (PTa switch) and
signals supplied to it from the engine RPM circuit, PTa shaft speed sensor, and dual shaft speed sensor. The PTa
clutch is applied with hydraulic pressure.

PTO Clutch Disengaged

When the PTa switch is moved to the disengaged position, the PTa solenoid cartridge valve is de-energized and
is shifted to a neutral position. This blocks the regulated supply to the top of the modulation piston and drains this
area to tank. Regulated supply is also lost at the bottom of the modulator spool. The outer modulator spring pushes
the modulator piston back up against the plug as the inner modulator spool lifts the modulator spool.

Rae 6-12790 Issued 7-02

 6020-12

PTa/DIFFERENTIAL LOCK VALVE

12 7 12

13
RT98A023 Rl02B035 AN D 6036

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 .MESH LUBE
5. TANK 12. PTO PROPORTIONAL CURRENT
CONTROL SOLENOID
6. PTO CLUTCH SUPPLY 13. DIFF LOCK SOLENOID
7. BLOCKED PASSAGE

Rae 6·12790 Issued 7-02

 6020-13

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. II the PTO icon is not displayed, this is an indication the electrical control circuit is functioning correctly. Go
to step 4.
B. If the PTO icon is displayed, this indicates a problem in the PTO electrical control circuit. Check fault
codes, controller, and data bus function.
3. Place the PTO switch in the OFF position. Check for voltage at PTO valve coil.
A. If voltage is not found, the electrical circuit is functioning properly.
B. If voltage is found, troubleshoot the PTO electrical circuit.
1.Check wires 597 A (LU) and 598A (BK) ground.
2.Check all connections for excessive resistance

Place the PTO switch in the ON position. Check for voltage at the PTO valve coil.
C. If voltage is found, the electrical circuit is functioning properly.
D. If voltage is not found, troubleshoot the PTO electrical circuit.
1.Check wires 597 A (LU) and 598A (BK) ground.
2.Check all connections for excessive resistance.
4. Install a 500 PSI gauge with hose into the PTO pressure test port. Use a 19mm socket to remove the plug.
Install diagnostic fitting from fitting kit 380040106. With PTO OFF pressure should be 0 PSI.
A. PTO solenoid cartridge valve may be sticking in the engaged position. Check PTO solenoid cartridge for
proper operation.
B. PTO modulation spool may be sticking in the engaged position. Remove PTO modulation spool , clean
and reinstall.
5. Check and repair the PTO clutch as needed.

NOTE: See the electrical schematic foldout at the rear of this section.

r- CL - -.f 'r - - - - - -o"'- ll - - - - - --

, , I .
\ j : I

I
- - :;l

1. PTO CLUTCH PRESSURE PORT ·2. PTO LUBE PRESSURE PORT

Rae 6·12790 Issued 7·02

6020-14

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). As the piston moves down the center
stem of the piston moves into the bore of the modulator spool (5) . The piston assembly does not directly shift the
modulator spool. The inner modulator spring force begins to shift the modulator spool. As the modulator spool first
begins to move, the metered lubrication oil supply to the PTO clutch is increased to prevent clutch wear as the
clutch is gradually engaged.
As the modulator spool shifts down it simultaneously blocks the PTO clutch return and begins increasing the clutch
supply pressure. The pressure available to the PTO clutch is also ported through a cross drilled and end drilled
holes to the bottom of the modulator spool. The balance between the increasing inner modulator spring force
against the increasing clutch pressure causes the pressure to gradually increase.
The engagement time for the PTO can range from approximately 2-6 seconds and is completely controlled by the
PTO controller based on monitored conditions (load, engine RPM , PTO shaft RPM).

AT9BH067 AT98A024

MODULATION MODE PTO CLUTCH LOCK UP

1. PTO SOLENOID 6. VALVE INLET/SUPPLY PASSAGE

2. MODULATOR PISTON 7. PTO CLUTCH OUTLET PORT
3. PRELOAD SPRING (OUTER) 8. LUBE SUPPLY
4. MODULATION SPRING 9. LUBE OUTLET
5. MODULATOR SPOOL

Rae 6-1 2790 Issued 7·02

 6020-15

TROUBLESHOOTING
Problem - PTO will not engage
1. Check for PTa faull codes.
A. If fault codes are found, follow procedures outlined in PTa fault code troubleshooting in this section.
2. Place the PTa switch in the ON position. Check tractor monitor for PTa icon in the instrumentation display.
A. If the PTa icon is displayed, this is an indication the electrical control circuit is functioning correctly. Go to
Step 4.
B. If the PTa icon is not displayed, this indicates a problem in the PTa electrical control circuit. Check fault
codes, controller, and data bus function.
3. Place the PTa switch in the ON position. Check for voltage at the PTa valve coil.
A. If voltage is found, the electrical circuit is functioning properly.
B. If voltage is not found , troubleshoot the PTa electrical circuit.
1.Check wires 597 A (LU) and 598A (BK) ground.
2.Check all connections for excessive resistance
3.Check solenoid coil for improper installation (loose etc.) .

Place the PTa switch in the OFF position. Check for voltage at PTa valve coil.
C. If voltage is not found, the electrical circuit is functioning properly.
D. If voltage is found , troubleshoot the PTa electrical circuit.
1.. Check wires 597 A (LU) and 598A (BK) ground.
2. Check all connections for excessive resistance.
3 . . Install a 500 PSI gauge with hose into the PTa pressure test port. Use a 19mm socket to remove the plug.
Install diagnostic fitting from fitting kit 380040106. Place the PTa switch in the ON position.The pressure
should read approximately 290 PSI (20 bar).
A. PTa solenoid cartridge valve may be sticking in the disengaged position. Check PTa solenoid cartridge
for proper operation.
B. PTa modulation spool may be sticking in the disengaged position . Remove PTa modulation spool, clean
and reinstall.
5. Check and repair the PTa clutch as needed.

I
r_Cl_--~ \----- __ 9..,..
, , ,
k---) <

L _~ -' \ol n.:; I

"IL =..J,

1. PTa CLUTCH PRESSURE PORT 2. PTa LUBE PRESSURE PORT

Rae 6·12790 Issued 7-02

! '
6020-16

PTO CLUTCH
PISTON

L DIFFERENTIAL
LOCK PISTON

r
PTO
CLUTCH
LUBE r--4-----------------

..-- -- - --- -- - -- - - -- - - - - -

( I.
IPTO
:SOLENOID
I ;::::;;::::1"
DI~F LOCK
I SOtENOID
I
l - ------
J

BEVEL
PIN
REGULATED LUBE
SUPPLY

RH02A059

ac 6-12790 Issued 7-02

 6020-17

Problem PTO engages too rapidly

1. Check for PTa fault codes.
A . If fault codes are found , follow procedures outlined in PTa fault code troubleshooting in this section .

B. If no fault codes are found, go to step 2.

2 . PTa clutch not filling and modulating properly.
A. Solenoid cartridge valve spool opening too fa r.
1. Replace solenoid cartridge.
B. PTa spool assembly sticking, or damaged.
I .Replace PTa spool.
C. PTa clutch plates damaged.
1. Repair PTa clutch .
D. PTa clutch piston hanging or damaged.
1. Repair PTa clutch .

Rae 6· 12790 Issued 7-02

6020-18

Problem PTO engages then stops

1. Check for PTa faults codes.
A. If fault codes are found, follow procedures outlined in PTa fault code troubleshooting in this section.
B. If no fault codes are found, go to step 3.
2. PTa clutch slipping excessively.
A. Load on PTa too heavy.
B. Reduce load
3. PTa clutch pressure too low.
A. PTa solenoid not energizing properly.
1. Check wires 597A (LU) and 598A (BK) ground for excessive resistance.
2. Check for loose connections.
3. Solenoid partial short. Check solenoid coil resistance.
4. Controller current supply is weak. Internal controller failure.
S. Clutch hydraulic circuit leaking. Check regulated pressure circuit.
1. Inspect PTa solenoid cartridge valve seals.
2. Inspect PTa clutch for leaking seals.
3. Internal tube supply leaking.
4. Engine speed signal too high.
A. Check wire 2160 (Y) .
B. Check connections.

5. PTa shaft speed signal too low.

A. Check sensor resistance.
B. Check sensor wires 295A (Y) and 174E (BK) single speed and 294A, 294B(W) and 174C and 0 for dual
speed.
C. Check connections.

NOTE: See the electrical schematic foldout at the rear of this section.

Rae 6- 12790 Issued 7-02

 6020-19

PTO CLUTCH
PISTON

'- DIFFERENTIAL
LOCK PISTON

r
PTO
CLUTCH
LUBE r--+----------~-----

-------- -- ---- -- --------

r
IPTO
:SOLENOID
I DIFF LOCK
SOLENOID

BEVEL
PIN
REGULATED LUBE
SUPPLY

. RH02 A059

Rae 6-12790 Issued 7-02

j
6020-20

DUAL SPEED 540/1000 RPM PTO

1 3/4 INCH 1000 RPM OUTPUT SHAFT

o
o

RH98H054
1. OUTPUT REDUCTION GEAR 34124 T 8. SPEED SENSOR
2. DUAL SPEED SENSOR 9. PTO CLUTCH PISTON
3. OUTPUT SHAFT 10. INPUT SHAFT
4. OUTPUT DRIVEN GEAR 38T 11 . PTO DRIVEN GEAR 125T
5. PTO CLUTCH ASSEMBLY 12. OUTPUT DRIVE GEAR 29T
6. PTO BRAKE FRICTION PLATE 13. SPEED CHANGE PIN
7. PTO DRIVE GEAR 57T

Rae 6· 12790 Issued 7·02

 6020-21

1 3/8 Inch 540 RPM Output Shaft

SEE LEGEND ON
PREVIOUS PAGE

AH98H05'

1 3/8 Inch 1000 RPM Output Shaft

SEE LEGEND ON
PREVIOUS PAGE

RH98H052

Rae 6·12790 Issued 7·02,

6020-22

SINGLE SPEED 1000 RPM PTO

1 3/4 Inch 1000 Wpm Output Shaft

o
o
o

RH98H053
1. OUTPUT SHAFT 5. PTO DRIVE GEAR 57T
2. PTO CLUTCH PISTON 6. INPUT SHAFT
3. PTO CLUTCH ASSEMBLY 7. PTO DRIVEN GEAR 125T
4. PTO BRAKE FRICTION PLATE

Issued 7·02
 6020-23

SINGLE SPEED INTERCHANGEBLE SHAFT 1000 RPM PTO

1 3/4 INCH 1000 RPM OUTPUT SHAFT

AI02B020

1. OUTPUT SHAFT 5. PTO DRIVE GEAR 57T

2. PTO CLUTCH PISTON 6. INPUT SHAFT
3. PTO CLUTCH ASSEMBLY 7. PTO DRIVEN GEAR 125T
4. PTO BRAKE FRICTION PLATE 8. SHAFT SUPPORT HOUSING ASSEMBLY

Rae 6·12790 Issued 7-02

6020-24

1 3/8 Inch 1000 RPM Output Shaft

SEE LEGEND ON
PREVIOUS PAGE

Ai02BOtB

ac 6·12790 Issued 7·02

 Section
6022

MFD PLANETARY HUB, STEERING KNUCKLE,

AND AXLE DRIVE SHAFT

CASE CORPORATION
Cl 2002 Case COrporation
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-13990 Oclober, 2002
6022-2

TABLE OF CONTENTS
SPECIFICATIONS ......................... _................................................................................... .................... .................. 3

SPECIAL TORQUES .. ...... ...... ........... .......... .................................................... ....................... .................. .. ............. 3
•
SPECIAL TOOLS .......... ..... .. ......... ........ ........ .................. ............ ................................................ ............................ 3

PLANETARY HUB DISASSEMBLY ................. ................................................................................. ... .. ..... .. .......... 4

STEERING KN UCKLE AND KINGPIN DISASSEMBLY ........ .......................... ................ ................. ...................... 9

AXLE DRIVE SHAFT DISASSEMBLY .. ... ......... .................................................................. .............. ....... ... .... ..... . 13

AXLE SHAFT ASSEMBLY ............................................. ................. ...................................................................... 14

KINGPIN ASSEMBLY ...... ... ........... .................................................. ............................. ........... ...... ................ ....... 16

STEERING KNUCKLE ASSEMBLY ................. ........................... ..... ... .. ........ ....... ...... ....... ................ ... .... ........ ..... 19

PLANETARY HUB ASSEMBLY .............................................................. ........... ........... ...... ................... ............... 23

Issued 10-02
 6022-3

SPECIFICATIONS
MFD Differenlial Oil Capacily (10 Boll)_ ........... .. .......... ................. ................................... 12.3 Liters (13 U.S. Quarts)
MFD 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 with Limited Slip Additive B91246
Planetary Hub Oil Capacity (10 Bolt) ..................................................................... .............. 1.3 Liters (2.8 U.S. Pints)
Planetary Hub Oil Capacity (12 Bolt) .................. __ ............................ ....... .... ........ .. ............ .. 3.2 Liters (6.8 U.S. Pints)
Planetary Hub Oil Type ............ .............. ........ .. ..... ............................. Case 135 H EP Gear Lubricant, SAE 85W-140

SPECIAL TORQUES
Planetary Ring Gear Retaining Plate Boll... ....... .. ... .. ... .. ..... ....... ..... .. .. ......... .. ... .. 110 to 125 Nm (82 to 92 Ib It)
Planetary Hub Cover Boll.. ........ ..... .. ............ .. ................_....................... .... ........ ..... .. ..... .. .. 10 to 16 Nm (8 to 12 Ib It)
King Pin Bearing Cap Boll... .. ... ... ............................................. ... ........ ................... .. 156 to 170 Nm (115 to 125 Ib tt)
Steering Cylinder Socket End Clamp Nut... .................... __ ................. .. ........................... 95 to 108 Nm (70 to 80 Ib tt)
Steering Cylinder Tapered Socket Stud Nut .................... ___ ......................... .............. ..................... 272 Nm (200 Ib tt)
Drain/Fill Plugs ................ ............................ ..................... .... .................... ............ ......... .. .. 38 to 41 Nm (28 to 30 Ib tt)
Tie Rod Tapered Socket Stud Nut ............................ ............................. .... ...................... ... ............ 372 Nm (275 Ib tt)
Tie Rod Tube Nut.. .................................................................................................... 374 to 442 Nm (276 to 326 Ib tt)
Rolling Torque of Kingpin Bearings .......... .... .... .. ... _.. .... .... ...................................... 34 to 74 Nm (25 to 55 Ib ft)
Rolling Torque of Planetary Hub Bearings .. ........ ........ .. ........ .. ........ ..... ............ 8 to 12.5 Nm (70 to 110 Ib inch)

SPECIAL TOOLS
CAS2599 Hub Bearing Cup Installer (12 Bolt Hub, Only)
CAS1716-3, or CNH299077 , or FNH00072 Handle
380000104 Cassette Seal Installer (12 Bolt Hub, Only)
CAS2597 Kingpin Seal Install er
CAS1768, orFNH00413 Hub Roll ing Torque Adapter (10 Bolt Hub)
CAS2595 Hub Rolling Torque Adapter (12 Bolt Hub)
380000805 Retaining Ring Offset Pliers

Rae 6-13990 Issued 10-02

6022-4
PLANETARY HUB DISASSEMBLY
STEP 1
Park the tractor on a hard , level surface. Put the
transmission shift lever in PARK. Turn the engine off
and remove the key. Place blocks in front of and
behind the rear wheels. Remove the front fenders
from the front axle, if equipped.
STEP 2
Raise the front axle. Install axle stands. Remove the
front tires.
WARNING: The tires on this tractor are very
~ heavy. Use a wheel remover or chain hoists
Lll to remove and install the tires. Use additional
help as required. SM188A
ac 6-13990
STEP 3
Allow the axle to cool before servicing. Slowly open
the axle fill plug to release any internal axle pressure.
Remove the axle drain plug (1). Drain the axle oil into
a suitable, clean container.
STEP 4
Before draining the oil from the planetary hub ,
position the hub cover so the planetary hub drain/lill
plug (1) is at the highest position. Make sure the axle
fill plug has been loosened to release any internal
axle pressure . Loosen the planetary hub plug and
rotate the hub cover so the plug is at the lowest
position. Remove the planetary hub fill plug and drain
the oil into a suitable container.
Issued 10-02

STEP 5
Properly support the planetary hub cover. Remove
the three (3) Allen head bolts. Separate and remove
the hub cover from the planetary hub.
STEP 6
Remove the retaining rings that secure the planetary
gear pins to the planetary hub cover.
STEP 7
Remove the planetary gear pins by threading a
suitable bolt into the pin and prying up on the bolt
head.
Rae 6-13990
6022-5
STEP 8
Remove the thrust washers from the top of the
planetary gear.
STEP 9
Remove the planetary gear through the center
opening of the gear plate. Remove the upper level of
needle bearings in the planetary gear. Remove the
spacer and the lower level of needle bearings.
Inspect all components for damage or wear.
STEP 10
Remove the lower thrust washers and inspect for
damage or wear.
Issued 10-02
6022-6

STEP 11 STEP 13

Remove the eight retaining plate bolts.

STEP 14

Swivel the steering knuckle to gain access to the

planetary gear shaft. Use 380000805 Retaining Ring
Offset Pliers to remove the snap ring (1). Remove
Remove the retaining plate and shims. Slide the
the washer (2) from the planetary gear shaft.
planetary gear assembly off the splines of the
NOTE: Axle shaft removed for photographic steering knuckle. The outer planetary hub bearing
purpose. will be removed with the planetary gear hub.

STEP 12 NOTE: Twelve bolt planetary hub assembly shown.

, Remove the thrust washer used on the ten bolt
planetary hub assembly, after the removal of the
shims.

two prybars at the steering knuckle to remove

planetary gear shaft from the yoke retaining ring.

Remove the thrust washer on the planetary

shaft for tractors equipped with ten bolt hubs.

Issued 10-02
 6022-7

STEP 15 STEP 18
:---=-;

Remove the planetary hub. Use a driver to remove the inner planetary hub
bearing cup.
NOTE: The hub seal may separate into two pieces
during removal.
STEP 19

STEP 16

Use a driver to remove the outer planetary hub

bearing cup.
Remove the oil seal and the inner planetary hub
bearing cone from the planetary hub.

STEP 17

Remove damaged wheel studs as needed.

Rae 6-13990 Issued 10-02

6022-8

STEP 20 STEP 21

Mark the position of the planetary gear hub (1) in the
planetary ring gear (2). Remove the wire retaining
ring (3) and remove the gear hub.
Place the planetary gear hub in a press . Use the
proper step plate adapter to remove the oute r
planetary hub bearing from the planetary gear hub.
Repeat the preceding procedure for the opposite
planetary hub, if necessary.

Rae 6-13990 Issued 10-02

 6022-9

STEERING KNUCKLE AN D KINGPIN DISASSEMBLY

STEP 22 STEP 25

AR98Kl 05

Place an identifying mark on the wheel stop before Remove the cotter pin from the lower end of the
removing the clevis locking pin. Remove the clevis steering cylinder clevis pin at the axle housing .
retaining pin (1), the clevis locking pin (2), and the Remove the clevis pin. Remove and discard the
wheel stop (3). clevis pin bushing O-rings.

STEP 23
STEP 26

Remove the cotter pin from the slotted nut on the

steering cylinder socket end. With the slotted nut in place on the steering cylinder
socket end, unseat the steering cylinder socket end
STEP 24 from the steering knuckle , using a soft metal
hammer. Remove the slotted nut and remove the
cylinder. Remove the opposite steering cylinder
using the same procedure, if necessary.

Loosen, do not remove, the steering cylinder socket

end nut.

Rae 6·13990 Issued 10-02

6022-10

STEP 27 STEP 30

Remove the cotter pin from the tie rod socket end
slotted nut. Loosen the slotted nut. Unseat the tie rod Remove the upper king pin bearing cap (1) and the
socket end from the steering knuckle, using a soft shims (2) .
metal hammer. Remove the slotted nut and the tie
rod end. Remove the opposite tie rod end using the
same procedure, if necessary.
STEP 31
-----.~
STEP 28

Install lifting eyes and properly support the steering

knuckle. Remove the lower king pin bearing cap and
shims.
Properly support the steering knuckle to retain the
position of the upper king pin bearing cap, when it is
removed.

STEP 29

Remove the planetary gear shaft oil seal from the

steering knuck le. Press the planetary gear shaft
bushing from the steering knuckle, if replacement is
Remove the three upper king pin bearing cap bolts.
necessary.

Rae 6·1 3990 Issued 10-02

 6022-11

STEP 33 STEP...;.,
36;....."....-=_
- -...,....

Remove the axle drive shaft.

Use a suitable puller (1), or a blind hole puller, to

remove the upper king pin bearing outer ring (2) from
the axle housing.
Remove the upper axle kingpin seal.
If the outer ring cannot be removed with the blind
hole puller, pierce the grease retainer and drive the
STEP 35 outer ring out with a punch (3) . A new grease retainer
plate will be required for assembly. Use the same
procedure for the removal of the lower king pin
bearing outer ring.

NOTE: Piercing the lower grease retainer and using

an extension and socket to remove the outer ring,
may be required.

RR99K248

Use a puller (1) with a bearing puller (2) to remove

the inner ring (3) from the upper king pin bearing cap,
if necessary. Use care not to damage the grease
seal area on the king pin bearing cap.

Issued 10-02
Rae 6-13990
 6022-12

STEP 37 STEP 38

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 . Use a suitable puller to remove the bushing ,
if necessary.

STEP 39
Repea t the removal p rocedure for the steering
knuckle and kingpins on the opposite side of the
MFD axle, if necessary.

I Rae 6-13990 Issued 10-02

 6022-13

AXLE DRIVE SHAFT DISASSEMBLY

STEP 40 STEP 43

AD02J015

Remove the universal joint retaining rings from the
centering yoke on front axle drive shaft.
STEP 41
Place the axle shaft in a press . Press the other
universal cap from the yoke and remove the outer
axle drive shaft yoke from the centering yoke. Repeat
the preceding procedure to remove the remaining
universal joint and the inner drive shaft yoke, from
the centering yoke. Remove and disassemble the
opposite MFD drive shaft, if necessary.
STEP 44

Place the axle shaft in a press. Apply pressure to the

upper universal joint cap until the opposite universal
joint cap is out of, or nearly out of, the yoke. RA98Kon

STEP 42
...--.....,.....,..........

RR98K07B

ROO2J016 Remove and discard the outer drive shaft yoke seal
. Place the universal joint cap in a vise. Use a lever to . (I ), the inner yoke seal, and the retaining ring (2) .
remove the cap from the yoke.
Rae 6· 13990 Issued 10-02

!.!
 6022-14

AXLE SHAFT ASSEMBLY

1. AXLE SHAFT BUSHING RIOZH044

6. UNIVERSAL JOINT RETAINING RING
2. AXLE SHAFT INNER OIL SEAL 7. YOKE
3. AXLE SHAFT OUTER OIL SEAL 8. DRIVE SHAFT YOKE INNER SEAL
4. AXLE SHAFT
9. DRIVE SHAFT YOKE RETAINING RING
5. UNIVERSAL JOINT
10. DRIVE SHAFT YOKE OUTER SEAL

ac 6·13990
Issued 10-02
, 6022-15

STEP 45 STEP 47

Install a new retaining ring into the drive shaft yoke. Install new universal joints by reversing the
disassembly procedure. Use a press to seat the
universal bearing caps into the axle shaft yokes and
STEP 46 the centering yoke.

STEP 48

Use a press and seal installers to install a new inner

and outer yoke seal. Install the yoke seals with the lip
of the seal facing away from the yoke. ROO2J015

Press the universal joint cap below the retaining ring

groove and install the retaining ring. Repeat this
procedure for each universal joint cap.

STEP 49
Repeat the assembly procedure for the opposite
MFD axle drive shaft, if removed .

Rae 6·13990 Issued 10-02

 6022-16

KINGPIN ASSEMBLY

R!99MOO7
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. GREASE RETAINING PLATE B. LOWER KING PIN GREASE SEAL

STEP 50 STEP 51

Use seal installers to install new inner and outer axle

"lJLI~III1IU.
if necessary. The bushing counterbore shaft oil seals.
outward. Install the bushing until it bottoms in
axle housing. NOTE: The outer oil seal is installed flush with the
axle housing.

Issued 10-02
 6022-17
STEP 52 STEP 55

'..
AR99K2S, RR99K252

Apply Loctite ® 515 to the bottom face of axle Use a bearing installer to install the king pin outer
housing bore, Install the grease retaining plate so ring into the axle housing.
that the grease cavity is below the bore.

STEP 56
STEP 53

Make sure the outer ring is fully seated in the

Place the kingpin bearing cap in a press and install a hou sing. App ly a layer of grease to the bearing
new inner ring . Use a flat plate to evenly start the surface.
inner ring on the kingpin bearing cap.

STEP 57
STEP 54

RR99K256

Lubricate the inner diameter of a new king pin seal

with grease. Position the new king pin oil seal in the
Complete the seating of the inner ring on the king pin
axle housing.
bearing cap by using the outer ring as the installer.

Rae 6-13990 Issued 10-02

! J
6022-18

STEP 58 STEP 59
--."...

Use CAS1716-3 Handle and CAS2597 Kingpin Seal
Installer to install the seal.
Install the MFD axle drive shaft into the axle housing .
Make sure the axle shaft splines engage the
differential side gears. Use care so as not to damage
the axle shaft seals . Repeat the kingpin assembly
procedure on the opposite side of the MFD axle, if
necessary.

ac 6-13990 Issued 10-02

 6022-19

STEERING KNUCKLE ASSEMBLY

CR.

Rt99M006
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. STEERING KNUCKLE
4. COTTER PIN 9. TIE ROD SOCKET END 14. LOWER KINGPIN BEARING CAP
5. STEERING CYLINDER 10. WASHER 15. TIE ROD SEAL

STEP 60 STEP 61

Inspect and clean the bores of the steering knuckle. Use a bushing installer to press the bushing in flush
Apply Loctite ® 609 to the planetary gear shaft with the machined bore in the knuckle. Wipe away
bushing bore and the outer diameter of the bushing. the excess Loctite ® 609.

Rae 6-13990 Issued 10-02

6022-20

STEP 62 STEP 64

AR98K118

Lubricate the inner diameter of the knuckle seal with Use the following procedure to make sure the kingpin
SAE 85W-140 gear lubricant. Install the axle shaft bearings are seated.
seal with the lip facing toward the planetary hub. The
1. Apply a layer of grease to the inner ring bearing
sea l s hould be pressed flush with the casting
surface.
su rface.
2. Properly support the steering knuckle. Install the
lower king pin bearing cap WITHOUT shims.
STEP 63
. , - -_ 11"'"':':' 3. Install the upper king pin bearing cap WITHOUT
shims.
4. Tighten all bolts to a torque of 156 to 170 Nm •
(115 to 125 Ib tt ).
DO NOT rotate the steering knuckle.

STEP 65

Install lifting eyes and properly support the steering

kn uckle . Gu ide the axle shaft outer yoke into the
steering knuckle.

Remove the king pin bearing caps after verifying that

the bearings are fully seated and install the king pin
shims.

NOTE: The same thickness king pin shims can be

used on top and bottom to serve as a starting point to
determine the new shim packs required.

, ~ac 6-13990 Issued 10·02

 6022-21

STEP 66 STEP 67

RR98K070

Install the king pin caps. Evenly tighten the bolts in a
crossing pattern to a torque of 156 to 170 Nm (115 to
125 Ib It).
Place a inclinometer on the top machined surface of
the knuckle and level the assembly to within ± 2
degrees of zero.
Rotate the steering knuckle clockwise and
counterwise several times before the torque to rotate
measurement is taken. Select a kingpin bearing cap
bolt and place a torque wrench on the bolt. Record
the torque required to rotate the knuckle in the
clockwise direction, and the torque required to rotate
the knuckle in the counterclockwise direction.
Average the two readings. The torque must be in the
range of 34 to 74 Nm (25 to 55 Ib It).
Add shims to decrease the torque effort or subtract
shims to increase torque effort as required . Always
shim the upper and lower king pins evenly. Repeat
the procedure until the torque required to rotate the
steering knuckle is within the specification.
When the final adjustments are complete, apply
anti seize lubricant to the king pin bore of the steering
knuckle. Lubricate the king pin through the grease
fitting on the kingpin bearing cap. Repeat the
installation procedure for the opposite steering
knuckle, if removed.

Rae 6-13990 Issued 10-02

 6022-22

STEP 70

Lubricate the two steering cylinder clevis pin bushing

Clean the tie rod end stud and the tapered bore in
O-rings with grease. Make sure an O-ring is installed
the steering knuckle. Install the tie rod seal and
on each side of the steering cylinder at the clevIs pm
washer. Install the tie rod and tighten the slotted nut
bushings. Make sure the flat on the head of the clevis
to a torque of 372 Nm (275 Ib tt) . If necessary,
pin is turned toward the axle hous ing _ Install the
advance the slotted nut until the cotter pin can be
clevis pin . Insert a cotter pin through the clevIs pm .
installed. Install the opposite tie rod end , if removed .
Install the steering cylinder on the opposite side of
the MFD axle, if removed.

STEP 71

Clean the steering cylinder tapered bore and steering

AR98Kl05
cylinder socket stud . Install and tighten the steering
Use the identifying mark made during disassembly to
cylinder slotted nut to a torque of 272 Nm (200 Ib It).
position the wheel stop. Install the wheel stop (1), the
If necessary, advance the slotted nut until the cotter
clevis locking pin (2), and the clevis retaining pin (3)_
pin can be installed .
Install the wheel stop on the opposite side of the
MFD axle, if removed .

j Rae 6-13990 Issued 10-02

 6022-23

PLANETARY H UB ASSEMBLY

~~ ~~ ';2";,,,_
,

10 O@e ~~

RI02J026
ING RING
9. WIRE RT;:~~~EAR HUB
1 RETAINING RING 17. BUTTON RY HUB COVER
18. PLAN;~~ASHER
2: WASHER
PLANETAR
Y HUB SEAL
10.PLAN~TARY
11. THRUSTW
PLAN
RING GEA~LT HUB ONLY)
ASHER (10 B
19. THRU
20. GEAR
3. BEARING CONE 12.

~! ~~~INING PLATE
: : BEARING CUP 21. PIN DLE BEARING
22. NEE
6. STUDETARY HUB 23. SPACER
7. PLAN
15. BOLT Y GEAR SHAFT 24. PLUG
8. NUT 16. PLANETAR

Rae 6-13990 Issu ad 10-02

6022-24
STEP 72
Lubricate the inner diameter of the outer planetary
hub bearing cone with Case 135 H EP SAE 85W-140
Gear Lubricant. Place the planetary gear hub in a
press. Use the proper step plate adapter to install the
bearing cone on the gear hub.
STEP 73
Use the position mark made during disassembly to
install the planetary gear hub (1) in the planetary ring
gear (2). Install the wire retaining ring (3) in the ring
gear groove.
Rae 6· 13990
STEP 74
RD02J038
Clean and inspect the planetary hub. Lubricate the
outer bearing cup with Case 135 H EP SAE 85W-140
Gear Lubricant. Place the hub in a press . Use a
suitable bearing cup installer to install the outer
bearin g cup in the hUb.
STEP 75
- - -........
Turn the planetary hub over. Lubricate the inner
bearing cup with CASE 135 H EP SAE 85W-140
Gear Lubricant. Use a suitable bearing cup installer
to press the inner bearing cup into the hub.
STEP 76
AR98KOBl
Install new wheel studs, if necessary.
Issued 10-02
 6022-25

STEP 77

AI02J041

Clean the bolt holes in the steering knuckle with

Loctite ® Safety Solvent. Install the inner planetary
hub bearing cone . Measure the thickness of the
retaining plate with a dial caliper, or micrometer, and
record the measurement. Install the planetary ring
gear assembly (with the outer planetary hub bearing
cone) , and the retaining plate . Tighten three of the
retaining plate bolts to a torque of 110 to 125 Nm (82
to 92 Ib It). Position a depth micrometer in the small
hole on the face of the retaining plate. Insert the tip
Use CAS2595 Hub Rolling Torque Adapter for the 12
through the hole until it contacts the face of the
bolt hub, or CAS1768 Hub Rolling Torque Adapter
steering knuckle. Record this measurement.
for the 10 bolt hub, to check the torque needed to
rotate the hub. The correct rolling torque reading
NOTE: If any of the hub components have been
should be 8 to 12.5 Nm (70 to 110 Ib in). If required ,
replaced (other than the hub oil seal), the procedure
add shims to decrease the torque value, or subtract
for shimming the planetary hub and adjusting the
shims to increase the torque value.
rolling torque must be followed. Reuse some of the
removed shims, if possible. If only the hub oil seal
has been replaced, reuse all removed shims (if not
damaged) and check the rolling torque of the
planetary hub to make sure it is within the
specification.

NOTE: The rolling torque of the planetary hub

bearings must be taken WITHOUT the hub seal
installed.

STEP 78
Using the measurements obtained in the previous
step, subtract the thickness measurement of the
retaining plate from the depth micrometer
measurement. Subtract 0.127 to 0.152 mm (0.005 to
0.006 inch). This is the thickness of the starting point
shim pack. Remove the three retaining plate bolts
and the retaining plate. Select the correct shim pack
for the calculated thickness . More shims or less
shims may be required upon rolling torque
verification.

Rae 6·13990 Issued 10-02

6022-26

STEP 80 STEP 83
-- - --.--,,...

Lubricate the inner planetary hub wheel bearing cone Install the planetary ring gear assembly (with the
and the inner diameter of the planetary hub seal with outer planetary hub bearing cone) on the splines of
CASE 135 H EP SAE 85W-140 Gear Lubricant. the steering knuckle. Install the shi,ms and the
Install the inner bearing cone. retaining plate.

STEP 81 NOTE: Twelve bolt planetary hub assembly shown.

Install the thrust washer used on the ten bolt
planetary hub assembly, before the installation of the
shims.

STEP 84

Apply Loctite ® 271 to the retaining plate bolts and

install the eight bolts. Tighten the bolts to a torque of
110 to 125 Nm (82 to 921b It).

Install the planetary hub. Use care not to damage the

seal.

6-13990 Issued 10-02

 6022·27

STEP 85 STEP 86

Install the planetary gear shaft into the axle shaft

splines. Make sure the retain ing ring in the spline of
the outer yoke of the axle shaft is fully engaged in the
ring groove on the planetary gear shaft.

NOTE: Install the thrust washer on the planetary

gear shaft before installing the gear shaft, on tractors
equipped with 10 bolt hubs.

Swivel the steering knuckle to gain access to the

planetary gear shaft. Install the washer (1) on the-
planetary gear shaft. Use 380000805 Retaini ng Ring
Pliers to install the retaining ring (2).

NOTE: Axle shaft removed for ph0topraPhic

purpose.

STEP 87

Apply petroleum jelly to the inner diameter of the

planetary gear. Install the needle bearings in one
side of the gear. Install the spacer. Install the needle
bearings in the other side of the gear.

Rae 6·13990 Issued 10-02

6022-28

STEP 88 STEP 90

Install the planetary gear pin and the retaining ring.

Repeat the proceeding procedures to install the rest
of the planetary gears in the planetary hub.

STEP 91

Install the lower thrust washers (1) and the planetary

gear (2) through the center opening (3) in the
planetary gear hub cover.

Clean the planetary hub cover flange surface. Apply

STEP 89 a bead of Loctite ® 515 Gasket Eliminator to the
planetary hub cover. Repeat the proceeding
procedures to install the opposite planetary hub, if
removed .

STEP 92

Install the upper thrust washers on the planetary

gear.

Properly support the planetary hub cover and install

on the hub. Install the three Allen head bolts. Tighten
the bolts to a torque of 10 to 16 Nm (7 to 12 Ib It).
6-13990 Issued 10-02
 6022-29

STEP 93 STEP 95

Install the axle drain plug . Tighten the plug to a
torque of 38 to 41 Nm (28 to 30 Ib ft).
STEP 94
~------------------~
Move the planetary hub cover so that the fill plug is in
the horizontal position . Fill the planetary hub with
Case 135 H EP Gear Lubricant until the oil is level
with the bottom edge of the hole. Alter a few minutes,
recheck the oil level. Tighten the planetary fill plug to
a torque of 38 to 41 Nm (28 to 30 Ib It).

AR98K074

Remove the axle fill plug located on the front of the

axle housing. Add Case 135 H EP Gear Lubricant
until the oil level is even with the bottom of the hole.
After a few minutes, recheck the oil level. Install the
fill plug. Tighten the plug to a torque of 38 to 41 Nm
(28 to 30 Ib It).

Rae 6-13990 Issued 10·02

6022-30

STEP 96 STEP 97

Properly support and install the front tires.
Install the front fenders, if equipped . Remove the
wheel blocks in front of and behind the rear wheels.
Make sure the transmission lever is in PARK. Start
the tractor and check the operation of the MFD axle
and the planetary hubs. Place the transmission shift
lever in PARK. Turn the engine off and remove the
key.

ac 6· 13990 Issued 10·02

 Section
6023

SUSPENSION MFD AXLE

Case, llC <C> 2003 Case , LLC

700 State Street Printed in U.S.A.
Rae 6-14420 April , 2003 ·
Racine. WI 53404 U.S.A.

I;
6023-2

TABLE OF CONTENTS
SPECIAL TORQUES ....... ...................................................................................... ... ...... .........•........ .... ............. ...... 2
SUS PENSION MFD AXLE .. ............................................................ ....... .... ........... ..................... .... ..... .... ........... ..... 3
Disassembly ................. ..... .... ......................... ..... .......... ..... .................. ................... .......... .................... .............. . 3
Assembly .................. ............ ..... .............. ............•. ... ....... .... ....... ..... ........... ..... .................................................. 13
Position Sensor Adjustment ............................. ...•...... ......... ... ... ............................................................ ........... 25

SPECIAL TORQUES
Shoulder bolt for cylinder mounting pin ......................................................................... ... 27 to 30 Nm (20 to 22 Ib It)
Shoulder bolt for upper cradle swing arm pin .................... ........................................ .......41 to 45 Nm (30 to 33 Ib It)
Retaining plate bolts ............................. ............................................................................ 56 to 64 Nm (43 to 47 Ib It)
Sensor to mounting bracket screws ............. ............. ......................... ....... ... .............. ....... 4 to 4.5 Nm (36 to 40 Ib in)
Link to sensor shalt nut .... .................................... .. ................... .... .. ..... ............ .. ...... 20 to 25.5 Nm (160 to 200 Ib in)
Sensor mounting bracket to axle housing bolts ........... ........... •.. ............ ........................... 22 to 24 Nm (16 to 16 Ib It)
Ball joint to axle housing .............................................................................................. 19 to 20 Nm (165 to 160 Ib in)

ac 6-14420 Issued 04-03

 6023-3

SUSPENSION MFD AXLE

Disassembly STEP 3

ATTENTI ON: Take time to familiarize yourself with

r
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.

IM PORTAN T: Carelessness and inattention on the

part of the technicians or others working on or
around this axle can create an increased risk of
injury.

Remove the angle sensor linkage from the axle.

STEP 1
STEP 4

RD02Ml04

Disassembly of the following parts is from location

"Stl.
Remove the angle sensor from the axle.

STEP 2
STEP 5

ROO2MOOl
Remove the angle sensor linkage from the sensor.
Remove the arm from the sensor.

Rae 6·14420 Issued 04·03

6023-4

STEP 6 STEP 9

ROO2Ml04

Remove the two sensor mounting screws and Disassembly of the following parts is from locatio n
remove the sensor from the bracket. "0 ".

STEP 7 STEP 10

AOO2M013

Loosen the set screw (1) and remove the sensor Install a slide hammer into the swing arm cradle pin .
shaft.

STEP 11
STEP 8

AD02M010 Move the pin out a small amount and remove the
nspect the bushing for wear or damage. Replace the dowel pin .
ushing if necessary.

ac 6-14420 Issued 04-03

 6023-5

STEP 12 STEP 14

RD02Ml 0S

Remove the swing arm cradle pin. The following parts are removed from locations "0"
and "E".

STEP 13
STEP 15

Remove the snap ring from the cylinder pins.

STEP 16

Remove the two shoulder bolts from location "C".

Install a slide hammer into the cylinder pin.

Rae 6-14420 Issued 04·03

6023-6

STEP 17 STEP 19
-----".

RD02Ml04

Slide the pin partially out. Do not let the spacer fall
out.

STEP 18

RD02Ml0S

The following parts are removed from location "G"

and "H".

STEP 20
Remove the pin and spacer.

Remove the five bolts from each retaining plate.

ac 6-14420 Issued 04-03

 6023-7

STEP 21 STEP 24

AOO2M027

Remove both retaining plates. Install a slide hammer into the upper swing arm pin.

STEP 22 STEP 25

Remove and discard the O-rings. Remove the pin.

STEP 23

Loosen and remove the shoulder boll.

Rae 6- 14420 Issued 04-03

6023-8

STEP 26 STEP 28

AD02Ml04 RD02M03O

Remove the snap ring from the lower suspension

swing arm.

•
STEP 29

ROO2Ml05

The following parts are removed from locations "A",

"K", and "J".

STEP 27 RD02M031

Use a magnet and remove the lower swing arm

thrust washer. Note that there is a dowel pin in the
shaft.

STEP 30

Install a sling and carefully lift the cradle off the axle
assembly.

Use a puller to remove the lower swing arm pin . Be

sure to catch the dowel pin when removing the puller.

ac 6- 14420 Issued 04-03

 6023-9

STEP 31 STEP 34

AD02M033

Remove the snap ring from the upper suspension Remove the upper pin.
swing arm.

STEP 32

RD02M034 Remove the snap ring from the suspension cradle.

Use a magnet and remove the upper swing arm
thrust washer. Note that there is a dowel pin in the
shaft. STEP 36

STEP 33

RD02M038

Remove and discard the seals from both sides.

NOTE: Seals are different sizes.

Use a puller to remove the upper swing arm pin. Be
sure to catch the dowel pin when removing the puller.

Rae 6-14420 Issued 04-03

6023-10

STEP 37 STEP 40

RD02Ml04

Inspect the bushing for wear or damage. Remove The following parts are removed from locations "E"
and replace if necessary. and "I.:.

STEP 38 STEP 41

RD02 M042

Connect a strap to the lower swing arm . Carefully Remove the snap rings from the cylinder mounting
remove the swing arm from the axle assembly. pins.

P 39 STEP 42
,\

ROO2M041
a strap securely to the upper swing arm and Remove the cylinders .
.i:erno,'e the arm.

Be sure the axle housing is secure to

Dre,verltinjury.

6-14420 Issued 04·03

 6023-11

STEP 43 STEP 46

AD02M044

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. The cylinder must be
replaced if either is present.
STEP 47

STEP 44

Remove the thrust washers.

Remove the shoulder bolts from the cylinder

mounting pins. STEP 48

STEP 45

Use a driver and remove the bushing from the bores.

Use a puller or slide hammer and remove the

mounting pins from the housing.

Rae 6-14420 Issued 04-03

 6023-12

STEP 49
STEP 50

AOO2M050
Remove the seals from the upper swing arm. RD02M051
Use a driver to remove the bushings from the swing
arm bores.

I oc6- 14420
Issued 04-03
 6023-13

Assembly
NOTE: For ease of assembly, it is recommended that the axle be assembled with the housing upside down.

AI02M063

1. CRADLE 8. AXLE PIN 15. PLATE

2. BEARING 9. SHOULDER BOLT 16. THRUST WASHER
3. SNAP RING 10. SPACER 17. DOWEL
4. UPPER SWING ARM 11 . LH CYLINDER 18. BRACKET
5. BUSHING 12. RH CYLINDER 19. SENSOR
6. SEAL 13. PIN 20. CONNECTING LINK
7. LOWER SWING LINK 14. O-RING 21 . SET SCREW

Issued 04·03
Rae 6-14420

! !
6023-14

STEP 51 STEP 54

; . . . - - - RD02M055

The following parts are assembled in location "t:' and Apply grease to the counter bore . Install the thrust
"En, washer.

STEP 52 STEP 55
--~ ....

Apply Loctite 609 to the new bushing. Apply Loctite 609 to the new seal case. Install an
appropriate driver.

STEP 53
STEP 56

- ----> RD02M053

an appropriate driver and install the bushing until AOO2M057

is flush with the bore. Install the seal into the bore. Be sure that the thrust
washer does not obstruct the seal when installing the
seal.

c 6-14420 Issued 04·03

 6023-15

STEP 57 STEP 60

RD02M058 RD02M l04

Apply grease to the housing bore. The following parts are assembled in locations "A"
and "0 ".

STEP 58
STEP 61

Install the cylinder mounting pin into the bore.

Apply Loctite 609 to the 00 of the new bushing.

STEP 59
STEP 62

RD02M06O

Install the shoulder bolt. Tighten to a torque of 27 to

30 Nm (20 to 22 Ib It). Place the cradle on a press. Press the bushing into
the bore using appropriate drivers.

Rac ·6·14420 Issued 04-03

6023-16

STEP 63 STEP 66

Install the snap ring. Apply grease to the pin.

STEP 64 STEP 67
---

Apply Loctite 609 to a new seal case.
NOTE: The cradle uses 2 seals which are different
sizes.
Install the pin into the housing. Align the bolt hole in
the pin with the shoulder bolt bore in the housing .
STEP 68

STEP 65

Install the shoulder bolt into the pin.

ROO2M067

Install the seal squarely in the bore. Use an

appropriate seal driver and seat the seal. Repeat the
procedure for the other side.

Rae 6-14420 Issued 04·03

 6023-17

STEP 69 STEP 72

Tighten the shoulder bolt to a torque of 27 to 30 Nm Install the snap rings.

(20 to 22 Ib It).

STEP 73
STEP 70

The following parts are assembled at locations "A" "I"

Install the cylinder spacer on to the pin. and "K".

STEP 71 STEP 74
------------~~--~-

ROO2M073

Install the lift cylinders. Install the grease fitting into the cradle.

Rae 6-14420 Issued 04-03

6023-18

STEP 75 STEP 78

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.
STEP 79

STEP 76

Apply Loctite to a new seal case.

Install the snap ring onto the cylinder pins.

STEP 80

STEP 77

Use an appropriate driver and install the new seal

into the bore.
Place the bearing on an appropriate driver. Apply
Loctite 609 to the 00 of the bearing.

Rae 6-14420 Issued 04·03

 6023-19

STEP 84

AD02M081

Apply grease to the swing arm pins. Install the dowel pin.

STEP 82 STEP 85
.---~ .

Align the cradle and upper swing arm and install the Continue to drive the pin until seated.
pin.

STEP 86
STEP 83

Install the thrust washer.

Align the dowel pin slot.

Rae 6· 14420 Issued 04·03

6023-20

STEP 87 STEP 90

Install the snap ring. Tighten the shoulder bolt to a torque of 41 to 45 Nm

(30 to 33 Ib It).

STEP 88
, - - - -. -- STEP 91

Install the upper cradle swing arm pin. Align the bolt
hole in the pin with the shoulder bolt bore in the Install a new O-ring in the receiver groove.
housing.

STEP 92
STEP 89

RD02M026 Apply Anti-Seize to the end of the pin . Install the

Install the shoulder bolt into the pin. retaining plate.

Rae 6-14420 Issued 04-03

 6023-21

STEP 93 STEP 96

Tighten the plate bolts to a torque of 58 to 64 Nm (43 Install the lower swing arm pins.
t047Ibft).

STEP 97
STEP 94

AD02M093

Install the dowel pin. Drive the pion in until seated.

The following parts are assembled at locations "J",
"N" and "0".
STEP 98

STEP 95

Install the thrust washer.

AD02M090
Move the lower swing arm assembly into position.

Rae 6-14420 Issued 04-03

6023-22

STEP 99 STEP 102

Install the snap ring. Install the pin.

STEP 100· STEP 103

Apply grease to the ID of the bearing . Align the dowel pin slot.

STEP 101 STEP 104

Apply grease to the lower swing arm/cradle pin. Install the dowel pin. Drive the pin in until seated.

Rae 6-14420 Issued 04·03

 6023-23

STEP 105 STEP 108

Install the thrust washer. Install the sensor shaft.

STEP 106 STEP 109

~--------------------~

Install the snap ring. Ali gn the set screw with the flat on the shaft. Tighten
the screw.

STEP 107
STEP 110

RD02M010

Install the bushing into the sensor housing.

Install the sensor onto the mounting bracket.

Rae 6-14420 Issued 04-03

6023-24

STEP 111 STEP 114

----------------------,

ROO2M006 I
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 Ib in). Install the ball joint onto the axle and tighten to a
torque of 19 to 20 Nm (165 to 180 Ib in) .

STEP 112
STEP 115

Install the short link with the cutout facing up towards

the bracket. Tighten the nut to a torque of 20 to 22 .5 With the unit in the collapsed position , install
Nm (180 to 200 Ib in). remaining ball joint onto the sensor arm. Tighten the
nut to a torque of 20 to 22.5 Nm (180 to 200 Ib in) .

STEP 113

Install the bracket on the housing. Tighten the bolts

to a torque of 22 to 24 Nm (16 to 18 Ib ft).

Rae 6· 14420 Issued 04-03

 6023-25

Position Sensor Adjustment

STEP 116 STEP 117

The angle position sensor must be checked at the Wh en adjustment is complete, tighten the sensor
fully collapsed and fully extended positions. Adjust screws to a torque of 4 to 4.5 Nm (36 to 40 Ib in) .
the sensor as follows:
NOTE : The axle must be calibrated after installing
1. Apply 10 to 30 volts DC to pin 2.
onto the tractor. See calibration information in
2. Measure the signal current at pin 3. (4 to 20 mAl Section 6024, Suspension MFD Axle How it Works.
3. Adjust the sensor slots to achieve 4 to 6 mA
when axle is compressed and 18 to 20 mA when
the axle is extended.

Rae 6-14420 Issued 04·03

t ,/
 6023-26

ac 6-14420
Issued 04-03
 Section
6024

SUSPENDED MFD AXLE SYSTEM

How It Works and Troubleshooting

Case , LlC <!:> 2003 Case, LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-14630 March,2003
6024-2

TABLE OF CONTENTS
SUSPENDED MFD AXLE OPERATION ................. ........ .... .....•. ... ..... ............................... ..... .... .... ............... ..... .. 3

SUS PENDED MFD AXLE - CALIBRATION MODE ............ .......... ............. ..... ....... .... .. ..... .. .. ............. ........... ........ 9
ERROR TABLE .................................................................................................... ................ ........ ................ ..... 11

SUSP EN DED MFD AXLE- MANUAL OPERATION MODE (TEST MODE ) .......... .................... .. ... .... .............. 13

SUS PE NDED MFD AXLE- DEMONSTRATION MODE ........... ................ .... ... .... .... .. ... ........... .. ........................ 16

ac 6-14630 Issued 3-03

 6024-3

SUSPENDED MFD 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. provides better front tire to ground contact for improved tractor control and prolonged tire life.
Automatic front suspension is beneficial in most applications, but can be disengaged when performing some front
hitch and loader operations.
The suspended axle will default to the auto mode when the tractor is started . However, the axle will be locked until
the tractor reaches 1.0 kmlh (0.6 mph) for one second. When the transmission controller sees 1.0 km/h (0.6 mph)
for one second it will energize both lockout solenoids (3 and 4) activating the system. Pressing and releasing the
suspended axle switch to the momentary position will turn off the system, this will lock the axle in position and the
light on the switch will illuminate. The lockout solenoids are PWM type and will ramp up from 0 to 1.5 amp in about
a 5 seconds. These solenoids are PWM to avoid any unwanted movement of the front axle that may occur if the
solenoids simply turn on or off.
With the system turned off, the axle will be locked in position until the tractor reaches 12 km/h (7.5 mph), at 12 kml
h (7.5 mph) the system will switch to the auto mode for roading. This can only be overridden with the Electronic
Service Tool (EST) connected and the DEMO mode accessed through the ICU.{See demonstration instructions in
this section). This will allow the operator to experience the difference at road speed with and without the
suspension axle function.
The transmission controller controls the suspension system. The controller receives a signal from the position
potentiometer. The controller in turn sends signals to four solenoids located on the hydraulic control valve. The
lockout solenoids (3 and 4) are energized anytime the system is on . The control valve receives its supply oil from
the PFC pump. The control valve is also connected to the PFC piston pump compensator through a signal line.
When additional oil is needed in the system the signal line communicates this need to the pump. The control valve
is also plumbed to sump for when oil flows over a relief valve and when the axle is lowered.

, __ _ _
.. .. .. .. .. _.
@
__ .. _.. -- -_ ._ .. _.. _.. _.,
r--------------------------1@
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0----"'A=A.

,---,
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r.;;, L r:;--.. .@
,--ol!9",,1
IL._.. 11 "-' \0 .
.._ .. __ ._ .. _. __ .. _ .. _ .. _. __ .. _ __ _ .. I ~

RIOJAOO3
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. SIGNAL LINE
4. LOCKOUT SOLENOID 9. ORIFICE 14. CHECK VALVE 19. ACCUMULATOR
5. UNLOAD VALVE 10. RELIEF VALVE 15. ORIFICE

Rae 6-14630 Issued 3·03

 6024-4

1"- " - " - " - -. _ ,, - " - ,, ,, - ,, - ,, - " - ,, - . 'l

r---------------------------f@
:
!
@S ,@
CD i
. 17

r---,
I I

~--~~~--~--~'~~--------~~~--~.~
I @ (}) i
L . _ ,,11 " _ ,, _ " _ " _ ,, _ " _ " _ . __ " _ " _ ,, _,,-.J

RIOJAOO3
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. SIGNAL LINE
4. LOCKOUT SOLENOID 9. ORIFICE 14. CHECK VALVE 19. ACCUMULATOR
5. UNLOAD VALVE 10. RELIEF VALVE 15. ORIFICE

Suspended axle turned off

There is no power from the controller to any of the system solenoids. The oil in the system is trapped between
check valve (14) , the check valve in the unload valve (5) and the relief valve (7) . There will be no movement of the
axle unless the axle hits an object hard enough to blow oil over the relief valve (7) to tank. There will be no makeup
oil available to the system when in the off position. PFC supply is blocked at the raise solenoid (1) and the lower
solenoid (2).

Suspended axle in ride control mode

The lock out solenoids (3 and 4) are energized and oil is allowed to flow from the piston side to the rod side of the
cylinder and to the accumulator. The difference in the volume from the rod side to the piston side of the cylinder
nd the pressure in the accumulator maintain the axle position.

\. hen the axle hits a small bump, oil will be forced from the piston side through the lockout valve (4) and check (11)
o the rod side of the cylinder and through lock out valve (3) and orifice (9) to the accumulator. Oil moving into the
ccumulator against the nitrogen charge absorbs the shock to the axle. No oil passes to tank, it is stopped at check
alve (14) , check in unload valve (5), and relief valve (7).

o return the axle to its original position the increased pressure in the accumulator will force oil flow back to the
iston end of the cylinder through check valve (8) . Oil displaced from the rod end of the cylinder will flow back
rough orifice (12) and lockout valve (4) back to the piston end of the cylinder.

C 6-14630 Issued 3-03

 6024-5
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. The
accumulator absorbs the shock to the axle. No oil passes to tank, it is stopped at check valve (14), the check in the
unload valve (5), and relief valve (7).

To return the axle to its original position the additional pressure now in the accumulator will force oil flow back to
the piston end of the cylinder through check valve (8). Oil displaced from the rod end of the cylinder will flow back
through orifice (12) and lockout valve (4) back to the piston end of the cylinder.

If the axle hits a large 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. With the volume of oil
now too great for the accumulator to absorb, excess oil will pass through lock out valve (4) then through relief valve
(7) to tank.

Returning the axle to its original position will require additional oil to the system since some was lost to sump.
When the potentiometer signals the controller that the axle has moved out of the mid point band for more than 0.1
second the controller will energize the raise solenoid (1) and maintain current to both lockout valves (3 and 4). PFC
oil will be directed to the signal line, through check valve (14), check (8), through the energized lockout solenoid (3)
to the piston end of the cylinder. Oil from the rod end will also flow through the orifice (12) through lockout valve (4)
into the piston end of the cylinder.

To lower the front of the tractor the lower solenoid (2) is energized along with the two lockout valves (3 and 4) . This
allows PFC pressure to flow through the solenoid (2) to open the unload valve (5). Oil from the piston side of the
cylinder will flow through the check in lockout valve (4) with some going to tank through the unloading valve and
some through check (11) and orifice (12) to fill the void in the rod side of the cylinder. Lowering the front of the
tractor will normally only occur during calibration or if weight is removed from the front of the tractor.

Specifications:

Lockout solenoid resistance 5.6 ohms.

Raise and Lower Solenoids resistance 10 ohms.

Accumulators come pre-charged to 420 to 450 PSI with dry nitrogen and are not serviceable.

Rae 6-14630 Issued 3-03

6024-6

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 8. TANK
YELLOW
4. ROD SIDE LOCKOUT SOLENOID - COLOR CODE BLUE 9. TO ACCUMMULATOR
5. UNLOAD VALVE 10. CONTROL VALVE BODY

Rae 6-14630 Issued 3-03

 6024-7

\
\--~-"/"'-T"";- --~-----li~===- -: :--;- rO~~ - ~I 1:
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TOP VIEW-REAR

I
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!8<1 I
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TOP VIEW-FRONT
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RHOOA I 06 ANO 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. PISTON SIDE LOCKOUT SOLENOID - COLOR CODE 10. LEFT SUS PENSION CYLINDER
YELLOW
4. ROD SIDE LOCKOUT SOLENOID - COLOR CODE BLUE 11 . RIGHT SUSPENSION CYLINDER
5. UNLOAD VALVE 12. SUPPLY HOSE
6. TO ACCUMMULATOR 13. RETURN TO TANK HOSE
7. ACCUMMULATOR 14. SIGNAL LINE HOSE

Rae 6-14630 Issued 3~03

6024-8

Iff: I
_J I
I
1----' I
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IL __ .J II

I
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SIDE VIEW-REAR

n ~
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I I I II
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SIDE VIEW-FRONT
'......
---- 0 _/ --

AH03A l 07 AND 109

1. RAI SE 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. PI STON SIDE LOCKOUT SOLENOID - COLOR CODE 10. LEFT SUSPENSION CYLINDER
YELLOW
4. ROD SIDE LOCKOUT SOLENOID· COLOR CODE BLUE 11 . RIGHT SUSPENSION CYLINDER
5. UNLOAD VALVE 12. SUPPLY HOSE
6. TO ACCUMMULATOR 13. RETURN TO TANK HOSE
7. ACCUMMU LATOR 14. SIGNAL LINE HOSE

ac 6-14630 Issued 3-03

 6024-9

SUSPENDED MFD AXLE- CALIBRATION MODE

STEP 3
-~

•.
• • f~'
'"

Push and hold the PROG key for two seconds within
ROO2J148
••••
the first ten seconds after starting the tractor. A short The display will read TRANS VIEW.
beep will indicate that the program mode has been
accessed and the display will read INST SET MENU. STEP 4
-"""i'I'

STEP 2 o TAA~t;;
.• FSlJS
~ . TRRHsl
SET ~lENUI
••
•• '
"::

*.111 ·
ROO3A011

Push the DECR key until the display reads TRANS

RD02J146
FSUS.
Push the DECR key until the display reads TRANS
SET MENU and press the PROG key again.

fO~
f Call

~• •
•• %!

-11111 '
Press the PROG key and the display reads FSUS
CAL

Rae 6-14630 Issued 3-03

6024-10

STEP 6

fO F'OS1
~ .
.' o F5usl
Cal Done
1953 mU

•• ••
••
••• II •
II

~.J=====:.:==::3L- RD03A011
RD03A014

Seconds later the display will read FSUS CAL DONE

Press the PROG key. The calibration process is now and the lamp will stop flashing.
activated . The lamp will flash at 2.5 Hertz. The
contro ller will lower and raise the front axle NOTE: If the display reads CAL FAILED, continue
auiomatically. Axle output sensor voltage will appear with Step 9.
on the display.
STEP 8
STEP 7

I:;: P~
rJ2S6 m

..
.. '
l....1::.========~L.J~ RD03A0 11

Press the DECR key until the display reads EXIT

As the calibration process is almost completed an FSUS. Next press the PROG to exit calibration.
asterikn will appear on the display.
Exit out of the calibration menu . If there are any
calibration errors, they will appear on the display.

Turn the ignition key off.

STEP 9
If the display reads CAL FAIL ED. Press the PROG
key to read the error message display. ,

Rae 6-14630 Issued 3-03

 6024-11

ERROR TABLE

DISPLAY ERROR 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.
Check position sensor 12 volt power. Check for 12 volts at fuse 26,
connector 10 pin 19, connector 185 pin A and connector 193 pin 2.
Change potentiometer. Potentiometer value (0-999) less than 51

Pot High Val Front axle potentiometer threshold is higher than set limit.
Look at potentiometer (0-999), if value is greater than 4.8 volts
Check potentiometer installation and adjust as necessary.
Change potentiometer

Pot Shrt Ckt Front axle potentiometer short circuit.

Automatic Calibration Procedure will not work.
Check wire harness.
Check the position sensor ground circuit. Check connector 193 pin 1 to
ground.
Change potentiometer.

Pot Low Val Front axle potentiometer threshold is lower than set limit.
Check potentiometer and adjust as necessary.
Change potentiometer.

Pot Low Rng Suspension is not reaching the minimum/ maximum position during
Automatic Calibration Procedure.
Look at the potentiometer values (1.0 to 4.8 volts) , if the total range between
the maximum and minimum values is less than 2 volts.
Check suspension mechanics.
Check potentiometer linkage.

Slow Up Mvmnt Suspension is stationary during raise command in the Automatic Calibration
Procedure
Check raise solenoid "RED" harness
Check suspension mechanics.
Check pressure of accumulator.
Check hydraulic pressure.
Disconnect Implement.

Rae 6-14630 Issued 3·03

6024· 12

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 On Mvmnt Suspension is stationary during lowering command in the Automatic

Calibration Procedure
Check unload solenoid "GREEN" harness.
Check suspension mechanics.
Check hydraulic pressure.
Disconnect Implement.

Slow to min Suspension unable to reach minimum height within 25 seconds.

Check unload solenoid "GREEN" installation.
Check hydraulic pressure.
Disconnect Implement.

Not Cal Unable to calibrate suspension.

Check suspension mechanics.
Check hydraulic pressure.

ACP error Automatic Calibration Procedure (ACP) stopped .

Vehicle not stationary.
Hand brake not applied .

Rae 6·1 4630 Issued 3-03

 6024-13

SUSPENDED MFD 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 controlier and gives the operator the
ability to directly command the valves. The manual TZ) TPANS
operation can be done through the front suspension
manual menu on the programmable display and SET t'lEt·lU
using the front suspended axle momentary switch on
the right hand fender console.

The Manual Operation Mode will only work when the

tractor is stationary. The manual mode operation is
useful to verify that the valves and potentiometer are
working and installed correctly.

In the manual mode the system valves can be used

ROO2J146
to raise, lower, or unlock the front suspension.
Push the DECR key until the display reads TRANS
SET MENU and press the PROG key again.

STEP ,.:.
3---....._- - - - -

GIll •
• • 'Ii

To enable the front suspension Manual mode:

STEP 1
•• • •
The display will read TRANS VIEW.

STEP 4
- ...
FS'Jsl
Cal l

••
.••
-

Push and hold the PROG key for two seconds within
RD02J148
II.
the first ten seconds after starting the tractor. A short
beep will indicate that the program mode has been
ROO3A012
accessed and the display will read INST SET MENU.
Push the DECR key until the display reads FSUS
CAl.

Rae '6· 14630 Issued 3-03

6024-14

STEP 5 STEP 7

o Fsus
t'lanua l 3139 ml.J

• 111 ••
•• RD03A01 7

Push the DEeR key until the display reads FSUS Next use the DEeR key until the display reads
MANUAL and press the PROG key. RAISE nnnn mV. The nnnn reading is the millivolt
reading for the position sensor output.
STEP 6
Press an hold down the front suspension momentary
rocker switch to energize the front suspension raise
o Pos solenoid. Release the rocker switch to turn off.

Press the DEeR key.

••
••
STEP 8

10 Lo'.·.tl? rl

•• 4511 rnVI
,

The display should read POS nnnn mV. where nnnn

is the millivolt reading of the position sensor. The
Front Suspension upper and lower lockout valves are
now both energized to the ON position.
•
••
When POS nnnn mV is displayed the front _.r:::=====:::~~_J RD03A019
suspension momentary rocker switch is disabled.
This display is for monitoring the front suspension The display will read LOWER nnnn mV. The nnnn
position sensor. reading is the millivolt reading for the position sensor
output.

Press an hold down the front suspension momentary

rocker switch to energize the front suspension lower
solenoid. Release the rocker switch to turn off.

Press the DEeR key.

Rae 6-14630 Issued 3-03

 6024·15

STEP 9 STEP 11

-o Lock
1987 mlJ

II
•••
.•
'
•• RD03A023

The display will read LOCK nnnn mV. The nnnn The display will read FSUS MANUAL. Press the
reading is the millivolt reading for the position sensor DECR key.
output.
STEP 12
Press and

hold down the front suspension momentary rocker

switch to turn off both the raise and lower lockout
solenoids. This can be used to troubleshoot the raise
and lower lockout circuits. Use a multimeter to check
the voltage at the lockout solenoids. Release the
rocker switch and both lockout solenoids will be
energized again.
II "
.11
Press the DECR key.

STEP 10

._-
o Exit ~
• ADOJA024

Press the DECR key until EXIT FSUS is displayed.

Press the PROG key.
Manual
STEP 13

••
t • • ,
to TRl=lNSj
I FSUS

The display will read EXIT MANUAL. Press the

PROG key.
RD03A022

.~

•
••
II'
•••
The display will read TRANS FSUS. Use the DECR
key to select TRANS EXIT. Turn ignition key to OFF

Rae 6·14630 Issued 3-03

6024-16

SUSPENDED MFD 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

••
•••
••••
The display will read TRANS VIEW.

STEP 4
RD02J148 - ...,..
Push and hold the PROG key for two seconds within
the first ten seconds after starting the tractor. A short
beep will indicate that the program mode has been
t0 TRI=1~~S
FSUS
I
accessed and the display will read INST SET MENU.

STEP 2

• • 'Il
2;0 IRAtE
SET t1Et1U
••• •
Push the DECR key until the display reads TRANS
FSUS.

STEP 5

RD02J146
~o FSIJS
Push the DECR key until the display reads TRANS Cal
SET MENU and press the PROG key again.

•
• • '!

•• RD03A012

Press the PROG key and the display reads FSUS

CAL

ac 6-14630 Issued 3·03

 6024-17

STEP 6

o Fsusl 10 Demol
Demol WOFkln-OI

ROO3A030 RDOOA034

Press the DEeR 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.

STEP 9

fO Exi t.)
Demol

••
•••• ==
Press the PROG key. The display will read DEMO
OFF.
••
R003A032
STEP 8
Press the PROG key. Press the DEeR key until the
display reads DEMO OFF. Next press the PROG
The display will read EXIT DEMO .

•••
•• • ,

Press the DEeR key. The display will read DEMO

ON.

Rae 6·14630 Issued 3·03

 6024-18

STEP 10

o FSJ.Jsj.·
STEP 12
-...... "'7~
10 " TRANS
.

I D&>Tflo

.•
! FSOS

.11 ,

••••
·" • • ,Ii
..
••••
'
'

Press the PROG key. The display will read FSUS

DEMO. Press the PROG key and the display will read
TRANS FSUS. Turn the key to the OFF position.

STEP 11

••
. • 11 ·
RDOJA032
Press the DEeR key and select EXIT FSUS

c 6-14630
Issued 3-03
 Section
7001

BRAKE VALVE

Case, LLC C> 2003 Case, LLC

700 State Street Printed in U.S.A.
Rae 6-14340 January, 2003
Raci ne, WI 53404 U.S.A.
 7001-2

TABLE OF CONTENTS
SPECIAL TORQUES ...... ............... .... ...... ....... .. .......••......................................................... ... ..•••..... .................. ..... . 2

BRAKE VALVE ................... .................................... •.•............................................. ................................................ . 3

Removal .... ...................... .............. ............... ..... ............................. ..... .. ... ................................................. ........... 3
Disassembly ...........•••.............•.............................••. ....................... ....... ............. ........ ... ....... ...................... .... ... ... 4
Assembly ............................................................................................•.................... .............. .................... .......... 6
Installation .................. ............................................ .... ... ............................................... ..... ... .... ............................ 8

SPECIAL TORQUES
Allen head plate to valve body retaining screw ................................ ..... .............. ............. 35 to 40 N.m (26 to 30 Ib tt)

Issued '·03 Printed in U.S.A.

\ ac 6·14340
 7001-3

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.(see Section 9008, Hood, Grill, Air
Conditioning Condenser, Air-to-Air Intercooler, and
Radiator}.

STEP 1
102R·4

Remove top cover Irom steering column .

STEP 4

RD02K118

Tag and remove the lour brake valve lines(1 ).Tag

and remove the two brake switch connectors (2) .

STEP 2
II equipped , remove the loot throttle by removing the
roll pin and sliding the throttle arm off the pivot shaft.

STEP 5

Remove steering column side cover.

10 1A-35A

Remove right Iro!')t air duct.

Rae 6-14340 Issued 1-03 Printed in U.S.A .

 7001-4
STEP 6
Disassembly

STEP 7

Remove the three brake valve mounting bolts.

Remove the brake valve and gasket from the fire
wall.
AD02Kl06
Place the valve on a clean surface and remove the
three allen head screws.

STEP 8

Remove the firewall brake plate.

STEP 9

RD02K112
Remove and discard the brake valve gasket.

ac 6-14340
Issued 1-03 Printed In U.S.A.
 7001-5

STEP 10 STEP 12

/9
f

RD02Kl08
RD02Kl10
Remove the poppet (1) and outer feathering spring Remove both brake switches. Discard 0 rings.
(2) from the sleeve (3). Remove the sleeve from the Inspect for damage or wear.
body. Remove the spool (4) and return spring (5)from
the spool. Inspect all parts for damage or
wear.Repeat steps for the second spool assembly. STEP 13

STEP 11

RD02Kl11

Remove and discard the two poppet sleeve seals.

RD02Kl09

Remove and discard the spool seal and 0

ring.Repeat for second spool.

Rae 6-14340 Issued 1-03 Printed in U .S.A.

 7001-6

Assembly

RI02 K072
1. BODY 6. SPOOL 11 . POPPET
2. SWITCH 7.0 RING 12. GASKET
3.0 RING 8. SEALRING 13. PLATE
4. SPRING 9. SLEEVE 14. SEAL
5. RETAINING RING 10. SPRING 15. SCREW

STEP 14 STEP 15

AD02K l 09
ROO2Kl1 0
stall a new backing 0 ring. then a new seal.
Install new 0 rings and install the brake switches.

c 6· 14340
Issued 1-03 Printed in U.S.A .
 7001-7

STEP 16 STEP 19

,/0

RD02Kl 06 ROO2Kl07

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
the valve body. Install the feathering spring (2) into STEP 20
the poppet (1) and install the poppet into the spool.
repeat for the second spool.

STEP 17

AD02K113
Install the three retaining scews and torque to 35-40
N.m (26 to 30 Ib It).

ROO2K112

Install a new brake valve gasket.

STEP 18

AOO2Kl11

Install new poppet shaft seals.

Rae 6·14340 Issued '-03 Printed in U.S.A.

7001-8

Installation STEP 23

STEP 21

Install the right side air duct.

Install a new firewall to brake valve gasket and install STEP 24

the brake valve, making sure that the brake link
rods(1) are installed into the poppet sleeves(2) .
Install and tighten the three mounting bolts(3). See
Section 9001 for brake pedal adjustment procedure.

STEP 22

If equipped, install the foot throttle.

STEP 25

IImaall new 0 rings on all hose and tube connectors.

the supply and return lines, the right and left
lines (1) and the brake switch connecto rs (2).
vehicle and check for leaks and proper brake
operation.

Install top steering col umn cover and connect all

electrical connectors.

6-14340 Issued 1-03 Printed in U .S .A.

 7001-9

Install the right side cover.

Issued 1·03 Printed in U.S.A .

Rae 6-14340
•
 Section
7002

BRAKE CYLINDERS

MX Series Tractors

CASE CORPORATION ~ 2002 Case Corporation

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6- 13460 October, 2002
7002-2
TABLE OF CONTENTS
SPECIAL TORQUES .........•........................................ .......................................... ......... .......................................... 3

SPECI FICATIONS ...........••.... ......... .................................•.............................••............................. .••................. ....... 3

BRAKE CYL INDERS ... .....•..... .. ... ........................... ................................................................... ......... .........•........... 4
Disassembly ..................•••........ ................ ............... ..... .. .... ............. .. .........••• ...... ... .......... ... ... ... ..•........................ 4
Assembly ............ ... .......................................................... ............... .... ...... •• .............. .......... ..... ................•• .. .. .. .... 6

Rae 6· 13460 Issued 10-02 Printed in U.S. A

 7002-3
SPECIAL TORQUES
Brake Cylinder Mounting Bolts ............................................................................. .... 177 to 179 Nm (130 to 145 Ib It)

SPECIFICATIONS
Friction Disc Minimum Thickness ................................................... ........................................... 3.45 mm (0.136 inch)

BRAKE CYLIN DERS

Disassembly STEP 3

ST~P 1

lift the supply tubes out of the brake cover. If the

Remove the rear axles and planetarium from the rear
frame. See Section 6019, Rear Axle and Planetaries,
in this service manual for axle removal.
supply tubes are to be removed from the rear frame,
remove the lower O-rings from the tube first.
STEP 4

STEP 2

Remove two brake cover mounting bolts and install

aligning dowels.

Remove the brake tube (1) and dill lock tube (2) from
the rear frame housing.

Rae 6·13460 Issued 10-02 Printed in U.S.A.

7002·4
STEP 5 STEP 8

Remove the remain ing bolts and the brake cover Remove the three brake adjusters from the
from the rear frame. differential retainer.

STEP 6 STEP 9

Remove the adjuster return plate from the brake dies. Remove the five locating pins from the differential
retainer.

STEP 7
STEP 10

Remove the friction and separator plates from the

rear frame. Remove the sun gear shaft seal from the differential
retainer.

Issued 10·02 Printed in U .S.A .

 7002-5

Assem

AH96B044
1. BEARING RETAINER 6. EXTERNAL RETA INING RING 11. PISTON
2. OIL SEAL 7. AXLE ASSEMBLY HOUSING 12. BRAKE COVER
3. SEPARATOR PLATE (4) 8. BRAKE ADJUSTER ASSEMBLY 13. O-RING
4. FRICTION PLATE (4) 9. LOCATING PIN 14. SUPPLY TUBE
5. BELLEVILLE WASHER 10. ADJUSTER RETURN PLATE

Rae 6-13460 Issued 1O~02 Printed in U.S.A.

7002-6

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

A2 1052

Inspect the brake friction plates. If there is damage or Carefully remove the piston from the cover. Repeat
heavy wear (the grooves worn away), replace the procedures for the other piston.
friction plates. The minimum thickness for a friction
plate is 3.45 mm (0.136 inch) .

Rae 6-13460 Issued 10-02 Printed in U.S.A.

 7002-7

STEP 15 STEP 18
r-"'-"'---

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 wi th a
soft face hammer until the piston is fully seated. Be STEP 19
careful not to damage the bonded seals.

__\ 2
STEP 16
---'----~ H~~--~

RH97K064

15. DOWEL
16. RETAINING RINGS
17. BELLEVILLE WASHER

r.7966
If new brake plates are to be installed, the brake
Use a driver to install a new seal in the differential adju sters must be reset. Adjust the depth of the
retainer. Lubricate the 10 of the seal with Hy-Tran retaining rings to 25.477 mm (1 in .). If the old plates
Plus fluid . are to be reused, do not change the brake adjusters.

STEP 17

Install aligning dowels in the differential carrier.

Rae 6-'3460 Issued 10-02 Printed in U.S.A.

d
 7002-8

STEP 22

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.
dowel assemblies.

STEP 23

I Install plates as follows:

, Install the brake cover onto the locating dowels.
1. Install a s~parator plate on to the locating pins
and against the differential plate carrier.
STEP 24
2. Install a friction plate against the separator plate.
3. Install three more separator and friction plates. A
friction plate must be the last part installed.

Insta ll the brake cover retaining bolts. Tighten the

bolts to a torque of 177 to .197 Nm (130 to 145 Ib ft.)

ae 6·13460 Issued 10-02 Printed in U.S.A .

 7002-9

STEP 25 STEP 27

RD02D050

Lubricate new O-rings with petroleum jelly and install See Section 6019, Rear Axle and Planetaries for the
the O-rings on the supply tubes. Install the tubes into installation of the rear axle housing.
the brake cover.

STEP 26
-~~--...,..--

Install the brake supply tube (1) and connect the diff
lock tube (2). Repeat installation procedures for the
other brake cylinder.

Rae 6-13460 Issued 10-02 Printed in U .S.A.

I h
 7002-10

Aac 6-13460
Issued 10-02 Printed in U.S.A.
 Section
7004

PARK BRAKE

Case, lLC © 2003 Case, LLC

700 State Street Printed in U.S.A.
Racine. WI 53404 U.S.A. Rae 7·86761 April , 2003

t'
7004-2

TABLE OF CONTENTS
SPEC IAL TOOLS ............. ................ ..... ........................ ••.... ................... ................................... .............. .......... .. ... . 2

PARK BRAKE ..... .......... ....... ..... .......................... ... .. .... .. •. ....... ... .......... ...... .....•......... ....... .... ... .............. .... •• ...... .... ... 3
Disassembly ....... .........................•................. .............•.............................................................................•...... ..... 3
Assembly ... ............. ...... ................ ..... .......... ....... .................... ............... ................................. .......... ......... ....... ... 6

SPECIAL TOOLS
CAS 2603 Belleville Spring Compressor

ac 7·86761 Issued 4-03 Printed In U.S.A

 7004-3

PARK BRAKE

Disassembly
NOTE : To remove the park brake assembly, See STEP 3
Section 6008, Range Transmission.

STEP 1

42·1 1

Release the pressure slowly. Remove tooi.

..
42·68R STEP 4
Use CAS 2603 tool to compress the Belleville spring
washers and take pressure off the snap ring.

STEP 2

Remove backing plate.

STEP 5
42·8BR

Remove the snap ring.

Remove the six Belleville washers.

Rae 7-86761
Issued 4-03

I;
 7004-4

STEP 6 STEP 9

42-34 43-10ABA

Turn brake housing over. Remove the snap ring. Remove the first park brake separator plate.

STEP 7 STEP 10

43-4BR 43· 11ABR

Remove the backing plate. Continue to remove the friction and separator plate.

STEP 8 STEP 11

43-SABR 43-24A

IIIR."1T1DV·" the first park brake friction plate. Remove the internal snap ring . Push piston out of
housing from side of friction plates.

7·86761 Issued 4-03

 7004-5

STEP 12 STEP 13

42-27BR

Remove the brake actuator piston. Remove the pairs of teflon seals and O-rings from
the piston. Discard the seals and O-rings.

Rae 7-86761 Issued 4-03

 7004-6

Assembly

. ~

RI98E032

ac 7·86761
Issued 4-03
 7004-7

1. SHAFT WIO MFD 19. SHIELD 42. BACKING PLATE

2. SHAFT WI MFD 20. SEAL RING 43. BRAKE DISC
3. BOLT 23. O·RING 44. SEPARATOR PLATE
4. ADAPTER 24. COVER 45. PISTON
5.0·RING 25. BALL 46. O·RING
6. TUBE 26. PLUG 47. SEAL RING
10. SHIELD 27.0·RING 48. O·RING
11. BOLT 28. SPRING 49. SEAL RING
12. CONE BEARING 29. BOLT 50. BELLEVILLE WASHER
13. CUP BEARING 30. BOLT 51 . BACKING PLATE
14. GEAR 31. WASHER 52 . RETAINING RING
15. SNAP RING 32. SPECIAL BOLT 55. SHIELD WIO MFD
16. SHIM 33. O·RING 56. PLUG
17. WASHER 40. CARRIER 57 . SHIELD WI MFD
18. RETAINING RING 41 . RETAINING RING 58. BOLT

STEP 14 STEP 16

89·19 89-25

Install large internal snap ring. Install first park brake friction plate . Install the
remaining four separator plates and four friction
plates. alternating the plates.
STEP 15
STEP 17

89R·21

Install first park brake separator plate on top of snap

43--4ABR
ring.
Install the backing plate. The flat side of the plate
must be facing down.

Rae 7-86761 Issued 4-03

•
 7004-8

STEP 18 STEP 21

42-34 90-15
Install snap ring. Align friction plates. Place housing Install the first Belleville washer. The concave side of
assembly over the shaft to align brake plates. the washer must be facing down.

STEP 19 STEP 22

9Or-7 9().13

Install new O-rings and seals on the piston . Install the second Belleville washer. The concave
side of the washer must be facing up. Install the
remaining four Belleville washers, alternating the
STEP 20 position of the washers u ntil the last washer is
installed with the concave side facing up.

STEP 23

9(). ' O

I nstall the brake actuator piston with small diameter

down.

90A-26

Install.backing plate. The flat side of the plate must

be facing down.

ac 7·86761 Issued 4-03

 7004-9

STEP 24 STEP 25

9R()'35

Install internal snap ring , release pressure slowly.

Use tool CAS 2603 to compress stack of Belleville Remove tool.
washers. The shaft must project through hole in tool.

STEP 26
Install into range transmission (see Section 6008,
Range Transmission .).

Issued 4-03
Rae 7-86761

It
 7004-10

c 7-86761
Issued 4·03
 Section
7005

TRAILER BRAKE SYSTEMS

How It Works

Case, lLC <!:> 2003 Case , LLC

700 State Street Printed in U.S.A.
Rae 6-14430 March, 2003 .
Racine, WI 53404 U.S.A.
7005-2

TABLE OF CONTENTS
TRAILER BRAKE SYSTEMS .......... ......... .. ....... ...................................................................... .... .......................... 3

HYDRAULIC BRAKE SYSTEMS ....... .............. ................•..................................... ................................................ 4

European / NAO Hydraulic Trailer Brakes ...................................... ........... ........... ......... ...... ............................. 4
Italian Hydraulic Trailer Brakes ....... .......................................................... .......... .... .... ....... ............ .................... 6

PNEUMATIC BRAKE SYSTEMS ......... .............. ........... ....... .............. .. ..........................•.. ................... ...... ....... .... 9
Pneumatic Trailer Brakes ............. ......... ......... ..... ... .. ........................... ..................................................... .......... 9
European Pneumatic Trailer Brakes ..... .................................................. ............................... ............................ 9
Italian Pneumatic Trailer Brakes .................................................................... ......... ............ ....................•..... ... 12
ROW (Rest of World ) Pneumatic Trailer Brakes (NAR. ANZ. CIS . LAR. EEAA) .......................................... 15

European / NAO Hydraulic Trailer Brake Schematic ...................... ............. .......... ........................ .................... 17

Italian Hydraulic Trailer Brake Schematic ... ... .... .... ......................... ... ..... ..................................... .......... ............. 18

Italian Pneumatic Trailer Brake Schematic ...... ................. ........ ............................ ...•............. ...... ........ ......... ...... 19

c 6-14430 Issued 03-03

 7005-3

TRAILER BRAKE SYSTEMS

There are two hydraulic trailer brake systems:

European / NAO hydraulic trailer brakes

Italian hydraulic trailer brakes

And there are three pneumatic trailer brake systems:

European pneumatic trailer brakes

Italian pneumatic trailer brakes

ROW (Rest of world.NAR. ANZ. CIS. LAR .EEAA) pneumatic trailer brakes

Rae 6-14430 Issued 03-03

7005-4

HYDRAULIC BRAKE SYSTEMS

European I NAO Hydraulic Trailer Brakes

The hydraulic trailer brake control system is a load sensing design and consists of a hydraulic trailer brake priority
valve (7) and trailer brake control valve (5). Both valves are located on the top of the range transmission. Supply
flow for this system is provided from the priority port of the tractor steering priority valve. This provides priority flow
to the steering and hydraulic trailer brake circuits over all other functions. The trailer brake priority valve then
ensures that steering has priority over the trailer brakes. The PFC piston pump ultimately provides supply flow to
the entire system.

The trailer brake control valve provides supply to the trailer brake coupler only when both tractor service brake
pedals are actuated. The trailer brake valve pilot circuit is supplied by teeing into the left hand and right hand
tractor service brake pressures. The tees supply a shuttle check valve located near the main brake control valve on
the fire wall. The outlet pressure from the shuttle check valve is routed to the pilot manifold of the trailer brake
valve. The shuttle valve will only supply the pilot manifold when both brake pedals are actuated. The pilot manifold
provides the ratio of tractor brake pressure in comparison to trailer brake pressure, in this case 33:1 .

When both brake pedals are actuated, the pilot pressure moves the main spool of the trailer brake valve, sending a
pressure signal back to the PFC piston pump which supplies the circuit. At the same time the main spool of the
trailer brake valve is controlled by the pilot pressure to provide pressure to the trailer brake coupler in proportion to
tractor brake pressure (33:1) to a maximum value of 150 bar (2175 PSI).

With no pressure applied to the trailer brake valve main spool, the trailer brake coupler pressure is relieved to zero
pressure.

C6-14430 Issued 03~03

 7005-5

"' - - ..
, ,
~ ," -, \
,-' , I
... _.. ' .
I

"II

RI02M073. RI02M074, RH02G335

European I NAO Hydraulic Trailer Brake

1. TO TRAILER BRAKE COUPLER 5. TRAILER BRAKE CONTROL VALVE
2. TUBE STEERING SENDER 6. TRAI LE R BRAKE PILOT TUBE
3. STEERING SUPPLY TUBE TO TRAILER BRAKES 7. TRAILER BRAKE PRIORITY VALVE
4. CHECK VALVE ASSEMBLY 8. BRAKE COUPLING

Rae 6- 14430 Issued 03-03

t d
7005-6

Italian Hydraulic Trailer Brakes

The Italian hydraulic trailer brake control system is a load sensing design and consists of a hydraulic trailer brake
priority valve (2) located on the top of the range transmission and a trailer brake control valve (1) located at the rear
of the tractor. Supply flow for this system is provided from the priority port of the tractor steering priority valve. This
provides priority flow to the steering and hydraulic trailer brake circuits over all other functions. The trailer brake
priority valve then ensures that steering has priority over the trailer brakes. The PFC piston pump ultimately
provides supply flow to the entire system.

The trailer brake control valve provides supply to the trailer brake coupler only when both tractor service brake
pedals are actuated. The trailer brake valve pilot circuit is supplied by teeing into the left hand and right hand
tractor service brake pressures. A shuttle check valve ensures that both left hand and right hand brake pressures
are required for the trailer brake valve to respond . If only one service brake is applied (right or left), the shuttle
valve prevents pilot pressure from reaching the trailer brake valve and the trailer brake valve is not actuated. This
allows free movement of the trailer when pivoting the tractor using the right or left service brake. The pilot manifold
located on the trailer brake valve provides the necessary ratio of tractor brake pressure in comparison to trailer
brake pressure.

When the tractor is running with normal system pressures, no service brakes applied, emergency brake off and the
trailer coupled to the trailer brake coupler, the trailer brake provides a control pressure of 12.5 bar (+1- 2.5 bar) to
the trailer brakes through the coupler.

When the service brakes are applied (right and left together), the service brake pressure (pilot pressure) is
communicated through the shuttle valve to port "V" on the trailer brake valve. The trailer brake valve is then
actuated using oil from the piston pump entering port "P" suppling it to the coupler where it flows to the trailer brake
cylinder, which causes the trailer brakes to respond . The pressure at port "8 " and the coupler increases from the
control pressure of 12.5 bar proportionally to the service brake pressure and is limited to 130 bar (+1- 10 bar).

If the tractor emergency brake is engaged, or if the transmission is in park, a pressure switch senses the drop in
ressure and closes, signaling the trailer brake to dump the 12.5 bar control pressure to zero. This in turn, engages
he trailer spring brake and stops the trailer. This also turns on the indicator lamp on the right hand console. If
ydraulic system pressure at the piston pump load sense port drops below a normal value the pressure switch at
his location closes and also signals the trailer brake valve to dump the 12.5 bar control pressure to zero. This
ngages the trailer spring brake and stops the trailer. This also turns on the indicator lamp on the right hand
onsole.

Rae 6- 14430 Issued 03-03

I .
 7005-7

TRAILER BRAKE PRESSURE

TRACTOR BRAKE PRESSURE

130 BAR r---------

I
I
I
TRAILER I TRAILER
BRAKES ON TRAILER I. ,' BRAKES ON
TRAILER
4- (SPRING -.:-- BRAKES -<or-----; (PRESSURE
APPLIED) RELEASED / APPLIED)
BRAKE
PRESSURE I
BAR I
I
I
I
I
I
I
12.5 BAR
:-------~
. /. NO TRACTOR
BRAKING
I PEDAL EFFOAT~
TRACTO~
BRAKING
TRACTOR TRACTOR ON
OFF

RI02MOB5

1. TRAILER BRAKE VALVE 4. SHUTTLE VALVE

2. TRAILER BRAKE PRIORITY VALVE 5. EMERGENCY BRAKE PRESSURE SWITCH
3. HYDRAULIC TRAILER COU PLER 6. LOW SYSTEM PRESSURE SWITCH

Rae 6-14430 Issued 03-03

I •
 7005-8

RI02MQ87

Italian Hydraulic Trailer Brake

1. TRAILER BRAKE VALVE 5. EMERGENCY BRAKE PRESSURE SWITCH

2. TRAILER BRAKE PRIORITY VALVE 6. LOW SYSTEM PRESSURE SWITCH
3. HYDRAULIC TRAILER COUPLER 7. CHECK VALVE
4. SHUTTLE VALVE 8. TRACTOR SERVICE BRAKE VALVE

! ac 6·14430 Issued 03·03

 7005-9

PNEUMATIC BRAKE SYSTEMS

Pneumatic Trailer Brakes

The pneumatic trailer brake control system is comprised of an engine driven compressor, air reservoirs (tanks),
pressure unloading/regulator valve, trailer control valve, solenoid valves and air brake couplings. The compressor
is located on the forward side of the engine. The air tanks are located on the left and right of the rear axle carriers.
The control valves are located on top of the transmission/rear frame and the couplings are at the rear of the tractor
above the hydraulic couplers.

European Pneumatic Trailer Brakes

The pneumatic trailer brake control system for non-Italian European tractors is a combined single and dual line
high pressure braking system. There are three couplers in this system. The black coupling (single line system) is
on the right side, the red coupling (dual line system) is in the center and the yellow coupling (dual line system) is on
the left side.

Dual line braking system: With dual line systems, air pressure is increased to apply positive braking force. When
the brake system is not activated, the brake lines have no pressure.

From the compressor, compressed air is supplied to the air reservoirs, with the pressure limited to B.l to B.5 bar
(117 to123 PSI) by an unloading regulator valve. Compressed air is supplied from the reservoirs to the inlet port of
the dual trailer control valve, to the inlet of the emergency brake solenoid valve and to the red coupling, providing
full operating pressure to that coupling at all times.

When the tractor brakes (either service or emergency) are not actuated and the tractor is out of park there should
be no pressure at the yellow coupling . When the tractor service brakes are actuated air pressure which is
proportional to the service brake pressure is supplied from the trailer brake control valve to the yellow coupler. The
maximum pressure at the yellow coupler is B.l to B.5 bar (117 to 123 PSI). This provides a braking force for the
trailer which is dependent on the tractor service brake force (tractor brake pressure). When the tractor emergency
brake is actuated , the same process applies, the pressure at the yellow coupler will rise continuously to the
maximum system operating pressure of B.l to B.5 bar (117 to 123 PSI) . When either the service brakes are
released, or the emergency brake is disengaged the pressure drops to zero.

Single line braking system: With single line systems, air pressure is decreased to apply positive braking force,
typically through a spring loaded brake. When this brake system is not activated the brake lines are fully
pressurized to maintain the trailer brakes in a released state.

From the compressor, compressed air is supplied to the air reservoirs and to the single line trailer brake control
valve to the black hose coupling of the single line system. A pressure reducing valve built into the trailer brake
control valve limits the output pressure to the black coupler to 4.B to 5.3 bar (70 to 77 PSI) . When the tractor
service brakes are not applied and the tractor is not in park, the trailer control valve maintains 4.B to 5.3 bar (70 to
77 PSI) at the black coupler. When the tractor service brakes or emergency brake is actuated, the pressure at the
black coupler is reduced by the trailer control valve in proportion to the increasing tractor service brake pressure. At
full tractor brake pressure, the pressure at the black coupling must be zero. When either the tractor service brakes
are released, or the emergency brake is disengaged the pressure gradually increases to 4.B to 5.3 bar (70 to 77
PSI).

Rae 6-14430 Issued 03-03

7005-10

:--- -- -:::=.~----/

- -r
/
i
~

RI02MQ64 RI02M065

1. AIR BRAKE COUPLER- YELLOW 5. LEFT SIDE AIR RESERVOIR

2. AIR BRAKE COUPLER- RED 6. RIGHT SIDE AIR RESERVOIR
3. AIR BRAKE COUPLER- BLACK 7. DUAL liNE CONTROL VALVE
4. TRAILER CONTROL VALVE

ac 6-14430 Issued 03-03

 7005-11

~---

,
,,, Iv
, """
"
,~
"

,
,,
~--
,
: r-~-"-....r---- - --'"
L ____ l L_

8. DOUBLE CHECK VALVE 10. AIR BRAKE UNLOADING VALVE

9. SOLENOID VALVE

Rae 6- 14430 Issued 03-03

1
7005-12

Italian Pneumatic Trailer Brakes

The pneumatic trailer brake control system for Italian European tractors is a dual line high pressure braking
system. A combined dual coupler is used.

Dual line braking system : With dual line systems, air pressure is increased to apply positive braking force. When
the brake system is not activated, the brake lines have no pressure.

From the compressor, compressed air is supplied to the air reservoirs, with the pressure limited to 7.0 to 7.5 bar
(102 tol 09 PSI) by an unloading regulator valve. Compressed air is supplied from the reservoirs to the inlet port of
the dual trailer control valve, to the inlet of the emergency brake solenoid val ve and to one of the couplings ,
providing full operating pressure to that coupling at all times.

When the tractor brakes (either service or emergency) are not actuated and the tractor is out of park, the other
coupling must have no pressure. When the tractor service brakes are actuated air pressure which is proportional to
the service brake pressure is supplied from the trailer brake control valve to the one coupler. The maximum
pressure at the coupler is 7.0 to 7.5 bar (102 tol 09 PSI). This provides a braking force for the trailer which is
dependent on the tractor service brake force (tractor brake pressure). When the tractor emergency brake is
actuated the pressure at the coupler will rise continuously to the maximum system operating pressure of 7.0 to 7.5
bar (102 tol09 PS I). When either the tractor service brakes are released, or the emergency brake is disengaged
the pressure drops to zero.

ac 6·14430 Issued 03·03

 7005-13

" ,
,,
" \--
\
\

,
,,

Italian Pneumatic Trailer Brake

1. ITALIAN AIR BRAKE DUAL COUPLER 3. RIGHT SIDE AIR RESERVOIR

2. LEFT SIDE AIR RESERVOIR 4. DUAL LINE CONTROL VALVE

Rae 6-14430 Issued 03-03

7005-14

:.. I
I " --~-~l
b.. __ '!.~ I

,c_
~~' ''1
' A
',

J-
y I-

RI02M067, RI02M092 AND RI02M069

Italian Pneumatic Trailer Brake

5. DOUBLE CHECK VALVE 7. AIR BRAKE UNLOADING VALVE

6. SOLENOID VALVE

Issued 03-03
 7005-15

ROW (Rest of World) Pneumatic Trailer Brakes (NAR, ANZ, CIS, LAR , EEAA)
The pneumatic trailer brake control system for ROW tractors is a dual line high pressure braking system. There are
two couplers included with this system, the red (emergency) coupling and the blue (service) coupling.

Dual line braking system : With dual line systems, air pressure is increased to apply positive braking force. When
the brake system is not activated , the brake lines have no pressure.

From the compressor, compressed air is supplied to the air reservoirs, with the pressure limited to 7.9 to B.3 bar
(114 to 120 PSI) by an unloading/regulator valve. Compressed air is supplied from the reservoirs to the inlet port of
the dual trailer control valve, to the inlet of the emergency brake solenoid valve and to the red coupling, providing
full operating pressure to that coupling unless the tractor is in Park, or the manual emergency trailer brake valve is
actuated (pushed down).

When the tractor service brake system is actuated , air pressure, which is proportional to tractor service brake
pressure, is supplied fro the dual line trailer control valve to the blue coupler. The maximum pressure is 7.9 to B.3
bar (114 to 120 PSI) . This provides a braking force for the trailer which is dependent on the tractor service brake
force (tractor brake pressure).

When the tractor is in Park and the manual trailer control valve is up, pressure at the red coupler is zero and the
trailer is braked by the trailer spring brake.

When the tractor is out of Park and the manual trailer control valve is up, pressure at the red coupler is still zero
and the trailer is still braked .

When the tractor is out of Park and the manual trailer control valve is pushed down, pressure is applied to the red
coupler and the trailer spring brake is released. The handle of the manual trailer control valve will stay down (with
the tractor running) and the trailer spring brake released, as long as system air pressure is above 2.4 bar (35 PSI).

Rae 6-14430 Issued 03-03

,

7005-16

" ,, ,,

:
:.«
I I
~ ___ -..J I

.',

,'-.,,
"y-...":;" ,
/~ ...... \ ,, --,
, I'
,-,\ 'I•' t
,-I,
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-, ~

,.(~ ~~, ()....... I

-~ --- --- ~:..=:::-~

,-- /--,
,-,-
'' - "' ,I
,
,,
- --,
,/ ,, ,

- I

, \--~
., ~:)
\
\
, - , - '" \
,' , ,"-''I
,
, ,

RI02Ml08 , RI02MQ69 AND AI02M1Q7

1. AIR BRAKE COUPLERS 5. UNLOADER VALVE TO RESERVOIR
2. HAND CONTROL VALVE 6. PRESSURE SWITCH
3. COMBINED UNLOADER VALVE 7. AIR BRAKE TEST PORT
4. AIR RESERVOIR 8. DUAL LINE CONTROL VALVE

Rae 6-14430 Issued 03-03

 Section
9001

PEDAL AND PEDAL SWITCH ADJUSTMENTS

CASE, llC
@)2002 Case, LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Rae 6-14360 November, 2002
9001-2

TABLE OF CONTENTS
INCHING PEDAL SWITCH ADJUSTMENT ......... ....... ............ ............................. ........... ....................... ................. 3

BRAKE PEDAL ADJUSTMENTS .. .................................................. ...... ....... ......................... .................................. 4

Rae 6-14360 Issued 11/02

 9001-3

INCHING PEDAL SWITCH ADJUSTMENT

:1, '0

-_I~ ,______ _
{ "

~~--o
,,~
I 0

I ~=-..::.c
==_=£t~, 0 ===::1
0 I'
__ 0
,11 -- 0 ~

/11 o

I
Iii:
'III
Iii: \ \

Ii! >\
1' :: (
L, 1

~
RT97K033 RT97K034

A. Install the switch (1) into the mounting bracket (2).

B. Turn the switch into the bracket until the tip of the switch plunger (3) is even with the mounting bracket.
C. Turn the switch an additional 2.3 turns so that the switch plunger protrudes from the bracket
approximately 4.0 mm.
D. Tighten the switch locking nuts (4) to secure the switch in position. Connect the switch to the wire harness.
E. Turn the key switch to the ON position. Enter the TRANS VIEW menu in the display. Go to the inching
pedal potentiometer position menu to observe the pedal position .
F. Shift the tractor out of park. Slowly cycle the inching pedal while watching the display. The display should
read 100% when fully up and smoothly go down to 0% when fully depressed.
G. The switch should turn OFF and ON (make a click noise) between 5 and 15% clutch travel as shown on
the display.
H. If the switch does not activate between this range, loosen the lock nut (4) and turn the switch (1) as
required until the switch will activate between 7 and 14% of pedal travel as shown on the display. Tighten
the lock nut.

Rae 6·14360 Issued 11 /02

&
9001-4

BRAKE PEDAL ADJUSTMENTS

- ---- --

---'T\
- - -rll -- - -- - -----1
,, ,,
- - - - -+ - - - - - - - - - - - - --.I

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1111

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1111
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lUI

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1111
11 11
, Ihl

r------------ J ,,,
1111
1111
, - __ _ J.III
___________ .J
, ,

RI02K092 RI02K093

Brake Pedal Stop Adjustments

A. Use the stop adjusting screw (1) to adjust the left brake pedal to the same height as the clutch pedal.
Tighten the lock nut (2) when done.
B. Adjust the right brake pedal to the same height as the left pedal. Be sure that the brake pedal lock (3) will
engage the right pedal easily. Tighten the lock nut when done.
NOTE: Be sure that there is no free play in the pedal springs (1a) after adjustment is complete. If there is, turn the
adjustment screw enough to remove any looseness in the spring.
Brake Link Rod Adjustment
C. Adjust the length of the left brake link rod (4) so that it just touches the bottom of the brake valve poppet
sleeve(5) when the brake pedal is fully extended. Tighten the clevis(6) lock nuts (7) when done. Repeat
for the right brake.
Brake Light Switch Adjustment
D. Adjust the left brake light switch (8) until the switch plunger (9) just touches the left pedal. Turn the switch
in an additional 1 to 1 1/4 turns. Tighten the lock nut (10). Repeat the procedure for the right brake pedal
switch.

Rae 6-14360 Issued 11/02

 Section
9005

CAB RAISE I REMOVAL AND INSTALLATION

MX Series Tractor

CASE, LLC
C> 2003 Case, LLC
700 State Street Printed in U.S. A.
Racine, WI 53404 U.S.A. April ,2003

s
9005-2

TABLE OF CONTENTS
SPEC IAL TORQUES .................... ...............•...... .......... ..•................... ...... ...... ....... ................. ................................. 3

SPECIAL TOOLS ................. .............. ......... ....................................................................................... ........ ............. 3

CAB RAISE PROCEDURE ..... ................ .................................................. ...... ...... ......... ......................................... 4

CAB LOWERING PROCEDURE ............. .. ................................. ............................................................................. 7

CAB REMOVAL ....................................... ...................................................... ......................... ..... .. .................... .... 10

CAB INSTALLATION ................................................................... .................... .. ............... ..................................... 16

Rae 6-13311 Revised 4~03

 9005-3

SPECIAL TORQUES
Cab Mounting Bolt to Threaded Flat Plate ............... ...................... .................................. 47 to 61 Nm (35 to 45 Ib It)
Cab Mounting Bolt Nut ............................................................................................. 190 to 244 Nm (140 to 180 Ib It)

SPECIAL TOOLS

Cab Lilt Tool CAS2531 Cab Raising Bracket Kit CAS2577

ROO2E108 Q4

Front Cab Lifting Bracket CAS2529-1 (Part Of Rear Cab Lifting Bracket CAS2529-2 (Part Of
CAS2529 Kit) CAS2529 Kit)

ROO3C059

Steering Line Quick Disconnect Tool 380000795

Rae 6-1 3311

!i
9005-4

CAB RAISE PROCEDURE

STEP 1 STEP 3

Park the tractor on a hard, level surface. Put the Open the rear window. Remove the two bolts
transmission shift lever in PARK. Place blocks in securing the rear cab panel to the cab. Remove the
front of and behind the rear wheels. Start the engine panel.
and fully raise the rear hitch. Turn off the engine and
remove the key.
STEP 4
NOTE: The right rear cab raising bracket cannot be
installed into the right rear cab support tube unless
the hitch is fully raised.

STEP 2

77·2
If equipped with rear fenders, remove the lower
fender retaining bolt and spring nut from the right
rear fender.

Loosen the thumbscrews and remove the toolbox

and battery cover. Disconnect the negative (-) battery
cable, first. Disconnect the positive (+) battery cable.

Rae &13311 Revised 4·03

 9005-5

STEP 5 STEP 7

Install a bolt (1). and a washer from the cab raising

bracket kit through the slot in the raising bracket and
the hole in the cab side panel. Install a washer and a
nut on the bolt threads and loosely tighten.

STEP 8

Remove the cab floor plugs . Remove the nuts and

washers from the front cab mounts. Remove the rear
cab mount nuts and washers.

STEP 6
Place one of the load bearings from CAS2577 under
the rear cab raising bracket. Insert one of the longer
threaded rods from the kit through the rear cab
raising bracket. the load bearing. and the through
hole in the cab support bracket. Th read the rod
through the raising bracket until the threads contact
the load bearing .

Install the right rear cab raising bracket CAS2577-1

(from CAS2577 Cab Raising Bracket Kit) into the
right rear cab support tube.

Rae 6-13311 Revised 4-03

g
9005-6
STEP 9
Insert the locking pin through the bottom of the
threaded rod. Tighten the nut on the bolt through the
raising bracket and the cab side panel.
NOTE: For photographic purposes, the locking pin
shown is on the left rear side of the cab.
STEP 10
Install the left rear cab raising bracket CAS2577-2
into the left rear cab support tube. Repeat Step 7
through Step 9 on the left rear side of the cab.
STEP 11
Remove the two screws (1) securing the left front cab
panel. Remove the three screws securing the right
front cab panel. Remove both panels from the
tractor.
Rae 6-13311
STEP 12
,&-0,
Install the upper cab raising bracket (1) from
CAS2577 Cab Raising Bracket Kit into the left front
cab support tube. Install CAS2577-3 lower raising
plate (2) on the front cab mounting bracket, using two
of the bolts from the kit. Place a load bearing on top
of the lower raising plate and insert one of the shorter
threaded rods through the upper raising bracket.
Thread the rod through the raising bracket until the
threads contact the load bearing. Insert the locking
pin through the bottom of the threaded rod . Repeat
this procedure on the opposite side of the cab.
NOTE: For easier installation of the right hand lower
raising plate (2), raise the front left side up a few
inches.
STEP 13
Turn in the four threaded rods on the cab raising
brackets in equal amounts to evenly lift the cab.
NOTE: Monitor all lines when raising or lowering the
cab to prevent breakage or bending of lines.
Revised 4-03
 9005-7

CAB LOWERING PROCEDURE

STEP 14 STEP 16

n-23
Turn out the four threaded rods on the cab raising Remove the threaded rod from the raising bracket.
brackets in equal amounts to evenly lower the cab. Remove the load bearing.
Make sure the sleeves on the cab mounting bolts
align with the holes in the cab support tubes. Begin
lowering the tractor cab. Check for pinched cables, STEP 17
lines, or hoses. Fully lower the cab.

NOTE: The cab must be evenly lowered. The cab

bolt mounting sleeves can bind in the cab support
tube holes, so the cab cannot be lowered.

STEP 15

Remove the bolt (1), nut, and the two washers from
the cab side panel and the slot in the right rear
raising bracket. Remove CAS2577-1 right rear
raising bracket (2) . Set the preload on the cab
isomounts to a torque of 47 to 61 Nm (35 to 45 Ib ft)
by holding the square plate and tightening the bolt.

Remove the locking pin from the bottom of the

threaded rod on the rear cab raising tool.

Rae 6-13311 Revised 4-03

s
9005-8
STEP 18
Install a new nut and the rear cab mount washer.
Tighten the nut to a torque of 190 to 244 Nm (140 to
180 Ib It). Have an assistant hold the head of the bolt
under the cab, if necessary.
STEP 19
Repeat the procedures from Step 15 through Step 18
on the lelt rear side of the cab to remove CAS2577-2
cab raising bracket.
STEP 20
If equipped with rear fenders, install the lower fender
retaining bolt and spring nut on the right rear fender.
Rae 6-1331 1
STEP 21
Remove the locking pin from bottom of the threaded
rod on the front cab raising tool. Remove the
threaded rod from the front cab upper raising bracket
(1) and remove the bracket. Remove the load
bearing. Detach CAS2577-3 lower raising plate (2)
by removing the two bolts. Repeat this procedure on
the opposite side of the cab.
STEP 22
Set the preload on the front cab isomounts to a
torque of 47 to 61 Nm (35 to 45 Ib It) by holding the
square plate and tightening the bolt. Have an
assistant hold the head of the bolt, if necessary
Install the front cab mount washer and a new nut.
Tighten the nut to a torque of 190 to 244 Nm (140 to
180 Ib It) on both sides of the cab. Install the cab floor
plug.
Revised 4-03
 9005-9

STEP 23 STEP 25

Open the rear window. Install the two bolts securing

the rear cab panel to the cab. Make sure the transmission shift lever is in PARK.
Start the engine and lower the rear hitch. Turn the
engine off and remove the key. Remove the wheel
STEP 24 blocks.

Install the positive (+) battery cable, first. Install the

negative (-) battery cable. Install the toolbox and
battery cover by tightening the thumbscrews.

Rae 6-13311 Revised 4-03

9005-10

CAB REMOVAL

STEP 26 STEP 28

Park the tractor on a hard, level surface. Put the
transmission shift lever in PARK. Turn off the engine
and remove the key. Place blocks in front of and
behind the front wheels. Drain the radiator on a cold
engine. Refer to the Operators Manual for cooling
system capacity. Properly support the tractor and
remove the rear wheels, if necessary.
Remove the air cleaner door from the left side of the
tractor. Remove the front windshield washer hose (1)
from the nozzle on the fixed hood. Remove the four
nuts (2) and lift the fixed hood from the right side of
the tractor.

NOTE: It is not necessary to remove the rear

STEP 29
_---:0
wheels, but may be required to gain enough
clearance at the tractor chassis and the top of the lift.

STEP 27

Remove the cab rear window washer hose (1) at the

check valve, if equipped.

Loosen the thumbscrews and remove the toolbox

and battery cover. Disconnect the negative (-) battery
cable, first. Disconnect the positive (+) battery cable.

Revised 4-03
 9005-11

STEP 30 STEP 33

ROO2E064

Disconnect the throttle linkage if equipped. Identify. tag. and remove the wiring harnesses on the
two brake light switches (1) on the brake valve.
STEP 31
STEP 34

Identify. tag. and remove the four hydraulic hoses (1)

RD02C116
and the steering sensing line (2) from the steering
hand pump. Cap the lines and open fittings. If your Tag the ground cables (1). and disconnect. Remove
tractor is equipped with quick disconnect fittings. use the cab connector (2) at the right hand front side of
special tool 380000795 to disconnect the lines. the cab.

STEP 32
STEP 35

Identify. tag . and remove the brake valve supply (1)

and return line to sump (2). Cap the lines and open
fittings.
NOTE: Hood support and air cleaner assembly
removed for photographic purposes only.
Dis connect the right hand cab heater and air
conditioning duct hose to move the transmission
wiring harness.

Rae 6-13311
9005-12

STEP 36 STEP 39

Remove the supply line to the left and right rear Remove the cab power cables at the right rear of the
brake. cab.

STEP 37 STEP 40

Remove the electrical connector from the cab Remove the cab wiring plug at the rear of the cab.
pressurization blower.
STEP 41
NOTE: Fuel tank removed for photographic
purposes.
STEP 38

Disconnect the electrical connectors for the rear cab

lights. Note the position of the four controller modules
on the rear of the cab and remove. Remove the cab
rear window washer hose from the nozzle on the left
Open the rear window. Remove the two bolts
rear fender, if equipped.
securing the rear cab panel to the cab. Remove the
panel.

Rae 6-13311
 9005-13

STEP 42 STEP 45

ROO2E068
Refer to Section 9020, Air Conditioning Component
Service, in this manual and evacuate the freon from
the air conditioning system at the capped line fittings
(arrows) attached to the rear of the air conditioning
compressor.
STEP 43
Remove the two screws (1) securing the left front cab
panel. Remove the three screws securing the right
front cab panel. Remove both panels from the
tractor.
STEP 46

101R-9A
Remove the three mirror retaining bolts and the Rem ove the cab floor plug . Remove the nut and
electrical plug, if equipped . Remove the mirrors. washer from th e front cab mount bolt. Have an
assistant hold the head of the bolt under the cab.
Repeat this ope ration on the opposite side of the
STEP 44 cab.

Install CAS2529-1 front cab lifting brackets.

Rae 6-13311 Revised 4·03

9005-14

STEP 47 STEP 50

Remove the rear cab mount nut and washer on both Attach the rear cab lifting bracket CAS2529-2.
sides of the cab. Repeat this step and the previous step on the
opposite side of the cab.
STEP 48
NOTE: Do not lift the cab until all electrical cables,
hydraulic lines, and mechanical parts needed for cab
removal have been tagged and disconnected.

STEP 51

Loosen the lower bolt, remove the upper bolt , and

swi ng the tractor rear warning marker lights down.
Finger tighten the upper boll.

38-SA2
STEP 49 Attach a lift hook to the cab lift tool CAS2531 .

STEP 52

Remove the plastic plug from the cab rear window

post and insert the J-hook from CAS2529-2 rear cab
lifting bracket in the hole. The hooked end faces Install CAS2531 cab lifting tool on the cab brackets.
downward. The rear window must be open in order to Make sure the chains do not bind against the roof or
insert the J-hook. cab lenses.

Rae 6-13311 Revised 4-03

 9005-15

STEP 53 STEP 56
\ '

Slightly lift the cab off the chassis and properly Remove the heater hoses at the air conditioning and
support the cab. heater box, located under the right hand side of the
cab. Plug the hoses and heater core fittings.

STEP 54
STEP 57
Continue lifting the cab and remove it from the
tractor. Carefully lower the cab. Properly support the
cab by the steel cab rails off the floor to provide
clearance for the cab pressurization blower.

Remove the hydraulic trailer brake supply lines (if

equipped) at the right rear side of the tractor.

STEP 55

Remove the air conditioning lines at the air

conditioning and heater box, located under the cab,
on the left side. Cap the lines and fittings.

Rae 6-13311 Revised 4-03

9005-16

CAB INSTALLATION

STEP 58 STEP 61

Make sure the chains attached to cab lift tool Lubricate new O-rings with refrigerant oil and install
CAS2531 do not bind against the roof or cab lenses. the air conditioning lines at the air conditioning and
heater box under the left hand side of the cab.

STEP 59
STEP 62

Lower the cab so that it is slightly above the chassis.

Properly support the cab. Lower the cab until the hydraulic trailer brake supply
lines (if equipped) can be installed at the right rear
STEP 60 side of the tractor. Properly support the cab. Tighten
the trailer brake supply lines.

Install the heater hoses at the air conditioning and

heater box, located under the right hand side of the
cab.

6-13311 Revised 4-03


STEP 63
00
Lower the cab on the tractor chassis, aligning the cab
mount bolts with the holes in the cab frame. Check
for pinched cables, lines, or hoses.
STEP 64
Set the preload on the rear cab isomounts to a torque
of 47 to 61 Nm (35 to 45 Ib It) by holding the square
plate and tightening the bolt. Install the rear cab
mount washer and tighten the nut to a torque of 190
to 244 Nm (140 to 180 Ib It) on both sides of the cab.
Have an assistant hold the bolt, if necessary.
6-13311
9005-17
STEP 65
Set the preload on the front cab isomounts using the
procedure in the previous step to a torque of 47 to 61
Nm (35 to 45 Ib It). Install the front cab mount washer
and tighten the nut to a torque of 190 to 244 Nm (140
to 180 Ib It) on both sides of the cab.
STEP 66
Install both front cab panels on the tractor. Install the
two screws (1) secu ring the lelt front cab panel and
the three screws securing the right front cab panel.
Revised 4-03
9005-18

STEP 67 STEP 70

Remove the cab lifting tool and the front and rear cab
lifting brackets. Install the plastic plugs in the cab
rear window posts.
STEP 68
Refer to Section 9020, Air Conditioning Component
Service, in this manual and recharge the ai r
conditioning system with freon at the capped line
fittings (arrows) attached to the rear of the air
conditioning compressor.
STEP 71

Remove the upper bolt and swing the tractor rear

warning lights up. Tighten the upper and lower bolts.
STEP 69
Install the four controller modules on the rear of the
cab. Plug in the connectors for the rear lamps. Install
the cab rear window washer hose to the nozzle on
the left rear fender, if equipped.

Install the mirrors and the three mirror retaining bolts.

Connect the electrical plug if equipped .

6-13311 Revised 4·03

 9005-19

STEP 72 STEP 75

Install the cab wiring plug at the rear of the cab. Insta ll the el ec trical connector from the cab
pressurization blower.

STEP 73 NOTE: Fuel tank removed for photographic

purposes.

STEP 76

Install the cab power cables at the right rear of the

cab.

STEP 74 Install the supply line to the left and right rear brake.

STEP 77

Install the two bolts securing the rear cab panel to the
cab.

Position the transmission wiring harness and install

the right hand cab heater and air conditioning duct
hose.

6·13311 Revised 4-03

9005-20

STEP 78 STEP 80

Using the identification tags from the disassembly
procedure, install the ground cables (I). Install the
cab connector (2) at the right hand front side of the
cab.
Use the identification tags to install the wiring
harnesses on the two brake light switches (I).
STEP 81

STEP 79
rr-:-"""'-:--"T""I_

Use the identification tags to install the four hydraulic

hoses (I) and the steering sensing line (2) on the
Use the identification tags to install the return and steering hand pump.
supply line on the brake valve.

NOTE: Hood support and air cleaner assembly

removed for photographic purposes only.

6-13311 Revised 4-03

 9005-21

STEP 82 STEP 85

Connect the throttle linkage. Connect the positive (+) battery cable, first. Connect
the negative (-) battery cable. Install the battery cover
NOTE: Only on Models MX210 and MX230 tractors. and toolbox. Tighten the four thumbscrews.

STEP 83 ...,....._ _ STEP 86

Install the cab rear window washer hose (1) at the Install the rear wheels, if removed. Apply anti seize to
check valve, if equipped. the wheel hub bolts and tighten in a crossing pattern
to a torque of 530 to 570 Nm (390 to 420 Ib ft).
STEP 84 Remove the rear axle supports, if the rear wheels
were removed. Fill the cooling system. Refer to the
Ope rato rs Manual for cooling system capacity.
Check the hydraulic fluid level. Add fluid as needed.
Remove the front axle wheel blocks.

Install the fixed hood on the right side of the tractor.

Install and tighten the four nuts (1). Install the front
windshield washer hose (2) to the nozzle on the fixed
hood. Install the air cleaner door on the left side of
the tractor.

6-13311 Revised 4·03

 9005-22

6-13311 Revised 4-03

 Section
9008

TILT AND FIXED HOODS, AC CONDENSER,

RADIATOR, AND AIR-TO-AIR AFTER COOLER

MX Series Tractor

CASE CORPORATION
C 2002 Case Corporation
700 State Street Printed in U.S.A.
Racine. WI 53404 U.S.A. Rae 6-13100 October, 2002

L
9008-2

TABLE OF CONTENTS

TILT AND FIXED HOODS ................................ .............. ....... ...................................................... ......... •••.. ...... ........ 3
Removal ......... ... ................ ...•. ............... .....................•.............••.. ................. ................... .................................... 3
Installation ................................ ...................... .................................................................................•......... ........... 5

AIR CONDITIONING CONDENSER .... ...................... ....•.................. .............................. ...................••••............... .. 6

Removal ................................................ .••. ................••........... ..•.....................•...............................•................ ..... 6
Installation .... .................. ........... ................................................. ..... ...... ............ ......................... ............. ............. 7

AIR-TO-AIR AFTERCOOLER ......................................................................................................................... ... ..... 9

Removal ..... ...... .................................. ........................................ ........... .......................... ........ ............................. 9
Installation ......................................... ......... ......... .. .....•...................... ............... ............................................. ..... 10

RADIATOR .. ...........................••........ ................. ............••....................................... .................................. ..... ........ 11

Removal ........................................................ ...........................••.......... ............................................•••..... .......... 11
Installation ................................... ......................................................................•............. ..................•................ 13

Rae 6-13100 Issued 10-02 Printed in U.S.A

 9008-3

TILT AND FIXED HOODS

Removal STEP 3

STEP 1

Lift up and remove the air cleaner door from the left
side of the tractor.

Park the tractor on a hard , level surface. Put the

transmission shift lever in PARK. Turn off the engine STEP 4
and remove the key. Place blocks in front of and
behind the rear wheels.

STEP 2

Remove the front windshield washer hose (1) from

the nozzle on the fixed hood. Remove the four nuts
(2) and lift the fixed hood from the right side of the
tractor.

Press the hood release button and open the tilt hood.

Rae 6-13100 Issued 10-02

9008-4

STEP 5 STEP 8

Disconnect the electrical plug for the tilt hood front

lamps.

STEP 6

Loosen, do not remove, the two bolts (1) on the hood

retaining bar. The retaining bar is shown in the
locked position (2). Move the bar down to the
unlocked position (3) and remove the tilt hood.
Properly support the hood.
NOTE: Tilt hood removed for photographic purpose.

STEP 7

Remove the wire retaining clip at the hood support

ball stud on both sides of the tractor. Remove the
hood supports.

Rae 6-13100 Issued 10-02

 9008-5

Installation STEP 12

STEP 9

Connect the electrical plug for the tilt hood front

lamps.
Properly support the tilt hood and move it into
position. STEP 13
STEP 10

Install the fixed hood on the right side of the tractor

Install the hood. Move the retaining bar into the
locked position (1). Tighten the bolts (2).
NOTE: Tilt hood removed for photographic purpose.
STEP 11
Install and tighten the four nuts (1). Install the front
windshield washer hose (2) on the nozzle located on
the fixed hood.
STEP 14

Install the air cleaner door on the left side of the

Install the hood supports and the wire retaining clip at
tractor.
the hood support ball stud on both sides of the
tractor.

Rae 6-13100 Issued 10·02

2
9008-6

AIR CONDITIONING CONDENSER

Removal STEP 17

STEP 15

Lift the tilt hood for access to the air conditioning

condenser. Refer to Section 9020, .l\ir Conditioning
Component Service, in this manual and evacuate the
freon from the air conditioning system.

STEP 16

Remove the two left upper condenser bracket

retaining bolts (1). Remove the left upper condenser
mounting bolt (2) and secure the ether start
assembly, horn, and receiver-drier out of the way.
Slide the spring clamps (3) on the hoses. Tag and
remove the fuel cooler hoses.

Tag and remove the two air conditioning hoses at the

condenser. Discard the O-rings.

Rae 6- 13100 Issued 10-02

 9008-7

STEP 18 STEP 20

Remove the two left lower condenser bracket

retaining bolts (1). Remove the right upper and lower
condenser bracket retaining bolts. Remove the
condenser from the tractor.

Installation

STEP 19

Install the fuel cooler hoses and the spring clamps

(1). Install and tighten the horn and receiver-drier
bracket and the ether start bracket (if equipped)
retain ing boits (2). Install and tighten the left upper
condenser mounting bolt (3).

STEP 21

Position the condenser on the mounting brackets.

Install and tighten the two left lower condenser
retaining bolts (1). Install the right upper and lower
condenser bracket retaining bolts . Check for
clearance between the air conditioning condenser
and the air-to-air aftercooler.

Lubricate new air conditioning O-rings with

refrigerant oil and install on the hose fittings. Install
the air conditioning hoses.

Rae 6-13100 Issued 10-02

9008-8

STEP 22

Refer to Section 9020, Air Conditioning Component

Service, in this manual and recharge the air
conditioning system with freon.

Rae 6-13100 Issued 10·02

 9008-9

AIR-TO-AIR AFTERCOOLER

Removal STEP 25

STEP 23

RD02G032

Loosen the lower hose clamp and remove both

aftercooler hoses.
RD02G030
Lift the tilt hood and remove the upper and lower air
conditioning condenser mounting bolts on both sides STEP 26
of the tractor.

NOTE: It is not necessary to open the air

conditioning system fittings or evacuate the freon
when replacing the air-to-air aftercooler.

STEP 24

Move the aftercooler tubes out to the sides of the

tractor. Remove the upper and lower aftercooler
mounting bolts on both sides of the tractor and
remove the aftercooler.

Place protection on top of the engine. Remove the

condenser with attached brackets and hoses and
secure the assembly on top of the engine.

NOTE: It is not necessary to remove the fixed hood

and the tilt hood. Tilt hood is removed for
photographic purpose.

Rae 6-13100 Issued 10·02

9008-10

Installation STEP 29

STEP 27

Remove the condenser assembly from the top of the

Install the aftercooler and the upper and lower
afte rcooler mounting bolts on both sides of the
tractor.
engine. Route the hoses and position the assembly
at the front of the tractor.
STEP 30

STEP 28

~ ..'"
RD02G03O
Install the upper and lower air conditioning
condenser mounting bolts on both sides of the
tractor.
Install both aftercooler hoses and tighten the lower
hose clamp.

Rae 6-13100 Issued 10-02

 9008-11

RADIATOR

Removal STEP 33

STEP 31

Remove the upper radiator hose at the clamp. Move

the upper radiator tube out of the way.

Remove the fixed hood and the tilt hood by following

the procedure in this section . Begin radiator removal STEP 34
by using the aftercooler removal procedure in this
section. Drain the coolant from the radiator into a
suitable, clean container.

STEP 32

Remove the left and right fan shields by removing the

bolt and pulling out on the shield.

STEP 35

Move the air-to-air aftercooler tubes off to the sides

of the tractor. Remove the left and right radiator top
plate mounting bolts.

Loosen the hose clamp at the radiator and remove

the lower radiator hose.

Rae 6-13100 Issued 10-02

 9008-12

STEP 36 STEP 37

Remove the four retaining bolts for the fan shroud

and slide the fan shroud toward the engine.

Remove the seal (1) under the left hydraulic oil

cooler. Disconnect the return line (2). and the supply
line (3). Discard the O-rings. Loosen the three front
and three rear oil cooler retaining bolts (4). Remove
the left oil cooler (5). Repeat this procedure for the
right hydraulic oil cooler. Remove the two lower
radiator mounting bolts (6) on both sides of the
tractor. Inspect the four lower radiator mounts .
Remove the radiator. Remove and discard the three
lower radiator seals.

Rae 6-13100 Issued 10·02

 9008-13

Installation STEP 39

STEP 38

Install the four fan shroud retaining bolts.

STEP 40

Replace the three lower radiator seals. Replace any Install the lower radiator hose on the radiator and
worn lower radiator mounts. Position the radiator on tighten the clamp.
the tractor. Install the two lower radiator mounting
bolts (1) on each side. Install new O-rings on the oil
cooler lines. Install the left oil cooler (2). Hand tighten STEP 41
the six oil cooler retaining bolts (6) at this time. Hand
tighten the return line (3), and the supply line (4).
Tighten the six oil cooler retaining bolts (6) . Tighten
the return line (3) and the supply line (4). Install the
seal (5). Repeat the above procedure for the right oil
cooler.

Install the upper radiator hose and tighten the clamp.

Rac 6~13100 Issued 10-02

9008-14

STEP 42 STEP 44

Install the left and right radiator top plate bolts.
STEP 43
Install the aftercooler, condenser, fixed hood , and tilt
hood by using the installation procedure in this
section. Fill the cooling system. Check the coolant
level at the coolant reservoir and the deaeration tank.
Fill the hydraulic system with hydraulic oil and check
the level. Make sure the transmission shift lever is in
Park. Start the engine briefly. Shut the engine off and
recheck all connections and fluid levels. Restart and
run the engine. Turn the engine off and remove the
key.

Install the left and right fan shields and tighten the
bolt.

Rae 6·13100 Issued 10-02

 Section
9010

AIR CONDITIONING TROUBLESHOOTING

MX MAGNUM TRACTORS 210, 230, 255 and 285

Case, LLC
© 2003 Case, LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. 6·12840 March,2003
9010·2

TABLE OF CONTENTS
SAFETY PROCEDURES ........................................... ........................................... ............... ........... ........................ 4

SPECIAL TOOLS ................................................................................ ........................................................ ............ 5

AlC THERMAL OPERATION ................................... .......... ................................... ... ............................................... 7

AlC SYSTEM COMPONENTS ....... ......... .............................. ................... ..... ........ .................................................. 9
Cab HVAC Box Components· Automatic Temperature Control .............................. .................................. ......... 9
Cab HVAC Components· Standard Systems .. ........... .................... ..................... ............. ...... ................... .... ... 11
MX 210/230 Chassis Components ............................. ..... ............................. .................. ..... .............................. 13
MX 255/285 Chassis Components ........ ................................................. ... .. ...... ........................ ........................ 14

Automatic Temperature Control (ATC) Troubleshooting .................................................. 15

Important Notes ..................... ....... ................................. ................. ................................ .................... •.............. 15

(ATC) AUTOMATIC TEMPERATURE CONTROL SCHEMATIC ................................ .......................................... 17

Fuse and Relay Panel, Key Electrical Connectors .......... ................................... ............ ................................... 18

AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION .......................................................................... 19

ATC FAULT CODES .......................................................................................................................... ................... 24

LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ... ............................................ ......... ................... 27
Controller·Based Resistance Tests ................................................................... ............. .. ......... ....................... . 27

ATC CONTROLLER TEST ...................................................... ...... ........ .. ..... ... .............................. ........................ 28

FIELD REPORTED SYM PTOMS/CAUSES ............................................. ........... .......... ........ ...... ........... ............. .. 31

COMPRESSOR AN D CLUTCH .. ............... ............ .. ...................................... ....................................................... 32

Operational Check ............................ ......................... ..................... .................. ..................... ............................ 32
Electrical Test · Compressor Clutch ....... ..................... ...... ................................................................................ 35
Compressor Clutch Control Circuit Test Proced ure ..... .................................. .................................................... 36

HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ............................................................. 38

Electrical Test - Pressure Switches ............................................................................................. ...................... 40
High Pressure Switch and Circuit Test .............................................................................................................. 41
Low Pressure Switch and Circuit Test ........................ .............................................................................. ......... 41

HEATER CONTROL VALVE ................ .............. ........ ........................................................ .......... ............... .......... 42
Operational Check ............. ..................... .......... ..................... .................................... .......... ........... ................... 42
Electrical Test - Heater Control Valve ............... .................... ........ ............................ ..................... ................... 43
Heater Control Valve Power, Signal and Ground Test ................................................... ............... .................... 44

BLOWER SPEED AND TEMPERATURE CONTROL POTS ............ .............................................. .................... . 45

Electrical Test - Potentiometers ........................................................................................................................ 46
Common Control Potentiometer and Circuit Test Procedure ... ..................................... ..................................... 47

BLOWER AND BLOWER SPEED DRIVER .......................................................................................................... 48

Blower Motor/Blower Driver Power, Signal and Ground Test ......................... ............................. ................... ... 49

CAB AND EVAPORATOR TEMPERATURE SENSORS ................................................................. ..................... 50

Electrical Test - Temperatu re Sensors ....................................................................................... .. ..................... 52
Cab Temperature Sensor and Circuit Test ........................................................................................................ 53
Evaporator Temperature Sensor and Circuit Test ............................... ..................................... ......................... 54
Rae 6·12840 Issued 3-03
 9010·3
CONTROLLER POWER AND GROUND, ATC SWITCH ......................................... ............................................ 56
Controller Power Supply and Ground Test ........................................................................................................ 57
ATC Switch and Circuit Test .................................................... ........................... ............ ................................... 57

LCD DiSPLAy ....................................................................................................................................................... 58

LCD Display and Circuit Test ............................................................................................................................. 59

FAHRENHEIT/CELSIUS DISPLAY ......... .................................................................... ...................... .................... 60

CAB PRESSURIZER BLOWER .... ......... .......... .............. ................. ............................. .... ..................................... 61
Cab Pressurizer Blower & Relay Power Supply and Ground Test ..................... .................... ........................... 62

Standard Air Conditioning (STD) Troubleshooting ............................................................ 63

Important Notes ...................................................................... ....... .................... ......... ....................................... 63

STANDARD AlC SCHEMATIC .............................................................................................................................. 65

Fuse and Relay Panel, Key Electrical Connectors ......................................................................................... ... 66

STANDARD AlC OPERATION ................. ............................................................. ........ ........................................ 67

SYMPTOM·BASED STANDARD AlC TROUBLESHOOTING ............... ............................................................... 69

STANDARD CONTROLLER TEST ............... ........................................................................................................ 71

COMPRESSOR AND CLUTCH ...................................................................... ...... ................... ............................. 73

Operational Check ................................. ........................................................................ ....... ......... .................... 73
Electrical Test - Compressor Clutch ........................ ................ ....... ................................................................... 76
Clutch Relay Power Supply and Ground Test .................................................... ..................... .......................... 77

HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ............................................................. 79

Electrical Test - Pressure Switches .. ...................... ............................................ ............................................... 81
High Pressure Switch and Circuit Test .............................................................................................................. 81
Low Pressure Switch and Circuit Test ............................................................................................................... 82

HEATER CONTROL VALVE ................................................................................................................................. 83

Operational Check ..................................... ........................................................................................................ 83
Electrical Test ..................................................... .................... ........................................................................... 84
Heater Control Valve Power, Signal and Ground Test ...... ..................... .................... ......................... .............. 84

TEMPERATURE CONTROL POT .......... ...... ................................................. ....................................................... 86

Electrical Test .......................... ....................... ............................... ...................... ....... .................... ................... 86
Temperature Control Potentiometer and Circuit Test ............ ............................................................................ 87

BLOWER SPEED SWITCH AND BLOWER MOTOR ......................................................................... .................. 88

Blower Speed Switch and Power Circuit Test ................................................................................. ................... 89
Blower Motor Power, and Control Circuit Test ....... ............................................................................................ 89

EVAPORATOR TEMPERATURE SENSOR ......................................................................................................... 91

Electrical Test - Sensor ..................................................................................................................................... 91
Evaporator Temperature Sensor and Circuit Test ............................................................................................. 92

CONTROLLER POWER AND GROUND, AlC SWITCH ................................................... .................................... 94

Controller Power Supply and Ground Test ........................................................................................................ 95
AlC Switch and Circuit Test ............................................... ........ ..................................................... ....... ............ 95

CAB PRESSURIZER BLOWER ............................................................................................................................ 96

Cab Pressurizer Blower & Relay Power Supply and Ground Test ........... ......... .......................... ...................... 97

Rae 6·12840 Issued 3-03

:10:0
9010-4

SAFETY PROCEDURES

THIS SAFETY ALERT SYMBOL INDICA TES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULL Y READ THE MESSAGE THA T
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEA TH. M171 B

ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems.
Refrigerant HFC-134a is the most stable and
easiest to work with of the refrigerants now used in
air conditioning systems. Refrigerant R-134a does
not contain chlorofluorocarbons (CFC's) which are
harmful to the earth's ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1 . Always wear combination impact and chemical
splash safety goggles when doing any service
work near an air conditio ner system . Liquid
refrigerant in the eyes can cause serious injury.
Do the following if you get refrigerant near or in
your eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately. M779
2. Always reclaim all refrigerant prior to opening an
AlC system. (See Section 9020.) A drop of liquid
refrigerant on your skin may cause frostbite
burns. Open fittings carefully and slowly when
servicing the air conditioning system. Your skin
must be treated for frostbite burns or a physician
must be seen if you get refrigerant on your skin.
M799
3. Keep refrigerant containers in correct upright
position . Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat. M743
4. Always check refrigerant purity with the
OEM4450 Refrigerant Identifier before
recovering refrigerant and before testing the
system. See Section 9020. M777
5. Use the air-powered OEM1691 ONLY to recover
contaminated refrigerant. Do NOT use OEM 1415
or OEM -1418 recycling stations to recover
contaminated refrigerant. If contaminated
refrigerant contains more than 2% hydrocarbon
(propane, butane or isobutance), the mixture
must be considered flammable; if more than 4%
hydrocarbon , the mixture must be treated as
explosive ; in both cases an electric-powered
recovery station may NOT be used. Avoid heat,
sparks and flame when working with th is
contaminated refrigerant. M800

Rae 6-12840 Issued 3-03

 9010-5

SPECIAL TOOLS
OEM1415 Refrigerant Recovery Station
6 Foot Length , Quick Disconnect Refrigerant
Charging Hoses : OEM1438 (Yellow). OEM1439
(Blue) , OEM1440 (Red)

20 Foot Length, Quick Disconnect Refrigerant Hoses

- OEM1442 (Set includes Yellow, Blue and Red
hoses)

Compressor Tool Set, CAS10747A

The compressor dipstick (1 ) can be found in the
Compressor Tool Set or purchased separately -
CAS10747-19.

RD99K079

9 Inch Stem Type Thermometer

0° TO 250°F CAS10248

299L7B

Combination Impact and Chemical Splash

Safety Goggles

299L78

Rae 6-12840 Issued 3-03

9010-6

Refrigerant Identifier OEM4450

Multimeter/Digital Voltmeter

Rae 6-12840 Issued 3-03

 9010-7

Ale 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.
(See diagram on next page to follow refrigerant flow.)
The refrigerant, still in high pressure liquid form,
flows from the receiver-drier to the expansion valve.
The expansion valve provides a restriction to
refrigerant flow to cause a pressure drop which
allows the liquid refrigerant to expand, decreasing its
temperature and pressure.
NOTE: The thermal expansion is internally
equalized: the need for refrigerant to handle the heat
load is balanced with the ability to fully vaporize the
refrigerant within the one valve.

The compressor receives the refrigerant as a low
pressure gas. The compressor then compresses the
refrigerant and sends it in the form of a high pressure
gas to the condenser. Air flow through the condenser
removes the heat from the refrigerant. As the heat is
removed the refrigerant is "condensed" to a high
pressure liquid.
This low temperature, low pressure liquid or mist
flows through the evaporator. The hot cab air passes
through the evaporator fins cooling the air and
evaporating the liquid refrigerant.
The low pressure gas returns to the compressor and
the cycle starts all over again.

The high pressure refrigerant liquid flows from the

condenser to the receiver-drier. The receiver-drier is
a container filled with moisture removing material,
which removes any moisture that may have entered
the air conditioner system in order to prevent
corrosion of the internal components.

NOTE: Not all refrigerant leaves the condenser as a

liquid. Some leaves as a gas without affecting
system performance. Liquid refrigerant pools at the
bottom of the receiver-drier, while the lighter gas
collects at the top. Since the pick-up tube draws
refrigerant from the bottom of the receiver-drier, only
liquid refrigerant flows to the thermal expansion
valve.

Rae 6-12840

g
9010-8

CD

<Sl[QJ[QJ[QJ[QJ[Q][Q]
[QJ [Q] [Q] [Q] [QJ [Q] ~ [Q] [QJ [Q]

CD

~ LOW PRESSURE GAS

[Q] [Q] [Q] LOW PRESSURE LIQUID
hOoOoOOl HIGH PRESSURE GAS
_ HIGH PRESSURE LIQUID
209l95
1. COMPRESSOR 3. RECEIVER-DRIER 5. EVAPORATOR
2. CONDENSOR 4. THERMAL EXPANSION VALVE

Rae 6· 12840 Issued 3·03

 901 0 -9

AlC SYSTEM COMPONENTS

Cab HVAC Box Components - Automatic Temperature Control

1. ATC CONTROLLER
2. BLOWER MOTOR/FAN ASSEMBLY
3. HEATER CONTROL VALVE
4. BLOWER SPEED DRIVER
5. COMPRESSOR CLUTCH RELAY
6. CAB T EMPERATURE SENSOR
7. EVAPORATOR TEMPERATURE SENSOR
8. THERMAL EXPANSION VALVE
9. LOW PRESSURE SWITCH
10. EVAPORATOR/HEATER ASSEMBLY

Rae 6- 12840 Issued 3·03

9010-10

Cab HVAC Box Components - Automatic Temperature Control

v 1. LID ASSEMBLY
1 2. CONTROLLER MOUTING PLATE
3. ATC CONTROLLER
I ~-----i 1 4. BLOWER SPEED DRIVER
5. BLOWER DRIVER MOUNTING PLATE
6. BLOWER/MOTOR ASSEMBLY
7. LOW PRESSURE SWITCH
8. THERMAL EXPANSION VALVE
9. NC SUCTION LINE TUBE
10. NC LIQUID LINE TUBE
11 . HEATER MOTORNALVE ASSEMBLY
12. HEATER SUPPLY TUBE
13. HEATER RETURN TUBE
14. EVAPORATOR/HEATER ASSEMBLY
15. EVAPORATOR TEMPERATURE SENSOR
16. CAB TEMPERATURE SENSOR
17. COMPRESSOR CLUTCH RELAY
18. HVAC GROUND STUD
19. CONDENSATE DRAIN HOSE
20. CHECK VALVE
21. EVAPORATOR BOX ASSEMBLY

At03B049

Rae 6-12840 Issued 3·03

 9010-11

Cab HVAC Components - Standard Systems

1. STANDARD CONTROLLER
2. COMPRESSOR CLUTCH RELAY
3. EVAPORATORIHEATER ASSEMBLY
4. EVAPORATOR TEMPERATURE SENSOR
5. HVAC BOX GROUND
6. HEATER CONTROL VALVE
7. THERMAL EXPANSION VALVE
8. LOW PRESSURE SWITCH
9. BLOWER MOTOR ASSY WITH RESISTORS

Rae 6-12840 Issued 3-03

b
9010-12

Cab HVAC Components - Standard Systems

RI99M043

1. LID ASSEMBLY 6. LOW PRESSURE SWITCH 13. EVAPORATOR TEMPERATURE SENSOR

2. STANDARD NC CONTROLLER 7. HEATERIEVAPORATOR COIL ASSEMBLY 14. BASE WELDMENT
3. BLOWER ASSEMBLY 8. HEATER CONTROL VALVE ASSY 15. EVAPORATOR BOX ASSEMBLY
4. RESISTOR ASSEMBLY 9. NC SUCTION LINE TUBE 16. THERMAL EXPANSION VALVE
A. RESISTOR 10. NC LIQUID LINE TUBE 17. CLUTCH RELAY
B. MOUNTING BRACKET 11 . HEATER SUPPLY HOSE 18. DRAIN HOSE
5. WIRE HARNESS (NOT SHOWN) 12. HEATER RETURN HOSE 19. CHECK VALVE

Rae 6-12840 Issued 3·03

:D
i!l !5:
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1. COMPRESSOR 5. RECEIVER-DRIER 9. COMPRESSOR (DISCHARGE LINE) TO CONDENSER HOSE
2. COMPRESSOR CLUTCH 6. HEATER SUPPLY LINE
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10. CONDENSER TO RECEIVER-DRIER HOSE
~ 3. AlC HIGH PRESSURE SWITCH 7. HEATER RETURN LINE 11. RECEIVER-DRIER TO THERMAL EXPANSION VALVE HOSE ~
~ ~
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4. CONDENSER 8. SHUT-OFF VALVE 12. EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE
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~ 1. COMPRESSOR 5. RECEIVER·DRIER 9. COMPRESSOR (DISCHARGE LINE) TO CONDENSER HOSE

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2. COMPRESSOR CLUTCH
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6.
7.
HEATER SUPPLY LINE
HEATER RETURN LINE
10.
11.
CONDENSER TO RECEIVER·DRIER HOSE
RECE IVER·DRIER TO THERMAL EXPANSION VALVE HOSE
~ ~

'"6 i 4. CONDENSER 8. SHUT·OFF VALVE 12. EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE
; LI________________________________________________________________________________________________________________________________-0
'"
 9010-15

Automatic Temperature Control (ATC)

Troubleshooting

Important Notes
ABBREVIATIONS: Connectors and their pins or
terminals are abbreviated throughout the
troubleshooting section. C139-V represents pin Von
connector 139; C333-15 represents pin 15 on
connector 333.

IMPORTANT: The ATC control/er and many

components are grounded to "HVAC ground." HVAC
ground is both a grounding stud at the rear of the
HVAC box and chassis ground at ring terminal 173F
- on wire 309_ATC-Or within the box and wire 177F-
Bk outside the box. The stability of this ground is
essential for reliable troubleshooting.

WARNING: All operating controls must be in neutral

or park lock position when performing these tests.
Ground Stud at Rear of HVAC Box
NOTE: Use a multimeter (OVOM) for these tests. Do
NOT use a self-powered test light for any of these
tests.

NOTE: The batteries must be fully charged and all

connections clean and tight. Inspect all connectors
for damage, bent or dislocated pins or improper
seating when troubleshooting.

Rae 6-12840 Issued 3-03

 9010-16

Aac 6-12840 Issued 3-03

 9010-19

AUTOMATIC TEMPERATURE CONTROL (AT C) OPERATION

The ATC controller is a closed loop control device
which takes the data from a variety of inputs and
executes output instructions to the devices it controls.
The controlling parameter for the system is cab
inside temperature.
The operator selects a desired cab temperature with
the temperature control. The controller uses the
compressor, heater control valve and blower speed
to drive to and maintain the desired setpoint.

The controller receives input from the following controls and sensors:

ATC Switch on the desired operational mode for the system: Off, Automatic or
Defog/Defrost,
Cab Temperature Sensor, located at the recirculated air return, on current cab temperature,
Setpoint Temperature, selected by the operator with temperature control, on desired cab
temperature,
Evaporator Temperature Sensor, inserted in the evaporator/heater assembly, on current cooling or
heating temperatures,
Low Pressure Switch on the status of abnormal system pressures on the low side,
High Pressure Switch on the status of abnormal system pressures on the high side,
Blower Speed Control when the operator chooses to override the blower speed selected
by the controller,
and °FfO C Display Selector which changes temperature display from fahrenheit to celsius.

To accomplish its heating and cooling functions, the controller uses the following output devices:

Compressor Clutch via Clutch Relay to engage or disengage the compresso r to achieve the
desired cab cooling setpoint,
Heater Control Valve, by varying the valve opening, to achieve the desired cab
heating setpoint,
Blower Speed via Blower Speed Driver to deliver the conditioned air from the evaporator/heater
assembly at a speed proportional to the gap between the
current cab temperature and the desired setpoint,
and LCD Display to display the desired cab temperature setpoint, operational
modes, system status and fault codes.

Rae 6-12840 Issued 3-03

9010-20
ATC Controls and Their Function
Manual selection of blower
1. B lower Speed Control speed which overrides
controller selection
2. ATe Switch Selects operational mode
Displays temperature selpolnt
3. LCD Display
and system status
Selects temperature selpolnl,
4. Temperature Control the controlling parameter for
the system
Rae 6·12840
RH03B059
A. Blower OFF
8. Maximum Blower Speed
C. Automatic Mode
D. OFF (Ambient Air Recirculation)
E. Defog/Defrost Mode
® ® CD
~
[ IiEJ
0
't-1
~
t-1
.......... ~
~ ~
® CD
RH98G032
F. Digital Temperature Display: Displays current selpoint selected by
the operator for desired cab temperature.
On start-up flashes "SS" for short time to indicate that the controller
is initializing.
When system fault occurs, display toggles between temperature
display and fault code number.
G. Displays OF or °C for Fahrenheit or Celsius; installing 5 amp fuse in
cavity 28 of fuse block 261 converts display to degrees Celsius.
H. Icon displays when system is operating in Defog/Defrost mode.
I. Icon displays when system is operating in Automatic mode.
J . Service Required Icon: Icon flashes along with a fault code when
system fault is detected .
K. ATC Temperature Range - 60 of to 90" F (15.5" C 10 32" C)
L. Maximum Cooling Zone - 60" F (15.5" C)
M. Maximum Heating Zone - 90" F (32" C)
Issued 3-03

Operational Modes
The ATC system has three operational modes
selected with the ATC switch : Off, Automatic or
Defog/Defrost.
NOTE: See the charts on the following pages for
specific information on automatic controller functions
when in automatic or defog/defrost mode.
Off
With the ATC switch Off, only the blower and blower
pot are energized. This provides cab ventilation with
ambient outside air. Blower speed is variable across
the range of the potentiometer - 30 positions.
The compressor, heater control valve, temperature
control and LCD are OFF.
NOTE: With this ATe system, those functions
normally associated with "manual mode" are only
available in Automatic mode when an operator
overrides the system controller.
Automatic Mode
With the ATC switch on "A" for automatic or
"s nowflake " icon, the controller engages the
compressor clutch or opens the heater valve as
needed to achieve or maintain cab temperature
set point. The controller selects blower speed based
on the difference between actual cab temperature
and the desired setpoint.
DefoglOefrost Mode
With the ATC switch on the "defog/ddefrost" icon, the
compressor runs continuously to remove moisture
from the air and is only cycled by the freeze setting of
the evaporator temperature setting. For proper use of
this mode, the temperature control setting should be
in the heating range.
The controller opens the heater control valve as
needed to achieve or maintain cab temperature
setpoint. The controller selects blower speed based
on the gap between actual cab temperature and the
desired setpoint.
Rae 6-12840
16
9010-21
Manual Override
In Automatic and Defog/Defrost modes, an operator
can override automatic control of blower speed by
turning the control manually.
The function remains manually controlled until the
ATC switch is cycled OFF and then returned to a
mode position. Overriding control of one function
does not affect the automatic operation of another;
the system still attempts to maintain the temperature
automatically.
Temperature control - engaging the compressor or
opening the heater valve - is always automatic.
The "A" disappears from the LCD when a function is
overridden in automatic mode or when the
temperature control is moved into either maximum
output zones ; however, the defog icon does not
disappear when a function is overridden in defog/
defrost mode.
Maximum Output Setting
At the extreme ends of the cooling and heating range
on the temperature control are the maximum system
output settings, indicated by hash marks on the
control decal.
Whe n the temperature control is moved into either
maximum zone, blower speed is increased to 100%.
In the cooling range, the compressor runs
continuously and is only cycled by the freeze setting
of the evaporator temperature sensor. In the heating
range, the heater control valve opens fully.
The maxim um output settings are active in both
automatic and defog/defrost modes.
When maximum output zone is entered in automatic
mode, the "A" disappears from the LCD. When the
temperature control is moved out of the maximum
zone, the system returns to automatic operation and
the "A" displays on the LCD.
In defog/defrost mode, the defog icon continues to
display on the LCD when the maximum zone is
entered . Auto matic control returns when the
temperature control is moved out of the maximum
zone.
Issued 3·03
9010-22

AUTOMATIC OPERATION SUMMARY

(ATC switch set to "A," and "A" displays on the LCD. 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. Selecting a setpoint one degree cooler or warmer than the temperature desired
may increase operator comfort.
Then the blower speed
If difference between cab temperature
used by the controller
and the setpoint is ...
is ...
less than or equal to 2°F (1 °C) 25%
greater than 2°F (1 0c) but less than or equal to 4°F (2°C) 35%'
Blower Speed greater than 4°F (2°C) but less than or equal to 6°F (3°C) 45%·

greater than 6°F (3°C) but less than or equal to 8°F (4°C) 550/0'"
greater than 8°F (4°C) but less than or equal to 1Q°F (5°C) 65%'
greater than 1Q°F (5°C) but less than or equal to 12°F (6°C) 750/0·
greater than 12°F (6°C) 100%'
Compressor Clutch Compressor clutch is cycled ON or OFF by the controller as needed to drive to or
Cycling maintain the desired cab temperature setpoint.
Heater Control Heater control valve is opened or closed as needed to drive to or maintain the desired
Valve cab temperature setpoint.

Manual Override of
•
•
Blower speed remains in position selected by operator.
LCD no longer displays "A" for automatic.
• Temperature control remains automatic, but controller cannot use any speed beyond
Blower Control
that selected to achieve the desired setpoint.
• Turning ATC switch OFF and then to "A" returns system to automatic operation.
• Blower speed at 100%.
• Compressor runs continuously. The clutch is only cycled OFF when the freeze
setting - 32° F (0° C) - is reached at the evaporator temperature sensor, and then ON
Maximum Cool
again when temperature sensed warms to 37° F (3° C).
Setting Selected
• LCD no longer displays "A" for automatic.
• Moving the temperature control outside the maximum range returns the system to
automatic control of compressor and blower speed .

•• Blower speed at 100%.'

Heater control valve at full open position
Maximum Heat
Setting Selected •• LCD no longer displays "A" for automatic.
Moving the temperature control outside the maximum range returns the system to
automatic control of valve and blower speed.
' When heating is selected, blower speed remains at 25% until temperature sensed at
Exception
evaporator exceeds 55° F (12.8° C).

Rae 6· 12840 Issued 3-03

 9010-23

DEFOG/DEFROST OPERATION SUMMARY

(ATC switch set to "defog/defrost" icon, and "defog" icon displays on LCD_ 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. Selecting a setpoint one degree cooler or warmer than the temperature desired
may increase operator comfort.
Then the blower speed
If difference between cab temperature
used by the controller
and the setpoint is ...
is ...
less than or equal to 2°F (1 °C) 25%
greater than 2 of (1 °C) but less than or equal to 4°F (2°C) 35%·
Blower Speed greater than 4°F (2°C) but less than or equal to 6°F (3°C) 45%·

greater than 6°F (3°C) but less than or equal to 8°F (4°C) 55%·
greater than 8°F (4°C) but less than or equal to 10°F (5°C) 65%·

greater than 10 °F (5°C) but less than or equal to 12°F (6°C) 75%·

greater than 12°F (6°C) 100%*

"Compressor runs continuously to remove moisture from cab. The clutch is only cycled
Compressor Clutch
OFF when the freeze setting - 32° F (0° C) - is reached at the evaporator temperature
Cycling
sensor, and then ON again when temperature sensed warms to 37° F (3° C).
Heater Control Heater control valve is opened or closed as needed to drive to or maintain the desired
Valve cab temperature setpoint.

•
•
Blower speed remains in position selected by operator.
LCD continues to display "defog" icon.
Manual Override of • Temperature control remains automatic, but controller cannot use any speed beyond
Blower Control that selected to achieve the desired setpoint.
• Turning ATC switch OFF and then to the ' snowflake" icon returns the blower to
standard defog operation.
Improper use of the system ; compressor is already running continuously in defog
Maximum Cool
mode. Temperature control should be in heating range to defog or defrost the cab - to
Setting Selected
remove moisture from the air.

Maximum Heat
•• Blower speed at 100%.*
Heater control valve at full open position

••
LCD continues to display "defog" icon.
Setting Selected
Moving the temperature control outside the maximum range returns the system to
standard defog control of valve and blower speed.
* When heating is selected, blower speed remains at 25% until temperature sensed
at evaporator exceeds 55° F (12.8° C).
Exceptions
.. On very cold days, compressor does not engage until temperature at the evaporator
sensor exceeds 32° F (0° F) .

Rae 6-12840 Issued 3·03

9010-24

ATC FAULT CODES

ATC fault codes display on the AlC control panel LCD display, not on the standard instrumentation 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 LCD and alternate with the temperature
setpoint. The service required icon also flashes on the LCD whenever a fault code is active.

Except for codes 01 and 02, all fault codes display immediately when the fault is detected and disappear if the fault
condition clears.

With the smart pressure switch counting feature, code 01 for high pressure does not display until two occurrences
within a 60 second interval; code 02 for low pressure does not display until four occurrences within a 60 second
internal. The interval starts with the first occurrence, but may be as short as 10 seconds if the pressure problem is
constant.

Only fault codes 01 and 02 "latch" the compressor clutch OFF. The keyswitch must be toggled OFF and ON , or the
ATC switch must be toggled OFF and then to the "A" or "snowflake" position before the clutch is reenabled.

While fault codes 10 and 11 disable the compressor clutch , the clutch is not latched off and reenagages if the fault
condition clears.

Fault
Description
Code
Controller has detected an open condition in high pressure switch circuit.
Compressor clutch is latched OFF.
Smart Code 01 is not activated until two occurrences within a 60 second interval, starting
Pressure with the first occurrence. Actual interval may be as short as 10 seconds if open
Switch condition is constant. Controller must be fully initialized before first occurrence can
Counting be detected.

01 1. High pressure switch has opened because of high side system pressures. High
pressure switch opens at system pressures above 400 psi ± 10 (2758 kPa ± 69).
The switch closes when system pressure drops below 250 psi ± 10 (1724 kPa ±
Causes 69).
2. Any intermittent open condition at a connector in the circuit appears the same to
the controller.
See High and Low Pressure Switch Clutch Latching Circuit , page 38, in this
Reference
Section.

Rae 6-12840 Issued 3-03

 9010-25

Fault
Description
Code
Controller has detected an open condition in low pressure switch circuit.
Compressor clutch is latched OFF.
Smart Code 02 is not activated until four occurrences within a 60 second interval, starting
Pressure with the first occurrence. Actual interval may be as short as 10 seconds if open
Switch condition is constant. Controller must be fully initialized before the first occurrence
Counting can be detected.
1. Low pressure switch has opened because of low side system pressures. Low
pressure switch opens at system pressures below 4 psi ± 2 (28 kPa ± 14). The
Causes switch closes when system pressures rise above 20 psi ± 3 (138 kPa ± 21).
2. Any intermittent open condition at a connector in the circuit appears the same to
02 the controller.
Code 02 may display when outside ambient air temperature is below 30° F (_1 ° C) .
The system does not require service. Toggle the ATC switch to OFF and then the
"snow1lake" icon to reset the system.

Exception NOTE: Case LLC AlC systems are designed to prevent AlC compressor failure due
to low pressure or low refrigerant charge. Operation on days below 40° F (4 ° C) may
actuate the low pressure sensing system and shut down the AlC system. The
system is not malfunctioning if this occurs. Toggle the ATC switch to OFF and then
the appropriate operational mode to reset the system.
See High and Low Pressure Switch Clutch Latching Circuit, page 38, in this
Reference
Section.
Controller has detected an open condition in blower speed control pot circuit.
Blower speed defaults to maximum output which cannot be varied with the control, but cooling/heating
continue.
04
1. Blower speed control potentiometer has failed.
Causes
2. Open condition in power or ground to blower speed pot.
Reference See Blower Speed Pot, page 45, in this Section.
Controller has detected an open condition in the temperature control pot circuit.
Controller provides a setpoint of 68° F (20° C) on the LCD display which cannot be varied with the
control; but cooling/heating continue.
05
1. Temperature control potentiometer has failed.
Causes
2. Open condition in power or ground to temperature control pot.
Reference See Temperature Control Pot, page 45, in this Section.
Controller has detected an open condition in the cab temperature sensor circuit.
Controller provides a default sensor value of 68° F (20° C); the setpoint must be adjusted to 73° F (23°
C) or higher to enable cab heating, to 66° F (190 C) or lower to enable cab cooling.
"A" displays on the LCD with ATC switch set to Automatic, but automatic temperature control does not
function; operator must assume manual control.
08 1. Open condition in wiring to the cab temperature sensor.
Cause
2. Cab temperature sensor has failed out of range.
At cab temperature below _2° F (-19° C) at the sensor, the fault code displays until
Exception the cab warms above this temperature. If fault code does not clear when cab warms,
the sensor requires service.
Reference See Cab Temperature Sensor, page 50, in this Section.

Rae 6-12840 Issued 3-03

9010-26

Fault
Description
Code
Controller has detected an open condition in the evaporator temperature sensor circuit.
Compressor clutch does not engage for cooling, but heater valve opens and closes for cab heating. "A"
displays on LCD, but only heating is automatic.
10
1. Open condition in wiring to evaporator temperature sensor.
Cause
2. Evaporator temperature sensor has failed out of range.
Reference See Evaporator Temperature Sensor, page 50, in this Section.
Controller has detected a short in the evaporator temperature sensor circuit.
Compressor clutch does not engage for cooling, but heater valve opens and closes for cab heating. "A"
displays on LCD, but only heating is automatic.
1. Wiring shorted to evaporator temperature sensor.
Cause
11 2. Evaporator temperature sensor has failed out of range.
At temperature above 1800 F (82 0 C) at the sensor, the fault code displays until the
Exception evaporator cools below this temperature . If fault code does not clear when the
evaporator cools, the sensor requires service.
Reference See Evaporator Temperature Sensor, page 50, in this Section.

Rae 6- 12840 Issued 3-03

 9010-27

LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES

Controller-Based Resistance Tests
18-Pin Wirel Fault
Conn Description Color Code Expected Result/Reference
Al --> Comp Clutch Relay 1A-Or
Less than 10 ohms with ATC switch to "snowflake." II open
A2 --> ATC Switch: Delog 266-0r
line, see ATC Switch , page 57.
Recirculation Door (Not Less than 10 ohms . A3 MUST be grounded to HVAC
A3 --> GRD-Bk
Used) ground. If open line, locate and correct.
If open line , see Sensors , page 52. Perform initial
10 or temperature versus resistance test to check if sensor is
Bl --> Evap Temp Sensor . PB-S
11 failing. See same reference. Retest at sensor locationl
temperature for most accurate result.
Less than 10 ohms with ATC switch to "A." If open line, see
B2 --> ATC Switch: Auto 136-0r
ATC Switch, page 57.
Less than 10 ohms. B3 must be grounded. If open line,
B3 --> Mode Door (Not Used) 154-0r
locate and correct.
Cl --> Low Pressure Switch LP-Or 02
If open line , see Sensors , page 52 . Perform initial
temperature versus resistance test to check if sensor is
C2 --> Cab Temp Sensor SEN-Or 08
failing. See same reference. Retest at sensor locationl
temperature for most accurate result.
Mode Door Signal (Not Less than 10 ohms . C3 must be grounded. If open line,
C3 --> 102-0r
Used) locate and correct.
01 --> High Pressure Switch 80-0r 01
02 --> Temperature Pot 103-0r 05
03 --> Controller Power (+) 252-0r
El --> Blower Speed Pot 326-0r 04
E2 --> Heater Valve Signal 9CB-Or If open line, see Heater Control Valve, page 42.
Less than 10 ohms. If open line, see Controller Power
E3 --> Controller Ground (-) 309B-Or
and Ground, page 56.
Fl --> Blower Driver Signal SBC-Or If open line, see Blower Speed Driver, page 49.
Less than 10 ohms . F2 MUST be grounded to HVAC
Recirculation Door (Not ground to prevent interference with proper LCD display: "A"
F2 --> GRD-N
Used) does not display, but system cools and heats okay. If open
line, locate and correct.
F3 --> Blower Speed Pot Gnd 32B-N

To perform the above resistance tests at the

controller, with the keyswitch OFF:
" " "

@
1. Disconnect the harness to the 18-pin connector F1 E1 01 Cl Bl A1
at the ATC controller. F2 E2 02 C2 B2 A2
F3 E3 03 C3 B3 A3
2. At the harness connector, test the resistance
'-' '-' '-'
between the pins indicated and the battery
negative post. AH01H031
Controller 18-pin Connector
NOTE: Use an appropriately sized probe when
testing to avoid damaging the pins.

Rae 6·12840 Issued 3-03

9010-28

ATC CONTROLLER TEST

The following tests determine whether the ATC In general , the service technician should resist the
controller requires replacement, since it tests primary temptation to replace the controller as the solution to
input and output circuits . Some test steps isolate all A! C system problems . Double check your test
system problems to specific circuits which can results to avoid a return service call. The absence of
simplify general troubleshooting . key control voltages or switched ground does require
controller replacement.
NOTE: The following tests are performed with both connectors installed on the controller using an appropriate
service probe and DVOM.

Test 18-Pin Wire! Fault

Number Conn Description Color Code Test Points
10 A1 --> Comp Clutch Relay 1A-Or Pin A 1 to chassis ground
13 A2 --> ATC Switch: Defog 266-0r Pin A2 to Battery GND
A3 --> Recirculation Door (Not Used) GRD-Bk
10 or
8 B1 --> Evap Temp Sensor PB-S Pin B1 to Battery GND
11
14 B2 --> ATC Switch: Auto 136-0r Pin B2 to Battery GND
B3 --> Mode Door (Not Used) 154-0r
7 C1 --> Low Pressure Sw~ch LP-Or 02 Pin C1 to Battery GND
9 C2 --> Cab Temp Sensor SEN-Or 08 Pin C2 to Battery GND
C3 --> Mode Door Signal (Not Used) 102-0r
6 D1 --> High Pressure Switch 80-0r 01 Pin 01 to Battery GND
11 D2 --> Temperature Control Pot 103-0r 05 Pin 02 to Battery GND
2 D3 --> Controller Power (+) 252-0r Pin 03 to Battery GND
12 E1 --> Blower Speed Pot 326-0r 04 Pin E1 to Battery GND
4 E2 --> Heater Valve Signal 9CB-Or Pin E2 to Battery GND
1 E3 --> Controller Ground (-) 309B-N Pin E3 to HVAC ground.
5 F1 --> Blower Driver Signal SBC-Or Pin F1 to Battery GND
F2 --> Recirculation Door (Not Used) GRD-N
F3 --> Blower Speed Pot Ground 328-N

S-Pin Wire! Fault

Conn Description Color Code Test Points
16 G --> Data to LCD Display 262-0r Pin G to Battery GND
15 H --> 5V Display Power (+) 263-0r Pin H to Battery GND
J --> Display Switched Ground 122-N
K --> ' F to ' C Selector 143-N
3 L --> Heat Valve Power (+) +MD-Or Pin L to Battery GND

*HVAC GROUND
CHASSIS GROUND
BATTERY GND - Battery Negative Post (-)

• The ATC controlfer and many components are grounded to "HVAC ground." HVAC ground is both a grounding stud at the rear
of the HVAC box and chassis ground at ring terminal 173F through C139-J on wire 177F-Bk.

Rae 6-12840 Issued 3·03

 9010-29

., ., l(GI IJ IKI L
)
Fl El 01
F2 E2 02
@ Cl
C2 .2 .2
H
I F3 E3 1D3 C3 B3 .3
I = I
AHQ1HQ31, RH01H032

Test Instructions and Actions

Test ground continuity to controller: Pin E3 to HVAC ground
Condition(s): ATC Switch OFF
CD Expected Result: Less than 1 ohm
Action: Restore clean ground and retry the unit.
Confirm switched B+ is present at controller: Pin 03 to Battery GNO
Condition(s): Keyswitch ON
0 Expected Result: 12V
Action : Restore 12V and retry the unit. See Controller Powe r and Grou nd, page 56, in this Chapter.
Confirm power output to heater valve: Pin L to Battery GNO
Condition(s) : Keyswitch ON and ATC Switch to "A"
® Expected Result: 12V
Action : If no voltage, replace the controller.
Confirm control signal to heater control valve: Pin E2 to Battery GNO
Condition(s): Keyswitch ON and ATC Switch to "A"
8) Expected Result: 11.5 to 1.5V while turning temperature control from max cool to max heat setting
Actions: If no voltage, replace the controller.
If no voltage change or drop out, test the pot circuit. See Temperature Control Pot, page 45 .
Confirm control signal to blower speed driver: Pin F1 to Battery GNO
Condition(s): Keyswitch ON and ATC Switch to "A"
® Expected Result: 11.5 to 1.5V while turning blower speed control from full CCW to full CW
Actions: If no voltage, replace the controller.
If no voltage change, test the pot circuit. See Blower Speed Pot, page 45.
Test high pressure switch circuit: Pin 01 to Battery GNO
Condition(s): Keyswitch ON and ATC Switch to DEFOG; disconnect harness to high pressure switch
® Expected Result: 5V
Action: If no voltage, replace the controller. (Reconnect harness if continuing testing. )
Test low pressure switch circuit: Pin C1 to Battery GNO
Condition (s): Keyswitch ON and ATC Switch to DEFOG , disconnect harness to low pressure switch
CD Expected Result: 5V
Action: If no voltage, replace the controller. (Reconnect harness if continuing testing.)
Test evaporator temperature sensor: Pin B1 to Battery GNO
Condition(s): Keyswitch ON and ATC Switch to "A"
CD Expected Result: 0.5V at 70"F (21 "C) at the sensor. Voltage decreases as temperature increases.
Actions : If no voltage, replace the controller.
If voltage out of range for temperature, test sensor. See sensor test, page 52.
Test cab temperature sensor: Pin C2 to Battery GNO
Condition(s): Keyswitch ON and ATC Switch to "A"
CD Expected Result: 0.5V at 70°F (21 "C) at the sensor. Voltage decreases as temperature increases.
Actions: If no voltage, replace the controller.
If voltage out of range for temperature, test sensor. See sensor test, page 52.

Rac 6-12840 Issued 3·03

9010-30

F1 ., D1 C1 ., " ( GI HI J I KI L))
F2 .2 D2
F3 .3 D3
@ C2 .2 A2
C3 B3 A3
v I = I
RH01H031 , RH01H032

Test Instructions and Actions

Test controller switched ground to clutch relay: Pin A (5-pin) to chassis ground
Condition(s): Keyswitch ON
Expected Result: O.OV or 12V, see actions.
@ Actions: ATC switch to DEFOG with normal pressures, O.OV indicates proper operation.
ATC switch OFF and keyswitch ON, 12 V indicates proper operation ; if no 12V, test relay
control circuit, page 36. If circuit tests normal , replace controller.
Test temperature control pot output: Pin 02 to Battery GND
Condition(s) : Keyswitch ON and ATC switch to "A"
@ Expected Result: 0.0 to 3.0V while turning temperature control from full CCW to full CW
Actions: If no voltage, replace the controller.
Test blower speed control pot output: Pin El to Battery GND
Condition(s) : Keyswitch and AlC switch ON
@ Expected Result: 0.0 to 3.0V while turning blower speed pot from full CCW to full CW
Actions: If no voltage, replace the controller.
Test ATC switch control function - Defog/Defrost mode: Pin A2 to Battery GND
Condition(s) : Keyswitch ON and ATC Switch OFF
@ Expected Result: 5V
Actions: If no voltage, replace the controller.
Test ATC switch control function - Automatic mode: Pin B2 to Battery GND
Condition(s): Keyswitch ON and ATC Switch OFF
® Expected Result: 5V
Actions: If no voltage, replace the controller.
Test controller power to LCD display: Pin H to Battery GND
Condition(s) : Keyswitch ON and ATC Switch to "A"
@ Expected Result: 5V
Actions: If no voltage, replace the controller.
Test data output to LCD display: Pin G to Battery GND
Condition(s) : Keyswitch ON and ATC Switch OFF
@ Expected Result: 5V
Actions: If no voltage, replace the controller.

Rae 6·12840 Issued 3-03

 9010-31

FIELD REPORTED SYMPTOMS/CAUSES

Symptom CorrectionlTest Point
Hot air discharge out of vents - above
1. Test cab temperature and evaporator temperature sensors and
100°F (38°C) - without adjusting the
temperature control during cooling circuits. See Sensors, page 50.
request. 2. Test heater control valve for leakage. See valve "leak through,"
page 42.
No fault codes display.
1. Check cab recirculation filter for obstruction.
System fails to heat or cool correctly, but
otherwise appears to function normally. 2. Check recirculation filter for cleanness.
3. Test cab temperature and evaporator temperature sensors. See
No fault codes.
Sensors, page 50.
Blower operates.
"A" does not display on LCD. Test blower speed potentiometer for short to ground.
System does not cool.
In Automatic mode, when switching from
maximum cool range to warmer setpoint,
if temperature sensed at cab
temperature sensor is less than the
setpoint selected , controller opens System anomaly.
heater valve and warm air blows out the
vents. Heat output continues until the
cab temperature sensor reaches the
setpoint.
No compressor/heater Check Fuse 47
valve operation. Blower Test power and ground to controller. See
LCD is blank. speed at 100% only. page 57.
System cools and heats
Test LCD Display. See page 59.
normally.
At startup for less than
Normal.
one minute
LCD displays "88," and icons and "88" Continuous with blower Test power and ground to controller. See
flash on and off. cutting in and out page 57.
Continuous without
Test LCD display. See page 59.
blower cutting in and out
60°F (16°C) displays continuously on Fault Code 05 displays. Test temperature control potentiometer
LCD. Cannot be changed with Fault Code 05 does not and circuit for a short. See Sensors,
temperature control. display page 53.

Rae 6-12840 Issued 3-03

L
9010-32

COMPRESSOR AND CLUTCH

Operational Check
1. When functioning normally, the compressor
clutch is always grounded to the chassis, and
switched 12V is supplied by a controller-
activated relay to energize the clutch coil and
engage the compressor.
With keyswitch ON, ATe switch to "A,"
temperature control on maximum cool, check
that clutch is engaged and the compressor is
operating.

2. Disconnect the clutch at the harness. The clutch

should disengage smoothly with little noise from
the pulley or the bearings. Reconnect the
harness to the clutch. The clutch should engage
rapidly, and operation should be smooth and
quiet.

3. If operation is noisy, feel the compressor next to

the clutch for vibration. If the compressor is
vibrating next to the clutch and the noise
changes when the clutch disengages, the clutch
has failed. If the compressor is vibrating , the
compressor has failed. The vibrating component
is usually the source of the problem.

WARNING: Do NOT attempt to test the

&. clutch directly with your hand. Rotating parts
can cause severe personal injury. M842

Rae 6-12840 Issued 3~03

 9010-33

4. With the clutch still engaged, momentarily touch

the suct i on and discharge hoses at the
compressor for temperature difference. The
suction line should be cool to cold, and the
discharge line should be hot to very hot.

"" WARNING : This is only a momentary

~ contact with the hose. M636

Little or no temperature difference between the

hoses is another indication of compressor failure:
internal leakage between discharge and suction
sides.
1. DISCHARGE/H IGH 2. SUCTIONILOW
NOTE: The compressor end plate is stamped with a PRESSURE LINE PRESSURE LINE
"0" and ' S" to indicate the discharge and suction
ports.

5. Verify an internal problem when compressor

failure is suspected . Turn the AIC system and
tractor OFF. Remove the three Torx® screws to
remove dust cover (1) from clutch. Use a wrench
to slowly rotate the compressor clockwise.
Compressor rotation should be smooth and not
require much effort. If severe rough spots or
catches are felt when turning the shaft, the
compressor has been damaged internally and
must be replaced.

Rae 6·12840 Issued 3-03

9010-34

6. Check for loose mounting bolts for the

compressor. Tighten the bolts to the correct
torque.

NOTE: Loose mounting can cause a "knocking"

sound at the compressor. A refrigerant overcharge
also causes a knocking sound at the compressor.

7. Clutch drive belt should be running smooth and

straight. Clutch pulley and the drive pulley must
be aligned within 1/ 16 inch (1 .6 mm) of each
other. Use a straight edge to check pulley
alignment. Adjust the compressor on the
mounting bracket if required.

The drive belt should be firmly seated in the

clutch grooves.

Check for too much belt wear: cracking , cord

wear, piling, chunking , glazing or separated
layers. Replace a worn or deteriorated belt.

On MX210, 230, 255 and 285 tractors, the belt is

self-tensioning.

Rae 6-12840 Issued 3·03

 9010-35

Electrical Test - Compressor Clutch

TO GROUND AT _ 600J Bk·1.0 - ----~ 199F
SPlICEEl ~
SHTl SECTION 19
ATCl

139M 139F AC COMPRESSOR

: 10F 10M 333F 333M CLUT~M nF
~ 835A 0·0.• --m-8358 O" '0 - m - 8 3 5 C 0·1.0 ~

G
H
J
II K
L

N
P
R 825A A-3.0 ---6\...9-- 102M R- 3.0 _ TO SWITCHED B+
S FUSE 147 AT RING TERM 138A
Or-C.B T lOA SHTt SECTION 21
U
V

COMPRESSOR x
CLUTCH y
RELAY Z

AH02H432. RH01H031

Background
The compressor clutch is cycled On or Off by the
controller based on the difference between the
selected cab temperature setpoint and the
temperature sensed at the cab temperature sensor.
When functioning normally, the clutch is always
grounded to the chassis through ring terminal 199F
at the compressor mounting boll.
The controller grounds the compressor clutch relay
to provide 12V from fuse 47 to energize the clutch
coil and engage the compressor.

Power and Ground Circuit

Switched 12V is fed to the compressor clutch relay
on pins 3 and 2 from fuse 47.
The controller energizes the relay by supplying
switched ground from A 1 to pin 1 on the relay.
12V is fed from pin 5 on the relay - through C139-C,
C10-84, and C333-15 - to energize the clutch coil at
C72-A.

o
The clutch is grounded from clutch ground screw (1)
through the compressor body and ring terminal 199F
to chassis ground at Splice E1.

Rac 6-12840 Issued 3-03

g
9010-36

Possible Failure Modes:

1. Short circuit or open circuit in clutch coil.
2. Open circuit in power or ground between controller and relay.
3. Open circuit in power and ground between cl utch and relay.
4. Controller fault.

Compressor Clutch Control Circuit Test Procedure

Steps and Test Point Corrective Actions
NOTE: This procedure assumes that the clutch has NOT been latched OFF by the controller due to high or low
pressure switch activation and that no fault codes are displayed on the LCD.

YES - Go to next Step.

1. Keyswitch and ATC switch OFF. Test continuity
between ring terminal ground 199F on the top , NO - Repai r open circuit or replace wire. Retry the
rear compressor mounting bolt and chass is at unit.
Splice El . Less than 1 ohm? NOT OK - Go to next Step.

YES - Go to next Step.

NO - If open line or resistance is severely out of range,
replace the clutch.
2. Measure resistance from C72-A through clutch to NOTE: If clutch is shorted, also check condition of
ground screw on bracket. Is resistance between fuse 47 (30 amp). The clutch draws enough amperage
3.6-4.2K ohms? to cause fuse 47 to blow.
3. Keyswitch ON, and ATC switch set to DEFOG. Is YES - Clutch tests okay. Check for fault codes on LCD.
12V present at male harness connector to clutch? NO - Go to next Step
4. Is 12V present between pin AI on IS-pin ATCI YES - Go to Step 9.
and chassis ground? NO - Go to next Step.
NOTE: Refer to Accessing the HVAC Box at the end
of this Section if required.

Rae 6-12840
 9010-37

Steps and Test Point Corrective Actions

5. Is 12V present at pin D3 on 18-pin ATCl at the YES - Go to Step 7.

controller?
6. Is 12V present at fuse 47 {30 amp}?
7. Is 12V present at terminal 3 of compressor clutch
relay?
8. A properly functioning relay can be heard
engaging. Toggle the ATC switch OFF and ON ,
and listen for a clicking sound. Is the relay
functioning?
9. Is 12V present at terminal 5 on the relay?
10. Keyswitch OFF. Measure resistance between pin
A 1 at the controller and terminal 1 at the relay.
Less than 1 ohm?
11 . Keyswitch ON and ATC switch to DEFOG. Supply
independent ground to pin AI on the 18- pin
connector at the controller. Does compressor
clutch engage?
NO - Go to next Step.
YES - Locate open condition and repair between fuse
47 and pin D3 at the controller through C139-R.
NO - Check condition of fuse 47 and/or locate and
repair open condition to fuse.
YES - Go to next Step.
NO - Locate and repair open between terminal 3 and
splice on wire 2520r.
YES - Relay coil functioning normally. Go to next Step.
NO - Replace the relay.
YES - Go to next Step.
NO - Replace the relay.
YES - Go to next Step.
NO - Locate and repair open condition between A 1 at
the controller and terminal 1 at the relay.
YES - Test the controller. See ATC Controller Test,
page 28, in this Section .
NO - Locat e open condition and repair between
terminal 5 on relay and C72-A at the clutch, through
C139-C, Cl0-84 and C333-15.

Service Note: Adjusting Clutch Air Gap

When replacing a clutch in the field , pay special

attention to the air gap between the clutch plate and
pulley. Too little gap will increase voltage draw at the
the clutch , resulting in premature failure. Too much
gap will introduce too much foreign material into the
clutch.
A spark plug gauge with 90° wire feelers may be
used to check the gap. Slip the wires between the
clutch plate and the pulley, and check the gap at the
three rivets. The gap must be 0 .016 to 0 .031 inch
{OAl to 0.79 mm} . The gap must be even all the way
around the plate. If necessary, lightly lift or push
down on the plate to make the gap even.
NOTE: If the gap does not meet the above
specifications, remove the front plate and add or
subtract clutch shims as required.

Reference:
See Section 9020 for clutch disassembly and
adjusting the air gap during clutch replacement.

Rae 6·12840 Issued 3-03

L
9010-38

HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT

Backg round
High pressure switch activation is generally caused
by a restriction or clog on the high pressure side of
the system. However, a refrigerant o r SP-20 PAG oil
overcharge, the presence of refrigerants other than
R134A or engi ne cooling problems can also cause
high pressure switch activation .

High Pressure Switch at Compressor

Low pressure switch activation is generally caused

by low refrigerant leve l resulting f ro m a leak(s).
Sometime low pressure switch activation, however,
is caused by a restriction, whe re because of t he
location either pressure switch may activate first. For
example, a restriction at the output of the receiver-
drier could cause either high o r low pressure switch
activation.

Refer to the AIC Troubleshooting Foldout an d

performance testing to locate th e cause for yo ur
system.

When either pressure switch opens within the smart

pressure counti ng conditions, a fau lt code displays Low Pressure Switch at Expansion Valve
on the LCD, and the compresso r clutch is latched
OFF by the controller.

Rae 6-12840 Issued 3-03

 9010-39

Possible Failure Modes - Fault Codes 01 and 02

Fault
Description
Code
Controller has detected an open condition in high pressure switch circuit.
Compressor clutch is latched OFF.
Smart Code 01 is not activated until two occurrences within a 60 second interval, starting
Pressure with the first occurrence . Actual interval may be as short as 10 seconds if open
Switch condition is constant. Controller must be fully initialized before first occurrence can
Counting be detected.
01
1. High pressure switch has opened because of high side system pressures. High
pressure switch opens at system pressures above 400 psi ± 10 (2758 kPa ± 69).
The switch closes when system pressure drops below 250 psi ± 10 (1724 kPa ±
Causes 69).
2. Any intermittent open condition at a connector in the circuit appears the same to
the controller.
Controller has detected an open condition in low pressure switch circuit.
Compressor clutch is latched OFF.
Smart Code 02 is not activated until four occurrences within a 60 second interval, starting
Pressure with the first occurrence. Actual interval may be as short as 10 seconds if open
Switch condition is constant. Controller must be fully initialized before the first occurrence
Counting can be detected.
1. Low pressure switch has opened because of low side system pressures. Low
pressure switch opens at system pressures below 4 psi ± 2 (28 kPa ± 14). The
Causes switch closes when system pressures rise above 20 psi ± 3 (138 kPa ± 21).
02 2. Any intermittent open condition at a connector in the circuit appears the same to
the controller.
Code 02 may display when outside ambient air temperature is below 30° F (_1 ° C).
The system does not require service. Toggle the ATC switch to OFF and then the
desired operation position to reset the system.

Exception NOTE: Case LLC AlC systems are designed to prevent Ale compressor failure due
to low pressure or low refrigerant charge. Operation on days below 40° F (4 ° C) may
actuate the low pressure sensing system and shut down the AlC system. The
system is not malfunctioning if this occurs. Toggle the ATC switch to OFF and then
the appropriate operational mode to reset the system.

Although system pressures may return to normal, the Switch Testing

clutch remains latched OFF until the keyswitch or
ATC switch is toggled OFF and then ON.
The controller disables the clutch by denying ground
to the clutch relay.
Cycling the power switch does not resolve the
pressure problem; however, install the pressure test
gauges and performance test the system.
When disconnected from the system, the low
pressure switch will test normally open; the high
pressure switch will test normally closed.
When installed in the AIC system under normal
operating pressures, both pressure switches should
test CLOSED.

Rae 6-12840 Issued 3-03

9010-40

Electrical Test - Pressure Switches

ATCl

TO CHASSIS GROUND
AT CONN 333M, CAV ee _ 179AJ Or· 1.0
SHT2 SECTION 57

0._0.,139~ ~39F O'-O.B~80lB

HIGH
PRESSURE
8O_ATC 80lA 0.-0.' -*':.o'C 0.-1.0 SWITCH

°E D
E
F F
G G
H H
,------1J J
K K
L L

N N
P P
R R
S S
T T
ATC2 U U
V V

LOW PRESSURE X X
SWITCH (Ne) y y
Z Z
LP-_ATC ~ O.B

AH02H433. RH01H031
Power and Ground
With high pressure switch activation, 5V is present at pin 01 at controller and pin B at the switch . The switch is
grounded to the chassis_
With low pressure switch activation, 5V is present at pin C1 at the controller and pin B at the switch. The switch is
grounded to F2 at the controller.
With no pressure switch activation, both circuits test O.OV at the switch and at the controller.

Rae 6-12840 Issued 3-03

 9010-41

High Pressure Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Refer to AlC Troubleshooting Foldout and follow YES - Perform corrective actions from A / C
the conditions for performance testing. Install AlC Troubleshooting Foldout.
high and low side pressure gauges. High reading NO - Go to next Step.
above 400 psi ± 10 psi (2758 kPa ± 69 kPa)?
2. Shut off the tractor. Disconnect the switch from the OK - Go to next Step.
harness and the unit. Check that switch is closed NOT OK - Replace switch.
across pins A and B.
3. Reinstall the switch in the unit; do not reconnect YES - Go to next Step.
the harness. Keyswitch ON and ATC switch to "A." NO - Go to Step 5.
Is 5V present at pin B at the harness to the
switch?
4. Keyswitch OFF. Measure resistance from pin A at YES - Go to next Step.
the connector to ground . Less than 1 ohm? NO - Locate open condition and repair between pin A
and ground.
5. Keyswitch ON and ATC switch to "A." Is 5V YES - Locate open condition and repair between pin
present at pin D1 at the controller? D1 at the controller and pin B at the switch.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1, 2 and 6.

Low Pressure Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Refer to AlC Troubleshooting Foldout and follow YES - Perfo rm corrective actions from A/C
the conditions for performance testing. Install AlC Troubleshooting Foldout.
high and low side pressure gauges. Low reading NO - Go to next Step.
below 4 psi ± 2 psi (28 kPa ± 14 kPa)?
2. Shut off the tractor. Disconnect the switch from the OK - Go to next Step.
harness and the unit. Check that switch is open NOT OK - Replace switch.
across pins A and B.
3. Reinstall the switch in the unit; do not reconnect YES - Go to next Step.
the harness. Keyswitch ON and ATC switch to "A." NO - Go to Step 5.
Is 5V present at pin B at the harness to the
switch?
4. Keyswitch OFF. Measure resistance from pin A at YES - Go to next Step.
the switch to HVAC ground. Less than 1 ohm? NO - Locate open condition and repair between pin A
and HVAC ground.
5. Keyswitch ON and ATC switch to "A." Is 5V YES - Locate open condition and repair between pin
present at pin C1 at the controller? C1 at the controller and pin B at the switch.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1, 2 and 7.

Rae 6-12840 Issued 3·03

9010-42

HEATER CONTROL VALVE

Operational Check
The controller opens or closes the heater control
valve based on the operator selected input at the
temperature control and the temperature sensed at
the cab and evaporator sensors.
The heater control valve can fail mechanically in any
position: open, closed or anywhere in the middle.
To confirm proper valve operation, observe the slot
on the front of the valve. Rotation of the slot must
mirror the movement of the temperature control.

NOTE: Mark the actuator, if required, to better

observe rotation.
The slot must rotate fully clockwise when the control 1. HEATER CONTROL 2. SLOTTED ACTUATOR
is turned fully clockwise; the slot must rotate fully VALVE
countercloc kwise when the slot is turned fully
counterclockwise.
If the valve does not mirror control movement or
does not move, perform the valve motor electrical
test.

Valve "leak Through"

A common problem with the valve is hot coolant flow
when cab cooling is desired. This usually occurs by a
when a valve does not close completely. To test for
leak through from the valve:

1. Operate the AlC system at maximum cooling and

blower speed for 15 minutes. See conditions for
Performance Testing.
2. Install a stem type thermometer in a cab louver,
and record the temperature.
3. Clamp off the coolant supply line (1) before the
valve w ith a vise grip pliers. (The supply line
connects at the bottom of the valve.) Wait a few
minutes and check the thermometer. If the
temperature drops , valve leak through is the
problem; replace the valve.

NOTE: Do not clamp off the heater supply line or

close the heater return line valve at the engine for
this test.

Rae 6-12840 Issued 3-03

 9010-43

Electrical Test - Heater Control Valve

ATC1
rcoMPCiJ

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rM:
139M

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A
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5vi v

~ ATc2
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X
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Z
HEATER
CONTROL VALVE
WVM

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' - SCB_ATC NO.8 WIII-)

~
~ - 6DB~TC Or- 0.8
"-I:I" CONTROl

WI/(+)

RH02H434, RH01H031, RH01HOO2

Power, Signal and Ground Circuit

The controller feeds 12V to the heater valve motor from pin L of ATC2 at the controller to pin 10 on the motor.
The control signal (1.5 to 11.5V) is fed from the controller on pin E2 of ATC1 to pin 8 on the motor.
The motor is grounded from pin 7 at the motor to HVAC ground.

Possible Failure Modes

1. Motor failure or valve physical failure.
2. Open condition in power, signal or ground to heater control valve.
3. Controller failure.

Rae 6-12840 Issued 3-03

 9010-44

Heater Control Valve Power, Signal and Ground Test

Steps and Test Point Corrective Actions
1. Keyswitch ON and ATC switch to "A." Test from pin 8 on valve to chassis ground. While turning the
temperature control from max cool to max heat setting, observe both voltmeter and slot on front of the valve.
If voltage change but no slot movement or slot movement is irregular, heater valve has failed physically or
actuator fault. Go to Step 2.
If no voltage or no voltage change, go to Step 5.
It voltage change and slot movement are continuous, heater valve tests okay.
2. Keyswitch OFF. Disconnect harness connector to YES - Replace the heater control valve assembly.
motor. Measure resistance through the motor from NO - Go to next Step.
pin 7 to pin 10. Open line reading?
3. Measure resistance from pin 7 on valve harness to YES - Go to next Step
HVAC ground. Less than 1 ohm? NO - Locate and repair open condition in ground from
pin 7.
4. Keyswitch ON and ATC switch to "A." Measure YES - Go to Step 6.
control signal at the harness connector on pin 8 NO - Go to next Step.
from pin E2 at the controller, while turning the
temperature control from max cool to max heat
position . Is range from 11.5V (max cool) to 1.5V
(max heat)?
5. Measure control signal at pin E2 at the controller YES - Locate open condition and repair between pin
while turning the control. Is range from 11.5V (max E2 at controller and pin 8 at the heater valve.
cool) to 1.5V (max heat)? NO - Test the controller. See ATC Controller Test ,
page 28, in this Section . Perform tests 1, 2 and 4.
6. Is 12V present at pin 10 at the harness connector? YES - Incorrect reading taken . Retest.
NO - Go to next Step.

7. Is 12V present at pin L at the controller? YES - Locate open condition and repair between pin L
at the controller and pin 10 at the valve.
NO - Test the controller. See ATC Controller Test ,
page 28, in this Section . Performs test 1, 2 and 3.

I Rae 6-12840 Issued 3-03

 9010-45

BLOWER SPEED AND TEMPERATURE CONTROL POTS

Background

Blower Speed Control Common Features

Blower speed is controller-selected in both automatic
and defog operational modes, but the operator can
override the selected speed by turning the control.
Blower speed remains at the operator-selected
speed until automatic or defog operation is
reselected.
The blower speed and temperature control
potentiometers are identical. Both have the same
resistance rating: 0-10K ohms. When a
potentiometer fails or an open condition is detected
in the control circuit, a fault code is displayed on the
LCD:

Temperature Control
The controller uses the setpoint input w ith the
temperature control potentiometer and the input
(resistance) from the cab and evaporator
temperature sensors to maintain or drive to cab
temperature.

Possible Failure Modes - Fault Codes 04 and 05

Fault
Description
Code
Controller has detected an open condition in blower speed control pot circuit.
Blower speed defaults to maximum output which cannot be varied with the control, but cooling/heating
04 continue.
1. Blower speed control potentiometer has failed.
Causes
2. Open condition in power or ground to blower speed pot.
Controller has detected an open condition in the temperature control pot circuit.
Controller provides a setpoint of 68 0 F (20 0 C) on the LCD display which cannot be varied with the
05 control; but cooling/heating continue.
1. Temperature control potentiometer has failed.
Causes
2. Open condition in power or ground to temperature control pot.

Rac 6·12840 Issued 3-03

9010-46

Electrical Test - Potentiometers

139M 139' Fl E1 01 C1 81 At
A A F2 E2 02 C2 82 A2
B B F3 E3 03 C3 83 A3
C C
D D
, ,
E E

G G
326~TC Or- O.B H H
J J
K K

9l
L L

4
N
P
N 322~ ;22' =m124:~24M ATC BLOWER
P SPEED
R R 850A LU-O.8 F F 850B LU-O.8 BB ( POTENTIOMETER
N-O.S S S 1-.--- SOJA Bk· 0.8 G SOle Bk· 0.8 CC 10K OHMS
Or-a.s T T

9l
U U
v V

" X
125M 125F
TEMPERATURE
~
X
Y Y CONTROL
Z
B07A LU-O.• ( POTENTIOMETER
Z
" 8038 Bk· 0.8 CC 10K OHMS

RH02H435, RH01H031

Power and Ground Circuit

Blower Speed
The pot is grounded from pin C, through C322-G and C139-S, to pin F3 at the controller 18-pin connector.
B+ is fed from El at the controller 18-pin connector, through C139-H AND C322-F, to pin B on the pot. B+ read at
from the controller with a DVOM will vary with the position of the pot: 0.0-3.xV.

Temperature Control
The pot is grounded from pin C, through C139-S, to pin F3 at the controller 18-pin connector.
B+ is fed from D2 at the controller 18-pin connector, through C139-T, to pin B on the pot. B+ read at from the
controller with a DVOM will vary with the position of the pot: 0.0-3.xV.

Possible Failure Modes:

1. Control potentiometer failure.
2. Open condition in power or ground to control potentiometer.
3. Controller failure.

Rae 6-1 2840 Issued 3-03

 9010-47

Common Control Potentiometer and Circuit Test Procedure

Steps and Test Point Corrective Actions

NOTE: If fault codes 04 and 05 display sequentially on the LCD, the ground from F3 at the controller through
C139-$ to the pot is the likely suspect and should be tested first for an open condition.
1. Keyswitch ON and ATC switch to "A." Turn the
control pot while observing the LCD display. If the
fault code displays - 04 or 05 - only in certain
locations, the pot is the likely suspect.
2. Open the right hand control panel. Remove and
resistance test the pot between pins Band C.
Resistance must change smoothly (a-10K ohms)
as the pot is turned from full CCW to full Cw. Drop
outs still present in certain locations?
3. Reconnect the pot to the harness. Is 0.0-3.0V
present between pin B at the and chassis ground
while turning the control?
4. Measure resistance between pin C at the pot and
pin F3 at the controller. Resistance greater than
11K ohms?
5. Keyswitch OFF. Measure resistance from pin F3
at controller to HVAC ground. Less than 1 ohm?
6. Is 0.0-3.0V present at pin indicated below at the
controller while turning the appropriate control?
Blower Speed Po!... ............................................... E1
Temperature Control Pot ....................................... 02
Go to next Step.
YES - Replace the pot.
NO - Go to next Step.
YES - Go to Step 5.
NO - Go to next Step.
YES - Locate open condition and repair between pin C
at the pot through C139-S to the controller at pin F3
NO - Go to next Step.
YES - Go to next Step.
NO - Test the controller. See ATC Controller Test,
page 28, in this Chapter. Perform tests 1 and 2.
YES - Locate open condition and repair between pin B
at the pot through C139 to the controller.
NO - Test the controller. See ATC Controller Test,
page 28, in this Chapter. Performs tests 1, 2 and
appropriate test below:
Blower Speed Pot ........................................... Test 12
Temperature Control Pot.. .......••...................... Test 11

Rae 6·12840 Issued 3-03

9010-48

BLOWER AND BLOWER SPEED DRIVER

BLOWER
SPEED DRIVER

~ Fl El 01

:;:
TO AING TEAMINAL 1386,
SECTION 21 F2 E2 02
F3 E3 03 @ Cl 81 Al
C2 82 A2
C3 83 A3
do

§, - FUSE '49
ATCl
I ~OA 322M 322F
L.........{) \...,9"-820A A-3.C ~1tc,:20B A-J .C - 1 1
139M 139F
A A
6 6
e e L L
0 o M
E E NN
N-3.0 F F 1788 Bk-3.0 - 2 2
G G
a: 326_ATC Or- 0.8 H H 850A lU-O.8 - 66 r--
w ATC BLOWER
-' J J SPEED
-' II 261_ATC Or- 0.8 K K 820C R-3.C -t-j----' ee
0 POTENTIOMETER
a: L L 10K OHMS
I- DO
Z 124F 124M
0 N N

~A
(J p P
AA
(J A A _~~=====~F Ft-BSOB LU-O.S BB
!< N-O.S
Or-0.6
S
T
S
T
803A Bk- 0.8 G Gt- 803C Bk· 0.8 C C.

U U
V V

V
TC RING TERM INAL 172F,
X X SECTION 21
Y Y
Z Z
ATC2

AH02H436, AH01H031

Background
In automatic and defog/defrost modes, blower speed
is selected by the controller based on the difference
between the desired setpoint and the actual cab
temperature , Refer to ATC Operation, page 19, in
this section for further information on how blower
speed is selected, overridden and exceptions.
Various blower speeds are accomplished by
modulating voltage to the blower motor with the
blower speed driver. There are no fault codes for the
blower motor or blower driver, although code 04
indicates a fault in the blower speed control circuit.

Power, Signal and Ground Circuit

12V is fed to the blower motor and blower driver on pin A from fuse 49 (30 amp) whenever switched power is
present.
The control voltage signal is fed from the controller on pin F1 to pin 0 on the blower speed driver.
The blower speed driver is grounded from pin C to chassis ground at ring terminal 172F. The blower motor is
grou nded within the speed driver.
NOTE: Refer to Blower Speed and Temperature Control Pots, page 45, in this Section for troubleshooting the
control pot.

Possible Failure Modes

1. Blower motor failure.
2. Blower speed driver failure.
3. Open condition in power, signal or ground to blower motor or blower speed driver.
4. Blower motor or blower speed driver shorted to ground.
5. Controller failure.

Rae 6-1 2840 Issued 3-03

 9010-49

Blower Motor/Blower Driver Power, Signal and Ground Test

Steps and Test Point Corrective Actions

NOTE: If blower motor intermittently cycles to full speed for short periods, blower speed driver may be entering
thermal protection mode. Check for an intermittent short to chassis at blower motor on wire 216-0r or wiring
short to heat sink on the blower driver.
NOTE: The blower speed driver is equipped with a short crossover harness. When testing the blower speed
driver, always test at the connector closest to the driver.
1. Keyswitch OFF. Disconnect the blower motor from YES - Go to next Step.
the harness. Test resistance through the motor NO - Replace the blower motor.
between pins A and B. Open line?
2. Reconnect the blower motor to the harness. Is YES - Go to Step 6.
12V present between pins A and C at the speed NO - Go to next Step.
driver?
3. Keyswitch OFF. Measure resistance from pin C at YES - Go to next Step.
driver connector, through C139-F, to chassis NO - Locate open condition and repair between pin C
ground at ring terminal 172F. Less than 1 ohm? and chassis ground.
4. Keyswitch ON. Is 12V present between pin A on YES - Go to Step 6.
the blower driver connector and chassis ground? NO - Go to next Step.
5. Is 12V present at fuse 49 (30 amp)? YES - Locate open condition and repair between pin A
at blower driver and fuse 49 through C139-K and
splice C16.
NO - Locate and correct problem from switched power
terminal 138B to fuse 49.
6. Keyswitch ON and ATC switch to "A." Measure YES - Go to Step 8.
voltage between pin B and pin A of the blower NO - Go to next Step.
driver while turning the blower speed control.
Does voltage follow pattern below?
Blower pot fully counterclockwise ..................... 12.8V
Blower pot 1/4 turn clockwise ............................. 4.8V
Blower pot fully clockwise ................................... 1.SV
7. Is voltage signal present (O-SV) at pin F1 at the YES - Locate open condition and repair on wire SBC-
ATC controller while turning the blower speed Or between F1 at controller and pin 0 at connector.
control? NO - Test the controller. See ATC Controller Test,
page 28, in this Section.
8. Keyswitch OFF. Disconnect blower motor and YES - Go to next Step.
speed driver from the harness. Measure NO - Locate and repair open condition.
resistance between pin B at motor to pin B at
driver. Less than 1 ohm?
9. Reconnect harness to blower speed driver. There YES - Go to next Step.
must be no continuity between pin B at the motor NO - Replace the blower speed driver.
harness and chassis ground with the keyswitch
OFF. Measure resistance between pin Band
chassis ground? Open line?
10. ATC switch to "A." Supply independent ground to YES - Replace the blower speed driver.
pin B at blower speed driver. Does motor operate? NO - Replace the blower motor.

Rae 6·12840 Issued 3-03

9010-50

CAB AND EVAPORATOR TEMPERATURE SENSORS

Background
The cab temperature sensor (1), located behind and
under the recirculation air filter, supplies a key value
to the controller for heating and cooling. Another key
value is the desired setpoint. The greater the
difference between the desired setpoint and the
temperature sensed at the cab sensor, the greater
the ATC system response.

The evaporator temperature sensor (2), sometimes

called the "freeze" or "core" sensor, is located in the
evaporator/heater assembly. The sensor measures
the effectiveness of system response to the current
demand for heating or cooling , another key value
which the controller uses to engage the compressor
or open the heater valve.

"Freeze" Control
The evaporator sensor also prevents the system
from operating in low ambient temperatures where
damage to the system might occur. When
temperature sensed at the evaporator falls to 32°F
(O°C) , the controller cycles the compressor clutch
OFF. When temperature sensed at the evaporator
rises to 37°F (3°C), the controller cycles the clutch
back ON . In Defog mode or in Automatic mode at the
maximum cooling setting where the compressor runs
continuously, the freeze range controls the cycling of
the compressor OFF or ON.

Sensor Location
Proper location of the evaporator sensor is essential
to system performance. The evaporator temperature
sensor must be installed 4.2 inches (107 mm) from
the left hand rear side of the evaporator. The sensor
must be installed below the second refrigeration tube
row at a 30° downward angle. Insert the sensor in the
evaporator core up to the angled section , being
careful not to kink the sensor.

RH990218
1. 4.2 INCH (107 mm) 3. EVAPORATOR CORE
2. EVAP TEMP SENSOR

Rae 6-12840 Issued 3-03

 9010-51

The cab temperature sensor must be installed in the

recirculation air stream which enters the HVAC box
at the rear. Do not install the sensor in contact with
any metal surface; see illustration for view from
inside the HVAC box.

Since the cab temperature sensor is located behind

the recirculation air filter. any obstruction in the return
air path will reduce system performance: The sensor
will only detect air temperature in the HVAC box and
not the true cab air temperature.

Check the area behind the operators seat for

obstructions at the recirculation filter. and check the
filter for cleanness before testing the sensor.

Rae 6·12840 Issued 3-03

9010-52

Electrical Test - Temperature Sensors

Both sensors have the same resistance vs
EVAPORATOR CAB TEMP
temperature response . Both sensors should TEMPERATURE SENSOR
measure 10-25K ohms at room temperature for SENSOR
normal operation.

Both sensors are thermistors - thermal resistors.

With these thermistors the colder the environment,
the greater the electrical resistance; and the warmer PB--"TC s- 0.8 - - - ,
the environment, the less electrical resistance.
ATC 1

If a fault 8, 10 or 11 is displayed, the most likely

problem is wiring to the sensor. The out of range
values are so high or low - 180° F (82°C) and _2° F (-
19°C) - that occurence is unlikely except as noted
below in the fault code explanations.

More importantly, these sensors can fail without

generating a fault code. Measure the resistance of
the sensor and the ambient temperature at the
sensor, and compare the readings to the Resistance
versus Temperature table on page 55. If the readings
are not within the minus or plus 2.5% range, replace
the sensor.

NOTE: For the test to be valid, the thermometer

used must be accUlate, and the temperature
recorded must be the temperature at the sensor.

RH02H437

Power Circuit
Both sensors are grounded at the HVAC box grounding stud.
Minimal voltage is fed to the sensors: about 0.5V at 70°F (21 °C) , and voltage drops as the temperature increases.
Current is fed to the evaporator sensor from pin Bl and the cab sensor from pin C2.

Service Note: Too Little Cooling/Too Much Heating without Symptoms

The sensors should be suspect when the complaint
is too little cooling when cooling and too much
heating when heating ("the cab is too hot or too cold
all the time"), and obvious symptoms are absent:
- System pressures are normal , and system is
properly charged.
- Coolant system operating normally.
- No faults codes displayed on the LCD.
- Compressor and heater valve are functioning
normally.
The sensors fail in a consistent pattern: they sense a
lower temperature then is actually present.
In cooling mode , actual cab temperature is 76°F
(24°C), but the cab sensor senses 70°F (21 °C) and
the compressor is not engaged with sufficient
frequency. In heating mode, actual cab temperature
is 72° F (22°C), but the cab sensor senses 66°F
(19°C) and heater valve is opened too widely.
Perform the resistance versus temperature test on
both sensors.

Rae 6-1 2840 Issued 3-03

 9010-53

Possible Failure Modes - Fault Codes 8,10 and 11

Since input from the sensors is essential for automatic control of heating and cooling functions, the controller
displays fault codes on the LCD when it detects a sensor failure:

Fault
Description
Code
Controlier has detected an open condition in the cab temperature sensor circuit.
Controlier provides a default sensor value of 68· F (20· C); the setpoint must be adjusted to 73· F (23·
C) or higher to enable cab heating, to 66· F (19· C) or lower to enable cab cooling.
"A" displays on the LCD with ATC switch set to Automatic, but automatic temperature control does not
function; operator must assume manual control.
08
1. Open condition in wiring to the cab temperature sensor.
Cause
2. Cab temperature sensor has failed out of range.
At cab temperature below _2° F (-19· C) at the sensor, the fault code displays until
Exception the cab warms above this temperature. If fault code does not clear when cab warms,
the sensor requires service.
Controlier has detected an open condition in the evaporator temperature sensor circuit.
Compressor clutch does not engage for cooling , but heater valve opens and closes for cab heating. "A"
10 displays on LCD, but only heating is automatic.
1. Open condition in wiring to evaporator temperature sensor.
Cause
2. Evaporator temperature sensor has failed out of range.
Controlier has detected a short in the evaporator temperature sensor circuit.
Compressor clutch does not engage for cooling , but heater valve opens and closes for cab heating. "A"
displays on LCD, but only heating is automatic.
1. Wiring shorted to evaporator temperature sensor.
11 Cause
2. Evaporator temperature sensor has failed out of range.
At temperature above 180° F (82· C) at the sensor, the fault code displays until the
Exception evaporator cools below this temperature . If fault code does not clear when the
evaporator cools, the sensor requires service.

Cab Temperature Sensor and Circuit Test

Steps and Test Point Corrective Actions
1. Keyswitch OFF. Disconnect the cab temperature YES - Go to next Step.
sensor from harness. Measure the resistance NO - Replace the sensor.
across the sensor leads. Measure the ambient
temperature at the sensor. Compare the readings
to the Temperature versus Resistance table on
page 55 . Is the resistance reading within the
minus or plus 2.5% range in the table?
2. Keyswitch ON and ATC switch to "A." Measure YES - Go to next Step 4.
voltage at female connector on sensor. Is voltage NO - Go to next Step.
present?

NOTE: Voltage reading will be very low: O.SV at lO·F

(21 °C); and voltage decreases as temperature
increases.

Rae 6-12640 Issued 3-03

9010-54

Steps and Test Point Corrective Actions

3. Measure voltage at pin C2 at the controller. Is
voltage present?
4. Measure resistance from the sensor to HVAC box
ground stud. Less than 1 ohm?
YES - Locate and repair open condition between pin
C2 at the controller and the sensor on wire SEN-Or.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section . Perform tests 1, 2, and 9.
YES - Wrong reading taken. Retest.
NO - Locate and repair open condition between
sensor and HVAC box ground stud.

Evaporator Temperature Sensor and Circuit Test

Steps and Test Point Corrective Actions
1. Keyswitch OFF. Disconnect the cab temperature YES - Go to nex1 Step.
sensor from harness. Measure the resistance NO - Replace the sensor.
across the sensor leads. Measure the ambient
temperature at the sensor. Compare the readings
to the Temperature versus Resistance table on
page 55 . Is the resistance reading within the
minus or plus 2.5% range in the table?
2. Keyswitch ON and ATC switch to "A." Measure YES - Go to nex1 Step 4.
voltage at female connector on sensor. Is voltage NO - Go to nex1 Step.
present?

NOTE: Voltage reading will be very low: 0.5Vat 70°F

(2 1°C); and voltage decreases as temperature
increases.
3. Measure voltage at pin B1 at the controller. Is
voltage present?
4. Measure resistance from the sensor to HVAC box
ground stud. Less than 1 ohm?
YES - Locate and repair open condition between pin
B1 at the controller and the sensor on wire PB-S.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1 , 2, and 8.
YES - Wrong reading taken. Retest.
NO - Locate and repair open condition between
sensor and HVAC box ground stud .

NOTE: Verify that the evaporator temperature sensor is installed in the right location. The temperature sensor
must be installed 4.2 inches (107 mm) from the left hand rear side of the evaporator. The sensor must be
installed below the second refrigeration tube row at a 3(J' downward angle. Insert the sensor in the evaporator
core up to the angled section.
NOTE: While installing the sensor in the wrong location causes faulty system performance, it will not cause the
sensor to fail or provide a faulty resistance reading for a given temperature. Replace the sensor if it tests out of
range for a given temperature.

Rae 6-12840 Issued 3-03

 9010-55

Temperature Versus Resistance Table

Ambien t Temperature ..- Range ~ Ambient Temperature ..- Range - . .

"F "c -2.5% Kohms +2.5% "F "C -2.5% Kohms +2.5%
0 -17.78 170.820 175.200 179.580 61 16.11 29.179 29.927 30.675
1 -17.22 165.360 169.600 173.840 62 16.67 28.434 29.163 29.892
2 -16.67 160.095 164.200 168.305 63 17.22 27.710 28.421 29.132
3 -16.11 155.025 159.000 162.975 84 17.78 27.008 27.701 28.394
4 -15.56 150.150 154.000 157.850 65 18.33 26.327 27.002 27 .677
5 -15.00 145.470 149.200 152.930 66 18.89 25.664 26.322 26.980
6 -14.44 140.985 144.600 148.215 67 19.44 25.020 25.662 26.304
7 -13.89 136.598 140.100 143.603 66 20.00 24.395 25.020 25.646
8 -13.33 132.308 135.700 139.093 69 20.56 23.787 24.397 25.007
9 -12 .78 128.213 131 .500 134.788 70 21.11 23.196 23.791 24.386
10 -12.22 124.313 127.500 130.688 71 21.67 22.623 23.203 23.783
11 -11.67 120.510 123.600 126.690 72 22.22 22.064 22.630 23.196
12 -11 .11 116.805 119.800 122.795 73 22.78 21 .522 22.074 22.626
13 -10.56 113.295 116.200 119.105 74 23.33 20.996 21 .534 22.072
14 -10.00 109.765 112.600 115.415 75 23.89 20.483' 21 .008 21.533
15 -9.44 106.470 109.200 111 .930 76 24.44 19.985 20.497 21.009
16 -8.89 103.350 106.000 108.650 77 25.00 19.500 20.000 20.500
17 -8.33 100.230 102.800 105.370 78 25.56 19.029 19.517 20.005
18 -7.78 97.227 99.720 102.213 79 26.11 18.571 19.047 19.523
19 -7.22 94.331 96.750 99.169 80 26.67 18.125 18.590 19.055
20 -6.67 91 .533 93.880 96.227 81 27.22 17.691 18.145 18.599
21 -6.11 88.832 91 .110 93.388 82 27.78 17.269 17.712 18.155
22 -5.56 86.219 88.430 90.641 83 28.33 16.859 17.291 17.723
23 ·5.00 83.694 85.840 87.986 84 28.89 16.460 16.882 17.304
24 -4.44 81.247 83.330 85.413 85 29.44 16.071 16.483 16.895
25 -3.89 7B.887 80.910 82.933 86 30.00 15.694 16.096 16.498
26 · 3.33 76.596 78.560 80.524 87 30.56 15.325 15.718 16.111
27 -2.78 74.383 76.290 78.197 88 31 .11 14.967 15.351 15.735
28 -2.22 72.248 74 .100 75.953 89 31 .67 14.618 14.993 15.368
29 -1 .67 70.171 71.970 73.769 90 32.22 14.279 14.645 15.011
30 -1.11 67.470 69.200 70.930 91 32.78 13.948 14.306 14.664
31 -0.56 66.232 67.930 69.628 92 33.33 13.627 13.976 14.325
32 0.00 64.350 66.000 67.650 93 33.89 13.314 13.655 13.996
33 0.56 62.532 64 .135 65.738 94 34.44 13.008 13.342 13.676
34 1.11 BO.n1 62 .329 63.887 95 35.00 12.712 13.038 13.364
35 1.67 59.066 60.580 62.095 96 35.56 12.422 12.741 13.060
36 2.22 57.414 58.886 60.358 97 36.11 12.141 12.452 12.763
37 2.78 55.814 57.245 58.676 98 36.67 11 .866 12.170 12.474
38 3.33 54.265 55.656 57.047 99 37.22 11 .599 11.896 12.193
39 3 .89 52.764 54 .117 55.470 100 37.78 11.338 11.629 11.920
40 4.44 51 .309 52.625 53.941 101 38.33 11.084 11 .368 11 .652
41 5.00 49.901 51.180 52.460 102 38.89 10.837 11 .115 11 .393
42 5.56 48.535 49.779 51.023 103 39.44 10.595 10.867 11 .139
43 6.11 47.211 48.422 49.633 104 40.00 10.360 10.626 10.892
44 6 .67 45.928 47.106 48.284 105 40.56 10.131 10.391 10.651
45 7.22 44.684 45.830 46.976 106 41.11 9.908 10.162 10.416
46 7.78 43.479 44.594 45.709 107 41.67 9.691 9.939 10.187
47 B.33 42.310 43.395 44.480 108 42.22 9.479 9.722 9.965
48 B.89 41 .176 42.232 43.288 109 42.78 9.272 9.510 9.748
49 9.44 40.076 41 .104 42.132 110 43.33 9.070 9.303 9.536
50 10.00 39.011 40.011 41 .011 111 43.89 8 .873 9.101 9.329
51 10.56 37.976 38.950 39.924 11 2 44.44 8.681 8.904 9 .127
52 11.11 36.973 37.921 38.869 113 45.00 8 .495 8.713 8 .931
53 11.67 36.000 36.923 37.846 114 45.56 8.312 8 .525 8.738
54 12.22 35.055 35.954 36.853 11 5 46.11 8.134 8 .343 8.552
55 12.78 34.139 35.014 35.889 116 46.67 7.961 8.165 8 .369
56 13.33 33.249 34.102 34.955 117 47.22 7 .791 7.991 8 .191
57 13.89 32.387 33.217 34.047 11 8 47.78 7.626 7 .822 8.018
58 14.44 31.548 32.357 33.166 119 48.33 7.466 7.657 7 .848
59 15.00 30.735 31.523 32.311 120 48.89 7.308 7 .495 7 .682
60 15.56 29.945 30.713 31.481 121 49.44 7 .155 7 .338 7 .521

Rae 6·12840 Issued 3-03

9010-56

CONTROLLER POWER AND GROUND, ATC SWITCH

ATCl

139M 139F
A A
322M 322F
B B TO CHASSIS GNO
136~TC Or- O.B C C AT SPLICE C14 1 1 ATCSWITCH
0 0 SHT2 SECTION 65 l l AUTOIOFFIDEFOG

309JTC N - 0.8
E
F
G
E
F
G
.'"
~
0
NN
M

2 2
~AUTO
OFF
DEF
H H ~ ,
I

J J 1nF Bk·3.0 ~ BB 123M

K K 1 ,
l l 826A Or-O.a cc BOl e Bk· 0.8
M M 827A Or- a.B
N N DO 826C Or-D.B
p p
A A 82SA A·3.0 AA 827C Or-O.B
S S
T
U
T
U ,•
v V 1 ,
X X
Y Y
Z Z
ATC2 102M R- 3.0 _ TO SW ITCHED B+
TO RI NG TERMIN AL 173F, FUSE _47 AT RING TERM 138A
SECTION 21 30A SHT 1 SECTION 21

RH02H438, RH01H031, AH01HQ32

Background
HVAC ground is both a grounding stud at the back of
the HVAC box and chassis ground through C139-J
on wire 177F-Bk to ring terminal 173F.
Sinc e so many controlled directed components
interact, intermittent HVAC ground can make reliable
troubleshooting very difficult.
The "intermittent" nature of the problem is further
complicated since the fault can appear to move from
component to component.
Early testing for a stable and consistent ground at the
HVAC ground stud and C139-J to ring terminal 173F
can greatly simplify troubleshooting.

Power and Ground Circuit

ATC Controller
Whenever switched power is present, 12V is fed the controller from fuse 47 (30 amp) through C139-R to pin D3 at
the controller.
The controller is grounded from pin E3 at the controller to HVAC ground.
ATC Switch
The controller feeds 5V from pin B2, through C139-L and C322-D, to the switch at pin 4; grounding pin B2 with the
switch provides the Automatic mode request to the controller.
The controller feeds 5V from pin A2, through C139-M and C322-A, to the switch at pin 6; grounding pin A2 with the
switch provides the DefoglDefrost mode request to the controller.
The switch is grounded from pin 5 to chassis at Splice C14.

Possible Failure Modes

1. Fuse 47 or open condition in power or ground to controller.
2. ATC switch failure.
3. Open condition in power or ground to switch.

Rae 6-12840 Issued 3-03

 9010-57

Controller Power Supply and Ground Test

Steps and Test Point
1. Keyswitch ON and ATC switch to "A." Measure the
voltage between pin 03 at the controller and
chassis ground. Is 12V present?
2. Check fuse no. 47 (30 amp). Is 12V present?
3. Measure resistance from pin E3 at the controller to
HVAC ground. Less than 1 ohm?
Corrective Actions
YES - Go to Step 3.
NO - Go to next Step.
YES - Locate and repair open condition between fuse
47 and pin 03 at the controller.
NO - Locate and repair open condition from fuse 47 to
switched B+. Go to next Step.
YES - See ATC Controller Test , page 28, in this
Section. Test the pins directly related to the faulty
component at the controller.
NO - Locate and repair open condition from pin E3 to
HVAC ground.

ATC Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Disconnect ATC switch from harness. ATC switch YES - Go to next Step.
to "A." Measure resistance between pins 4 and 5 NO - Replace switch.
on switch? Less than 1 ohm?
2. ATC switch to "snowflake." Measure resistance YES - Go to next Step.
between pins 6 and 5 on switch? Less than 1 NO - Replace switch.
ohm?
3. Measure resistance from pin 5 at the harness to YES - Go to next Step.
chassis ground . Less than 1 ohm? NO - Locate and repair open condition between pin 5
and ground.
4. Keyswitch ON. Is 5V present between pin 4 and YES - Go to next Step.
chassis ground at the harness connector. NO - Go to Step 6.
5. Is 5V present between pin 6 and chassis ground at YES - Wrong reading taken. Retest.
the harness connector? NO - Go to Step 7.
6. Is 5V present between pin B2 at the controller and YES - Locate and repai r open condition between pin
chassis ground? B2 at controller, through C139-L and C322-D, and pin
4 at the switch.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1, 2 and 14.
7. Is 5V present between pin A2 at the controller and YES - Locate and repair open condition between pin
chassis ground? A2 at controller, through C139-M and C322-A, and pin
6 at the switch.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1, 2 and 13.

Rae 6-12840 Issued 3-03

9010-58

LCD DISPLAY
ATCl
CQMP CLUTCH RELAY 1
AIC SWITCH; DEFOG
"
~
13~ 139F
RECIR DClOH (Not Used} ~ 3 A A
EVAPTE MP SENSOR 1 B 322M 322F
AIC SWITCH: AUTO "
~ 2 C
B
C 1 1
MOOE DOOR (No! Used} ~ 0 0 LL
lCNI PRESSURE SWITCH 1 E
CAB TEMP SENSOR "
Q 2 F
E
F NN
M

MOOE 000fl SIG (No! 0-:1) C3 G G 2 2

HIGH PRESSURE SWITCH 1 H
a:
W TEMP CONTROl POT "
~ J
H
J B B
-' CONTROLLER PWR (+J 00 3 K K
-'
0
a:
Z
0
BlOWER SPEED POT
I- HEATER VALVE SIGNAl
CONTROU.ER GROUND
BLOWER ORNER SIGNAl
"
"" :
1
l~G I H I J IKI L] L

N
P
L
N
CC
DO

""!;; " P
RECIR DOOR {No! U$ed}
BLWR SPO/TEMP POT GND fl " 2
3
1= 1 R
S
R
S
A A
F F
T T G G 132F 132M ATCOISPLAY
r- 804B Bk-o.a=tID'
IBiBI
122JTC N -O.8- U Ui- 804A Bk -O.8 - J J
DATA TO DISPLAY G Gr---t, 263JTC Or- 0.8 - V V-;-- 80SA A-O.B - H H r- 8058 A-o.8 A A
5VDISPlAY POWER (+J HH 262_ATC Or- 0.8 - 1"'- 80SA LU-O.B - K Kf-806B LU-O.8 c c
DISPlAY GROUND J J f----J X
~ E~
'C\ 'FSELECTQR K K Y
HEATER VALVE f"OWER (+) , L Z Z
ATC2
AH02H439. RH01 H032

Background
The LCD display, because of its immediate feedback to the operator, provides several indicators for general system
condition :

Display Condition System Symptoms Corrective Action

No compressor/heater valve Check Fuse 47

operation. Blower speed at 100% Test power and ground to
LCD is blank. only. controller.
System cools and heats normally. Test LCD Display
At startup for less than one minute Normal during controller initializing .
Continuous with blower cutting in Test power and ground to
LCD displays "88," and icons and and out controller.
"88" flas h on and off.
Continuous without blower cutting
in and out. System cools and heats Test LCD display.
normally.

Power, Data and Ground Circuit

The controller feeds 5V from pin H to pin A at the LCD.
The controller provides switched ground from pin J to the LCD at pin B.
Data for display (5V) is sent from pin G at the controller to pin C at the LCD.

Possible Failure Modes

1. Display defective.
2. Open condition in power, signal or ground to display.
3. Controller fault.

Rae 6-1 2840 Issued 3-03

 9010-59

LCD Display and Circuit Test

Steps and Test Point Corrective Actions
NOTE: This test presumes the LCD is blank or the icons and "88" on the display are flashing continuously
1. Keyswitch ON and ATC switch to "A.n Disconnect YES - Go to next Step.
the harness to the LCD. Is SV present between pin NO - Go to Step 4.
A and pin 8 at the connector?
2. Is SV present between pin C and pin 8 at the YES - Replace the display.
connector? NO - Go to next Step.

3. Keyswitch OFF. Measure resistance from pin 8 at YES - Go to next Step.

display connector to pin J at the controller. Less
than 1 ohm?
4. Keyswitch ON and ATC switch to "A." Is SV present
at pin H at the controller?
5. Is SV present at pin G at the controller?
NO - Locate open condition and repair between pin 8
at the display, through C322-J and C139-U, and pin J
at the controller.
YES - Locate open condition and repair between pin H
at the controller, through C139-V and C322-H, and pin
A at the display.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform test 1, 2 and 15.
YES - Locate open condition and repair between pin G
at the controller, through C139-W and C322-K, and pin
C at the display.
NO - Test the controller. See ATC Controller Test,
page 28, in this Section. Perform tests 1, 2 and 16.

Rae 6-12840 Issued 3-03

,
9010-60

FAHRENHEIT/CELSIUS DISPLAY
ATCl

139M 139F
A A
B B
C C
D D
E E
F F
G G
H H
J J
K K
L L

N N
P P GND CONTINUITY
A A FUSE '28, SA
S S FUSE BLOCK 261.
T T ATC DISPLAY WILL READ IN CElCIUS WHEN
U U FUSE IS INSTALLED, AND IN FAHRENHEIT
V V WHEN FUSE IS REMOVED.

143_ATC N - 0.8 X X 765A Y-a.s ~ 179AW Y·0.8 _ TO CLEAN GROUND

y y AS SPLICE C7
ATC2 Z Z SHT2 SECTION 50

RH02H440. RH01H032

Background
The controller displays setpoint temperature in
degrees fahrenheit or celsius, depending on the
absence or present of fuse 28 (5 amp) in block 261.
When fuse 28 is installed , the ground circuit is
completed to pin K at the controller, and the setpoint
displays in celsius on the LCD.
When fuse 28 is not installed, the ground circuit is
incomplete and the setpoint displays in fahrenheit.

Possible Failure Modes

When fahrenheit is desired, any short to chassis between pin K at the controller and the fuse closes the ground
circuit, switching display to celsius. Locate short and repair.
When celsius is desired, a blown fuse or open condition in the ground circuit results in fahrenheit display. Inspect
fuse or locate open cond~ion and repair.

Rae 6-12840 Issued 3-03

 9010-61

CAB PRESSURIZER BLOWER

CAB
PRESSURE
BLOWER
RELAY
#10
A2 AS A4 264F

CAB
PRESSURE
BLOWER

1 - 1958 K- 1.0 ~ffi

~
195C K-1 .0
179AY Bk- 1.0
90F 90M

~ ~I ~ ffi(~
TO ENGINE RELAY
AT CONN 264F
TO CLEAN GROUND
AT SPLICE F3
~
CAV82 SHT 2 SECTION 57
SHl1 SECTION 20
RH03BOSO

Background
Whenever switched power is present, the cab The motor is energized by a relay, activated by
pressurizer motor should operate. The motor/blower switched B+.
assembly draws air from the cab cap through the left
Only the pressurizer blower relay and motor
hand cab post and fresh air filter and feeds it directly
troubleshooting are covered here.
to the HVAC box under the operators seat. The
motor/blower assembly is located behind the fresh
air filter.

Power and Ground

Unswitched B+ is continuously provided to the relay on pin A3 from fuse 10 (15 amp). The relay is grounded on pin
A2 to the engine relay.
Whenever Switched B+ is present, the relay is energized on pin A 1, and Unswitched B+ is supplied to the cab
pressurizer motor on pin A through C1 0-85.
Clean ground is continuously supplied to the motor on pin B from the Splice F3.

Rae 6-12840 Issued 3-03

9010-62

Cab Pressurizer Blower & Relay Power Supply and Ground Test
Steps and Test Point Corrective Actions
1. Keyswitch ON . Check fuse 10 (IS amp) . Is 12V YES - Go to next Step.
present?
NO - Replace fuse 10 and!or locate and repair open
condition to the fuse.

2. Measure the voltage on pin A at the pressurizer YES - Go to next Step.

motor. Is 12V present?
3. Disconnect the motor from the harness and check
for continuity through the motor between pins A
and B. Is continuity present?
4. Keyswitch OFF. Measure resistance between pin
8 at the motor and clean ground at Splice F3.
Less than 1 ohm?
S. Reconnect motor to the harness. Keyswitch ON. Is
12V present at pin A3 of the blower relay and
chassis ground?
6. Is 12V present at pin AI of the blower relay and
chassis ground?
7. Keyswitch OFF. Measure resistance between pin
A2 at the motor relay and pin 82 at the engine
relay. Less than 1 ohm?
B. Measure resistance between pin AS at relay and
pin A at the motor. Less than 1 ohm?
NO - Go to Step 4.
YES - Go to next Step.
NO - Replace the motor.
YES - Go to next Step.
NO - Locate and repair open condition between pin 8
at the motor and Splice F3 on wire 179-8k.
YES - Go to next Step!
NO - Locate and repair open between fuse 10 and
relay on wire 19S-K.
YES - Go to next Step.
NO - Locate and repair open condition between the
relay pin Aland Splice C40 on wire 312-K.
YES - Go to next Step.
NO - Locate and repair open between pin A2 and pin
82 at the relays on wire 177-8k.
YES - Replace the motor relay.
NO - Locate and repair open condition between pin AS
at the relay and pin A at the motor on wire 19S-K.

Rae 6-12840 Issued 3-03

 9010-63

Standard Air Conditioning (STD)

Troubleshooting

Important Notes
ABBREVIATIONS: Connectors and their pins or
terminals are abbreviated throughout the
troubleshooting section. C139- T represents pin Ton
connector 139; C333-15 represents pin 15 on
connector 333.

IMPORTANT: The standard controller and many

components are grounded to "HVAC ground." HVAC
ground is both a grounding bolt at the rear of the
HVAC box and chassis ground at ring terminal 172F
- on wire 85_ CCU-N within the box and wire 177F-
Bk outside the box. The stability of this ground is
essential for reliable troubleshooting.

WARNING: All operating controls must be in neutral

or park lock position when performing these tests.
Ground Stud at Rear of HVAC Box
NOTE: Use a multimeter (DVOM) for these tests. Do
NOT use a self-powered test light for any of these
tests.

NOTE: The batteries must be fully charged and all

connections clean and tight. Inspect all connectors
for damage, bent or dislocated pins or improper
seating when troubleshooting.

Rae 6-12840 Issued 3-03

9010-64

Rae 6-12840

STANDARD Ale OPERATION
The standard Ale controller is an open loop control
device. The controller provides electronic thermostat
control. The compressor clutch is engaged and
disengaged by the standard controller. The clutch is
cycled from 32° to 66°F (0° to 19°C) evaporator
temperatu re sensor values proportional to the
temperature control potentiometer position from 12
o'clock to full counterclockwise.
66°F
Evaporator
Temp Sensor
Setting for
Clutch Control
Maximum Cold 32°F
C)
Standard AlC Temperature Control
Smart Pressure Switch Cycling System
The standard Ale system is equipped with pressure
switch cycle counters. The compressor is latched
OFF after four activations of the low pressure switch
within a 60 second interval. The compressor is also
latched OFF after two activations of the high
pressure switch within a 60 second interval. The 60
second interval starts with the first activation of the
switch in both cases.
IMPORTANT: Actual interval may be as short as 10
seconds if the open condition is constant.
The controller flashes the pressure warning lamp
(mounted in the Al e On l Off switch) slowly,
approximately 7 times in a 10 second period for the
low pressure switch , or quickly, approximately 13
times in a 10 second period for the high pressure
switch.
Rae 6-12840
9010-67
The sta ndard controller opens the heater control
valve from full closed to full open position
proportional to the temperature control potentiometer
position from 12 o'clock to full clockwise.
If cab temperature is to be made cooler or warmer or
if blower speed is to be increased or decreased, it is
the operator who makes the adjustment.
0%
Percent of
Heater Control
Valve Travel
"""""--'-100% Maximum Hot
RD990022
The compressor clutch remains latched OFF until the
Ale switch or keyswitch is toggled OFF and then ON.
However, toggling the switch does not correct the
pressure problem, and system service is required.
NOTE: Case LLC AlC systems are designed to
prevent AlC compressor failure due to low pressure
or low refrigerant charge. Operation on days below
40° F (4 ° C) may actuate the low pressure sensing
system and shut down the AlC system. The system
is not malfunctioning if this occurs. Toggle the AlC
switch OFF and then ON to reset the system.
9010-68

Standard AlC Controls and Their Function

RHOOB05B
Manual selection of blower speed: Low, Medium or High or OFF.

1. Blower Speed Control With NC switch in the OFF position and any blower speed selected, the control provides fresh air
circulation for the cab with outside ambient air introduced with the cab pressurizer blower to the HVAC
box.
A. Pressure Warning Indicator: the warning lamp blinks slowly,
approximately 7 times in a 10 second period for low pressure switch
2. Ale ON/OFF Switch Toggles cooling On or Off
activation, or quickly, approximately 13 times in a 10 second period
for the high pressure switch activation.
B. Maximum Cooling Zone - 32° F (0° C) ; compressor runs
Compressor is engaged or continuously until the freeze setting at the evaporator temperature
heater valve is opened in sensor cycles the clutch OFF. The clutch is cycled ON again when
3. Temperature Control
direct proportion to the the evaporator thaws to 37° (3°C) .
movement of the control.
C. Maximum Heating Zone, heater control valve at 100% open position

Rae 6-12840 Issued 3-03


SYMPTOM-BASED STANDARD Ale TROUBLESHOOTING
Symptom
AlC system is inoperative
Compressor operates, but
blower is inoperative.
Blower operates, compressor
is inoperative.
Blower operates, no heat, too
much heat or heat output
cannot be changed.
Rae 6·12840
9010-69
Possible Cause Test or Reference
Blower speed switch defective See Blower Speed Switch
and Blower Motor, page 88,
Fuse 49 in this Section.
Power and ground to blower motor See Blower Speed Switch
and Blower Motor, page 88,
Blower motor defective in this Section.
High pressure switch activated locking out the
clutch
See High and Low Pressure
Standard AlC controiler blinks warning lamp Clutch Latching, page 79, in
(in the AlC ON/OFF switch) quickly, this Section.
approximately thirteen times in a 10 second
period
Low pressure switch activated locking out the
clutch
See High and Low Pressure
Standard AlC controiler blinks warning lamp Clutch Latching, page 79, in
(in the AlC ON/OFF switch) slowly, this Section.
approximately seven times in a 10 second
period
See Evaporator
Evaporator temperature sensor '1reeze"
Temperature Sensor, page
setting reached cycling the clutch OFF
91 , in this Section.
Open in switched ground to relay from
controiler See Electrical Test for
Clutch Relay, page 76, in
Power and ground to clutch relay
this Section.
Clutch relay defective
See Standard Controller
Controiler defective
Test, page 71, in this Section .
See Controller Power and
Fuse 47 or power and ground to controiler Ground Test, page 94, in this
Section.
Loose or broken drive belts
See Operational Check for
Compressor clutch defective compressor and clutch, page
73, in this Section.
Compressor defective.
Heater control valve defective (Control valve
can fail in any position - open, closed, See Heater Control Valve,
midway.) page 83, in this Section.
Power and ground to heater control valve
Temperature control potentiometer See Temperature Control
disconnected or defective Pot, page 86, in this Section.
See Engine Cooling Section
Coolant not hot
in this manual.
Issued 3·03
9010-70
Symptom
Blower operates but not at all
speeds: no low speed and/or
no medium speed but high
speed operates.
Too little cooling, too little
heating with system
pressures and components
normal
Cab pressurization blower
does not run when switched
B+ is present.
Rae 6-12840
Possible Cause Test or Reference
Blower speed switch defective
See Blower Speed Switch
Open line from in-line connector to motor and Blower Motor, page 88,
in this Section.
Motor resistor disconnected or defective
Evaporator temperature sensor failing See Evaporator
Temperature Sensor, page
Open line to evaporator temperature sensor 91 , in this Section.
Power and ground to cab pressurizer blower.
Fuse 10
See Cab Pressurizer
Cab pressurizer relay disconnected or Blower, page 96, in this
defective. Section.
Power and ground to cab pressurizer blower
relay.
Issued 3-03
 9010-71

STANDARD CONTROLLER TEST

The following tests determine whether the A/C
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.
In general, the service technician should resist the
temptation to replace the controller as the solution to
all A/C system problems. Double check your test
results to avoid a return service call. The absence of
key control voltages or switched ground does require
controller replacement.

NOTE: The following tests are performed with both connectors installed on the controller using an appropriate
service probe and DVOM.

Pin 10
Test 6-Pin Wirel
Number Conn Description Color Test Points
2 A --> Controller Power (+) 2S2-0r Pin A to Battery GND
7 B --> Evaporator Temp Sensor PB-S Pin B to Battery GND
5 C --> High Pressure Switch SO-Or Pin C to Battery GND
9 0 --> Temperature Control Pot 103-0r Pin D to Battery GND
11 E --> AlC On/Off Switch 112-0r Pin E to Battery GND
1 F --> Controller Ground (.) MOD-Bk Pin F (6-pin) to HVAC ground

5-Pin Wirel
Conn Description Color Test Points
8 A --> Comp Clutch Relay 1A-Or Pin A (S-pin) to chassis ground
6 B --> Low Pressure Switch LP-Or Pin B (S-pin) to Battery GND
10 C --> Pressure Warning Lamp 111-0r Pin C (S-pin) to Battery GND
4 0 --> Heater Cont Valve Sig 9C-Or Pin D (S-pin) to Battery GND
3 E --> (+) Heater Cont Valve Pwr 6D-Bk Pin E (S-pin) to Battery GND
'HVAC GROUND
CHASSIS GROUND
BATTERY GND - Battery Negative Post (-)

• The standard controller and many components are grounded to "HVAC ground." HVAC ground is both a grounding stud at the
rear of the HVAC box and chassis ground at ring terminal 172F through C139-F on wire 178-Bk.

Test Instructions and Actions

Test ground continuity to controller: Pin F (6-pin) to HVAC ground

CD Condition(s): AlC Switch OFF

Expected Result: Less than 1 ohm
Action: Restore clean ground and retry the unit.
Confirm switched B+ is present at controller: Pin A to Battery GND

® Condition(s): Keyswitch ON
Expected Result: 12V
Action: Restore 12V and retry the unit. See Controller Power and Ground, page 94, in this Chapter.

Rae 6·12840 Issued 3-03

9010-72

Test Instructions and Actions

Confirm power output to heater valve: Pin E (S-pin) to Battery GND
Condition(s): Keyswitch and AlC Switch ON
CD Expected Result: 12V
Action: If no voltage, replace the controller.
Confirm control signal to heater control valve: Pin 0 (S-pin) to Battery GND
Condition(s): Keyswitch and AlC Switch ON
CD Expected Result: 1.5 to 11.5V while turning temperature control from max heat to max cool setting
Actions: If no voltage, replace the controller.
If no voltage change or drop out, test the pot. See Temperature Control Pot, page 86.
Test high pressure switch circuit: Pin C to Battery GND
Condition(s): Keyswitch and AlC Switch ON, disconnect harness to high pressure switch
® Expected Result: 5V
Action: If no voltage, replace the controller. (Reconnect harness before continuing testing.)
Test low pressure switch circuit: Pin B (S-pin) to Battery GND
Condition(s): Keyswitch and AlC Switch ON , disconnect harness to low pressure switch
CD Expected Result: 5V
Action: If no voltage, replace the controller. (Reconnect harness before continuing testing.)
Test evaporator temperature sensor: Pin B to Battery GND
Condition(s): Keyswitch and AlC Switch ON
(j) Expected Result: 0.5V at 70°F (21 °C) at the sensor. Voltage decreases as temperature increases.
Actions: If no voltage, replace the controller.
If voltage out of range for temperature, test sensor. See sensor test, page 91.
Test controller switched ground to clutch relay: Pin A (S-pin) to chassis ground
Condition(s): Keyswitch ON
Expected Result: O.OV or 12V, see actions.
CD Actions: AlC switch ON , with temperature control to max cool and normal pressures, O.OV indicates
proper operation.
A/C switch OFF and keyswitch ON, 12V indicates proper operation ; if no 12V, test relay
control circuit, page 94. If circuit tests normal, replace the controller.
Test temperature control output: Pin 0 to Battery GND
Condition(s): Keyswitch and AlC switch ON
® Expected Result: 5V
Actions: If no voltage, replace the controller.
Test the pressure warning lamp circuit in AlC switch: Pin C (S-pin) to Battery GND
Condition(s): Keyswitch and AlC switch ON, disconnect harness to either pressure switch
Expected Result: 5V
@ Actions: If no voltage, test the AlC switch circuit; see page 95. If circuit and switch test normal, and
warning lamp does not blink with pressure switch harness disconnected, replace the
controller. (Reconnect harness before continuing tests.)
Test AlC switch control function : Pin E to Battery GND
Condition(s): Keyswitch ON
@ Expected Result: 5V with AlC OFF, O.OV with AlC switch ON
Actions: Test the A/C switch circuit; see page 95. If circuit and switch test normal , but compressor
does not engage with proper request and conditions, replace the controller.

Rae 6·12840 Issued 3·03

 9010-73

COMPRESSOR AND CLUTCH

Operational Check
1. When functioning normally, the compressor
clutch is always grounded to the chassis, and
switched 12V is supplied by a controller-activated
relay to energize the clutch coil and engage the
compressor.
With keyswitch ON , A l e switch to ON
temperature control on maximum cool, check
that clutch is engaged and the compressor is
operating.

2. Disconnect the clutch at the harness. The clutch

should disengage smoothly with little noise from
the pulley or the bearings. Reconnect the
harness to the clutch. The clutch should engage
rapidly, and operation should be smooth and
quiet.

3. " operation is noisy, feel the compressor next to

the clutch for vibration . " the compressor is
vibrating next to the clutch and the noise
changes when the clutch disengages, the clutch
has failed. " the compressor is vibrating, the
compressor has failed. The vibrating component
is usually the source of the problem.

WARNING : Do NOT attempt to test the

&. clutch directly with your hand. Rotating parts
can cause severe personal injury MB42

Rae 6-12840 Issued 3-03

9010-74

4. With the clutch still engaged, momentarily touch

the suction and discharge hoses at the
compressor for temperature difference. The
suction line should be cool to cold , and the
discharge line should be hot to very hot.

1,\
WARNING: This is only a momentary
~ contact with the hose. M636

Little or no temperature difference between the

hoses is another indication of compressor failure:
internal leakage between discharge and suction
sides.
1. DISCHARGElHIGH 2. SUCTION/lOW
NOTE: The compressor end plate is stamped with a PRESURE LINE PRESSURE LINE
"0 " and "5" to indicate the discharge and suction
ports.

5. Verify an internal problem when compressor

failure is suspected. Turn the AIC system and
tractor OFF. Remove the three Torx<il> screws to
remove dust cover from clutch. Use a wrench to
slowly rotate the compressor clockwise.
Compressor rotation should be smooth and not
require much effort. If severe rough spots or
catches are felt when turning the shaft, the
compressor has been damaged internally and
must be replaced.

Rae 6-12840 Issued 3-03

 9010-75

6. Check for loose mounting bolts on the

compressor. Tighten the bolts to the correct
torque.

NOTE: Loose mounting can cause a "knocking"

sound at the compressor. A refrigerant overcharge
a/so causes a knocking sound at the compressor.

7. Clutch drive belt should be running smooth and

straight. Clutch pulley and the drive pulley must
be aligned within 1/16 inch (1.6 mm) of each
other. Use a straight edge to check pulley
alignment. Adjust the compressor on the
mounting bracket if required.

The drive belt should be firmly seated in the

clutch grooves.

Check for too much belt wear: cracking, cord

wear, piling, chunking, glazing or separated
layers. Replace a worn or deteriorated belt.
On MX210, 230, 255 and 285 tractors, the belt is
self-tensioning .

Rae 6-12840 Issued 3-03

9010-76

Electrical Test - Compressor Clutch

TO RING TERMINAL 138B, SECTION 21 -A ~

1 ~~- __ ,===="":::;l
STD Ale BLOWER SWITCH

t
STANDARD
AIC CONTROLL.ER CCUl 126F 126M
1 1 I
139MM 139F 820. A- 3.0 1 1 8200 R- 3.0 2 2
A BOOA Or- 2.0 l L 800B Or- 2.0 3 3
B M M 4 4
C N N 5 5
0 2 2 6 6
E
F
G '"
0

H is TOGROUNOAT_600J Bk-1.0 ---c::x:Q)l99F

J <0( SPLICE E1
K ~ SHTI SECTION 19 AC COMPRESSOR
L

~
OF 10M 333F 333M 72M 72F
CCU_RELAY M
N S4 835B Or - l .0~835C Or-l .0~
P 855 ~
0
CLUTCH
RELAY
R
S "
T
U
V

x
y
z

RHOOB051, AH01H029

Background
The compressor clutch is cycled On or Off by the
controller based on the temperature sensed at the
evaporator.
When functioning normally, the clutch is always
grounded to the chassis through ring terminal 199F
at the compressor mounting bolt.
The blower speed switch must be in any position but
OFF to engage the compressor.
The controller grounds the compressor clutch relay to
provide 12V from fuse 49 via the blower switch to
energize the clutch coil and engage the compressor.

Power and Ground Circuit

Switched 12V is fed to the compressor clutch relay
on pins 3 and 2 through the blower switch from fuse
49.
The controller energizes the relay by supplying
switched ground from pin A on CCUI to pin 1 on the
relay.
12V is fed from pin 5 on the relay - through CI39-C,
Cl0-84, and C333-15 - to energize the clutch coil at
C72-A.
OJ
Rae 6-12840 Issued 3-03
 9010-77

Possible Failure Modes:

1 . Short circuit or open circuit in clutch coil.
2. Open circuit in power and ground between clutch and relay.
3. Defective relay.
4. Controller fault.

Clutch Relay Power Supply and Ground Test

Steps and Test Point Corrective Actions
NOTE: If both the blower motor and the compressor are not operating, check fuse 49 and the blower control
circuit before testing the clutch relay.
NOTE: This procedure assumes that the clutch has NOT been latched OFF by the controller due to high or low
pressure switch activation and that the pressure warning lamp is not flashing on the Ale switch.
YES - Go to next Step.
NO - Repair open circuit or replace wire. Retry the
unit.
NOT OK - Go to next Step.

1. Keyswitch and AlC switch OFF. Test continuity

between ring terminal ground 199F on the top,
rear compressor mounting bolt and chassis at
Splice E1. Less than 1 ohm?
YES. - Go to next Step.
NO - If open line or resistance is severely out of range,
replace the clutch .
NOTE: If clutch is shorted, also check condition of
fuse 49 (30 amp). The clutch draws enough amperage
to cause fuse 49 to blow.

2. Measure resistance from C72-A through clutch to

ground screw on bracket. Is resistance between
3.6-4.2K ohms?
3. Keyswitch and AlC switch ON; blower control on YES - Clutch tests okay. Check for flashing warning
any speed but OFF, temperature control to lamp on AlC switch.
maximum cooling. Is 12V present at male harness NO - Go to next Step
connector to clutch?

Rae 6-12840 Issued 3·03

9010-78

Steps and Test Point Corrective Actions

4. Is 12V present between pin A on CCU2 at YES - Go to Step 6.
controller and chassis ground? NO - Go to next Step.
NOTE: Refer to Accessing the HVAC Box at the end
of this Section if required.
5. Is 12V present at pin 3 of compressor clutch YES - Go to next Step.
relay? NO - Locate and repair open condition between pin 3
on relay and pin F on blower speed switch, through
C139-A.
6.A properly functioning relay can be heard YES - Relay coil functioning normally. Go to next Step.
engaging. Toggle the A/ C switch OFF and ON, NO - Replace the relay.
and listen for a clicking sound. Is the relay
functioning?
7. Is 12V present at terminalS on the relay? YES - Go to next Step.
NO - Replace the relay.
8. Keyswitch OFF. Measure resistance between pin YES - Go to next Step.
A on CCU2 and pin 1 at the relay. Less than 1 NO - Locate and repair open condition on wire 1A-Or
ohm? between pin A and pin 1.
9. Keyswitch and AlC switch ON; blower control on YES - Test the controller. See Standard Controlier
any speed but OFF, temperature control to Test, page 71 , in this Section.
maximum cooling. Supply independent ground to NO - Locate open condition and repair between pin 5
pin A on the 5-pin connector at the controller. on relay and C72-A at the clutch, through C139-C ,
Does compressor clutch engage? C 10-84 and C333-1 5.

Service Note: Adjusting Clutch Air Gap

When replacing a clutch in the field , pay special
attention to the air gap between the clutch plate and
pulley. Too little gap will increase voltage draw at the
the clutch, resulting in premature failure. Too much
gap will introduce too much foreign material into the
clutch.
A spark plug gauge with 90· wire feelers may be
used to check the gap. Slip the wires between the
cl utch plate and the pulley, and check the gap at the
three rivets. The gap must be 0.016 to 0.031 inch
(0.41 to 0.79 mm). The gap must be even all the way
around the plate. If necessary, lightly lift or push
down on the plate to make the gap even.

NOTE: If the gap does not meet the above

specifications, remove the front plate and add or
subtract clutch shims as required.

Reference:
See Section 9020 for clutch disassembly and
adjusting the air gap during clutch replacement.

Rae 6-12840 Issued 3-03

 9010-79

HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT

Background
High pressure switch activation is generally caused
by a restriction or clog on the high pressure side of
the system. However, a refrigerant or SP-20 PAG oil
overcharge, the presence of refrigerants other than
R134A or engine cooling problems can also cause
high pressure switch activation.

High Pressure Switch at Compressor

Low pressure switch activation is generally caused

by low refrigerant level resulting from a leak(s) .
Sometime low pressure switch activation , however,
is caused by a restriction , where because of the
location either pressure switch may activate first. For
example, a restriction at the output of the receiver-
drier could cause either high or low pressure switch
activation .

Refer to the AIC Troubleshooting Foldout and

performance testing to locate the cause for your
system.

NOTE: Case LLC AlC systems are designed to

prevent AlC compressor failure due to low pressure Low Pressure Switch at Expansion Valve
or low refrigerant charge. Operation on days below
40° F (4 ° C) may actuate the low pressure sensing
system and shut down the AlC system. The system
is not malfunctioning if this occurs. Toggle the AlC
switch to OFF and then ON to reset the system.

When either pressure switch opens within the smart

pressure counting conditions, the pressure warning
lamp flashes on the Ale switch, and the compressor
clutch is latched OFF by the controller.

Rae 6·12840 Issued 3-03

9010-80

Possible Failure Modes - Flashing Pressure Warning Lamp

Warning Lamp Description
Conlroller has detected an open condition in high pressure switch circuit.
Compressor clutch is latched OFF.
Pressure Clutch latching is not activated until two occurrences within a 60 second
Warning lamp Switch interval, starting with the first occurrence. Actual interval may be as short
flashes rapidly, Counting as 10 seconds if open condition is constant.
about 13 times 1. High pressure switch has opened because of high side system
in a 10 second pressures. High pressure switch opens at system pressures above
period_ 400 psi ± 10 (2758 kPa ± 69). The switch closes when system
Causes pressure drops below 250 psi ± 10 (1724 kPa ± 69).
2. Any intermittent open at a connector in the circuit appears the same
to the controller.
Controller has detected an open condition in low pressure switch circuit.
Compressor clutch is latched OFF.
Pressure Clutch latching is not activated until four occurrences within a 60 second
Switch interval, starting with the first occurrence. Actual interval may be as short
Counting as 10 seconds if open condition is constant.
Warning lamp 1. Low pressure switch has opened because of low side system
flashes slowly, pressures. Low pressure switch opens at system pressures below 4
about 7 times in psi ± 2 (28 kPa ± 14). The switch closes when system pressures rise
Causes above 20 psi ± 3 (138 kPa ± 21).
a 10 second
period. 2. Any intermittent open at a connector in the circuit appears the same
to the controller.
NOTE: Case LLC AlC systems are designed to prevent AlC compressor
failure due to low pressure or low refrigerant charge. Operation on days
Exception below 40° F (4 ° C) may actuate the low pressure sensing system and shut
down the AlC system. The system is not malfunctioning if this occurs.
Toggle the AlC switch to OFF and then ON to reset the system.

Although system pressures may return to normal, the Switch Testing

clutch remains latched OFF until the keyswitch or
AlC switch is toggled OFF and then ON .
The controller disables the clutch by denying ground
to the clutch relay.
Cycling the power switch does not resolve the
pressure problem, however, install the pressure test
gauges and periormance test the system.
When disconnected from the system, the low
pressure switch will test normally open ; the high
pressure switch will test normally closed.
When installed in the AIC system under normal
operating pressures, both pressure switches should
test CLOSED.

Rae 6-12840 Issued 3-03

 9010-81

Electrical Test - Pressure Switches

L
TO CHASSIS GROUND
HIGH
STANDARD AT CONN 333M, CAY ee
PRESSURE
Ale CONTROLLER CCUl 10F 10M SHT 2 SECTION 57 SWITCH
139MM 139F 7 1F 7 1M
A "" , 33~3M 179AJ Or- 1.0
B 802B Or- O.8~ 802C Or- 1.0 -----1
C
D
E 00
0
F
G 0
H
CCU2
J '"
N
iii
K
L
M
N
P
R

Power and Ground

The controller feeds 5V from pin C (CCU1) to pin B on the high pressure switch. The switch is grounded to the
chassis.
The controller feeds 5V from pin B (CCU2) to pin B on the low pressure switch. The switch is grounded to the
grounding stud in the HVAC box.

High Pressure Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Refer to NC Troubleshooting Foldout and follow YES - Perform co rrective actions from A / C
the conditions for performance testing. Install A/C Troubleshooting Foldout.
high and low side pressure gauges. High reading NO - Go to next Step.
above 400 psi ± 10 psi (2758 kPa ± 69 kPa)?
2. Shut off the tractor. Disconnect the switch from the OK - Go to next Step.
harness and the unit. Check that switch is closed NOT OK - Replace switch .
across pins A and B.
3. Reinstall the switch in the unit; do not reconnect YES - Go to next Step.
the harness. Keyswitch and A/C ON . blower NO - Go to Step 5.
control on any speed. and temperature control on
maximum cool setting. Is 5V present at pin 1 at the
harness to the switch?

Rae 6-12840 Issued 3-03

 -

9010-82

Steps and Test Point Corrective Actions

4. Keyswitch OFF. Measure resistance from pin A at
the switch to ground. Less than 1 ohm?
5. Keyswitch ON. Is SV present at pin C at the
controller (CCU1)?
YES - Go to next Step.
NO - Locate open condition and repair between pin A
and ground .
YES - Locate open condition and repair between pin C
at the controller and pin B at the switch.
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.

Low Pressure Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Refer to AlC Troubleshooting Foldout and follow YES - Perform corrective actions from A / C
the conditions for performance testing. Install AlC Troubleshooting Foldout.
high and low side pressure gauges. Low reading NO - Go to next Step.
below 4 psi ± 2 psi (28 kPa ± 14 kPa)?
2. Shut off the tractor. Disconnect the switch from the OK - Go to next Step.
harness and the unit. Check that switch is open NOT OK - Replace switch .
across pins A and B.
3. Reinstall the switch in the unit; do not reconnect YES - Go to next Step.
the harness. Keyswitch and A / C ON, blower NO - Go to Step 5.
control on any speed, and temperature control on
maximum cool setting , Is SV present at pin B at
the harness to the switch?
4. Keyswitch OFF. Measure resistance from pin A at YES - Go to next Step.
the switch to the HVAC ground stud. Less than 1 NO - Locate open condition and repair between pin A
ohm? and HVAC ground stud.
5. Keyswitch ON . Is SV present at pin B at the YES - Locate open condition and repair between pin B
controller (CCU2)? at the controller and pin B at the switch .
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.

Rae 6-12840 Issued 3·03

 9010-83

HEATER CONTROL VALVE

Operational Check
The controller opens or closes the heater control
valve based on the operator selected input at the
temperature control and the temperature sensed at
the evaporator sensor.
The heater control valve can fail mechanically in any
position: open, closed or anywhere in the middle.
To confirm proper valve operation, observe the slot
on the front of the valve. Rotation of the slot must
mirror the movement of the temperature control.

NOTE: Mark the actuator, if required, to better

observe rotation.
The slot must rotate fully clockwise when the control 1. HEATER CONTROL 2. SLOTTED ACTUATOR
is turned fully clockwise; the slot must rotate fully VALVE
counterclockwise when the slot is turned fully
counterclockwise.

If the valve does not mirror control movement or does

not move, perform the valve motor electrical test.

Valve "Leak Through"

A common problem with the valve is hot coolant flow
when cab cooling is desired. This usually occurs by a
when a valve does not close completely. To test for
leak through from the valve:

1. Operate the AlC system at maximum cooling and

blower speed for 15 minutes. See conditions for
Performance Testing.
2. Install a stem type thermometer in a cab louver,
and record the temperature.
3. Clamp off the coolant supply line (1) before the
valve with a vise grip pliers. (The supply line
connects at the bottom of the valve.) Wait a few
minutes and check the thermometer. If the
temperature drops, valve leak through is the
problem; replace the valve.

NOTE: Do not clamp off the heater supply line or

close the heater return line valve at the engine for
this test.

Rae 6-12840 Issued 3-03

9010-84

Electrical Test
STANDARD
Ale CONTROLLER ceUl
CONTROLLER POWER (.. ) AA l ,-- 139MM
EVAPORATOR TEMP SENSOR BB A
HIGH PRESSURE SWITCH C C B
TEMPERATURE CONTROL POT o D
lYe ONfOfF SWITCH EE C

1
0
CONTR(x'lER GROUND (-) FF
r E
F
§ G

CCU2 t::
r-
H
J
COMP CLUTCH RELAY H AA K
lCJ.N PRESSURE SWITCH BB '---
PRESSURE WARNING C C IA B C 0 E
l
M
HEATEA ell VALVE SlG o D - N
(+) HEATER ell VALVE POWER
EEl P
A
l 04~CCU N-O.8
I 5CA_CCU N-O.8 S
ro ro
ci ci T
ii U

'"'=>" "=> wvc

V

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D Y
'I ~

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7 7 WV( -)

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1 ,,
o 0
CONTROL

WV( .. )
Z

HEATER
CONTROL VALVE

AH03B053, RH01H029

Power, Signal and Ground Circuit

The controller feeds 12V to the heater valve motor from pin E (CCU2) to pin lOon the motor.
The control signal (1.5 to 1' .5V) is fed from the controller on pin D (CCU2) to pin 8 on the motor.
The motor is grounded from pin 7 at the motor to the HVAC ground stud.

Possible Failure Modes

1. Motor failure or valve physical failure.
2. Open condition in power, signal or ground to heater control valve.
3. Controller failure.

Heater Control Valve Power, Signal and Ground Test

Steps and Test Point Corrective Actions
1. Keyswitch and Blower Speed Control ON . Test from pin 8 on valve to chassis ground. While turning the
temperature control from max cool to max heat setting, observe both voltmeter and slot on front of the valve.
If voltage change but no slot movement or slot movement is irregular, heater valve has failed physically or
actuator fault. Go to Step 2.
If no voltage or no voltage change, go to Step 5.
If voltage change and slot movement are continuous, heater valve tests okay.
2. Disconnect harness connector to motor. Measure YES - Go to next Step
resistance through the motor from pin 7 to pin 10. NO - Replace the heater control valve assembly.
Open line?
3. Measure resistance from pin 7 on valve harness to YES - Go to next Step
HVAC ground stud. Less than 1 ohm? NO - Locate and repair open condition in ground from
pin 7.

Rae 6-12840 Issued 3·03


Steps and Test Point
4. Keyswitch and Ale switch ON. Measure control
signal at the harness connector on pin B from pin
D at the controller, while turning the temperature
control. Is range from 1.5 to 11 .5V?
5. Measure control signal at pin D at the controller
while turning the control. Is range from 1.5 to
11.5V?
6. Is 12V present at pin 10 at the harness connector?
7. Is 12V present at pin E at the controller?
Rae 6-12840
9010-85
Corrective Actions
YES - Go to Step 5.
NO - Go to next Step.
YES - Locate open condition and repair between pin D
at controller and pin B at the heater valve.
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.
YES - Incorrect reading taken. Retest.
NO - Go to next Step.
YES - Locate open condition and repair between pin E
at the controller and pin 10 at the valve.
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.
Issued 3-03
9010-86

TEMPERATURE CONTROL POT

Background
The controller uses the setting on the temperature
control potentiometer and the input (resistance) from
the evaporator temperature sensor to maintain cab
temperature.
The resistance rating for the temperature control
potentiometer is 0-10K ohms.
If the potentiometer fails, the controller attempts to
maintain the last temperature request it received
when it had input. If the heater valve was opened
40% at the last request, that is the position it
maintains . An operator experiences this as cab
temperature cannot be varied with the control.
An intermittent open condition in the control circuit
and a faulty potentiometer act the same in this
system.

Electrical Test
STANDARD
Ale CONmOLLER CCUl
139MM 139F
A A
B B
e C
0 D
E E
F F
G G
H H
CCU2 J J
K K
L
"
N
p
M
N
P
R
A TEMPERATURE
N-D.a 5 S CONTROL
l03_CCU Or-Q.B T T B07A l U- 0.8 POTENTIOMETER
U U BOOB Bk- 0.8 10K OHMS
v V

x x
y y
Z Z

RH03B054, RHOl H030

Power and Ground Circuit

The pot is grounded from pin C, through C139-S, to the HVAC ground stud.
B+ read from the controller will vary with the position of the pot: 0.0-3.xV. B+ is fed from pin D at the controller
(CCU1 ), through C139-T, to pin B on the pot.

Possible Failure Modes:

1. Control potentiometer failure.
2. Open condition in power or ground to control potentiometer.
3. Controller failure.

Rae 6-1 2840 Issued 3-03


Temperature Control Potentiometer and Circuit Test
Steps and Test Point
1. Keyswitch and AlC switch OFF. Open the right
hand control panel. Disconnect the potentiometer
from the harness. Check for variation in resistance
(0 - 10K ohms) across Band C on connector 125F
while turning the control.
NOTE: Turn the control slowly and check for any
dead spots - points of infinite resistance - across the
range of the potentiometer.
2. Keyswitch and AlC switch ON, blower control on
any speed. Is 0.0-3.0V present between pin B at
the harness and chassis ground while turning the
control?
3. Is 0.0-3.0V present at pin D at the controller
(CCU 1)?
4. Keyswitch OFF. Measure resistance between pin
C at the pot to the HVAC ground stud. Less than 1
ohm?
Rae 6-12840
9010-87
Corrective Actions
OK - Go to next Step.
NOT OK - Replace potentiometer.
YES - Go to Step 4.
NO - Go to next Step.
YES - Locate open condition and repair between pin B
at the pot through C139-T to the controller.
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.
YES - Wrong reading taken. Retest.
NO - Locate open condition and repair between pin C
at the pot through C139-S to the HVAC ground stud.
Issued 3·03
9010-88

BLOWER SPEED SWITCH AND BLOWER MOTOR

~ TO RING TERM1NAll38B, SECTION 21

~
~

~
~ FUSE '49
30.
~B20A R.3.0

,, CCU4 ,, ,
139MM 139F

..
800A Or- 2.0
22 63_CCU W-2.0
C •C '---Ji,T,"--_ 820D R- 3.0
" 84_CCU A-2.0
110_CCU Or-2.0 0 0 822A Or- 2.0 l L 8000 Or- 2.0
, , 8228 Or-2.0 -t--,
=
=i=~==~~M
E E 823A Or - 2.0 STO AJC BLOWER SWITCH
G G
1788
824A
Bit· 3.0
Or - 3.0
N N
2 2
5236 Or- 2.0
6248 Or - 3.0 ,,
126F 126M

0
0 ·M
," J" 2 2

•" ,, l ,,
~

'--t+---1"~~
~2: K
~~
U8 § 55
U1...,1
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~ P
R R TO RING TERMINAL InF.

, ,S
SECTION 2\

f
S

," "
V

,, ,X

Z Z

RH03B055,

Background
Various blower speeds are accomplished by passing
voltage through step-down resistors for low and
medium speeds. Voltage is jumpered directly to the
motor for high speed.
If only high speed operates, resistor failure or an
open condition in the in-line connector are the likely
suspects. Resistor failure requires replacement of the
motor.

Power and Ground Circuit

12V is fed to blower motor from fuse 49 (30 amp)
whenever switched B+ is present and whenever the
blower speed switch is set to any position other than
OFF.
Based on the speed switch position , 12V is routed
through the in-line con nector to the step-down
resistors.
The blower motor is grounded from pin B to the
HVAC ground stud and ring terminal 172F chassis ground.

Possible Failure Modes

1. Fuse 49 or power and ground to blower speed switch.
2. Switch failure.
3. Blower motor failure.
4. Open condition in power or ground to blower motor.
5. Resistor failure.

Rae 6-12840 Issued 3-03

 9010-89

Blower Speed Switch and Power Circuit Test

Steps and Test Point Corrective Actions

NOTE: If the blower motor does not run at any speed, test the switch and power circuit - fuse 49. If the blower
motor does not operate on all speeds, test the control circuit for the motor.
1. Keyswitch ON. Measure voltage at blower speed YES - Go to Step 3.
switch on pin 2. Is 12V present? NO - Fuse no. 49 is bad or there is an open circuit in
blower speed switch power supply circuit. Go to next
Step.
2. Measure voltage at fuse 49 (30 amp). Is 12 volt YES - Locate and repair open circuit in 820(R).
present? NO - Locate and repair open circuit in switched B+
power to fuse.
3. While turning blower speed switch from LOW to YES - Go to next Step.
MEDIUM to HIGH, is 12V present at pin 6 in all NO - Replace the switch.
positions?
4. Turn blower control to LOW. Measure voltage at YES - Go to next Step.
blower speed switch pin 5. Is 12V present? NO - Replace switch .
5. Turn blower control to MEDIUM. Measure voltage YES - Go to next Step.
at blower speed switch pin 4. Is 12V present? NO - Replace switch.
6. Turn blower control to HIGH. Measure voltage at YES - Go to next Step.
blower speed switch pin 3. Is 12V present? NO - Replace switch.

Blower Motor Power, and Control Circuit Test

Steps and Test Point Corrective Actions
NOTE: If the blower motor does not run at any speed, test the switch and power circuit - fuse 49. If the blower
motor does not operate on all speeds, test the control circuit for the motor.
1. Keyswitch ON. Turn blower control to HIGH. Does YES - Go to Step 4.
blower motor operate at high speed? NO - Go to next Step.
2. Disconnect the motor from the connector. Is there YES - Go to next Step.
continuity through the motor between pins A and NO - Replace motor.
B?
3. Measure voltage on connector to blower motor on YES - Go to next Step.
pin A. Is 12V present? NO - Go to next Step.
4. Turn blower control to Law. Does blower motor YES - Go to Step 9.
operate at low speed? NO - Go to next Step.
5. Measure voltage at blower motor resistor terminal YES - Replace motor.
L. Is 12V present? NO - Go to next Step.
6. Measure voltage at terminal 2 of blower motor YES - Locate and repair open circuit between in-line
resistor in-line connector (CCU3,4) . Is 12V connector terminal 2 and blower motor resistor
present? terminal L.
NO - Go to next Step.

Rae 6-12840 Issued 3-03

 9010-90

Steps and Test Point Corrective Actions

7. Measure voltage at in-line C139-D. Is 12V YES - Repair open circuit between C139-D and in-line
present? connector on terminal 2.
NO - Go to next Step.
8. Measure voltage at blower speed switch pin 5. Is YES - Locate and repair open circuit between switch
12V present? pin 5 and C139-D.
NO - Test the Switch.
9. Turn blower control to MEDIUM? Does blower YES - Go to Step 13.
motor operate at medium speed? NO - Go to next Step.
10. Measure voltage at blower motor resistor on YES - Replace blower motor.
terminal M. Is 12V present? NO - Go to next Step.
11 . Measure voltage at terminal 3 of blower motor YES - Locate and repair open circuit between in-line
resistor in-line connector (CCU3,4). Is 12V connector terminal 3 and blower motor resistor
present? terminal M.
NO - Go to next Step.
12. Measure voltage at C139-E. Is 12V present? YES - Locate and repair open circuit between C139-E
and in-line connector terminal 3.
NO - Go to next Step.
13. Measure voltage at blower switch on pin 4. Is 12V YES - Locate and repair open circuit between C139-E
present? and the switch pin 4.
NO - Test switch.
I
14. Turn blower control to HIGH. Does blower motor YES - Wrong reading taken. Retest.
operate at high speed? NO - Go to next Step.
15. Measure voltage at blower motor resistor in-line YES - Locate and repair open circuit between in-line
connector (CCU3 ,4) on terminal 4 . Is 12V connector and blower motor resistor on terminal H.
present? NO - Go to next Step.
16. Measure voltage at C139-G. Is 12V present? YES - Locate and repair open circuit between C139-G
and blower motor resistor in-line connector terminal 4.
NO - Go to next Step.
17. Measure voltage at blower speed switch on pin 3. YES - Locate and repair open circuit between switch
Is 12V present? pin 3 and C139-G.
NO - Test switch.

Rae 6-12840 Issued 3-03

 9010-91

EVAPORATOR TEMPERATURE SENSOR

Background
The evaporator temperature sensor, sometimes
1,.o,..~I_--\ 1
called the "freeze" or "core" sensor, is located in the
evaporator/heater assembly. The sensor measures
the effectiveness of system response to the current
demand for heating or cooling.

"Freeze" Control
The evaporator sensor also prevents the system from
operating in low ambient temperatures where
damage to the system might occu r. When 3
temperature sensed at the evaporator falls to 32°F
(DoC), the controller cycles the compressor clutch
OFF. When temperature sensed at the evaporator Evaporator Core Rear View
RH990218

rises to 3rF (3°C), the controller cycles the clutch

1. 4.2 INCH (107 mm) 3. EVAPORATOR CORE
back ON . At the maximum cooling setting where the 2. EVAP TEMP SENSOR
compressor runs continuously, the freeze range
controls the cycling of the compressor OFF or ON.

Sensor Location
Proper location of the evaporator sensor is essential
to system performance. The evaporator temperature
sensor must be installed 4.2 inches (107 mm) from
the left hand rear side of the evaporator. The sensor
must be installed below the second refrigeration tube
row at a 30° downward angle. Insert the sensor in the
evaporator core up to the angled section , being
careful not to kink the sensor.

Electrical Test - Sensor

STANDARD
Ale CONTROLLER CCUl

CCU2

RH03B056,AH01HQ30

The sensor has a well known resistance vs
temperature response: It should measure 10-25K
ohms at room temperature for normal operation.
The sensor is a thermistor - thermal resistors. With
this thermistor, the colder the environment, the
greater the electrical resistance; and the warmer the
environment, the less electrical resistance.
The sensor can fail without indicating an open
condition. Measure the resistance of the sensor and
the ambient temperature at the sensor, and compare
the readings to the Resistance versus Temperature
table on page 93. If the readings are not within the
minus or plus 2.5% range, replace the sensor.
NOTE: For the test to be valid, the thermometer
used must be accurate, and the temperature
recorded must be the temperature at the sensor.

Rae 6-12840 Issued 3·03

9010-92

Power Circuit
The sensor is grounded to the HVAC ground stud .
Minimal voltage is fed to the sensor - about 0.5V at 70°F (21 °C) - and voltage drops as the temperature increases.
Current is fed to the evapcrator sensor from pin B at the controller (CCU1).

Service Note: Too Little CoolingfToo Much Heating without Symptoms

The sensor should be suspect when the complaint is
too little cooling when cooling and too much heating
when heating ("the cab is too hot or too cold all the
time"), and obvious symptoms are absent:
- System pressures are normal , and system is
properly charged.
- Coolant system operating normally.
- Compressor and heater valve are functioning
normally.
The sensor fails in a consistent pattern: It senses a
lower temperature then is actually present.
In cooling mode, actual temperature at the
evaporator is 50°F (10°G), but the sensor senses
45°F (7°G) and the compressor is not engaged with
suff icient frequency. In heating mode, actual
evaporator temperature is 80 ° F (2rC), but the
sensor senses 75 ° F (24°C) and heater valve is
opened too widely.
Perform the resistance versus temperature test on
the sensor.

Evaporator Temperature Sensor and Circuit Test

Steps and Test Point Corrective Actions
1. Keyswitch OFF. Disconnect the cab temperatu re YES - Go to next Step.
sensor from harness. Measure the resistance NO - Replace the sensor.
across the sensor leads. Measure the ambient
temperature at the sensor. Compare the readings
to the Temperature versus Resistance table on
page 93. Is the resistance reading within the
minus or plus 2.5% range in the table?
2. Keyswitch and AlC switch ON . Measure voltage at YES - Go to next Step 4.
pin 1 to sensor. Is voltage present? NO - Locate open and repai.
NOTE: Voltage reading will be very low: 0.5V at 70°F
(21 °C); and voltage decreases as temperature
increases.
3. Is voltage present at pin B (CCU1 ) at the YES - Go to next Step.
controller? NO - Locate and repair open condition between pin B
and sensor.

4. Measure resistance from sensor to the HVAC YES - Test the controller. See Standard Controller
ground stud. Less than 1 ohm? Test, page 71 , in this Section.
NO - Locate open circuit and correct.
NOTE: Verify that the evaporator temperature sensor is installed in the right location. The temperature sensor
must be installed 4.2 inches (107 mm) from the left hand rear side of the evaporator. The sensor must be
installed below the second refrigeration tube row at a 3(1' downward angle. Insert the sensor in the evaporator
core up to the angled section.
NOTE: While installing the sensor in the wrong location causes faulty system per.formance, it will not cause the
sensor to fail or provide a faulty resistance reading for a given temperature. Replace the sensor if it tests out of
range for a given temperature.

R.e 6-12840 Issued 3-03

 9010-93

Temperature Versus Resistance Table

Ambient Temperature ..- Range - . . Ambient Temperature ..- Range ~

'F ·C ·2.5% Kohms +2.5% 'F 'C -2.5% Kohms +2.5%

0 -17.78 170.820 175.200 179.560 61 16.11 29. 179 29.927 30.675
1 -17.22 165.360 169.600 173.840 62 16.67 28.434 29.163 29.892
2 -16.67 160.095 164.200 168.305 63 17.22 27.710 28.421 29.132
3 -16.11 155.025 159.000 162.975 64 17.78 27.008 27.701 28.394
4 -15.56 150.150 154.000 157.850 65 18.33 26.327 27.002 27.677
5 -15.00 145.470 149.200 152.930 66 18.89 25.664 26.322 26.980
6 -14.44 140.985 144.600 148.215 67 19.44 25.020 25.662 26.304
7 -13.89 136.598 140.100 143.603 68 20.00 24.395 25.020 25.646
8 -13.33 132.308 135.700 139.093 69 20.56 23.787 24.397 25.007
9 -12.78 128.213 131.500 134.788 70 21.11 23.196 23.791 24.386
10 -12.22 124.313 127.500 130.688 71 21 .67 22.623 23.203 23.783
11 -11 .67 120.510 123.600 126.690 72 22.22 22.064 22.630 23.196
12 -11.11 116.B05 119.800 122.795 73 22.78 21.522 22.074 22.626
13 -10.56 113.295 116.200 119.105 74 23.33 20.996 21.534 22.072
14 -10.00 109.785 112.600 115.415 75 23.89 20.483 21.008 21.533
15 -9.44 106,470 109.200 111 .930 76 24.44 19.985 20.497 21.009
16 ..a.89 103.350 106.000 108.650 77 25.00 19.500 20.000 20.500
17 -8.33 100.230 102.800 105.370 78 25.56 19.029 19.517 20.005
18 -7.78 97.227 99.720 102.213 79 26.11 18.571 19.047 19.523
19 -7.22 94 .331 96.750 99.169 80 26.67 18.125 18.590 19.055
20 -6.67 91.533 93.880 96.227 81 27.22 17.691 18 .145 18.599
21 -6. 11 88.832 91.110 93.388 82 27.78 17.269 17.7 12 18.155
22 -5.56 86.219 88.430 90.641 83 28.33 16.859 17.291 17.723
23 -5.00 83.694 85.840 87.986 84 28.89 16.460 16.882 17.304
24 4 .44 81.247 83.330 85.413 85 29.44 16.071 16.483 16.895
25 -3.89 7B.887 80.910 82.933 86 30.00 15.694 16.096 16.498
26 -3.33 76.596 78.560 80.524 87 30.56 15.325 15 .718 16.1 11
27 -2.78 74.383 76.290 78.197 88 31.11 14.967 15.351 15.735
28 -2.22 72.248 74.100 75.953 89 31.67 14.618 14.993 15.368
29 -1.67 70. 171 71 .970 73.769 90 32.22 14.279 14.645 15.011
30 -1.1 1 67.470 69.200 70.930 91 32.78 13.948 14.306 14.664
31 -0.56 66.232 67.930 69.628 92 33_33 13.627 13.976 14.325
32 0.00 64.350 66.000 67.650 93 33.89 13.314 13.655 13.996
33 0.56 62.532 64.135 65.738 94 34.44 13.008 13.342 13.676
34 1.11 6O.n1 62.329 63.887 95 35.00 12.712 13.038 13.364
35 1.67 59.066 60.580 62.095 96 35.56 12.422 12.74 1 13.060
36 2.22 57.414 58.886 60.358 97 36.11 12.141 12.452 12.763
37 2.78 55.814 57.245 58.676 98 36.67 11 .866 12.170 12.474
38 3.33 54.265 55.656 57.047 99 37.22 11 .599 11.896 12.193
39 3.89 52.764 54.117 55.470 100 37.78 11 .338 11.629 11 .920
40 4.44 51.309 52.625 53.94 1 101 38.33 11 .084 11 .368 11.652
41 5.00 49.901 51 .180 52.460 102 38.89 10.837 11 .115 11.393
42 5.56 48.535 49.n9 51.023 103 39.44 10.595 10.867 11.139
43 6.11 47.211 48.422 49.633 104 40.00 10.360 10.626 10.892
44 6.67 45.928 47. 106 48.284 105 40.56 10.131 10.391 10.651
45 7.22 44.684 45.830 46.976 106 41 .11 9.908 10.162 10.416
46 7.78 43.479 44 .594 45.709 107 41 .67 9.691 9.939 10.187
47 8.33 42.310 43.395 44 .480 108 42.22 9.479 9.722 9.965
48 8 .89 41.176 42.232 43.288 109 42.78 9.272 9.510 9.748
49 9.44 40.076 41 .104 42.132 110 43.33 9.070 9.303 9.536
50 10.00 39.011 40.011 41.011 111 43.89 8.873 9.101 9.329
51 10.56 37.976 38.950 39.924 11 2 44.44 8 .681 8.904 9.127
52 11 .11 36.973 37.921 38.869 11 3 45.00 8 .495 8 .713 8 .931
53 11 .67 36.000 36.923 37.846 114 45.56 8 .312 8 .525 8.738
54 12.22 35.055 35.954 36.853 11 5 46.11 8 .134 8.343 8 .552
55 12.78 34.139 35.014 35.889 116 46.67 7.96 1 8 .165 8.369
56 13.33 33.249 34.102 34 .955 117 47.22 7.791 7.991 8.191
57 13.89 32.387 33.217 34 .047 118 47.78 7.626 7.822 8.Q18
58 14.44 31 .548 32.357 33.166 119 48.33 7.466 7.657 7.848
59 15.00 30.735 31.523 32.311 120 48.89 7.308 7.495 7.682
60 15.56 29.945 30.713 31.481 121 49.44 7.155 7.338 7.521

Rae 6-12840 Issued 3-03

9010-94

CONTROLLER POWER AND GROUND, AlC SWITCH

STANDARD
AIC CONTROLLER
c ::l
CCUl ~.,.z
139MM 139F ~o2 STANDARD
AlCOHIOFF
A A oowU
B B ~g~ SWITCH
I~N
C e uoo~
0 0 g~a5 "1o-0N
E E 126M I

~
N. 3.0 F
G
H
F
G
1788 Bk- 3.0 322M 322F
,,
1 ,

821. R--O.8 88 8218 R.O.8 3 ,

eeU2 H
4 •
J
Or-O.8
K
K lnzSk-O.S CC 80 1BBk-O.8
,,
5 ,

= +======~ Ao 0A
L 826A Or-0.8
Or-O.6 826B Or-0.8
~
" "
N
p N
627A Or-0.8 8278 Or· 0.8 7 ,
B,
~
m
p 9 ,
o,
252~CCU Or-O.8 R R 825A R-3.0 102M R. 3.0 _ TO SWITCHED B+
=> S S AT RING TERM 138...
U
U, T T SHT1SEcnON21
c u u LU'
0 y V COlORED
'" CONNEClOR

i
TO RING TERMINAL 172F,
X X SECTION 21
V V
Z Z

Background
HVAC Ground Intermittent Ground
HVAC ground is both a grounding stud at the rear of Intermittent HVAC ground can make reliabl e
the HVAC box and chassis ground at ring terminal troubleshooting very difficult. The "intermittent"
172F through C139-F on wire 17B-Bk. nature of the problem is further complicated since the
fault can appear to move from component to
component. Early testing for a stable and consistent
ground at the ground bolt and ring terminal 172F can
greatly simplify troubleshooting.

Power and Ground Circuit

Standard Controller
Whenever switched B+ is present, 12V is fed the controller from fuse 47 (30 amp) through C139-R to pin A at the
controller (CCU1).
The controller is grounded from pin F (CCU1) to the HVAC ground stud.
AlC Switch
The controller feeds 5V from pin E (CCU1 ) through C139-L to the switch at pin 6; grounding pin 6 with the switch
provides the ON request to the controller.
The switch is grounded from pin 5 to chassis at Splice C14.
Pressure Warning Lamp
The controller provides switched ground from pin C on (CC U2) through C139-M to the switch at pin 9 for the
pressure warning lamp.
The lamp is powered at pin 10 with switched B+ from Splice C43.

Possible Failure Modes

1. Fuse 47 or open condition in power or ground to controller.
2. NC switch failure.
3. Open condition in power or ground to switch or pressure warning lamp.

Rae 6-12840 Issued 3-03

 9010-95

Controller Power Supply and Ground Test

Steps and Test Point
1. Keyswitch ON. Measure the voltage between pin A
at the controller (CCU1) and chassis ground. Is
12V present?
2. Check fuse no. 47 (30 amp) . Is 12V present?
3. Measure resistance from pin F at the controller
(CCU1) to the HVAC ground stud. Less than 1
ohm?
Corrective Actions
YES - Go to Step 3.
NO - Go to next Step.
YES - Locate and repair open condition between fuse
47 and pin A at the controller.
NO - Locate and repair open condition from fuse 47 to
switched B+. Go to next Step.
YES - Test the controller. See Standard Controller
Test, page 71 , in this Section.
NO - Locate and repair open condition from pin F to
HVAC ground.

AlC Switch and Circuit Test

Steps and Test Point Corrective Actions
1. Disconnect AlC switch from harness. With switch YES - Go to nex1 Step.
ON, measure resistance across pins 5 and 6 on NO - Replace switch.
switch. Less than 1 ohm?
2. Measure resistance across pins 9 and 10 at YES - Go to next Step.
switch. Less than 1 ohm? NO - Replace switch.
3. Measure resistance from pin 5 at the harness YES - Go to nex1 Step.
connector to chassis ground. Less than 1 ohm? NO - Locate and repair open condition between pin 5
and ground.
4. Keyswitch ON . Is 5V present at pin 6 at the YES - Go to Step 6.
harness connector? NO - Go to nex1 Step.
5. Is 5V present at pin E at the controller (CCU1)? YES - Locate and repair open condition between pin E
at controller and pin 6 at switch through C139-L and
C322-A.
NO - Test the controller. See Standard Controller
Test, page 71 , in this Section.
6. Is 5V present at pin 10 at the harness connector to YES - Go to nex1 Step.
the switch? NO - Locate and repair open condition in switched B+
to pin 10 at switch.
7. Reconnect the AlC switch to harness. Disconnect YES - Test the controller. See Standard Controller
the harness to the low pressure switch. Keyswitch, Test, page 71 , in this Section .
A/C switch and blower control ON. Temperature NO - Locate and repair open condition between pin C
control to maximum cooi. Is 5V present between at controller and pin 9 at the switch through C322-A
pin C at the controller (CCU2) and chassis and C139-M.
ground?

Rae 6-12840 Issued 3-03

9010-96

CAB PRESSURIZER BLOWER

FUSE #10
15A
,312D K-0.8 ~21195A K-1.0 - - - O \ y - - - 1 0 1 M _ UNSWITCHED8+
I FROM SPLICE C33
TO SWITCHED B+ A1 A3 264F SHT1 SECTION 19
AT SPLICE C40
SHl1 SECTION 34 CAB
PRESSURE
BLOWER
RELAY
#10
A2 AS A4 264F
I
d CAB
'" PRESSURE
OJ BLOWER
10F 10M
~
1 - 1958 K-1.0
---m- 195C K-1.0 i 179AY
90F 90M

8k-1.0~~I~Jg:~
TO ENGINE RELAY TO CLEAN GROUND
AT SPLICE F3
.---J
AT CONN 264F
CAV 82 SHT 2 SECTION 57
SHl1 SECTION 20
RH<l3B050

Background
Whenever switched power is present , the cab The motor is energized by a relay, activated by
pressurizer motor should operate. The motorlblower switched B+.
assembly draws air from the cab cap through the left
Only the pressurizer blower relay and motor
hand cab post and fresh air filter and feeds it directly
troubleshooting are covered here.
to the HVAC box under the operators seat. The
motor/blower assembly is located behind the fresh air
filter.

Power and Ground

Unswitched B+ is continuously provided to the relay on pin A3 from fuse 10 (15 amp). The relay is grounded on pin
A2 to the engine relay.
Whenever Switched B+ is present, the relay is energized on pin A 1, and Unswitched B+ is supplied to the cab
pressurizer motor on pin A through C1 0-85.
Clean ground is continuously supplied to the motor on pin B from the Splice F3.

Rae 6-12840 Issued 3·03

 9010-97

Cab Pressurizer Blower & Relay Power Supply and Ground Test
Steps and Test Point Corrective Actions
1. Keyswitch ON . Check fuse 10 (15 amp). Is 12V YES - Go to next Step.
present? NO - Replace fuse 10 and!or locate and repair open
condition to the fuse.

2. Measure the voltage on pin A at the pressurizer YES - Go to nex1 Step.

motor. Is 12V present?
3. Disconnect the motor from the harness and check
for continuity through the motor between pins A
and B. Is continuity present?
4. Keyswitch OFF. Measure resistance between pin
B at the motor and clean ground at Splice F3.
Less than 1 ohm?
5. Reconnect motor to the harness. Keyswitch ON. Is
12V present at pin A3 of the blower relay and
chassis ground?
6. Is 12V present at pin A 1 of the blower relay and
chassis ground?
7. Keyswitch OFF. Measure resistance between pin
A2 at the motor relay and pin B2 at the engine
relay. Less than 1 ohm?
8. Measure resistance between pin A5 at relay and
pin A at the motor. Less than 1 ohm?
NO - Go to Step 4.
YES - Go to nex1 Step.
NO - Replace the motor.
YES - Go to nex1 Step.
NO - Locate and repair open condition between pin B
at the motor and Splice F3 on wire 179-Bk.
YES - Go to nex1 Step!
NO - Locate and repair open between fuse 10 and
relay on wire 195-K.
YES - Go to nex1 Step.
NO - Locate and repair open condition between the
relay pin A 1 and Splice C40 on wire 312-K.
YES - Go to nex1 Step.
NO - Locate and repair open between pin A2 and pin
B2 at the relays on wire 177-Bk.
YES - Replace the motor relay.
NO - Locate and repair open condition between pin A5
at the relay and pin A at the motor on wire 195-K.

Rae 6-12840 !ssued 3-03

9010-98

Rae 6-12840 Issued 3·03

 Section
9020

AIR CONDITIONER SYSTEM SERVICE

MX MAGNUM TRACTORS 21 0, 230, 255, 285

Case, LLC
<C> 2003 Case, LLC
700 State Street Printed In U.S.A.
Racine. WI 53404 U.S.A. 6-13050 March, 2003
9020-2

TABLE OF CONTENTS
SPECIFICATIONS ........................................... ......................... ...... ........................................ .............. ................... 4

SPECIAL TORQUES ............ .............................................................. .......................... ................................... ........ 4

SPECIAL TOOLS ....................... .............................. ......................... ........................... ........................................... 4

SAFETY PROCEDURES ... ................ ........................................................................................ ............................. 9

AIR CONDITIONER SYSTEM REFRIGERANT RECOVERy ............ .............. ........................... ...... .................... 10

RECOVERING PURE 134A REFRIGERANT ................................................................................ ......... .............. 12

RECOVERIN G CONTAMINATED REFRIGERANT WITH OEM1691 .................................................................. 16

Preparing the Tank ..... ........ .. ...... ............... .......................................... ....................... .................................... ... 16
Recovery Process ........................................................ ..... .............. ......................... ................ .......................... 20

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ............................................... ..................... 26

MX AIR CONDITIONING TEMPERATURE/PRESSURE CHART .... .. ....................................................... ........... 33

LEAK DETECTION .................................... ............. ........ .... ...................... .... ................................ ........... .... ......... . 34
Electronic Testing with OEM1437 ...................................... ....... ..... .................................................................... 35
Florescent Leak Detection ............ ................. ..... ................................................................... ................... ......... 36
Fluorescent Dye Injection ................................. .................... ...................... ....................................................... 36
Recovery Station Dye Injector Tool with a System in a Vacuum ..................................................................... 37
Recovery Station Dye Injector Tool with a Charged System ...................................................... ..................... 38
Quick and Easy Dye Injector Tool with a Charged System ............................. ................................................. 39
Compressor Oil Port .......... .. .................................................................................................................... ......... 40
SP-20 PAG Oil Return Bottle ................. ...................... ........................................................... ................ ......... 41
Fluorescent Leak Testing ... .............................................................................. ..................... ..... .......... .............. 42

AlC SYSTEM FLUSHING PROCEDURE ..... .................................. ....... .............................................. .................. 43

Required Tools .... ............ .......... ............... ......... ................................. ............... .......................... ....................... 44
Precautions ....... ....................................... ................................................................ .......................................... 45
Component Flushing Procedure with Power Flush 17550 .......................... .................... ................................... 46
Complete Circuit Flushing Procedure with Power Flush 17550 ........................... .............................................. 50
Back Flushing the Thermal Expansion Valve or Refrigerant Line ............................................ ........ .................. 55
Post Flushing Procedures ................. ............................ ..... ....... .... .. ..... ................................. .... ......................... 57
Flushing Solvent Disposal ...................................... .................... ........................................................................ 59

AlC SYSTEM COMPONENTS ..... ............ ....... .......... .......................................................................... .................. 60

Cab HV AC Box Components - Automatic Temperature Control ....................................................................... 60
Cab HVAC Components - Standard Systems .................. ................................................................................. 62
MX Magnum 210/230 Chassis Components .............. ............ .. ......................................................................... 64
MX Magnum 255/285 Chassis Components .................. .... ..... ...... ....... ....................................... ...................... 65

AlC COMPRESSOR CLUTCH ............. ................................................................................................................. 66

Clutch Removal ............................................................................. ..................................................................... 66
Exploded View of Clutch ..... ....... ............................. ................................... .... ................................................ .. .. 72
Compressor Clutch Replacement ...................................................................................................................... 72

6-13050 Issued 3·03

 9020-3
AlC COMPRESSOR .......... ................. .•.............•................................................................................................... 80
Oil Level Check or Adjustment .... .......................... .. ........... ...... ........•....................... .......................................... 80
Injection Method .............................................................................................. ................................................. 80
Dipstick Method ................................................... ......................... ..•................................................................. 81
Compressor Removal ........................................... ................................................... ............... ..... ............. ......... 83
Compressor Installation ............ ................. ................ ............................................ ............................................ 86

CONDENSER AND RECEIVER·DRIER ........ ... .................... ................... ................ ... .................................. ........ 88
Condenser .................................. ....................................... ................................................................................ 88
Receiver·Drier ............................................................. ............... ...... ..................... ........................ ..................... 90

ACCESSING THE HVAC BOX .... ...................................................... ................................ .................................... 92

THERMAL EXPANSION VALVE TESTING ...................................... ................................ .................................... 94

THERMAL EXPANSION VALVE REPLACEMENT .............. .... ............................................................................. 96

EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION ..................................................................... 98

BLOWER MOTOR REPLACEMENT ..................... ....................................... ............................ ..................... ........ 99

HEATER CONTROL VALVE REPLACEMENT ............................................ ............... ........................................ 100

EVAPORATOR/H EATER ASSEMBLY ..................................................... .... ............. .......................................... 101

Evaporator/Heater Assembly Removal ............................................................................................................ 101
Evaporator/Heater Assembly Installation ......................................................................................................... 104
Post Replacement Procedures .......................................................................................................... .............. 107

EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING ........ ........................................ .... ............... 108

BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION ........................................................................ 109

CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT .................................................................. 110

ATC Controller ............................................... ...................................................... .... ..... ..................... .............. 110
Standard AlC Controller ................................................................................................................................... 110
Blower Speed Driver (ATC Units Only) ............................................................................................................ 111

CAB AIR FILTER SERVICE ................................................................................................................................ 112

CAB RECIRCULATION AIR FILTER SERVICE .................................................................................................. 113

CAB PRESSURIZATION TEST .......................................................................................................................... 114

CAB PRESSURIZER MOTOR REPLACEMENT ................................................................................................ 116

VISCOUS FAN DRIVE ..................................................................................................................................... ... 118

6·13050 Issued 3-03

9020-4

SPECIFICATIONS
Air Conditioning System Refrigerant Capacity ... ...... ...... ........ .. ...... MX Tractor Models - 4.63 Ib (US) (2.1 kg)
Clutch Front Plate Air Gap ............................ ... ... ............................................. 0.016 to 0.031 Inch (0.41 to 0.79 mm)

SPECIAL TORQUES
Compressor Clutch Retaining Nut ................ .... .. ............. ... ...... .. .... ......... .. ............. 15 to 20 Nm (11 to 15 Ib It)
Oil Filler Plug ................ .................................................. ........................... ...... ................. 15 to 24 Nm (11 to 18 Ib It)
Dust Cover Screws ................................................................ ................................................ . 7 to 11 Nm (5 to 8 Ib It)

SPECIAL TOOLS
Combination Impact and Chemical Splash .------------0--------,
Safety Goggles

' 09L7

Compressor Tool Set, CAS10747A

The compressor dipstick (1) can be found in the
Compressor Tool Set or purchased separately -
CAS10747-19.

Refrigerant Recovery Station, OEM1415

6 Foot Length , Quick Disconnect Refrigerant
Charging Hoses: OEM1438 (Yellow), OEM1439
(Bl ue), OEM1440 (Red)
20 Foot Length, Quick Disconnect Refrigerant Hoses
- OEM1442 (Set includes Yellow, Blue and Red
hoses)

6-13050 Issued 3-03

 9020-5

Refrigerant Identifier OEM4450

Air-Powered Recovery Station with Tank

OEM1691

Additional 50 Ib Contaminated Refrigerant Tanks

OEM1692

RROOE140

1/4 Inch FFLX to 1/2 Inch Acme Adapter

OEM1693

AROOE139

6-13050 Issued 3-03

9020-6

Electronic Leak Detector OEM1437

A22090

UV Leak Detection Lamp and Goggles

BSL750

Recovery Station UV Dye Injector for R-134a

Refrigerant - BSL734

UV Leak Detection Dye for R-134a Refrigerant

B726012

6-13050
 9020-7

R134a Quick and Easy Dye injector Tool

8SL738

I
RD01F248

Quick and Easy R134a Charge Cans - 6-Pack

8SL634

AD01F249

UV Fluorescent Dye Cleaner - 8795016

RROOF1QO

Power Flush Model 17550

8S33801 - AlC Flushing Solution, case of six 1-
gallon containers

RROOF093

6-13050 Issued 3-03

9020-8

Flush Gun Kit Model 17585

8533801 - AlC Flushing Solution, case of six 1-
gallon containers

Coalescing Air FilterlDryer (1) Similar to

Ingersoll-Rand ModellR5CHE or Grainger Model
4KR65

RIOOF041

Pressure Regulator Capable of Providing 45 psi

at 4.0 cfm (310 kPa at 0.11 cmm)
with Integrated Pressure Gauge

17582 Universal Flush Fitting Kit

6-13050 Issued 3·03

 9020-9

SAFETY PROCEDURES

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULL Y READ THE MESSAGE THA T
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B

ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems.
Refrigerant HFC-134a is the most stable and
easiest to work with of the refrigerants now used in
air conditioning systems. Refrigerant HFC-134a
does not contain chlorofluorocarbons (CFC's)
which are harmful to the earth's ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear combination impact and chemical
splash safety goggles when doing any service
work near an air conditioner system. Liquid
refrigerant in the eyes can cause serious injury.
Do the following if you get refrigerant near or in
your eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately. M779
5. Use the air-powered OEM1691 ONLY to recover
contaminated refrigerant. Do NOT use OEM1415
or OEM1418 recycling stations to recover
contaminated refrigerant. If contaminated
refrigerant contains more than 2% hydrocarbon
(propane , butane, or isobutane), the mixture
must be treated as flammable; if more than 4%
hydrocarbon, the mixture must be treated as
explosive; in both cases an electric-powered
recovery station may NOT be used. Avoid heat,
sparks and flame when working with this
contaminated refrigerant. MBOO
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never inhale
fumes. M745
7. Never leak test with compressed air or flame
tester. Tests have indicated that compressed
mixtures of HFC-134a and air can form a
combustible gas. M746

2. Always recover all refrigerant prior to opening an

AlC system. A drop of liquid refrigerant on your
skin may cause frostbite burns. Open fittings
carefully and slowly when servicing the air
conditioning system. Your skin must be treated
for frostbite burns or a physician must be seen if
you get refrigerant on your skin. M799

3. Keep refrigerant containers in correct upright

position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat. M743

4. Always check refrigerant purity with OEM4450

Refrigerant Identifier before recovering
refrigerant and before testing the system. M777

6-13050 Issued 3-03

9020-10
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY
IMPORTANT: There are no repair procedures for the compressor or compressor clutch . If the clutch or
compressor are defective, replace them.
WARNING: 134a is the only refrigerant
approved in 134a systems. Alternative
"'" refrigerants which boast better cooling
Ll). capabilities are in most cases highly
flammable. Do not expose contaminated
refrigerant to spark, flame or yourself. M748
IMPORTANT: Refrigerant contamination has
become an issue since the introduction of 134a as a
replacement for R-12. Contamination refers to a
refrigerant blend and/or mixture of alternative
refrigerants and 134a. Typically R-12 systems which
are in need of repair or recharge are suspect to
refrigerant contamination due to the number of so
called "drop-in" replacements or substitutes for 134a.
Systems designed for 134a, such as the MX
MAGNUM, may be at lower risk for contamination,
but precautions should be taken to prevent
contamination of service equipment and/or other AlC
systems.
IMPORTANT: A refrigerant identifier should be used
to determine refrigerant contamination prior to
recovery. Case recommends using OEM4450
refrigerant identifier. If a refrigerant contamination
level of 2% or greater is discovered, do not recover
the system to a tank with pure 134a refrigerant.
Recover only to a tank reserved for contaminated
refrigerant with the air-powered station - OEM1691.
WARNING: OEM1415, and its predecessor
OEM 1418, were designed for the recovery
and recycling of pure 134a refrigerant. Do
NOT use OEM1415 and OEM1418 to
.&. recover contaminated refrigerant; you will
void your warranty, you may damage the
compressor and filter-drier in the recovery
station, and you may expose yourself to the
danger of an explosion. M795
6-13050
WARNING: If the refrigerant identifier
indicates the system contains more than 2%
hydrocarbon (propane, butane or isobutane),
the system and its contents must be treated
as flammable; if more than 4% hydrocarbon,
the system and its contents must be treated
"'" as explosive. Do not operate the vehicle or
~ the A/ C system . Do not recover this
contaminated refrigerant with an electric-
powered unit (OEM1415 or OEMI418). Use
the air-powered station - OEM1691 - to
recover this refrigerant. Avoid heat, sparks
and open flame when working with this
contaminated refrigerant. M796
IMPORTANT: If contaminated refrigerant is
discovered and recovered with OEM1691 , replace
the receiver-drier in the tractor being serviced
BEFORE you recharge the system with pure 134a
refrigerant. OEM1415 or OEM1418 should be used
to evacuate and recharge the system after the
contaminated refrigerant has been safely recovered.
NOTE: Check with your local environmental agency
for regulations on the proper disposition of
contaminated refrigerant.
NOTE: In the United States, EPA regulations require
that tanks of contaminated refrigerant be sent to a
refrigerant reclaimer for the contents to be purified or
destroyed. Call 1-800-296-1996 to locate a reclaimer
in your area.
WARNING: Do NOT use a tank without a
.&. limit switch to recover contaminated
refrigerant with OEMI691. The limit switch
prevents overfilling the tank and protects
your safety M797
WARNING: When working with SP-20 PAG
oil, follow these safety precautions: 1) Avoid
contact with eyes, skin and clothing. 2) Avoid
"'" breathing vapor, aerosol and mist. 3) Do not
~ swallow. 4) Use only with adequate
ventilation. 5) Wear protective safety goggles
and non-permeable gloves when handling
SP-20 PAG oil. M798
Issued 3-03
 9020-11

Overview
In many countries , recovery, recycling and
reclamation have legal definitions and standard
meanings in the mobile AlC industry.
Recovery is transferring refrigerant in any condition
from a system to a storage container without testing
or purifying the refrigerant in any way.
Recycling is the cleaning of refrigerant for reuse by
oil-separation, non-condensable gas removal and
single or multiple passes through filter/moisture
absorption devices.
Reclamation is processing refrigerant to a level
equal to new product specifications as determined by
chemical analysis, (testing to ARI 700) .
In servicing Case LLC AlC systems with OEM1415,
when "recover" is depressed, the refrigerant in the
vehicle is transferred to the recovery tank on the unit
without testing or purifying. At the same time, SP-20
PAG oil is separated from the refrigerant and stored
separately in the reservoir. This oil requires proper
disposal and should never be returned to the vehicle.
When "vacuum" is depressed, the vacuum pump on
OEM1415 evacuates the atmosphere in the vehicle
A/C system to a vacuum of 28 to 29-1/2 inches of
mercury (Hg). Air and moisture are removed in the
process, and only SP-20 PAG oil remains in the
vehicle's AlC system.
A22094
When "recycle" is depressed, the entire contents of OEM1415
the recovery tank on OEM1415 are "recycled." The
refrigerant in the tank is passed through a filter-drier
in OEM1415 and cleaned; non-condensables are
removed , and air is purged automatically. (Older
recovery units like OEM1418 have manual air purge.)

NOTE: In automatic operation, recycling begins

about 5 seconds after the vacuum pump starts.

NOTE: During recycling, some additional SP-20

PAG oil is separated from the refrigerant and stored
separately in the reservoir.

Only new SP-20 PAG oil is added to replace the oil

which was separated during recovery, and when
" recharge " is depressed, only clean " recycled"
refrigerant is returned to the vehicle's AlC system.

OEM1415 (or OEM1418) does not perform

"reclamation."

6-13050 Issued 3-03

9020-12

RECOVERING PURE 134A REFRIGERANT

STEP 1
Start the tractor and run the engine at 1500 RPM . If
possible, operate the air conditioner for 15 minutes at
maximum cooling and maximum blower speed . ATC
switch set to DEFOGIDEFROST, standard AI C
switch set to ON.

Standard AlC Controls

RH02J045
ATe AlC Controls
1. BLOWER CONTROL 3. TEMPERATURE
CONTROL
2. ATC OR STANDARD NC 4. LCD DISPLAY
SWITCH

STEP 2
Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction and pressure lines.

RD02HQ32

6-13050 Issued 3-03

 9020-13

STEP 3
IMPORTANT: Use Refrigerant Identifier OEM4450
to verify refrigerant purity. If refrigerant is 98% pure
HFC-134a and/or the only non-condensibles test as
air and moisture, then proceed with Step 4. If not, go
to Step 12.
With the charging station manifold gauge valves in
the closed position , connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve
depressor.

STEP 4
Open the drain valve to make sure that the oil
separator is drained prior to recovery. Oil may have
mistakenly been left in the recovery unit itself from
the previous service job. An oily mist will discharge if
the separator has been drained.
Check that the oil reservoir has been drained prior to
recovery to avoid returning additional oil to the
system.

1. DRAIN VALV E 2. RESERVOIR DRAIN

6-13050 Issued 3-03

9020-14

STEP 5
Open the high and low valves.

STEP 6
Make certain the refrigerant tank gas and liquid
valves are open.

STEP 7
Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position and
depress the RECOVER switch.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe
the manifold pressure gauges for a pressure rise. If
no pressure rise. recovery is complete. If pressure
rises above 0 PSI . depress the HOLD/CONT switch
and repeat until pressure holds for two minutes. Then
wait for the compressor to automatically shut OFF.

NOTE: Refrigerant may pool inside the tractor's Ale

system. When the recovery unit's compressor is
turned off, the refrigerant will vaporize in the ambient
heat causing the system pressure to rise again.
Repeat the recovery process until the system
remains at a vacuum for at least two minutes.

6-13050 Issued 3--03

 9020-15

STEP 8
Some recovery units require a manual air purge to
remove non-condensables from the recovery tank.
Refer to the operators manual for your unit. Air purge
is automatic on an OEM1415 when it evacuates the
AlC system.

STEP 9
Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.

STEP 10
Record the amount of oil in the reservoir. This
amount of new oil should be added back to the
system. Dispose of any oil in the bottle in an
appropriate manner and return the bottle to the
station.

STEP 11
All refrigerant has been removed from the A /C
system; replace components or make any repairs at
this time.
A22111

6·13050 Issued 3·03

9020-16

RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691

IMPORTANT: When contaminated refrigerant is
discovered with Refrigerant Identifier OEM4450,
additional care is necessary to protect your safety
and prevent the contamination of service equipment
and your refrigerant supply. Recover the refrigerant
with OEM1691 station to a recovery tank reserved for
contaminated refrigerant. Do NOT use OEM1415 or
OEM1418 to recover the contaminated refrigerant.
IMPORTANT: Read all safety warning and
maintenance sections of the operators manual
before operating the station.
WARNING: Do NOT use a tank without a
A limit switch to recover contaminated
refrigerant with OEM1691 . The limit switch
prevents overfilling of the tank and protects
your safety. M797

Preparing the Tank

STEP 12
The tank for the station may be filled with 10 to 15 psi
of dry nitrogen which must be removed before it can
be used. Remove the cap from the red valve outlet.
Open the tank valve to release the nitrogen. Close
the tank valve.

STEP 13
Use the vacuum pump (1) on OEM1415 or OEM141 B
to pull a 5 minute vacuum on the tank. Connect the
tank at the location (2) shown .

6-13050 Issued 3·03

 9020-17

STEP 14
A 114 inch FFLX to 112 inch Acme adapter
(OEM1693) should have been ordered with the unit.
Connect the adapter to the red tank valve.

STEP 15
Connect the 96 inch (2.4 m) blue hose with the
R134a service coupler to the adapter.

STEP 16
Connect the R134a service coupler to the tee fitting
on top of the vacuum pump on OEM1415 or
OEM1418. Open the valve on the service coupler by
turning it clockwise.

AROOEl54

6-13050 Issued 3-03

9020-18

STEP 17
Open the valve on the tank.

STEP 18
Open the low side manifold on the control panel of
OEM1415 or OEM1418.

STEP 19
Press SHIFT/RESET and ENTER at the same time.
Press 1 . The vacuum pump starts and runs
continuously until any other key is depressed.
Run the vacuum pump for a minimum of 5 minutes.
Then press 1 to stop the pump.

6· 13050 Issued 3-03

 9020-19

STEP 20
Press SHIFTIRESET again to return to the normal
display mode.
Close the valve on the tank.
Close the valve on the service coupler by turning it
counterclockwise and disconnect the blue hose from
the vacuum pump.

STEP 21
Set the tank on the platform at the rear of the station.
Tighten the black strap securely around the tank.

STEP 22
Disconnect the R134a hose from the adapter.
Disconnect the adapter from the tank and store for
future use. Reinstall the cap on the red valve outlet
port.
The tank is now prepared. See the operators manual
to prepare the recovery station for use.

6-13050 Issued 3-03

 9020-20

Recovery Process
IMPORTANT: If a recovery tank becomes full during
a recovery, the float switch will automatically turn off
the scavenger. See Step 35 for changing tanks in the
middle of a recovery.

STEP 23

*'
l.ll
WARNING: Do not operate the vehicle or
the Ale system if the refrigerant identifier
shows more than 2% hydrocarbon in the
mixture. MB01

Start the tractor and run the engine at 1500 RPM. If

possible, operate the air conditioner for a few
minutes at maximum cooling and maximum blower
speed, with ATC switch set to DEFOG/DEFROST, or
standard A/C switch to ON . Tests have shown that
more refrigerant will be recovered if this action is
performed.

NOTE: Turn the system and tractor OFF before

connecting the station.

STEP 24
Remove the cap on the low pressure port at the
compressor. Connect the blue R134a recovery hose
from the station to the low side service port at the
compressor.

STEP 25
Open the tank valve for the R134a hose. Open the
valve at the service port.

I 6· 13050 Issued 3-03

 9020-21

STEP 26
Turn the control panel valve to START.

NOTE: This will equalize pressure on both sides of

the compressor for easier starting.

STEP 27
Connect a compressed air line to the air inlet on the
regulator at the rear of the station.

NOTE: The air system must offer a minimum of 120

psi (827 kPa) and a maximum of 200 psi (1379 kPa)
at sustained volume of 10 cfm (0.28 cmm).

AROOEl33

6·13050
9020-22

STEP 28
Connect the red power lead to the + (positive) post of
the vehicle's battery or to another 12V DC power
supply. Connect the black ground lead to a ground
source away from the battery, NOT the battery -
(negative) post. The compressor should start idling.

NOTE: Batteries generate explosive gases during

normal battery operation. Use the remote ground to
reduce the risk of sparks around the contaminated
system.

NOTE: Use a jumper cable to extend the negative

lead if necessary to reach an engine ground.

STEP 29
Turn the control panel valve to RECOVERY. The
comp ressor sound should change. Inlet pressure
gauge should decrease and tank pressure increase
on the gauges.

6-13050
 9020-23

STEP 30
When inlet pressure gauge shows a vacuum ,
disconnect the air line. Wait five minutes. If inlet
pressure rises above 0 psi, repeat Steps 33 and 35.

NOTE: Refrigerant may pool inside the system.

When the station is turned off, the refrigerant will
vaporize in the ambient heat causing the system
pressure to rise again. Repeat the recovery process
until the system remains at a vacuum for at least two
minutes.

1. NC SYSTEM PRESSURE 2. TANK PRESSURE

GAUGE GAUGE

STEP 31
When the recovery process is complete, close the
valve on the recovery tank. Close the low pressure
hose valve and remove the hose from the port at the
compressor.

STEP 32
Disconnect the compressed air line from the inlet on
the regulator.

6-13050 Issued 3·03

9020-24

STEP 33
Disconnect the black ground lead. Disconnect the
red power lead from the 12V power source.

STEP 34
After each recovery, carefully open the accumulator
oil drain and drain any collected compressor oil in a
proper container.

NOTE: Small amounts of refrigerant may remain in

the accumulator and build a slight pressure. Drain
the accumulator when the inlet pressure gauge
shows a vacuum. There mayor may not be any oil to
drain; this will vary from tractor to tractor. Dispose
any oil drained in a proper manner.

NOTE: If any significant amount of oil is drained,

measure and record that amount. Add that
equivalent of new SP-20 PAG oil back into the
system at the end of the evacuation process.

IMPORTANT: If the oil is suspected to be other than

SP-20 PAG oil:
1. See the flushing procedures in this Section for
complete circuit flushing to remove the oil.
2 . Drain all oil from the compressor, and add back
to the compressor 8.5 oz (250 ml) of new SP-20
PAG oil.
3. Back flush the thermal expansion valve.
4. Reintroduce the fluorescent dye for R-134a in
the system.
5. Replace the receiver-drier before evacuating and
recharging the system.
6. Operate the system for 15 minutes to circulate
the new oil throughout the circuit.

6-13050 Issued 3~ 03
 9020-25

STEP 35
If a recovery tank becomes full during a recovery, the
float switch will automatically turn off the station . To
change a full tank in the middle of a recovery:
A. Close the blue tank valve and the valve on the
black hose from the station .
B. Unscrew and remove the float cable from the
tank.
C. Disconnect the hose from the tank valve.
D. Remove the tank from the station.
E. Replace the tank with a properly prepared tank
(dry nitrogen charge released and vacuum
drawn and held for five minutes).
F. Connect the tank valve hose and the float
cable.
G. Open the tank valve and the tank hose valve.
Recovery will continue as soon as both valves
are open .

IMPORTANT: Do not use recovered contaminated

refrigerant in any Ale system. Send full tanks to a
reclamation center for purifying or disposal of the
contents.

STEP 36
All refrigerant has been removed from the AI C
system, replace components or make any repairs at
this time.

IMPORTANT: Replace the receiver-drier on the

tractor being serviced before you evacuate or
recharge the system with OEM1415 orOEM1418.

STEP 37
See evacuation and recharging in this Section to
recharge the AlC system with pure R134a refrigerant
using OEM1415 orOEM-1418.

6-13050 Issued 3-03

9020-26

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or

more of the following conditions occurs before you
remove the air and moisture from the system:
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold or
brown particles).
D. Large system leak (broken hose, break in line).
E. Too much air or moisture in system.
F. Removal of compressor or any other
component caused the system to be open
(uncapped) longer than 5 minutes.
G. Testing with refrigerant identifier OEM4450
showed contamination.

STEP 38
With the charging station manifold gauge valves in
the closed position , connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose (blue).
2. Connect the hose from the high pressure gauge
to the port on the discharge hose (red).
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the system has been opened for
maintenance. A vacuum pump must be used to lower
the pressure enough to change the moisture to vapor
which can be removed from the system.

NOTE: Refer to the vacuum pump manufacturer's

user manual for additional information.

6-13050 Issued 3-03

 9020-27

STEP 39
Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position. "
program and vacuum do not appear at the top of the
display press the VACUUM key. Program a minimum
of 45 minutes and press the ENTER key. The display
will flash once indicating the programmed data has
been accepted.

STEP 40
Fully open the low and high pressure valves.

STEP 41
Open the red (vapor) and blue (liquid) valves on the
tank.

6·13050 Issued 3-03

9020-28

STEP 42
Press the VACUUM key. Automatic will show on the
display. VACUUM will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
When the programmed time has elapsed, an
auto matic hold occurs. Check the low pressure
gauge to see that the AlC system maintains a 28 to
29-1/2 inches of mercury (Hg).

NOTE: The low pressure gauge must not increase

faster than one inch of mercury (Hg) in 15 minutes. If
the system will not hold vacuum, a leak exists that
must be corrected before recharging can begin. See
leak test information in this section.

STEP 43
IMPORTANT: Do not inject the PAG oil until the
system will hold a proper vacuum.
OEM1415 has an injection system to return new SP-
20 PAG oil equal to the amount recovered at the end
of the evacuation process.
To add the new oil, adjust the O-ring around the oil
return bottle to the required oil charge level.

NOTE: If 2.4 oz (71 ml) was recovered in the oil

reservoir, 2.4 oz (71 ml) of new SP-20 PAG must be
returned.
1. OIL RETURN BOTILE 2. OIL INJECTION VALVE
Open the oil injection valve to add the oil into the
system. Close the valve when the oil level reaches
the O-ring .

IMPORTANT: Do not let oil level fall below the dip

tube in the return bottle or air will be introduced into
the refrigerant circuit.

STEP 44
Press the CHARGE key. PROGRAM and CHARGE
will appear on the display.

6-13050 Issued 3-03

 9020-29

STEP 45
Program the prope r refrigerant amount for your
tractor and press the ENTER key:
All MX Tractor Models .......... ........ ..4.63 Ibs (2.1 kg)
The display will flash once indicating the
programmed data has been accepted.

STEP 46
Press the CHARGE key to begin refrigerant
charging. AUTOMATIC and CHARGE will appear on
the display. The display shows the programmed
amount and counts down to zero as charging
proceeds. When charging is completed , the display
shows CPl.

IMPORTANT: Check the OEM equipment manual

before performing Step 47 to avoid damaging
recovery unit. Pressure reading should be obtainable
with valves closed. Damage may occur if the tractor
is started with the valves accidently open or if either
or both valves are opened while the AlC system is
operating.

STEP 47
Completely close the high and low pressure manifold
valves.

6-13050 Issued 3·03

9020-30

STEP 48
Start the tractor and run the engine at 1500 RPM.
Operate the air conditioner system at maximum
cooling setting and blower speed with the door and
service door open, Standard A/C switch ON or ATC
switch in DEFOG/DEFROST position.

NOTE: The compressor does not operate if the

system pressure is too low or too high because the
clutch is latched off by the controller. Standard NC
units blink the indicator light on the NC ON/OFF
switch indicating a system pressure problem. To
restart the compressor, the switch must be turned to
the OFF position and then ON. ATC units display a Standard AlC Controls

o
fault code on the LCD display indicating a pressure
problem. To restart the compressor, the ATC switch
must be turned to OFF and then AUTO or DEFOG!
DEFROST position.

AH02J045
ATC AlC Controls
1. BLOWER CONTROL 3. TEMPERATURE
CONTROL
2. ATC OR STANDARD AlC 4. LCD DISPLAY
SWITCH

6-13050 Issued 3-03

 9020-31

STEP 49
Observe the pressure gauge readings to determine
that the correct amount of refrigerant has entered the
system. See chart on page 33 for temperature and
pressure variations. Check louver temperature for
proper cooling at the mid-cab vents.

STEP 50
Close any open valves on the couplers and carefully
remove the gauge hoses from the ports on the
suction and discharge lines.

6-13050 Issued 3-03

9020-32

STEP 51
Install the caps on the service ports on the suction
and discharge lines.

6-13050 Issued 3-03

'!: MX MAGNUM AIR CONDITIONING TEMPERATURE/PRESSURE CHART
'"go
Models 210, 230, 255 and 285
Ambient Normal Low Side Pressure Normal High Side Pressure Louver Temperature"
Temperature
Low Relative Humidity" I High Relative Humidity I Low Relative Humidity" I High Relative Humidity Low RH" High RH
HOC
(52°F)
19°C
(57°F)

(71°F)
25°C
(75°F)

(81 "F)
49°C 255 to 319 kPa 283 to 345 kPa 2034 to 2482 kPa 2089 to 2551 28°C 30°C
(120°F) (37 to 45 psi g) (41-50 psig) (295 to 350 psig) (303 to 370 psi g) (82°F) (85°F)
"Temperatures shown are highest normal temperatures expected ; actual louver temperatures may be cooler.
Louver temperature measured in the louvers facing the operator.
"" Compressor clutch cycling may occur under low humidity, low temperature condition.
The pressure-temperature chart is based on the following conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Blower speed control in the highest speed position.
4. Door and rear window open.
5. Air conditioner temperature control setto maximum cooling.
5. Air conditioner control switch set to ON (Standard AlC) or DEFOG/DEFROST (ATC) mode.
7. Gauge readings taken 15 minutes after start up.
8. Hood closed with all side panels in position.
9. Heater supply line clamped and return valve closed at the engine.
10. All cab air louvers open.

~ co
[ ~
o
'f W
8
'"
9020-34

LEAK DETECTION

"" WARNING: Never leak test with an open

~ flame ora flame-type detector. M816

WAR NING: When refrigerant comes in

""
contact with an open flame , it can form
~ dangerous gas. Never breathe these
fumes. SM1 09A

Two methods are recommended to test the AIC

system for refrigerant leaks: electronic leak testing
with OEM1437 and UV-florescent leak detecting.
Whatever method is used, the following components
or areas should be checked, always looking for signs
of leakage - oily residue, dust accumulation:

A. Compressor: line connections, surfaces where

parts are joined, compressor to clutch seal.

NOTE: When checking compressor seal for a leak,

remove the dust cover and rotate the compressor
shaft clockwise.
A22090
OEM1437
B. Condenser: line connections, all welded joints,
any visible damage.

C. Receiver-drier: line connections.

D. Thermal expansion valve: line connections.

NOTE: Remove the thermal insulation tape to check

the expansion valve for leaks; replace the tape when
completed.

E. Service ports: valve core under the caps.

RROOF098
F. Low and high pressure switches: Check UV Leak Detecting Lamp and Goggles
a round the entire switch body whe re it is
threaded into the line.

G. Hoses: line connections where the hose end

meets a metal connector, any area that shows
damage or rubbing contact.

6-13050 Issued 3-03

 9020-35

Electronic Testing with OEM1437

When performing electronic leak detection with
OEM1437, follow these general guidelines:

1. There must be enough refrigerant in the system

to produce normal pressures (at least 50 psi).

2. Leak test in an area free of wind and drafts.

3. Operate the tractor long enough to circulate the

refrigerant and produce normal system
pressures.

4. Shut the tractor and system off when leak

testing .

5. Clean oily spots with dry shop cloths; solvents

can leave a residue which may confuse
OEM1437 .

6. Hold the leak detector probe under the point

being checked, since refrigerant is heavier than
air.

7. The probe on the leak detector should never

come into contact with the component being
checked.

B. If OEM1437 indicates a leak, move the probe

away, blowout the area with clean shop air and
verify the leak with the detector.

9. If the leak cannot be found with OEM1437, use

UV florescent leak testing to locate the problem.

10. Repair all leaks and recharge the system.

6-13050 Issued 3~03

9020-36
Florescent Leak Detection
Fluorescent tracer or dye solutions are now
commonly used to detect refrigerant leaks. Your MX
tractor had an ultraviolet fluorescent tracer or dye
introduced into the A / C system at the time of
manufacture. This dye will glow a bright yellowl green
at a leak location under ultraviolet light.
The dye has been tested for compatibility with
HFC- t 34a systems and approved for use in all Case
IH HFC-134a A/C systems. Special tools are also
available to aid in injection and leak detection. See
SPECIAL TOOLS, page 4 in this Section.
Fluorescent Dye Injection
Many methods are available to introduce the dye to a
system for the first time or to reinject the dye into an
AlC system. Select the method most appropriate to
the needs of the A/C system and where you are in
the service process:
6-13050
The dye , which dissolves into the SP-20 PAG oil in
the system , is particularly helpful in detecting
intermittent leaks that occur only when the system is
running because of change of temperature , high
system pressures, vibration or contact between
components.
WARNING: Wear safety goggles and non-
& permeable gloves when working with the
fluorescent dye and leak testing. M817
This fluorescent dye will normally remain useful over
the life of the system . However, due to a large
refrigerant leak, system flush or major component
failure, it may become necessary to reintroduce the
dye into the refrigerant circuit.
1. Recovery Station Dye Injector Tool with a
System in a Vacuum
2. Recovery Station Dye Injector Tool with a
Charged System
3. Quick and Easy Dye Injector Tool with a
Charged System
4. Compressor Oil Port
5. SP-20 PAG Oil Return Bottle
Issued 3-03
 9020-37

Recovery Station Dye Injector Tool with a System in a Vacuum

The R134a dye injector tool is designed to be used
with the OEM1415 recycling station.
1. Disconnect the low pressure hose (blue) from the
1/2 inch Acme flare fitting on the rear of the
station. Connect the dye injector to the fitting.
2. Connect the low pressure hose to the dye
injector.
NOTE: The dye injector can be permanently
mounted on the recycling station with the two
threaded holes on the bottom of the reservoir.
3. Open the valves on either side of the reservoir on Valves Shown in OPEN Position
the dye injector.
1. VALVE TOWARD 3. VALVE ,OWARD
4. Recover and recycle the refrigerant from the AlC RECYCLING STATION TRACTOR
2. RESERVOIR CAP 4. RESERVOIR
system and evacuate the system.
5. With the system in a vacuum, close the valves on
either side of the reservoir on the dye injector.
6. Remove the cap from the reservoir and fill the
reservoir with the contents of one bottle of
fluorescent dye . Reinstall the cap on the
reservoir and tighten securely.
7. Open the valve on tractor side of the reservoir on
the dye injector.
8. Recharge the AlC system with the proper
amount of refrigerant. Start the recharging
process and immediately open the valve on the
station side of the dye injector to prevent drawing
the dye into the charging station. The dye will be
injected into the system while recharging.
9. Install the dye identification sticker on a clearly
visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.
10. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.
NOTE: The operating time needed for the dye to
penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

11. After repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

6-13050 Issued 3-03

9020-38

Recovery Station Dye Injector Tool with a Charged System

The R134a dye injector tool is designed to be used - , - - - ' - - - - - - - - - - -----:=::---,
with the OEM1415 recycling station.

1. Disconnect the low pressure hose (blue) from the

1/2 inch Acme flare fitting on the rear of the
station.

2. Connect the dye injector to the fitting.

3. Connect the low pressure hose to the dye

injector.

NOTE: The dye injector can be permanently Valves Shown in OPEN Position
mounted on the recycling station with the two
1. VALVE TOWARD 3. VALVE TOWARD
threaded holes on the bottom of the reservoir. RECYCLING STATION TRACTOR
2. RESERVOIR CAP 4. RESERVOIR
4. Open the valves on either side of the reservoir on
the dye injector.

5. Recover 0.5 Ib (0.23 kg) of refrigerant from the

system. This amount of refrigerant will act as a
carrier to inject the dye.

6. Close the valve on the tractor side of the dye

injector and continue to recover. This will draw
the refrigerant out of the reservoir on the dye
injector.

7. Close the valve on the station side of the dye

injector and stop recovering.

8. Remove the cap from the reservoir and fill the

reservoir with the contents of one bottle of
fluorescent dye. Reinstall the cap on the
reservoir and tighten securely.

9. Open the valve on tractor side of the reservoir on

the dye injector.

10. Recharge the AlC system with the proper

amount of refrigerant removed earlier - 0.5 Ib
(0.23 kg). Start the recharging process and
immediately open the valve on the station side of
the dye injector to prevent drawing the dye into
the charging station. The dye will be injected into
the system while recharging.

11. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

6-13050 Issued 3·03

 9020-39

12. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.
13. After repairing the system, use fluorescent dye
cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

NOTE : The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

Quick and Easy Dye Injector Tool with a Charged System

The quick and easy R134a dye injector tool is
designed to insert the dye in a charged system. The
dye injector tool has a quick coupler, for connecting
to the low pressure port of the tractor A/C system,
and a valve with T-handle on the other end.

1. Examine the threaded end of the valve to see if

the point of the valve stem is flush with the
rubber washer. If not, turn the T-handle until the
point is flush.

2. Screw the Quick and Easy can and the valve

together until the can seats on the rubber
washer.
1. QUI CK COUPLER 3. T-HANDLE
NOTE: Do not turn the T-handle at this time to tap 2. VALVE 4. SUPPLY CAN
the can.

3. Connect the quick coupler to the low pressure

service port under the instructional seat in the
cab.

4. To purge air from the hose, slowly unscrew the

untapped can a half turn or more . Allow
refrigerant from the AlC system to force the air
out of the hose, and then retighten the can on the
valve.

5. Turn the T-handle clockwise to tap the can.

6. Hold the can upside down to allow the can

contents to enter the A / C system. When
complete, turn the T-handle counterclockwise to
close the valve. Disconnect the tool from the low
pressure port.

NOTE: You may have to operate the tractor and the

Ale system for a few minutes to completely empty
the can.

6-13050 Issued 3-03

 9020-40

7. Install the dye identification sticker on a clearly
visible area on the compressor body close to the
service port. This will alert service personnel in
the future to the presence of the dye in the
system.
B. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/ green glow of the
dye.
NOTE: The operating time needed for the dye to
penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.
9. After repairing the system, use fluorescent dye
cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

Compressor Oil Port

1. Recover the refrigerant from the AlC system.

2. Remove the oil filler plug and pour the contents

of one bottle of fluorescent dye into the
compressor.

3. Check the O-ring on the oil filler plug and replace

if necessary. Reinstall the oil plug on the
compressor and torque to 11 to 1B Ib ft (15 to 24
Nm).

4. Evacuate and recharge the AlC system with the

proper amount of refrigerant.

5. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

6. Operate the AlC system for about 15 minutes to

circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.

NOTE: The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

7. After repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

I 6-13050 Issued 3-03

 9020-41

SP-20 PAG Oil Return Bottle

NOTE: This is the least preferred method for

injecting the dye since it requires very careful
measurement of the PAG oil in the bottle and risks
the introduction of air into the system if the dip tube in
the bottle is exposed.

1. Recover the refrigerant from the AlC system.

2. Carefully measure the amount of SP-20 PAG oil

in the reservoir which was separated from the
refrigerant.

3. Pour the new replacement oil i"nto the oil return

boltle plus some additional oil to prevent
uncovering the dip tube.

4. Pour the contents of one bonle of fluorescent dye

into the oil return bonle and seal the bon Ie.

5. Evacuate the system and inject the oil and dye

mixture into the system, making sure the oil level
in the oil return boltle does not drop below the
dip tube.

6. Recharge the AlC system with the proper

amount of refrigerant.

7. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

8. Operate the AlC system for about 15 minutes to

circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.

NOTE: The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very sma/lleak could take hours or days
of system operation to appear.

9. After repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

6-13050 Issued 3-03

9020-42

Fluorescent Leak Testing

To perform UV fluorescent leak testing:
1. Operate the tractor long enough to circulate the
refrigerant and produce normal system
pressures.
2. Shut the tractor and system off when leak
testing.
3. Always wear fluorescent enhanced safety
glasses when leak testing.
4. Attach the lamp to a fully charged 12V battery or
RROOF098
an alternate 12V power supply for best lamp
performance.
5. Shine the high intensity ultraviolet light at the
various Ale components, hoses and lines to
search for a glowing fluorescent trail or puddle
which identifies the leak location.
6. The ultraviolet lamp is intended for intermittent
use only. The lamp has a momentary contact
push button switch to briefly light suspected leak
locations.
7. Do not work with the lamp ON for more than 5
minutes. If the lamp heats up uncomfortably,
cease operation.
B. Do not expose eyes or skin to ultraviolet light. Do
not stare into an ultraviolet light beam or operate
the lamp without the ultraviolet lens filter in place.
9. In direct sun sunlight or very bright ambient light,
use a cover of any type over the suspected area
to reduce this light.
10. If the lamp cannot be directed straight at a
suspected leak location, use a mechanics mirror
to reflect the light at the location. Or wipe the
suspected leak site with a clean shop cloth, and
shine the lamp at the cloth to check for traces of
fluorescent dye.
11 . The exact location of a small leak at a connection
point or sealing point can be further narrowed by
daubing a wet film of soap solution over the
suspected area. Watch for bubbles to confirm the
exact point of leakage.
12. Repair all leaks and recharge the system .
13. Use fluorescent dye cleaner to remove any
traces of dye from around the leak location to
avoid false diagnosis in the future.

6-13050 Issued 3-03


AlC SYSTEM FLUSHING PROCEDURE
When flushing is necessary, all effected components
should be flushed to eliminate the possibility of
contaminants remaining in the system.
There are two methods of AI C system flushing:
individual component flushing and complete
circuit flushing. The complete circuit is the system
minus the compressor, receiver-drier and thermal
expansion valve. The compressor, receiver-drier and
thermal expansion valve are always bypassed
(removed) during circuit flushing and serviced
individually. The receiver-drier is always replaced
anytime a system is flushed. The expansion valve,
due to its small orifices, is removed from the system
and cleaned (or replaced). The compressor is either
replaced or reused, but is NEVER flushed.
The preferred method of system flushing is individual
component flushing. Given the size of Case IH
equipment and the distance between components,
individual component flushing will dislodge and flush
out more contamination than complete circuit
flushing. Which individual components are flushed
will depend on the source of the contamination and is
left to the discretion of the technician .
For "mild ly" contaminated systems, complete circuit
flushing may be used, where the contamination is
oxidized refrigerant oil or small amounts of receiver-
drier desiccant. Complete circuit flushing requires
little system disassembly, minimal special
connectors and the least amount of service time.
The most likely sources of contamination are
compressor failure and receiver-drier failure.
Compressor Failure
A failed compressor generally sends debris
downstream to the condenser, the receiver-drier and
towards the thermal expansion valve. If the
compressor fails internally, it must be replaced . Also
individual flushing of the hose between the
compressor and condenser, of the hose between the
condenser and receiver-drier, of the condenser itself
and replacing the receiver-drier are appropriate
service actions for compressor failure.
For most Case IH condensers with a single flow path,
flushing effectively removes debris. For condensers
with parallel flow paths, since flushing takes the path
of least resistance around any blockage, condenser
replacement may be the only option.
6-13050
9020-43
The receiver-drier has a fine mesh screen to capture
contaminants, but the contaminants may penetrated
the screen. Check the discharge port of the receiver-
drier to see if contaminants have penetrated the
screen. If so, individual flushing of the hose between
the receiver-drier and the expansion valve and
cleaning the thermal expansion valve are
appropriate . If the thermal expansion valve is
damaged, replace it as well.
Additional flushing of the system beyond the thermal
expansion valve is at the discretion of the service
technician who can best judge how far the
contamination has traveled .
Receiver-Drier Failure
Receiver-driers should not normally fail if replaced:
A. when system has been opened before.
B. when receiver-drier has been in service two or
more years.
C. when the system has been open for a long
period of time because of a leak (broken
hoses, loose connection) that has permitted air
and moisture to enter the system.
D. when contaminated refrigerant was recovered
from the system.
However, if the desiccant pouch is punctured by a
debris from a fa iled compressor or fails from age,
desiccant particles may flow downstream toward the
thermal expansion valve and the evaporator. An
indicator of receiver-drier failure is soft golden-brown
particles found at its outlet. The thermal expansion
valve should always be checked after receiver-drier
failure.
If the recei ver-drier fails, it must be replaced. Also
individual flushing of the liquid hose between the
receiver-drier and the thermal expansion valve and
cleaning the valve are appropriate.
Che ck the suct ion line from the valve to the
compressor and the compressor suction port. If
golden brown particles is found, flush the evaporator
and suction line individually. The compressor may be
reused AFTER all contaminants are removed:
1. Use the dipstick to measure the compressor oil
level.
2. Drain and refill the compressor with PAG oil until
the drained oil is free of particles.
Issued 3-03
9020-44

3. Rotate the compressor clockwise to check for
binding caused by the presence of particles.
4. Drain or add PAG to return the compressor to
measured dipstick level.
Additional system flushing is at the discretion of the
service technician who can best judge how far the
contamination has traveled and what components
may have been damaged and require replacement.

IMPORTANT: Flushing solvent CANNOT be used to

remove compressor contaminants.

Required Tools
The following tools are required when flushing an AlC system or components:

• Power Flush 17550

• Flush Gun Kit 17585

• Case IH AlC Flushing Solvent, one case of six one

gallon containers, BS33801

• Dry shop air source, use filter below or equivalent:

Coalescing air filter/dryer (Ingersoll-Rand IR5CHE or
Grainger 4KR65). Desiccant-type air driers should
not be used.

• Adapters to connect flush unit to the various AlC

system components. These adapters can be
purchased in kit form or built in the shop. RAOOF093
Power Flush 17550
• Clear Plastic Reinforced Hose to connect the tank
to various components and small lengths for
bypassing components like the receiver-drier or
thermal expansion valve.

See SPECIAL TOOLS, page 4 in this Section.

Optional tools include:

• Pressure regulator to control flow to the flush unit;

regulator must be capable of delivering 45-90 psi
(310-620 kPa) at 4.0 cfm (310 kPa at 0.11 cmm). Do
not exceed 90 psi (620 kPa).

• Pressure indicator gauge (which may be Flush Gun Kit 17585

integrated into the pressure regulator)

6- 13050 Issued 3·03


Precautions
WARNING: 00 NOT use solvent containing
alcohol, lacquer thinner, brake cleaner or
A other non-approved solvents. Use only Case
illlH approved flushing solvent. Other flushing
agents or solvents may damage AlC system
components. M815
Case IH AlC flushing solvent is a hazardous material.
Read all warnings on the flushing solvent container
prior to use and observe these safety precautions:
1. The flushing solvent is combustible. Avoid heat,
sparks and open flame.
2. Use only in a well ventilated area. Mechanical
exhaust and an appropriate respirator may be
needed in warm and confined areas to protect
your safety.
3. Avoid breathing mist and vapor.
4. Wear chemical splash safety goggles.
5. Wear rubber gloves and a rubber apron when
handling the solvent or flushing components.
6. Observe all local, state and federal regulations
regarding the safe disposal of used flushing
solvent. M802
6-13050
9020-45
The goal of flushing is to remove contaminants from
the AI C system . Your shop air must be properly
filtered and dried with coalescing filter, or you will
simply replace one source of contamination with
another using dirty, moisture saturated air.
The c ompressor, receiver-drier and thermal
expansion valve must be bypassed (removed) when
performing circuit flushing . The compressor and
receiver-drier may never be flushed ; the thermal
expansion valve can be back flushed .
Keep the lid on the flushing recovery bucket closed
when flushing to minimize the circulation of solvent
vapors.
Never allow the flushing solvent to remain in or on
the hoses for a n extended period of time.
Overexposure of the hoses to the solvent, especially
the exterior, may cause hose swelling.
Do not open the fill cap on the flush reservoir when
the reservoir is under pressure. Release pressure
before removing cap.
9020-46

Component Flushing Procedure with Power Flush 17550

STEP 52
All refrigerant must be recovered from the system
before flushing.

STEP 53
The 17550 power flush unit uses shop air to atomize
the flushing solvent and a pulsing action to scrub
residue and contaminants out of components.
Attach flushing adapters to the compo nent to be
flushed . These adapters can be shop built or a
universal AlC flushing fitting set is available - Model
17582.

RPOOG013
Evaporator and Universal Fittings Shown

STEP 54
Fill the flushing reservoir 3/4 full with approved Case
IH flushing solvent. Do not overfill the reservoir or
you will restrict the pu lsing action of the unit.

STEP 55
Close the air and the flushing valves.

1. AIR VALVE 2. FLUSH VALVE

6-13050 Issued 3·03

 9020-47

STEP 56
Remove the flushing tank hose quick coupler from
the evaporation plug.

STEP 57
Connect the flushing tank hose quick coupler to an
extension or an adapter hose.

STEP 58
Connect CLEAN and DRY shop air supply to the
quick coupler on the flushing valve.

6·13050 Issued 3-03

I
9020-48

STEP 59
Connect flushing and drain hoses to flushing
adapters on component being flushed so the flushing
solvent moves in the opposite direction of refrigerant
flow - back flushing. Reinforced clear hose is
preferred to monitor the condition and removal of the
used solvent.

IMPORTANT: Secure the lid on the return bucket so

all flush vapors pass through the bucket filter.

NOTE: Back flushing is done first to dislodge any

contaminants, and then forward flushing is performed
to remove the contaminants. 1. FROM THE FLUSH PUMP 2. TO THE RETURN
BUCKET

STEP 60
Open the air valve 1/2 to 3/4 turn.

IMPORTANT: Do not exceed this rate of air delivery.

This rate delivers one gallon per minute of flush
solvent which is ideal for the orifice openings on the
components being flushed.
Turn the flushing valve to the FLUSH position and
flush the component for 30 seconds.

1. AIR VALVE 2. FLUSH VALVE

STEP 61
Close the flushing and air valves. Reverse hose
connections for forward flushing. Open flushing and
air valves and repeat flushing until the solvent is
clear.

1. FROM THE FLUSH PUMP 2. TO THE RETURN

BUCKET

6·13050 Issued 3·03

 9020-49

STEP 62
Turn the flushing valve to the AIR position. Allow air
to flow through the component until no noticeable
mist is discharged.

NOTE: Air pressure is the only means to remove the

flushing solvent from the Ale system, and no solvent
must remain in the system when it is evacuated and
recharged. Turn the component so gravity can assist
in solvent removal.

STEP 63
Turn the flushing valve to the CLOSED position .
Disconnect the flushing and drain hoses and
adapters from the component.

STEP 64
Install the flushing tank hose quick coupler on the
evaporation plug to prevent evaporation of the
solvent remaining in the tank during storage.
See Post Flushing Procedures, page 57.

6-13050 Issued 3-03

9020-50

Complete Circuit Flushing Procedure with Power Flush 17550

STEP 65
All refrigerant must be recovered from the system
before flushing.

STEP 66
The 17550 power flush unit uses shop air to atomize
the flushing solvent and a pulsing action to scrub
,
---
residue and contaminants out of components.
Fill the flushing reservoir 3/4 full with approved Case
IH flushing solvent. Do not overfill the reservoir or
you will restrict the pulsing action of the unit.

RDOOH209

STEP 67
Remove the receiver-drier and join th e hoses
together with an adapter hose. Discard the receiver-
drier.

Al00G02

STEP 68
Remove the thermal expansion valve and use
adapters to connect the hose lines to the evaporator.

6-13050 Issued 3-03

 9020·51

STEP 69
Disconnect the suction and discharge lines from the
compressor. Attach flushing adapters to the lines.

Universal Ale Flush Fittings Shown RH01F' "

STEP 70
Close the air and the flushing valves.

1. AIR VALVE 2. FLUSH VALVE

STEP 71
Remove the flushing tank hose quick coupler from
the evaporation plug.

6·13050
9020-52

STEP 72
Connect the flushing tank hose quick coupler to an
extension or adapter hose.

STEP 73
Connect CLEAN and DRY shop air supply to the
quick coupler on the flushing valve.

STEP 74
Connect flushing and drain hoses to adapters on
compressor lines so flushing solvent moves in the
opposite direction of refrigerant flow - back flushing.
Connect the hose from the flush tank to the suction
line; connect the hose to the return bucket to the
discharge line. Reinforced clear hose is preferred to
monitor the condition and removal of the used
solvent.

NOTE: Back flushing is done first to dislodge any

contaminants, and then forward flushing is performed
to remove the contaminants.

NOTE: The suction and discharge ports on the

compressor are marked with the leffers Sand D,
respectively.

IMPORTANT: Secure the lid on the return bucket so

all flush vapors pass through the bucket filter.

AH01F1 12
1. FROM THE FLUSH TANK 2. TO RETURN BUCKET

6-13050 Issued 3-03

 9020-53

STEP 75
Open the air valve 1/2 to 3/4 turn.

IMPORTANT: 00 not exceed this rate of air delivery.

This rate delivers one gallon per minute of flush
solvent which is ideal for the orifice openings in the
circuit being flushed.
Turn the flushing valve to the FLUSH position and
flush the circuit until the solvent appears clear at the
return hose to the solvent waste container.

1. AIR VALVE 2. FLUSH VALVE

STEP 76
Close the flushing and air valves. Reverse hose
connections for forward flushing. Connect the hose
from the flush tank to the discharge line; connect the
hose to the return bucket to the suction line. Open
flushing and air valves and repeat flushing until the
solvent is clear.

AH01F112
1. FROM THE FLUSH TANK 2. TO RETURN BUCKET

STEP 77
Turn the flushing valve to the AIR position. Allow air
to flow through the circuit until no noticeable mist is
discharged.

NOTE: Air pressure is the only means to remove the

flushing solvent from the Ale system, and no solvent
must remain in the system when it is evacuated and
recharged.

6-13050 Issued 3-03

 9020-54

STEP 78
Turn the flushing valve to the CLOSED position.
Disconnect the flushing and drain hoses and
adapters from the compressor lines.
Install the flushing tank hose quick coupler on the
evaporation plug to prevent evaporation of the
solvent remaining in the tank during storage.
See Post Flushing Procedures, page 57.

6- 13050
Issued 3-03
 9020-55

Back Flushing the Thermal Expansion Valve or Refrigerant Line

STEP 79
Flush gun 17585 can be used to back flush the
thermal expansion valve or a refrigerant line. Solvent
is added to the canister, and then the canister is
pressurized with CLEAN and DRY shop air. Pulse
the trigger on the flush gun for greater flushing
effectiveness.

STEP 80
To fill the canister, remove the cap assembly. Add no
more than 20 oz. (590 ml) of Case IH flushing solvent
to the canister. Replace the cap assembly.

STEP 81
Pressurize the canister to a maximum of 90 psi (620
kPa) with CLEAN and DRY shop air.

6-13050 Issued 3-03

 9020-56

STEP 82
Connect the hose with flush gun to the canister.

STEP 83
NOTE: To prevent sprayback, press the rubber nose
cone on the gun into the opening on the refrigerant
line or thermal expansion valve when flushing.
When back flushing the thermal expansion valve, the
suction and discharge ports must be flushed in
different directions. Collect used solvent in a
container for proper disposal.

STEP 84
Use CLEAN and DRY shop air to purge the solvent
and dry the valve.
Back flush the discharge port

Back flush the suction port

6·13050
Issued 3-03
 9020-57

Post Flushing Procedures

STEP 85
Identify and remove the source of the contamination.

STEP 86
Reconnect all fittings using new HNBR "green"
HFC-134a compatible a-rings. Lubricate the a-rings
with mineral oil prior to installation.

STEP 87
Install a new receiver-drier.

NOTE: The receiver-drier should be replaced just

before the system is drawn to a deep vacuum to
avoid saturating it with moisture.

STEP 88
Clean or replace the thermal expansion valve.

RPOOG011

6-13050 Issued 3-03

9020-58

STEP 89
Install a new compressor if required.

STEP 90
Adjust the level of SP-20 PAG oil in the system .
When each component was flushed, some SP-20
PAG oil was removed from the system. Use the
following guidelines when adjusting PAG oil :
If the compressor is to be replaced and the entire
system was flushed, the new compressor will contain
all the SP-20 PAG oil needed and no further
adjustment is required.
If the compressor is not to be replaced and the entire
system was flushed , drain the oil from the
compressor to remove any remaining contaminants.
Add back to the compressor one container, 8.5 oz
(250 ml), of new SP-20 PAG oil. (Some oil , about 1.2
oz (35 ml), will remain in the compressor even after it
has been drained.)
If the entire system was not flushed, drain the oil from
the compressor to be installed. Add back new SP-20
PAG oil equal to 8.5 oz (250 ml) minus oil amounts
still in the components that were not flushed. Use the
table below.

NOTE: Total system PAG oil should be 9.6 oz (285

ml) and about 1.2 oz (35 ml) will remain in a drained
compressor.

Amount Of SP-20
Component Flushed
PAG Oil To Add
Condenser 1.7 oz (50 ml)
Evaporator 1.4 oz (40 ml)
Receiver-Drier 0.85 oz (25 ml)
Each Hose 0.34 oz (10 ml)

Because the system has been open for a prolonged

time, it is very important to draw the system to a deep
vacuum to remove all moisture. Evacuate the system
for at least 45 minutes to a vacuum of 29.5 inches
(0.75 mm) of mercury.

6-13050 Issued 3·03

 9020-59

Final System Oil Check

After the system has been drawn to a deep vacuum 3. Recover refrigerant from the system. Use the
and recharged, dipstick method to check the PAG oil level in the
compressor. If needed, adjust the oil level. See
1. Operate the AlC system for 15 minutes to
Dipstick Method , page 81. For MX 210, 230,
thoroughly circulate the PAG oil throughout the
255 and 285 tractors, the oil should cover five
system.
lines on the dipstick.
2. Install the gauge set and test the AlC system for
4. Evacuate and recharge the system.
proper operation referring to the pressure/
temperature table on Page 33.

IMPORTANT: If oil level was measured and

adjusted properly according to the guidelines, Steps
3 and 4 are unnecessary.

Flushing Solvent Disposal

Never reuse contaminated flushing solvent. In the United States, SAFETY-KLEEN will recycle
used flushing solvent. For more information on
Good stewardship of our natural resources is SAFETY-KLEEN's recycling program, call 800-323-
everyone's business. Case IH flushing solvent is a 5040.
hazardous material. Never dispose of this solvent by
pouring it down the drain or treating it as water
soluble waste. Observe all local, state and federal
regulations when disposing the solvent.

6-13050 Issued 3·03

9020-60

AlC SYSTEM COMPONENTS

Cab HVAC Box Components - Automatic Temperature Control

1. ATC CONTROLLER
2. BLOWER MOTOR/FAN ASSEMBLY
3. HEATER CONTROL VALVE
4. BLOWER SPEED DRIVER
5. COMPRESSOR CLUTCH RELAY
6. CAB TEMPERATURE SENSOR
7. EVAPORATOR TEMPERATURE SENSOR
8. THERMAL EXPANSION VALVE
9. LOW PRESSURE SWITCH
10. EVAPORATORIHEATER ASSEMBLY

Rae 6-13050 Issued 3-03

 9020-61

Cab HVAC Box Components - Automatic Temperature Control

~ 1. LID ASSEMBLY
i
• 2. CONTROLLER MOUNTING PLATE
3. ATC CONTROLLER
.;..;.~----{ 1 4. BLOWER SPEED DRIVER
5. BLOWER DRIVER MOUNTING PLATE
6. BLOWER/MOTOR ASSEMBLY
7. LOW PRESSURE SWITCH
8. THERMAL EXPANSION VALVE
9. AlC SUCTION LINE TUBE
10. AlC LIQUID LINE TUBE
11. HEATER MOTORNALVE ASSEMBLY
12. HEATER SUPPLY TUBE
13. HEATER RETURN TUBE
14. EVAPORATOR/HEATER ASSEMBLY
15. EVAPORATOR TEMPERATURE SENSOR
16. CAB TEMPERATURE SENSOR
17. COMPRESSOR CLUTCH RELAY
18. HVAC GROUND STUD
19. CONDENSATE DRAIN HOSE
20. CHECK VALVE
21. EVAPORATOR BOX ASSEMBLY

RI038049

Rae 6-13050 Issued 3·03

9020-62

Cab HVAC Components - Standard Systems

1. STANDARD CONTROLLER
2. COMPRESSOR CLUTCH RELAY
3. EVAPORATOR/HEATER ASSEMBLY
4. EVAPORATOR TEMPERATURE SENSOR
5. HVAC BOX GROUND
6. HEATER CONTROL VALVE
7. THERMAL EXPANSION VALVE
B. LOW PRESSURE SWITCH
9. BLOWER MOTOR ASSY WITH RESISTORS

Rae &-13050 Issued 3-03

 9020-63

Cab HVAC Components - Standard Systems

RI99M043

1. LID ASSEMBLY 6. LOW PRESSURE SWITCH 13. EVAPORATOR TEMP SENSOR

2. STANDARD AlC CONTROLLER 7. HEATERIEVAPORATOR COIL ASSY 14. BASE WELDMENT
3. BLOWER ASSEMBLY B. HEATER CONTROL VALVE ASSY 15. EVAPORATOR BOX ASSEMBLY
4. RESISTOR ASSEMBLY 9. AlC SUCTION LINE TUBE 16. THERMAL EXPANSION VALVE
A. RESISTOR 10. AlC LIQUID LINE TUBE 17. CLUTCH RELAY
B. MOUNTING BRACKET 11 . HEATER SUPPLY HOSE 1B. DRAIN HOSE
5. WIRE HARNESS (NOT SHOWN) 12. HEATER RETURN HOSE 19. CHECK VALVE

Rae 6-13050 Issued 3-03

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AlC HIGH PRESSURE SWITCH
5.
6.
7.
RECEIVER·DRIER
HEATER SUPPLY LINE
HEATER RETURN LINE
9.
10.
11 .
COMPRESSOR (DISCHARGE LINE) TO CONDENSER HOSE
CONDENSER TO RECEIVER-DRIER HOSE
RECEIVER-DRIER TO THE RMAL EXPANSION VALVE HOSE
i!. ~
8. SHUT-OFF VALVE
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4. CONDENSER 12. EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE

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~ ~ 2. COMPRESSOR CLUTCH 6. HEATER SUPPLY LINE 10. CONDENSER TO RECEIVER-DRIER HOSE
~
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3. AlC HIGH PRESSURE SWITCH
4. CONDENSER
7.
8.
HEATER RETURN LINE
SHUT-OFF VALVE
11 .
12.
RECE IVER-DRIER TO THERMAL EXPANSION VALVE HOSE
EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE ~
:3'" ~--------------------------------------------------------------------------
'"
(}l
 9020-66

AlC COMPRESSOR CLUTCH

Clutch Removal
NOTE: This procedure shows a compressor with six screws holding the dust cover on the clutch. Your
unit has three Torx'fP screws for attaching the dust cover and only differs in this manner.

STEP 91
See this section for compressor removal. Clean the
external surfaces of the compressor before doing
any work on the compressor.

A21250

STEP 92
Remove the three Torx<!!> screws for the clutch dust
cover.

STEP 93
Remove the clutch dust cover.

I 6-13050 Issued 3·03

 9020-67

STEP 94
Remove the retaining nut for the front plate. Use the
special spanner wrench from the service tool set to
keep the plate and shaft from turning.

A2 1253

STEP 95
Install the special puller from the service tool set on
the clutch front plate.

STEP 96
Turn the center screw to pull the clutch front plate.

6-13050 Issued 3-03

 9020-68

STEP 97
Remove the shim(s) from the shaft.

STEP 98
Carefully remove the dust cover.

STEP 99
Remove the key from the rotor shaft.

A21258

6-13050 Issued 3-03

 9020-69

STEP 100
Remove the external snap ring for the bearing and
pulley assembly.

A2,260

STEP 101
Install the special puller internal collars into the
groove in the pulley. Install the special tool onto the
shaft. Tighten the mounting screws finger tight.

A21261

STEP 102
Turn the center screw on the puller.

A21262

6-13050 Issued 3-03

 9020-70

STEP 103
Remove the pulley and bearing assembly.

A21263

STEP 104
Remove the snap ring for the clutch coil assembly.

STEP 105
Disconnect the clip for the lead wire.

A21 264

I 6-13050 Issued 3-03

 9020-71

STEP 106
Remove the clutch coil assembly.

STEP 107
Remove the internal snap ring and remove the
bearing from the pulley.

A21267

6-13050 Issued 3-03

 9020-72

Exploded View of Clutch

1016L9
1. COIL ASSEMBLY 4. BEARING DUST COVER 7. DUST COVER
2. PULLEY 5. FRONT PLATE 8. COMPRESSOR
3. BEARING 6. SHIM(S)

Compressor Clutch Replacement

STEP 108
Method 1: Use a ammeter, voltmeter and a 12 volt
battery to check the amperage of the clutch coil. The
current draw must be 3.6 to 4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short
within the coil.
No amperage reading indicates an open circuit in the 1
coil.
Replace the clutch coil if the amperage reading is not
correct.
OR
102L7

Method 2: Measure resistance. Resistance must be 1. AMMETER 2. 12V BATTERY

2.66 to 3.3 ohms . Replace the clutch coil if the
resistance reading is not correct.

I 6-13050 Issued 3-03

 9020-73

STEP 109
Install a new clutch coil assembly. Align the coil so
the lead wire is next to the clip mounting hole.

...,..
STEP 110
Install the clip for the coil lead wire.

...,..
STEP 111
Install the snap ring for the clutch coil assembly.

A21265

6-13050 Issued 3-03

 9020-74

STEP 112
Install the bearing in the pulley and install the internal
snap ring.

A21267

STEP 113
Put the pulley and bearing assembly on the front
housing hub. Install a driver on the pulley assembly.
Make sure that the tool is on the inner race of the
bearing.

RA 99D245

STEP 114
Support the compressor on the four mounting ears at
the compressor rear. Press the pulley assembly on
the front housing hUb. Make sure the bearing is
against the bottom of the hub.

RA 990245

6- 13050 Issued 3·03

 9020-75

STEP 115
Install the external snap ring on the front housing
hub.

A21260

STEP 116
Install the key in the rotor shaft.

A21259

STEP 117
Place the bearing dust cover in the bore. Place driver
from special tool kit over the dust cover.

A21269

6-13050 Issued 3-03

 9020-76

STEP 118
Install the dust cover.

A21270

STEP 119
Install the shim(s) on the rotor shaft.

STEP 120
Install the front plate on the rotor shaft . Make sure
the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.

A21271

6-13050
Issued 3-03
 9020-77

STEP 121
Use a hammer to tap the plate onto the shaft. Make
su re the plate is against the clutch shims. As the
plate is tapped onto the shaft you can hear the
difference in sound when the plate is fully installed.

A2 1272

STEP 122
Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to a
torque of 11 to 15 Ib ft (15 to 20 Nm).

A21253

6-13050 Issued 3-03

9020-78

STEP 123
Two methods can be used to measure and adjust the
air gap between the clutch plate and pulley:

Magnetic Dial - Mount a magnetic base dial indicator

on the outer face of the pulley so that there is no
interference with the clutch plate. Apply battery
ground to compressor body and 12V B+ to clutch
wire lead. Position the dial indicator pointer on the
flat surface on the outer diameter of the clutch plate
midway between any two outer rivets or on one of the
outer rivet heads. Clutch plate travel should measure
from 0.016 to 0.031 inch (0.41 to 0.79 mm) . This
measurement should be taken between each of the
three rivets or on each outer rivet head to get an
average measurement. If necessary, lightly lift or
push down on plate to even the gap.
~-

Spark Plug Gauge - If a dial indicator is not available ,-

to check air gap clearance, a spark plug gauge with
,. fi
f
90° wire feelers may be used to check initial air gap ,-
in the field. Slip the wire between the clutch plate and .'C,l I '-~
" .

~
'--:~
the pulley and check the gap at the three rivets. The '"
gap must be 0.016 to 0.031 inch (0.41 to 0.79 mm).
:
--
The gap must be even all the way around the plate. If
necessary, lightly lift or push down on the plate to
make the gap even. ok; ..:
.•.. •
NOTE: If the gap does not meet the above
specifications remove the front plate and add or
subtract clutch shims as required.

STEP 124
Install the clutch dust cover.

A21252

6-13050 Issued 3-03

 9020-79

STEP 125
Install and tighten the three Torx® screws that attach
the dust cover to the compressor clutch. Torque to 5
to 8 Ib It (7 to 11 Nm).

A21251

6-13050
9020-80

AlC COMPRESSOR

Oil Level Check or Adjustment

Since the refrigerant is recovered as a gas, during a During normal servicing - recovery, evacuation and
typical recovery only about 25% of the oil in the recharge, oil is simply injected back into the system
vehicle's AIC system is recovered and separated. during the recharge process . Use the dipstick
The other 75% remains in the closed system method to check the compressor oil level or to adjust
normally on the low pressure side. (These oil level when any of the following occurred:
percentages are representative and will vary from
A. Broken refrigerant hose.
recovery unit manufacturer to manufacturer.) The
only reliable method for determining if the AIC B. Large refrigerant leak.
system has the correct amount of oil is the dipstick
C. Compressor leak.
method.
D. Damage to or replaced system components.
Too much oil in the closed system causes poor
E. New compressor installed.
condensation and reduced cooling since the oil
accumulates on the evaporator and condenser
IMPORTANT: If a new compressor is to be installed,
surfaces. Too little oil in the system causes poor
its oil level must be adjusted to match the oil volume
lubrication which equates to poor refrigerant
of the removed compressor.
circulation and reduced compressor efficiency and
high pressures. Both conditions cause more system
NOTE: SP-20 PAG oil must be added whenever
wear and shorter system life.
a component is replaced.
These conditions are not self-correcting.

Injection Method

STEP 126
OEM1415 has an injection system to return new SP-
20 PAG oil equal to the amount recovered at the end
of the evacuation process.
To add the new oil, adjust the O-ring around the oil
return bottle to the required oil charge level.

NOTE: If 2.4 oz (71 ml) was recovered in the oil

reservoir, 2.4 oz (71 ml) of new SP-20 PAG must be
returned.
Open the oil injection valve to add the oil into the
system. Close the valve when the oil level reaches
the O-ring. 1. OIL RETURN BODLE 2. OIL INJECTION VALVE

IMPORTANT: Do not let oil level fall below the dip

tube in the return bottle or air will be introduced into
the refrigerant circuit.

6-13050 Issued 3-03

 9020-81

Dipstick Method

STEP 127
When all refrigerant has been recovered, remove the
oil filler plug.

STEP 128
Use a TOrJ<'~ socket to remove the three screws, and
remove the dust cover from the clutch. Use a wrench
to rotate the compressor shaft clockwise until the
internal parts are in a position to allow dipstick
insertion.
ALTERNATE METHOD: Use a jumper wire to supply
12V B+ to the compressor clutch and rotate by hand .

STEP 129
Put the dipstick in the oil filler hole to the stop
position. Make sure the dipstick is inserted all the
way to the stop. The dipstick stop should be flush
with the filler hole boss.
Take several readings for accuracy. For all MX 210,
230, 255 and 285 tractors, the oil level should
cover five lines on the dipstick.

NOTE: The illustration shows a front view of the

compressor with the dust cover removed and the
proper positions of the counterweight for insertion of
the dipstick. RB99N057

IMPORTANT: When compressor is replaced, the

old compressor oil should be drained and the oil
volume measured. This amount of new oil should be
put into the replacement compressor after it has
been drained. Or use the dipstick to measure and
match the replacement compressor oil level to the
old compressor oil level.

6-13050 Issued 3-03

 9020-82

STEP 130
If the oil level is not correct, add or subtract oil to the
correct level described above. Always add oil in small
quantities to avoid overfilling; to subtract oil the
compressor must be removed and drained.

IMPORTANT: Use only SP-20 PAG oil.

STEP 131
Check O-ring on the oil filler plug and replace if
necessary. Install the plug and tighten to a torque of
11 to 18 Ib It (15 to 24 Nm).

6-13050
Issued 3-03
 9020-83

Compressor Removal
STEP 132
Open the hood and remove the right hand panel for
access to the fan drive belt.
Recover the refrigerant.

STEP 133
Use a 1/2 inch ratchet drive in the belt tensioner to
relieve pressure on the belt and remove the belt from
the compressor pulley.

STEP 134
Disconnect the compressor clutch wire above the
test ports on the suction and discharge lines.

6·13050 Issued 3-03

9020-84

STEP 135
Disconnect the high pressure switch at the
connector.

STEP 136
Disconnect the high pressure line from the discharge
port. Install protective caps on the open port and line.

STEP 137
Support the 90· fitting to the suction port , and
disconnect the low pressure line from the fitting.
Remove the 90· fitting from the suction port. Install
protective caps on the open ports and lines.

6- 13050 Issued 3-03

 9020-85

STEP 138
Remove the three mounting bolts and remove the
compressor/clutch assembly from the tractor for
service or replacement.

NOTE: Note the location of the ring terminal ground

on the upper rear mounting bolt.

••

6-13050 Issued 3-03

9020-86

Compressor Installation
IMPORTANT: If a new compressor is to be installed, its oil level must be adjusted to match the removed
compressor. See Oil Level Check or Adjustment, page 80.

STEP 139
Install the compressor with the th ree bolts removed
earlier. Torque to 29 ± 4 ft Ib (39 ± 4 Nm).

IMPORTANT: Install the ring terminal ground to the

upper rear bolt when installing the compressor.

STEP 140
Slowly remove the protective cap, and install the 90 0
elbow in the suction port on the compressor.

NOTE: Use caution when removing the caps on a

new compressor; new compressors are pressurized
when shipped.

STEP 141
Install a new a-ring and connect the low pressure
line to the 90 0 elbow. Support the elbow with a
wrench when connecting the line.

NOTE: Lubricate the D-ring with mineral oil before

installation.

6-13050 Issued 3-03

 9020-87

STEP 142
Install a new O-ring and connect the high pressure
line to the discharge port on the compressor.

NOTE: Lubricate the O-ring with mineral oil before

installation.

STEP 143
Reconnect the high pressure switch at the connector.

STEP 144
Reconnect the clutch at the connector.

STEP 145
Use a 1/2 inch ratchet drive on the belt tensioner to
release tension and install the belt over the clutch
pulley.
Reinstall the right hand panel.

6·13050 Issued 3~03

9020-88

CONDENSER AND RECEIVER-DRIER

Condenser
STEP 146
Keep the condenser (and fuel cooler) fins clean and
straight to make sure that there is maximum air flow
though the condenser and radiator at all times. Use
compressed air or a soft brush to clean the
condenser. Also check and clean the grille screen
and radiator. Maximum air flow prevents engine
overheating and offers the most efficient A/C
operation.

IMPORTANT: Because the condenser fins bend

easily and are sharp, be careful when cleaning the
condenser.

STEP 147
Recover all refrigerant before replacing/servicing the
condenser/fuel cooler.
Use the two hand, two wrench method to disconnect
and reconnect the lines to the condenser.
Cap all A/C lines while the condenser/fuel cooler is
disconnected from the circuit.

&- 13050 Issued 3-03

 9020-89

STEP 148
Remove the two upper and lower bolts on each side
of the condenserlfuel cooler to replace the unit.

STEP 149
When installing a new condenser, also install new 0-
rings on the Al e lines before connecting . Lubricate
the O-rings with clean mineral oil prior to installation.
Use the two hand , two wrench method when
connecting the line from the compressor and to the
receiver-drier.

6-13050 Issued 3-03

 9020-90

Receiver-Drier
STEP 150
Replace the receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years.
C. Disassembly show small particles of moisture
removing material (gold or brown particles).
D. If the system has been open for a long period
of time because of a leak (broken hoses, loose
connection) that has permitted air and
moisture to enter the system.
E. If contaminated refrigerant was recovered from
the system.
The receiver-drier orientation is critical. Make sure
the outlet flange is within 5 degrees of true level (the
decal should face up).
The receiver-drier must be installed with the inlet
connected to the hose from the condenser and the
outlet connected to the hose going to the thermal
expansion valve.
The receiver-drier is normally the last item replaced
when servicing the system, just before the system is
evacuated . This prevents saturating the drier with
moisture.

STEP 151
Use the two hand , two wrench method to prevent
i damage to the tubes and fittings when you loosen or
tighten the tube connections.

6-13050 Issued 3-03

 9020-91

STEP 152
Always install new O-rings when the receiver-drier is
connected to the system. Lubricate the O-rings with
clean mineral oil prior to installation.

6- 13050 Issued 3-03

9020-92

ACCESSING THE HVAC BOX

NOTE: The following procedure applies to both the standard and Automatic Temperature Controlled (ATC)
systems.

STEP 153
Disconnect the harness to the right hand control
console.

STEP 154
For tractors equipped with mechanical remote
hydraulic controls, the right hand control console
must be disconnected from the seat:
A. Loosen the 13 mm nut at the front of the right
hand side of the seat.
B. Remove the 18 mm bolt at the right hand rear
of the seat and remove the console . The
console can be rested on the rear shelf or slid
out the rear window and rested on the three-
point hitch for better access to the HVAC box.

STEP 155
Tilt the steering wheel to the full upright position.
Adjust seat to the full upright and back position.

STEP 156
Remove the floor mat wrap (1) which surround the
seat base.

NOTE: If the return air filter covers are dislodged, be

sure to reinstall later.

STEP 157
Remove four bolts in the seat base corners.

AP99E013

6-13050 Issued 3-03

 9020-93

STEP 158
Disconnect the seat harness.

STEP 159
Hinge seat forward and rest on steering wheel for
access to the box.

ATC HVAC Box Shown

STEP 160
After completion of service:
A. Align ATC controller mounting plate, if
equipped, with mounting holes.
B. Return the seat to its operating position. Align
the seat and HVAC box mounting hole and
reinstall the four bolts removed earlier.
C. Reinstall the seat harness and floor mat wrap.
D. Reinstall right hand control console (if
applicable).
E. Reconnect right hand control harness.
F. Ensure cab recirculation air filter is properly
installed.

6-13050
9020-94

THERMAL EXPANSION VALVE TESTING

IMPORTANT: The following test is performed with the thermal expansion valve mounted in the system. No repair
or adjustment is recommended for the valve.

STEP 161
See ACCESSING THE HVAC BOX, page 92. Tilt the
controller mounting plate forward to access the
valve.

STEP 162
Disconnect the low pressure cutout switch . Install a
jumper wire across the harness leads.

STEP 163
Start the tractor and run the engine at 1500 RPM.
Turn blower speed control to maximum position,
temperature control valve fully clockwise, ATC switch
to DEFOG/ DEFROST or Standard AlC switch to ON ,
and check the low pressure gauge reading.
Compare the gauge readings to the Temperature/
Pressure chart for your ambient temperature and
humidity.

Rae 6-13050 Issued 3·03

 9020-95

STEP 164
Remove thermal insulation tape from top of valve.
Use the palm of your hand to warm the expansion
valve and watch the low pressure gauge.
The valve will open and pressure should rise.

STEP 165
Use ice to cool the expansion valve and watch the
low pressure gauge.
Within seconds, the expansion valve will close and
the pressure must drop at the low pressure gauge.

STEP 166
If there is little or no change at low pressure gauge,
the thermal expansion valve must be replaced.

Rae 6-13050 Issued 3-03

 9020-96

THERMAL EXPANSION VALVE REPLACEMENT

STEP 167
Recover all refrigerant from the system. Remove the
thermal insulation tape from the fittings and
expansion valve to replace the expansion valve.

STEP 168
Using the two hand, two wrench method, disconnect
the liquid and suction lines from the thermal
expansion valve. Discard the O-rings in the fittings.

STEP 169
Using the two hand, two wrench method , disconnect
the thermal expansion valve from the evaporator
tubes. Discard the O-rings on the tubes.

STEP 170
IMPORTANT: Lubricate O-rings with mineral oil
NOT SP-20 PAG.
Lubricate new O -rings with clean mineral oil
and install between the evaporator core and thermal
expansion valve. Connect the new valve to the
evaporator using the two hand, two wrench method.

I Rae 6-13050 Issued 3-03

 9020-97

STEP 171
Lubricate new O-rings with clean mineral oil and
install in the fittings on the suction and liquid lines.
Connect the liquid and suction lines to the expansion
valve using the two hand, two wrench method.

STEP 172
Remove air and moisture from the system and
charge the system . Leak test all connections with
OEM1437 before reapplying any thermal insulation
tape.

STEP 173
Replace all thermal insulation tape and reconnect the
low pressure cutout switch.

NOTE: The thermal insulation tape is available in 30

ft (9150 mm) bulk rolls - 1954475C1 - 0. 12 x 2.5
inches x 30 ft [3 x 63.5 x 9150 mmj.

Rae 6-13050 Issued 3·03

9020-98

EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION

STEP 174
The evaporator temperature sensor MUST be I"::"'~I---i. 2
installed 4.2 inches (107 mm) from the left hand rear
side of the evaporator. The sensor must be installed
below the second refrigeration tube row at a 30°
downward angle.
Insert the sensor in the evaporator up to the angled
section, being careful not to kink the sensor.

RH99D218
Rear View

Side View
1. EVAPORATOR TEMPERATURE SENSOR
2. 4.2 INCH (107 mm) 3. EVAPORATOR CORE

STEP 175
The cab temperature sensor must be installed
without contact with any box components in the
return air stream at the rear of the HVAC box.
•

6-13050 Issued 3-03

 9020-99

BLOWER MOTOR REPLACEMENT

STEP 176
To replace the blower motor:
1. See ACCESSING THE HVAC BOX, page 92.
2. Move the controller mounting plate forward to
gain better access to the motor.
3. Disconnect the 18-pin and 5-pin harness
connector to the ATe controller if applicable.

4. Disconnect the blower motor assembly from the

harness at the connector.

5. Remove the four screws across the top of the

motor assembly and two screws (not visible on
photo) at the sides, and remove the assembly.
6. Install a new motor assembly with the existing
hardware and connect the motor to the harness.

Rae 6-13050 Issued 3-03

9020-100

HEATER CONTROL VALVE REPLACEMENT

STEP 177
To replace the heater control valve:
1. See ACCESSING THE HVAC BOX, page 92.
2. Move the controller mounting plate forward to
gain better access to the valve.
3. Disconnect the control valve from the harness.

NOTE: Be prepared to collect a small amount of

coolant when the valve hoses are disconnected.

4. Pinch the clamp (1) and disconnect the inlet

hose to the core from the valve. Pinch the clamp
(2) and disconnect the supply hose at the bottom
of the valve. Remove the valve.
5. Install a new heater control valve to the same
connecting hoses. Connect the valve to the
harness.

Rae 6-13050 Issued 3-03

 9020-101

EVAPORATOR/HEATER ASSEMBLY

Evaporator/Heater Assembly Removal

NOTE: The thermal expansion valve, heater valve and evaporator/heater assembly are located under the operator
seat. See ACCESSING THE HVAC BOX, page 92.

NOTE: Rotate the cab temperature control to the Maximum Heat position before shutting off the tractor for service.
This fully opens the heater control valve and allows more coolant to drain from the evaporatoriheater assembly.

STEP 178
Use a vise clamp to clamp off the heater supply hose
on the right hand side of the engine. Close the valve
on the heater return hose at the engine . See
component locations in this Section for your engine.

STEP 179
Remove the thermal insulation tape from the
expansion valve and the evaporator lines.
To test the valve see thermal expansion valve testing
in this section. Recover the AIC system to remove
the evaporator heater core.

STEP 180
Using the two hand, two wrench method, disconnect
the air conditioning suction and liquid lines at the
thermal expansion valve. Remove and discard the 0 -
rings. Cap or plug the lines to prevent dirt and
moisture from entering the system.

NOTE: Clean packaging tape may be used to seal

the expansion valve ports.

6-1 3050 Issued 3·03

 9020-102

STEP 181
Pinch the clamp with a pliers to open it and move it to
the side. Disconnect the heater return line (1) from
the evaporator heater core.
Loosen the clamp and disconnect the short hose (2)
between the heater valve and evaporator/ heater
core. Be prepared to collect a small amount of
coolant that will drain into the HVAC box.

STEP 182
Remove the two screws securing the blower speed
driver and its mounting plate at the rear of the box.
Remove the 6-pin connector from the driver and
move the blower driver assembly out of the way.

• • • • • ••••• n .. .......... . • .............. "

I STEP 183
Remove the evaporator temperature sensor from the
evaporator/heater assembly.

6-13050 Issued 3-03

 9020-103

STEP 184
Remove the evaporator top gasket and save for
reinstallation. Remove the grommet (1) and sensor
harness from the evaporator by sliding it out of the
slot opening.

NOTE: The gasket seals the top of the evaporator

and forces the air to move through the core rather
than around it. Replace the gasket if it is worn or
damaged.

STEP 185
Slide the evaporator assembly straight up and out of
its side mounting brackets.

STEP 186
Put the assembly on a clean bench. Remove the
expansion valve from the evaporator heater core.
Use the two wrench, two hand method when
removing the thermal expansion valve to prevent
damage to the tubes.

6-13050 Issued 3·03

9020-104

Evaporator/Heater Assembly Installation

STEP 187
Lubricate new O-rings with clean mineral oil and
install new O-rings on the evaporator suction and
discharge lines.

STEP 188
Install the expansion valve. Tighten the fittings to a
torque of 18 to 25 Ib It (25 to 34 Nm). Use the two
wrench, two hand method w hen installing the
expansion valve to prevent damage to evaporator
lines.

STEP 189
Install the evaporator/heater assembly into the slide
mounting brackets of the HVAC box.

STEP 190
Install the sensor harness with grommet in slot in the
the evaporator. Reinstall the top gasket on the
evaporator.

NOTE: The gasket seals the top of the evaporator

and forces the air to move through the core rather
than around it. Replace the gasket if it is worn or
damaged.

Issued 3·03
•
6-13050
 9020-105

,.. '.···"·· ..... 1·.·''' •. ·· 'to,

STEP 191
Install the evaporator temperature sensor in the
evaporator/heater assembly. The evaporator
temperature sensor MUST be installed 4.2 inches
(107 mm) from the left hand rear side of the
evaporator. The sensor must be installed below the
second refrigeration tube row at a 30 0 downward
angle.
Insert the sensor in the evaporator up to the angled
section , being careful not to kink the sensor.

STEP 192
Install the 6-pin connector on the blower speed
driver. Install the two screws to secure the driver and
its mounting plate at the rear of the box.

6·13050 Issued 3-03

 9020-106

STEP 193
Connect the short hose (1) from the heater valve to
the evaporator/heater core. Pinch the clamp to open
it and secure the hose at the evaporator line.
Connect the heater return line (2) to the evaporator
heater core and secure with the clamp.

STEP 194
Remove the caps or plugs from the liquid and suction
lines to the thermal expansion valve.
Install new O-rings on the lines before reconnecting .
Lubricate the O-rings with clean mineral oil prior to
installation.

STEP 195
Using the two hand, two wrench method , reconnect
the air conditioning suction and liquid lines to the
valve.

I 6-13050 Issued 3-03

 9020-107

Post Replacement Procedures

STEP 196
Since the evaporator assembly has been replaced,
adjust compressor oil level.
Evacuate and charge the air conditioning system .
Test system performance following procedures on
the foldout.
Leak test the valve and evaporator connections with
OEM1437.

STEP 197
The thermal expansion valve and line along with the
inlet and outlet to the evaporator must be insulated
for maximum evaporator performance. Apply thermal
insulation tape around the expansion valve,
connectors, and the inlet and outlet lines of the
evaporator.

NOTE: The thermal insulation tape is available in 30

ft (9150 mm) bulk rolls - 1954475C1 - 0. 12 x 2.5
inches x 30 ft (3 x 63.5 x 9150 mm).

STEP 198
To remove air from the cooling system after
installation of a replacement evaporator/ heater
assembly:

A. Fill the radiator completely and fill the coolant

recovery bollie to the full line.

B. Operate the engine for 10 minutes.

C. Stop the engine and allow the radiator to cool.

D. Top off radiator and recovery bollie.

6-13050
9020-108

EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING

Sealing
The top and bottom of the evaporator/ heater
assembly must be properly sealed to allow air
movement through the assembly but not around it.
Check the condition of the foam seal on the top of the
assembly where it seals with the HVAC box cover.
Check the condition of the sealing strip at the front of
the evaporator/heater bottom.
Replace/repair any seal which has deteriorated with
age or which no longer seals properly.

Cleaning
If the evaporator/heater assembly is plugged with dirt
and debris, locate the source of the debris, correct
and then clean the assembly. See CAB
PRESSURIZATION TEST, page 114.
If the assembly is dry, clean with low pressure
compressed air. If the assembly is wet, flush with
water using a low pressure hose.

NOTE: Check that the condensate drain valves are

not plugged before cleaning the assembly with low
pressure wash. 1. TOP FOAM SEAL 2. SEALING STRIP

13050 Issued 3·03

 9020-109

BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION

~ [j~·--------~CD

,
(Df---' ~

RI99DOBO
1. THERMAL EXPANSION VALVE 4. CHECK VALVE 7. EVAPORATOR TEMP SENSOR
2. BLOWER MOTOR 5. CON DENSATE DRAI N TUBE 8. EVAPORATOR CORE
3. BOX DRAINAGE 6. EVAPORATOR BOX ASSEMBLY

6-13050 Issued 3-03

 9020-110

CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT

ATC Controller

STEP 199
With the ignition switch in the OFF position, to
replace the ATC controller:

A. See ACCESSING THE HVAC BOX, page 92.

B. Inclining the seat also frees the controller

mounting plate (1).

C. Disconnect the 1B pin (2) and 5 pin (3) wiring

harnesses connected to the ATC controller.

IMPORTANT: Do not touch exposed pins on ATe

controller to avoid static electricity voltage spikes.
Voltage spikes may result in equipment damage.

D. Remove the three screws (4) securing the ATC

controller and remove the controller.

E. Install a new ATC controller using the existing

hardware. Reconnect the harnesses. Align the
controller mounting plate with the cover holes.
Reinstall the seat with existing hardware.

Standard AlC Controller

STEP 200
The standard A/C controller is located behind the
evaporator and is mounted to the rear of the HVAC
upper case . With the ignition switch in the OFF
position, to replace the standard controller:
I A. See ACCESSING THE HVAC BOX, page 92.
B. Disconnect the 6 pin and 5 pin wiring
harnesses connected to the standard
controller.

MPORTANT: Do not touch exposed pins on the

ontroller to avoid static electricity voltage spikes.
Voltage spikes may result in equipment damage.
C. Remove the single nut securing the controller
to the mounting stud and remove the
controller.
D. Install a new controller using the existing
hardware. Reconnect the harnesses. Reinstall
the seat with existing hardware.

· 13050 Issued 3-03

 9020-111

Blower Speed Driver (ATe Units Only)

STEP 201
To replace the blower speed driver in ATC systems,
with the keyswitch in the OFF position:

A. See ACCESSING THE HVAC BOX, page 92.

B. Remove the two screws securing the blower

speed driver assembly to the rear of the HVAC
box.

C. Disconnect the six pin connector to the blower

speed driver.

D. Remove the four screws securing the driver to

the mounting plate.

E. Install a new blower speed driver with the

existing hardware. Install the 6-pin connector
on the driver, and secure the assembly to the
HVAC box rear with the two screws removed
earlier. Reinstall the seat.

I. 6-13050 Issued 3-03

9020-112

CAB AIR FILTER SERVICE

NOTE: The cab intake air filter will need service at different intervals according to local operating conditions. Clean
the filter as required. Replace the filter if there is damage or when the filter cannot be cleaned for efficient
operation.

STEP 202
The cab air filter is located under the cab entry door.
The cab pressurizer blower draws outside air from
the vents in the cab cap through the filter and feeds it
directly to the HVAC box.

STEP 203
Open the two retaining clamps and remove the
cover.

STEP 204
Pull the filter straight out. Clean the inside of the filter
housing.
Install a new filter by pushing straight in until it seats
in the upper gasket. Close the cover and the
retaining clamps.

6-13050 Issued 3-03

 9020-113

STEP 205
Clean the filter element by one of two methods:

A. Tap the outside of the filter. This method can

be used to clean the filter when most of the dirt
is dust. Tap the filter against a flat surface. Do
not use force that can cause damage to the
filter.

B. Clean with compressed air. The compressed

air method is used if most of the dirt is dust.
Direct the air flow from the inside of the filter
outward.

IMPORTANT: The maximum air pressure at the

nozzle must not be more than 35 PSI (242 kPa). Too
much air pressure will cause damage to the filter.

IMPORTANT: Do not use a washing method with

filter washing compound to clean the filter.

CAB RECIRCULATION AIR FILTER SERVICE

STEP 206
A. Remove the vent and the recirculation air filter
on both sides of the operators seat.

B. Clean the filter as frequently as required by

operating conditions or whenever the cab air
filter is serviced.

C. Use mild soap and water. Rinse with clear

water and squeeze out the excess.

D. Reinstall the filters and vents.

NOTE: Never place objects in front of the

recirculation vents that could block air flow.

6-13050 Issued 3·03

9020-114

CAB PRESSURIZATION TEST

NOTE: Perform the cab pressurization test whenever an unusual amount of dirt accumulates in the cab or in the
evaporator box or if the evaporator core is plugged.

NOTE: When performing this test, the door and window must be closed and latched.

STEP 207
Insert the sensing tube from a digital manometer
through the access panel in the right hand corner of
the rear cab window provided for monitor harness
routing between the cab and the implement.

NOTE: Do not attempt this test through the door

since the metal reinforcement in the seal will pinch
off the sensing tube.

STEP 208
Start the engine. Take a reading from the digital
manometer. Cab pressurization must be between
0.25 (6 mm) and 1 inch (25.4 mm) of H20 .

STEP 209
If a digital manometer is not avai lable, a simple one
can be made with B ft (2.B m) of 3/B inch 00 clear
vinyl tubing and a yard stick. Tape the vinyl tubing to
a yard stick as shown.

A099M029

6-13050 Issued 3-03

 9020-115

STEP 210
Partially fill the looped section of tubing with water.
(Food coloring may be added to the water to improve
visibility.)

STEP 211
Insert the long end of the tube through the access
panel in the right hand corner of the rear cab window
provided for monitor harness routing between the
cab and the implement.

NOTE: Do not attempt this test through the door

since the metal reinforcement in the seal witt pinch
off the sensing tube.

STEP 212 -e
Hold the yard stick vertical. Record the water level

-- ...
-III
reading without the engine running. Start the engine
and measure the movement of water on one side of
the yard stick. Multiply that value by two. Cab --
..._..
pressurization must be between 0.25 (6 mm) and 1
inch (25.4 mm) of H2 0. -N

STEP 213 ...-s

If the reading is below 0.25 inch of H2 0, check the
f,:...
following seals and retest:
- Door and rear window seals
- RD99M02 7
- Window seals
- Customer supplied radio/telephone antenna
cable routing
If the reading is above 1 inch (25.4 mm) of H2 0 ,
check for extra cab sealing, missing filter or broken
fresh air inlet.

6·13050 Issued 3-03

9020-116

CAB PRESSURIZER MOTOR REPLACEMENT

NOTE: The cab pressurizer motor is located under the cab entry and behind the cab air filter. To replace the
motorlblower assembly, the cab fresh air filter must be removed.

STEP 214
Remove the two screws and remove the trim panel at
the filter front.

STEP 215
Open the two clamps and remove the cover for the
fresh air filter.

STEP 216
Remove the air intake line from the cab filter housing
the post. Remove the filter.

6- 13050 Issued 3-03

 9020-117

STEP 217
Remove the four bolts and remove the filter housing.

AD02E270

STEP 218
Disconnect the motor assembly from the harness.

STEP 219
Remove the bolt, nut and washer and remove the
assembly from the tractor.

6-13050 Issued 3·03

9020-11 B

STEP 220
Remove the four screws to disconnect the motor/
blower assembly (1) from the mounting bracket (2).

STEP 221
Reverse the steps to install a replacement motor/
blower assembly.

VISCOUS FAN DRIVE

Since the viscous fan creates air flow at the
condenser, a properly functioning fan drive is
essential to proper air conditioning performance. A
defective fan drive can cause engine overheating
and/or high pressure switch activation. But a plugged
grille, radiator, condenser and oil cooler can also
cause the same.
To separate a fan drive problem from other possible
causes, perform the Viscous Fan Drive Test in this
manual.
NOTE: When performing the viscous fan drive test,
the air conditioning system should be OFF

6-13050 Issued 3-03

 Section
9030

VISCOUS FAN DRIVE TEST

MX210, MX230, MX255 and MX285

Case, LLC
700 State Street
I!:> 2003 Case, LLC
Printed in U .S.A.
Racine, WI 53404 U.S.A. Rae 6-14780 March,2003
9030-2

TABLE OF CONTENTS
REQUIRED TOOLS .......... ......................... .................. ........ ............ .. ............................................. .. ......... .. .. ......... 3
DIAGNOSTIC PROCEDURE .............................. .................................................. ................. ........... ...................... 4
Physical Check ........ .... .................... .................................. ........... .. .......................................................... ........... 4
Fan Speed Test ........... ..... ......................................................... ..... ...... ..................... ................... ........... .... ........ 6

,.

Rae 6-1 4780 Issued 3-03

 9030-3

REQUIRED TOOLS
Digital Photo Tachometer OEM1057A or
Equivalent

Digital Thermometer with Probe (380001301) OR

Digital Multimeter with Air Probe Equivalent

6-14780 Issued 3-03

9030-4

DIAGNOSTIC PROCEDURE

Physical Check

STEP 1
Check the torque of the fan blade mounting bolts -
13-16 Ib It (18-22 Nm).

STEP 2
Check the torque of the fan driven pulley bolts - 20-
22 Ib It (27-30 Nm).

STEP 3
Check the torque of the fan drive pulley - 34-38 Ib It
(46-52 Nm).

6-14780 Issued 3-03

 9030-5

STEP 4
Check the torque on the drive shalt hub - 120-150 Ib
It (163-203 Nm).

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.

STEP 6
Rotate the fan by hand one complete turn (360°).
The fan should turn smoothly with some uniform
internal resistance. If the fan rotates with strong or
non-uniform resistance, replace the fan drive.

NOTE: Fan resistance must result from the internal

drive, not from interference with a non-rotating part.

STEP 7
There should be minimal forwardlrearward play in the
fan drive. Grasp the center of the blade assembly,
and attempt to move the drive forward and rearward.
If there is more than 1/16-inch (1.6 mm) play in the
drive itself, replace the fan drive.

NOTE: This Step checks for internal play within the

drive itself, movement which is not the result of loose
mounting bolts or pulley bearing wear.

6-14780 Issued 3·03

9030-6

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.

IMPORTANT: Do NOT steam clean or use high

pressure jets to clean the fan drive. The high forces
used may cause foreign material to be forced past
external seals, contaminating the grease or silicone
seal. Do NOT aim the low pressure wash directly at
the fan bi-metal drive while cleaning.

STEP 9
Check that the cooling system is filled to the proper
level and with the correct coolant mixture.

Fan Speed Test

STEP 10
IMPORTANT: This test is most effective at an
ambient air temperature of 80° F (26. r 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.
Warm a cold engine to shorten the run time during
this procedure:
A . Turn the air conditioning system OFF.
B. Close the heater supply valve on the left hand
side of the engine.
C. Start the engine and operate until the
Heater Supply Valve
thermostat opens; then turn the engine OFF.

NOTE: The AlC system and the heater valve should

remain closed throughout this test.

14780 Issued 3-03

 9030-7

STEP 11
Place a piece of reflective tape (1) - from the Digital
Photo Tachometer Kit - on the engine side of the fan
blade. Install the tape near the outside edge of the
blade, the left corner of the blade as viewed from the
left side of the tractor.

RH03C034

STEP 12
Apply another strip of reflective tape to the fan drive
shaft so drive shaft RPM can be read with the photo
tachometer.

STEP 13
Loosen the shroud mounting screws on the left hand
side of the fan, and route the temperature probe with
its leads to the between the front of the viscous drive
and the radiator.

6-14780 Issued 3-03

9030-8

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
olthe fan drive_
Route the electrical lead to the probe so temperature
readings can be taken with the hood closed.

STEP 15
Start the engine, and turn electrical loads ON (lights
and work lamps).
Measure the fan drive shaft speed with the photo
tachometer aimed at the reflective tape on the shaft.
Increase engine speed until fan drive shaft speed
reaches 2500 RPM on the MX255 and MX285 and
2200 on the MX210 and MX230.

NOTE: Fan drive shaft speed is not the same as

engine speed.

Lock the throttle at this RPM. This establishes the fan

drive shaft test RPM .

STEP 16
Install the magnetic base for the photo tachometer on
the top of the left hand rail. Install the photo pickup on
the base and aim it at the reflective tape on the fan
blade. Route the leads to the photo pickup so they
will not interfere with any rotating parts with the hood
closed.
Reinstall any side panels removed. Close the hood.
Cover the front grille screen.
Measure the fan blade speed with the photo
tachometer.

6-14780 Issued 3·03

 9030-9

STEP 17
As the engine warms uP.
A. The fan RPM should stabilize between 800-
COOLANT TEMP
1000 RPM.
B. When engine coolant reaches 200-220° F
~
(93.3-104.4° C). fan speed should increase to
2125 RPM on the MX255 and MX285 and
1870 RPM on the MX210 and MX230.
C. Air temperature at the fan drive should be 165-
195° F (73.9-90.6° C) when the fan engages.
210 F
With the fan engaged. record fan RPM . coolant
AH03C032
temperature and air temperature at the drive.
With the fan engaged while maintaining the test
RPM . fan speed should begin to decrease as
temperature decreases. After 2-3 minutes. the fan
should slow to the initial fan speed - about 1000
RPM on the MX255 and MX285 and 880 RPM on the
MX210 and MX230.
Repeat this cycle several times while recording
temperatures and fan RPM.

STEP 18
1. Replace the viscous fan drive if:
MX255 and MX285: If the fan fails to reach 2125 RPM or higher (at least 85% of the test RPM) at
200-220° F (93.3-104.4° C) coolant temperature AND air temperature at the fan drive exceeds
195° F (90.6° C).

MX210 and MX230: If the fan fails to reach 1870 RPM or higher (at least 85% of the test RPM) at
200-220° F (93.3-104.4° C) coolant temperature AND air temperature at the fan drive exceeds
195° F (90.6° C).

2. The fan drive is not faulty if the fan fails to reach 85% of the test RPM and the coolant temperature EXCEEDS
220° F (104.4° C) and air temperature at the fan drive does NOT exceed 195° F (90 .6° C) . Check for the
following:
A. Air flow restrictions through the air cooler. oil cooler and radiator.
B. Internal radiator plugging .
C. Faulty thermostat.
D. Defective water pump.

3. If fan speed fails to slow down to 800-1000 RPM after the fan drive disengages (with the test RPM maintained).
replace the viscous fan drive.

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.

6-14780 Issued 3·03

9030-10

Issued 3·03
6-14780
 Section
9020

AIR CONDITIONER SYSTEM SERVICE

MX MAGNUM TRACTORS 210, 230, 255, 285

Case, LLC
@2003 Case, LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. 6·13050 March. 2003
9020-2

TABLE OF CONTENTS
SPECI FICATIONS ............................... ............ ............. .................. ................................................. ........................ 4

SP ECIAL TORQUES ..... ....... ................................................. ............... ........................ ....... .................................... 4

SPECIAL TOOLS ....... ............ .... ....... ................... ...... ...... ............. ..... .. .... .. .................. ....... ..... .................. .. ....... .... 4

SAFETY P ROC EDURES ....... ........................................ ............................. ......... ............................. ........... ........... 9

AIR CONDITIO NER SYSTEM REFRIGERANT RECOVER Y ....................................... .............. ...... .................. .. 10

RECOVER ING PURE 134A REFRIGERANT ........................ ...... ...... ...................... ........ .......... .... .. ............ ....... .. 12

RECOVERIN G CONTAMINATED REFRIGERANT WITH OEM1 691 .......... ........ ............................ ,.... .... .. ......... 16
Preparing the Tank ..... ...... .. ....... .................................. ..... ...... ......... .... ...... ........ ...................... .............. ..... .... ... 16
Recovery Process .................................................................... ....... ......................................... .......................... 20

AIR CONDIT IONER SYSTEM EVACUATION AND RECHARGING ............ ........................... ............... ...... ........ 26

MX AIR CON DITIONING TEMPERATURE/PRESSURE CHART ................ .............. .... ....................... .... ........... 33

LEAK DETECTION ........ ....... ..... ........................ ........ ......................... ..... ..... ........... ... ......... .... ..... ........... .... ......... . 34
Electronic Testing with OEM 1437 .................... .... ....... ............. ...... ....... .... ............................... .................... ... ... 35
Florescent Leak Detection ........................... ....... ...................... ............. ............................ ... ..... ............... ......... 36
Fluorescent Dye Injection .................................................. ........................................ ................................ ........ 36
Recovery Station Dye Injector Tool with a System in a Vacuum .............. .................... .......................... ......... 37
Recovery Station Dye Injector Tool with a Charged System ....................................................... ........... ......... 38
Quick and Easy Dye Injector Tool with a Charg ed System ....................... .. ......................... ............ ....... ......... 39
Compressor O il Port .......................................................... ...................................................................... ......... 40
S P-20 PAG Oil Return Bottle .............. .. .. ......... ......... .......................... ............................. ........ .. ...... .. ..... ......... 41
Fluorescent Leak Testing ... ............... ................................................................................................................. 42

AlC SYSTEM FLUSH ING PROCEDURE ... .. .................................. ....... .......... ....... ..... .. ..... ......... ........ .................. 43
Required Tools ................ ..... ..... ......... .............. ....... ............ .. ...... ....... ............... ............................. ""' '' ''''' ........ 44
Precautions ....... ....................................................................................... ... ....... ...... .................................. ..... ... 45
Component Fl ushing Procedure with Power Flush 17550 .. ................................................................ ............... 46
Complete Circuit Flushing Procedure with Power Flush 17550 ............. .. ................. ................... .... .......... ........ 50
Back Flushing the The rmal Expansion Valve or Refrigerant Line .......... .. ........................ .................................. 55
Post Flushing Procedu res .. ............. .. ...... ........................... ............. ..... ................................ .............................. 57
Flush ing Solvent Disposal ..................................... ..................... ..... ..............".... ..... .. .. ......... ............. ...... .......... 59

AlC SYSTEM COM PO NE NTS ....... ...... .............. ...... .......................... .......................... .... .. ................. ... .... ..... ... ... 60
Cab HVAC Box Components - Automatic Temperature Control ............................................................... ........ 60
Cab HV AC Components - Standard Systems ................... ................................................................................ 62
MX Magnu m 210/230 Chassis Components ........................... .............. .................. .................... ............. ......... 64
MX Magnum 255/285 Chassis Components ............... ....... ....................................................................... ........ 65

AlC COM PRESSOR CLUTCH .......... ................. ...... ....................... .................................. ....... ......... ............ ........ 66
Clutch Removal ........ ....... .... ................ ............... ............ ..... ... .. .... .... .... ........... ........ .................................. ......... 66
Exploded View of Clutch ..... ....... .................... .. ...., ........... ..... ..................... ........... ....................... ........ ...... ..... ... 72
Compressor Clutch Replacement ............................................................... ............................. .................. ........ 72

6·13050 Issued 3·03

 9020-3
AlC COMPRESSOR ...................................... .............................................. ... ........................ ................ ......... ...... 80
Oil Level Check or Adjustment .... ............................................. ...... ................ .................................................... 80
Injection Method ............................................................................................................................... ................ 80
Dipstick Method ................................................... .... ................. .... ......... ........................... ........ ........................ 81
Compressor Removal .. ........ ................................................. .................................... ................................ .... ..... 83
Compressor Installation ........ ..................................... .............. ................... ............... .................. ...................... 86

CONDENSER AND RECEIVER-DRIER ............................................. ..... .............•... .. .......................................... 88

Condenser .............. .................... ................... .............................................................................. .. ............ ........ 88
Receiver-Drier ................................. ................................... ................................... ............................................. 90

ACCESSING THE HVAC BOX .............................................................................................................................. 92

THERMAL EXPANSION VALVE TESTING .................................................... ...................................................... 94

THERMAL EXPANSION VALVE REPLACEMENT .... .......... ....... .......................................................................... 96

EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION ..................................................................... 98

BLOWER MOTOR REPLACEMENT ..................... ................................................................................................ 99

HEATER CONTROL VALVE REPLACEMENT ............................................... .................................................... 100

EVAPORATOR/HEATER ASSEMBLY ........................... .............................. ..................................... ................. . 101

Evaporator/Heater Assembly Removal .................................... .............................................. ......................... . 101
Evaporator/Heater Assembly Installation ...................................... ...... ............................................................. 104
Post Replacement Procedures .... ..... ..................................................................... ..................... ..................... 107

EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING ................................................................... 108

BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION ........................................................................ 109

CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT .................................................................. 110

ATC Controller ..................... .......................... .......... ................................................ .................... .................... 110
Standard AlC Controller ............ ........ ................................................... ................................................ ............ 110
Blower Speed Driver (ATC Units Only) ............................................................................................................ 111

CAB AIR FILTER SERVICE ................................................................................................................................ 112

CAB RECIRCULATION AIR FILTER SERVICE .................................... .............................................................. 113

CAB PRESSURIZATION TEST ............................................................................................................ .............. 114

CAB PRESSURIZER MOTOR REPLACEMENT .............................................................. .................................. 116

VISCOUS FAN DRIVE ......................................................... ..................................................... .......................... 118

6·13050 Issued 3·03

9020-4

SPECIFICATIONS
Air Conditioning System Refrigerant Capacity ......... ...... ........ .. ...... MX Tractor Models - 4.63 Ib (US) (2.1 kg)
Clutch Front Plate Air Gap ............................ ... ... ............................................. 0.016 to 0.031 Inch (0.41 to 0.79 mm)

SPECIAL TORQUES
Compressor Clutch Retaining Nut ... ................. ................ .. ........................... ......... 15 to 20 Nm (11 to 15 Ib It)
Oil Filler Plug ......................................................................... ........................................... 15 to 24 Nm (11 to 18 Ib It)
Dust Cover Screws ........... ................................. ....................... .............................................. 7 to 11 Nm (5 to 8 Ib It)

SPECIAL TOOLS
Combination Impact and Chemical Splash r-------------------,
Safety Goggles

'09L7

Compressor Tool Set, CAS10747A

The compressor dipstick (1) can be found in the
Compressor Tool Set or purchased separately -
CAS10747-19.

Refrigerant Recovery Station, OEM1415

6 Foot Length, Quick Disconnect Refrigerant
Charging Hoses: OEM1438 (Yellow), OEM1439
(Blue), OEM1440 (Red)
20 Foot Length, Quick Disconnect Refrigerant Hoses
- OEM1442 (Set includes Yellow, Blue and Red
hoses)

6-13050 Issued 3-03

 902 0-5

Refrigerant Identifier OEM4450

Air-Powered Recovery Station with Tank

OEM1691

Additional 50 Ib Contaminated Refrigerant Tanks

OEM1692

RROOE140

1/4 Inch FFLX to 1/2 Inch Acme Adapter

OEM1693

AROOE139

6- 13050 Issued 3-03

9020-6

Electronic Leak Detector OEM1437

A22090

UV Leak Detection Lamp and Goggles

BSL750

Recovery Station UV Dye Injector for R-134a

Refrigerant - BSL734

UV Leak Detection Dye for R-134a Refrigerant

B726012

6-13050
 9020-7

R134a Quick and Easy Dye injector Tool

8SL738

-
I
RD01F248

Quick and Easy R134a Charge Cans - 6-Pack

8SL634

ROO1F249

UV Fluorescent Dye Cleaner - 8795016

--.

RROOF100

Power Flush Model 17550

8S33801 - AlC Flushing Solution, case of six 1-
gallon containers

RROOF093

6-13050 Issued 3·03

9020-8

Flush Gun Kit Model 17585

8533801 - AlC Flushing Solution, case of six 1-
gallon containers

Coalescing Air FilterlDryer (1) Similar to

Ingersoll-Rand ModellR5CHE or Grainger Model
4KR65

RIOOF041

Pressure Regulator Capable of Providing 45 psi

at 4.0 efm (310 kPa at 0.11 emm)
with Integrated Pressure Gauge

RtOOF042

17582 Universal Flush Fitting Kit

6-13050 Issued 3·03

 9020-9

SAFETY PROCEDURES

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULL Y READ THE MESSAGE THA T
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B

ATTENTION: Only authorized technicians certified
by an approved training and certification organization
may service or repair motor vehicle or mobile air
conditioning systems.
Refrigerant HFC-134a is the most stable and
easiest to work with of the refrigerants now used in
air conditioning systems. Refrigerant HFC-134a
does not contain chlorofluorocarbons (CFC 's)
which are harmful to the earth's ozone layer.
Safety procedures must be followed when working
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear combination impact and chemical
splash safety goggles when doing any service
work near an air conditioner system. Liquid
refrigerant in the eyes can cause serious inju ry.
Do the following if you get refrigerant near or in
your eyes:
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately. M779
5. Use the air-powered OEM1691 ONLY to recover
contaminated refrigerant. Do NOT use OEM1415
or OEM1418 recycling stations to recover
contaminated refrigerant. If contaminated
refrigerant contains more than 2% hydrocarbon
( propane , butane, or isobutane), the mixture
rnust be treated as flammable; if more than 4%
hydrocarbon, the mixture must be treated as
explosive ; in both cases an electric-powered
recovery station may NOT be used . Avoid heat,
s parks and flame when working with this
contaminated refrigerant. MBOO
6. Dangerous gas can form when refrigerant cornes
in contact with an open flame . Never inhale
fumes. M745
7. Never leak test with compressed air or flame
tester. Tests have indicated that compressed
mixtures of HFC-134a and air can form a
combustible gas. M746

2. Always recover all refrigerant prior to opening an

AlC system. A drop of liquid refrigerant on your
skin may cause frostbite burns. Open fittings
carefully and slowly when servicing the air
conditioning system. Your skin must be treated
for frostbite burns or a physician must be seen if
you get refrigerant on your skin. M799

3. Keep refrigerant containers in correct upright

position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat. M743

4. Always check refrigerant purity with OEM4450

Refrigerant Identifier before recovering
refrigerant and before testing the system. M777

6-13050 Issued 3-03

9020-10
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY
IMPORTANT: There are no repair procedures for the compressor or compressor clutch . If the clutch or
compressor are defective, replace them.
WARNING: 134a is the only refrigerant
approved in 134a systems. Alternative
"'" refrigerants which boast better cooling
L.l). capabilities are in most cases highly
flammable. Do not expose contaminated
refrigerant to spark, flame or yourself. M748
IMPORTANT: Refrigerant contamination has
become an issue since the introduction of 134a as a
replacement for R-12. Contamination refers to a
r efrigerant blend and/ or mixture of alternative
refrigerants and 134a. Typically R-12 systems which
are in need of repair or recharge are suspect to
refrigerant contamination due to the number of so
called "drop-in" replacements or substitutes for 134a.
S y stems designed for 134a, such as the MX
MAGNUM, may be at lower risk for contamination,
b ut precautions should be taken to prevent
contamination of service equipment and/or other AlC
systems.
IMPORTANT: A refrigerant identifier should be used
to determine refrigerant contamination prior to
rec o very. Case recommends using OEM4450
refrigerant identifier. If a refrigerant contamination
le vel of 2 % or greater is discovered, do not recover
the system to a tank with pure 134a refrigerant.
Recover only to a tank reserved for contaminated
refrigerant with the air-powered station - OEM1691.
WARNING: OEM1415, and its predecessor
OEM 1418, were designed for the recovery
and recycling of pure 134a refrigerant. Do
NOT use OEM1415 and OEM1418 to
& recover contaminated refrigerant; you will
void your warranty, you may damage the
compressor and filter-drier in the recovery
station, and you may expose yourself to the
danger of an explosion. M795
6-13050
WARNING: If the refrigerant identifier
indicates the system contains more than 2 %
hydrocarbon (propane, butane or isobutane),
the system and its contents must be treated
as flammable; if more than 4% hydrocarbon,
the system and its contents must be treated
"'" as explosive. Do not operate the vehicle or
L.l). the A/ C system . Do not recover this
contaminated refrigerant with an electric-
powered unit (OEM1415 or OEMI418). Use
the air-powered station - OEM1691 - to
recover this refrigerant. Avoid heat, sparks
and open flame when working with this
contaminated refrigerant. M796
IMPORTANT: If contaminated refrigerant is
discovered and recovered with OEM1691, replace
the receiver-drier in the tractor being serviced
BEFORE you recharge the system with pure 134a
refrigerant. OEM1415 or OEM1418 should be used
to evacuate and recharge the system after the
contaminated refrigerant has been safely recovered.
NOTE: Check with your local environmental agency
for regulations on the proper disposition of
contaminated refrigerant.
NOTE: In the United States, EPA regulations require
that tanks of contaminated refrigerant be sent to a
refrigerant reclaimer for the contents to be purified or
destroyed. Call 1-800-296-1996 to locate a reclaimer
in your area.
WARNING: Do NOT use a tank without a
& limit switch to recover contaminated
refrigerant with OEMI691. The limit switch
prevents overfilling the tank and protects
your safety M797
WARNING: When working with SP-20 PAG
oil, follow these safety precautions: 1) Avoid
contact with eyes, skin and clothing. 2) Avoid
"'" breathing vapor, aerosol and mist. 3) Do not
L.l). swallow. 4) Use only with adequate
ventilation. 5) Wear protective safety goggles
and non-permeable gloves when handling
SP-20 PAG oil. M798
Issued 3-03
 9020-11

Overview
In many countrie s , recovery, recycling and
reclamation have legal definitions and standard
meanings in the mobile AlC industry.
Recovery is transferring refrigerant in any condition
from a system to a storage container without testing
or purifying the refrigerant in any way.
Recycling is the cleaning of refrigerant for reuse by
oil-separation , non-condensable gas removal and
single or multiple passes through filter/ moisture
absorption devices.
Reclamation is processing refrige rant to a level
equal to new product specifications as determined by
chemical analysis, (testing to ARI 700) .
In servicing Case LLC AlC systems with OEM1415,
when " recover" is depressed , the refrigerant in the
vehicle is transferred to the recovery tank on the unit
without testing or purifying. At the same time, SP-20
PAG oil is separated from the refrigerant and stored
separately in the reservoir. This oil requires proper
disposal and should never be returned to the vehicle.
When "vacuum" is depressed , the vacuum pump on
OEM1415 evacuates the atmosphere in the vehicle
A/C system to a vacuum of 28 to 29-1/2 inches of
mercury (Hg). Air and moisture are removed in the
process , and only SP-20 PAG oil remains in the
vehicle's AlC system.
A22094
When "recycle" is depressed , the entire contents of OEM1415
the recovery tank on OEM1415 are "recycled ." The
refrigerant in the tank is passed through a filter-drier
in OEM1415 and cleaned; non-condensables are
removed , and air is purged automatically. (Older
recovery units like OEM1418 have manual air purge.)

NOTE: In automatic operation, recycling begins

about 5 seconds after the vacuum pump starts.

NOTE: During recycling, some additional SP-20

PAG oil is separated from the refrigerant and stored
separately in the reservoir.

Only new SP-20 PAG oil is added to replace the oil

which was separated during recovery, and when
"recharge " is depressed, only clean " recycled "
refrigerant is returned to the vehicle's AlC system.

OEM1415 (or OEM1418 ) does not perform

"reclamation."

6-13050 Issued 3-03

9020-12

RECOVERING PURE 134A REFRIGERANT

STEP 1
Start the tractor and run the engine at 1500 RPM . If
possible, operate the air conditioner for 15 minutes at
maximum cooling and maximum blower speed. ATC
switch set to DEFOGIDEFROST, standard AI C
switch set to ON.

Standard AlC Controls

ATe AlC Controls

1. BLOWER CONTROL 3. TEMPERATURE
CONTROL
2. ATC OR STANDARD NC 4. LCD DISPLAY
SWITCH

STEP 2
Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction and pressure lines.

6-13050 Issued 3-03

 9020-13

STEP 3
IMPORTANT: Use Refrigerant Identifier OEM4450
to verify refrigerant purity. If refrigerant is 98% pure
HFC-134a and/or the only non-condensibles test as
air and moisture, then proceed with Step 4. If not, go
to Step 12.
With the charging station manifold gauge valves in
the closed position , connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve
depressor.

STEP 4
Open the drain valve to make sure that the oil
separator is drained prior to recovery. Oil may have
mistakenly been left in the recovery unit itself from
the previous service job. An oily mist will discharge if
the separator has been drained.
Check that the oil reservoir has been drained prior to
recovery to avoid returning additional oil to the
system.

1. DRAIN VALV E 2. RES ERVOIR DRAIN

6-13050 Issued 3-03

9020-14

STEP 5
Open the high and low valves.

STEP 6
Make certain the refrigerant tank gas and liquid
valves are open.

STEP 7
Connect the mai n power plug to a 115 volt AC outiet.
Move the main power switch to the ON position and
depress the RECOVER switch.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe
the manifold pressure gauges for a pressure rise. If
no pressure rise, recovery is complete. If pressure
rises above 0 PSI, depress the HOLD/CaNT switch
and repeat until pressure holds for two minutes. Then
wait for the compressor to automatically shut OFF.

NOTE: Refrigerant may pool inside the tractor's Ale

system. When the recovery unit's compressor is
turned off, the refrigerant will vaporize in the ambient
heat causing the system pressure to rise again.
Repeat the recovery process until the system
remains at a vacuum for at least two minutes.

6-13050 Issued 3-03

 9020-15

STEP 8
Some recovery units require a manual air purge to
remove non-condensables from the recovery tank.
Refer to the operators manual for your unit. Air purge
is automatic on an OEM1415 when it evacuates the
AlC system.

STEP 9
Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.

STEP 10
Record the amount of oil in the reservoir. This
amount of new oil should be added back to the
system . Dispose of any oil in the bottle in an
appropriate manner and return the bottle to the
station .

STEP 11
All refrigerant has been removed from the AlC
system; replace components or make any repairs at
this time.
A22111

6·13050 Issued 3 03
w
9020-16

RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691

IMPORTANT: When contaminated refrigerant is
discovered with Refrigerant Identifier OEM4450,
additional care is necessary to protect your safety
and prevent the contamination of service equipment
and your refrigerant supply. Recover the refrigerant
with OEM1591 station to a recovery tank reserved for
contaminated refrigerant. Do NOT use OEM1415 or
OEM1418 to recover the contaminated refrigerant.
IMPORTANT: Read all safety warning and
maintenance sections of the operators manual
before operating the station.
WARNING : Do NOT use a tank without a
A •
limit switch to recover contaminated
refrigerant with OEM1591 . The limit switch
prevents overfilling of the tank and protects
your safety. M797

Preparing the Tank

STEP 12
The tank for the station may be filled with 10 to 15 psi
of dry nitrogen which must be removed before it can
be used. Remove the cap from the red valve outlet.
Open the tank valve to release the nitrogen. Close
the tank valve.

STEP 13
Use the vacuum pump (1) on OEM1415 or OEM1418
to pull a 5 minute vacuum on the tank. Connect the
tank at the location (2) shown .

6- 13050 Issued 3-03

 9020-17

STEP 14
A 114 inch FFLX to 112 i nch Acme adapter
(OEM1693) should have been ordered with the unit.
Connect the adapter to the red tank valve.

STEP 15
Connect the 96 inch (2.4 m) blue hose with the
R134a service coupler to the adapter.

STEP 16
Connect the R134a service coupler to the tee fitting
on top of the vacuum pump on OEM1415 or
OEM1418. Open the valve on the service coupler by
turning it clockwise.

6-13050 Issued 3-03

9020-18

STEP 17
Open the valve on the tank.

STEP 18
Open the low side manifold on the control panel of
OEM1415 or OEM1418.

STEP 19
Press SHIFT/RESET and ENTER at the same time.
Press 1 . The vacuum pump starts and runs
continuously until any other key is depressed.
Run the vacuum pump for a minimum of 5 minutes.
Then press 1 to stop the pump.

6-13050 Issued 3-03

STEP 20
Press SHIFTIRESET again to return to the normal
display mode.
Close the valve on the tank.
Close the valve on the service coupler by turning it
counterclockwise and disconnect the blue hose from
the vacuum pump.

STEP 21
Set the tank on the platform at the rear of the station.
Tighten the black strap securely around the tank.

STEP 22
Disconnect the R134a hose from the adapter.
Disconnect the adapter from the tank and store for
future use. Reinstall the cap on the red valve outlet
port.
The tank is now prepared. See the operators manual
to prepare the recovery station for use.

6-13050
9020-20

Recovery Process
IMPORTANT: If a recovery tank becomes full during
a recovery, the float switch will automatically turn off
the scavenger. See Step 35 for changing tanks in the
middle of a recovery.

STEP 23

* WARNING: Do not operate the vehicle or

the Ale system if the refrigerant identifier
~ shows more than 2% hydrocarbon in the
mixture. M801

Start the tractor and run the engine at 1500 RPM . If

possible, operate the air conditioner for a few
minutes at maximum cooling and maximum blower
speed, with ATC switch set to DEFOG/DEFROST, or
standard AlC switch to ON. Tests have shown that
more refrigerant will be recovered if this action is
performed.

NOTE: Turn the system and tractor OFF before

connecting the station.

STEP 24
Remove the cap on the low pressure port at the
compressor. Connect the blue R134a recovery hose
from the station to the low side service port at the
compressor.

ROO2H03O

STEP 25
Open the tank valve for the R134a hose. Open the
valve at the service port.

6-13050 Issued 3-03

 9020-21

STEP 26
Turn the control panel valve to START.

NOTE: This will equalize pressure on both sides of

the compressor for easier starting.

STEP 27
Connect a compressed air line to the air inlet on the
regulator at the rear of the station.

NOTE: The air system must offer a minimum of 120

psi (827 kPa) and a maximum of 200 psi (1379 kPa)
at sustained volume of 10 cfm (0.28 cmm).

6·13050 Issued 3-03

9020-22

STEP 28
Connect the red power lead to the + (positive) post of
the vehicle's battery or to another 12V DC power
s upply. Connect the black ground lead to a ground
source away from the battery, NOT the battery -
(negative) post. The compressor should start idling.

NOTE: Batteries generate explosive gases during

normal battery operation. Use the remote ground to
reduce the risk of sparks around the contaminated
system.

NOTE: Use a jumper cable to extend the negative

lead if necessary to reach an engine ground.

STEP 29
Turn the control panel valve to RECOVERY. The
compressor sound should change . Inlet pressure
gauge should decrease and tank pressure increase
on the gauges.

6-13050
 9020-23

STEP 30
When inlet pressure gauge shows a vacuum ,
disconnect the air line. Wait five minutes. If inlet
pressure rises above 0 psi, repeat Steps 33 and 35.

NOTE: Refrigerant may pool inside the system.

When the station is turned off, the refrigerant will
vaporize in the ambient heat causing the system
pressure to rise again. Repeat the recovery process
until the system remains at a vacuum for at least two
minutes.

1. NC SYSTEM PRESSURE 2. TANK PRESSURE

GAUGE GAUGE

STEP 31
When the recovery process is complete, close the
valve on the recovery tank. Close the low pressure
hose valve and remove the hose from the port at the
compressor.

STEP 32
Disconnect the compressed air line from the inlet on
the regulator.

6-13050 Issued 3·03

9020-24

STEP 33
Disconnect the black ground lead. Disconnect the
red power lead from the 12V power source.

STEP 34
After each recovery, carefully open the accumulator
oil drain and drain any collected compressor oil in a
proper container.

NOTE: Small amounts of refrigerant may remain in

the accumulator and build a slight pressure. Drain
the accumulator when the inlet pressure gauge
shows a vacuum. There mayor may not be any oil to
drain; this will vary from tractor to tractor. Dispose
any oil drained in a proper manner.

NOTE: If any significant amount of oil is drained,

measure and record that amount. Add that
equivalent of new SP-20 PAG oil back into the
system at the end of the evacuation process.

IMPORTANT: If the oil is suspected to be other than

SP-20 PAG oil:
1. See the flushing procedures in this Section for
complete circuit flushing to remove the oil.
2. Drain all oil from the compressor, and add back
to the compressor 8.5 oz (250 ml) of new SP-20
PAG oil.
3. Back flush the thermal expansion valve.
4. Reintroduce the fluorescent dye for R-134a in
the system.
5. Replace the receiver-drier before evacuating and
recharging the system.
6. Operate the system for 15 minutes to circulate
the new oil throughout the circuit.

6-13050 Issued 3~03

 9020-25

STEP 35
If a recovery tank becomes full during a recovery, the
float switch will automatically turn off the station . To
change a full tank in the middle of a recovery:
A. Close the blue tank valve and the valve on the
black hose from the station .
B. Unscrew and remove the float cable from the
tank.
C. Disconnect the hose from the tank valve.
D. Remove the tank from the station.
E. Replace the tank with a properly prepared tank
(dry nitrogen charge released and vacuum
drawn and held for five minutes).
F. Connect the tank valve hose and the float
cable.
G. Open the tank valve and the tank hose valve.
Recovery will continue as soon as both valves
are open .

IMPORTANT: Do not use recovered contaminated

refrigerant in any Ale system. Send full tanks to a
reclamation center for purifying or disposal of the
contents.

STEP 36
All refrigerant has been removed from the AI C
system, replace components or make any repairs at
this time.

IMPORTANT: Replace the receiver-drier on the

tractor being serviced before you evacuate or
recharge the system with OEM1415 orOEM1418.

STEP 37
See evacuation and recharging in this Section to
recharge the AlC system with pure R134a refrigerant
using OEM1415 orOEM-1418.

6-13050 Issued 3-03

 - - - - -- - - -

9020-26

AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or

more of the following conditions occurs before you
remove the air and moisture from the system:
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years .
C. Disassembly of compressor shows small
particles of moisture removing material (gold or
brown particles).
D. Large system leak (broken hose, break in line) .
E. Too much air or moisture in system.
F. Removal of compressor or any other
component caused the system to be open
(uncapped) longer than 5 minutes.
G. Testing with refrigerant identifier OEM4450
showed contamination.

STEP 38
With the charging station manifold gauge valves in
the closed position , connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose (blue) .
2. Connect the hose from the high pressure gauge
to the port on the discharge hose (red).
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the system has been opened for
maintenance. A vacuum pump must be used to lower
the pressure enough to change the moisture to vapor
which can be removed from the system.

NOTE: Refer to the vacuum pump manufacturer's

user manual for additional information.

6-1 3050 Issued 3-03

 9020-27

STEP 39
Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position. "
program and vacuum do not appear at the top of the
display press the VACUUM key. Program a minimum
of 45 minutes and press the ENTER key. The display
will flash once indicating the programmed data has
been accepted.

STEP 40
Fully open the low and high pressure valves.

STEP 41
Open the red (vapor) and blue (liquid) valves on the
tank.

6·13050 Issued 3-03

9020-28

STEP 42
Press the VACUUM key. Automatic will show on the
display. VACUUM will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the AlC system maintains a 28 to
29-1 /2 inches of mercury (Hg) .

NOTE: The low pressure gauge must not increase

faster than one inch of mercury (Hg) in 15 minutes. If A22 123

the system will not hold vacuum, a leak exists that

must be corrected before recharging can begin. See
leak test information in this section.

STEP 43
IMPORTANT: Do not inject the PAG oil until the
system will hold a proper vacuum.
OEM1415 has an injection system to return new SP-
20 PAG oil equal to the amount recovered at the end
of the evacuation process.
To add the new oil, adjust the a-ring around the oil
return bottle to the required oil charge level.

NOTE: If 2.4 oz (71 ml) was recovered in the oil

reservoir, 2.4 oz (71 ml) of new SP-20 PAG must be
returned.
1. OIL RETURN BOTTLE 2 . OIL INJECTION VALVE
Open the oil injection valve to add the oil into the
system . Close the valve when the oil level reaches
the a-ring.

IMPORTANT: Do not let oil level fall below the dip

tube in the return bottle or air will be introduced into
the refrigerant circuit.

STEP 44
Press the CHARGE key. PROGRAM and CHARGE
wi ll appear on the display.

6-13050 Issued 3-03

 9020-29

STEP 45
Program the prope r refrigerant amount for your
tractor and press the ENTER key:
All MX Tractor Models .......... ......... .4.63 Ibs (2.1 kg)
The display will flash once indicating the
programmed data has been accepted.

STEP 46
Press the CHARGE key to begin refrigerant
charging. AUTOMATIC and CHARGE will appear on
the display. The display shows the programmed
amount and counts down to zero as charging
proceeds. When charging is completed , the display
shows CPl.

IMPORTANT: Check the OEM equipment manual

before performing Step 47 to avoid damaging
recovery unit. Pressure reading should be obtainable
with valves closed. Damage may occur if the tractor
is started with the valves accidently open or if either
A22115
or both valves are opened while the AlC system is
operating.

STEP 47
Completely close the high and low pressure manifold
valves.

6-13050 Issued 3·03

9020-30

STEP 48
Start the tractor and run the engine at 1500 RPM.
Operate the air conditioner system at maximum
cooling setting and blower speed with the door and
service door open, Standard A/C switch ON or ATC
switch in DEFOG/DEFROST position.

NOTE: The compressor does not operate if the

system pressure is too low or too high because the
clutch is latched off by the controller. Standard NC
units blink the indicator light on the NC ON/OFF
switch indicating a system pressure problem. To
restart the compressor, the switch must be turned to
the OFF position and then ON. ATC units display a Standard AlC Controls

o
fault code on the LCD display indicating a pressure
problem. To restart the compressor, the ATC switch
must be turned to OFF and then AUTO or DEFOG/
DEFROST position.

AH02J045
ATC AlC Controls
1. BLOWER CONTROL 3. TEMPERATURE
CONTROL
2. ATC OR STANDARD AlC 4 . LCD DISPLAY
SWITCH

6-13050 Issued 3-03

 9020-31

STEP 49
Observe the pressure gauge readings to determine
that the correct amount of refrigerant has entered the
system. See chart on page 33 for temperature and
pressure variations. Check louver temperature for
proper cooling at the mid-cab vents.

STEP 50
Close any open valves on the couplers and carefully
remove the gauge hoses fro m the ports on the
suction and discharge lines.

6-13050 Issued 3-03

9020-32

STEP 51
Install the caps on the service ports on the suction
and discharge lines.

6-13050 Issued 3-03

'!: MX MAGNUM AIR CONDITIONING TEMPERATURE/PRESSURE CHART
'"go
Models 210, 230, 255 and 285
Ambient Normal Low Side Pressure Normal High Side Pressure Louver Temperature"
Temperature
Low Relative Humidity" High Relative Humidity Low Relative Humidity" High Relative Humidity Low RH" High RH
21°0 117 to 138 kPa"
·'. 1~:~72~",~. . 938 to'-W; kPa 1040 to 1214. IIPa 13"C 17°C
(7O"F) . (171020 j'isig) ... .. ' ~ ' ., .. j; (13810 1 ·. 'paIO) , ..
(151
,
to 116
"
jl$ig) (55°F) (52°F)
2rC 145 to 172 kPa 172 to 207 kPa 1158 to 1379 kPa 1262 to 1469 kPa 16°C 19°C
(80' F) (21 to 25 psi g) (25 to 30 psi g) (168 to 200 psig) (183 to 213 psig) (60' F) (67' F)
,.··.,,~C .' 1.1 . to 207 kPa ;. . ; 207 10 234JIP.!i.,.•~. :t· l,~tOl841~ · " 1482 io1~4 kPa 19°C 22°C
.......
.-
,+~ ..
,
.. '.'
. .
··~84Mt ·;,; " 11 ill tf 238 PllliV,\,' _ ; (215 tUlle) paig) ,
.. ~ toao paIgJ . .: ..-.<: ~,' .,.'_ .- '. ~. ;r:.~:i~~ . -· . "s.... .1.-::r- .'Co._ • - ,
(trrF) (71°F)
38' C 200 to 241 kPa 228 to 276 kPa 1593 to 1951 kPa 1662 to 2027 kPa 22' C 25' C
(100' F) (29 to 35 psi g) (33 to 40 psig) (231 to 283 psig) (241 to 294 psig) (71 ' F) (76' F)
......~:,.> 228 to 218 kPa . . rt6'31', ~ F . ' 1813 to 2213~ 1875 to 2289 kPa
...
25·C ' 27"C
., .•.., «;I,.,
fD!':.',f'
... .•.:" (lSlo,oUt paIgJ " . .
"'<'" (3f
',- to' paIgJ.-d'":-
45 , "~ ,:; ' {2e3 10 821 PI!IO r •. . (272to332pslg) (77"F) (81 "F)
" c.
49' C 255 to 319 kPa 283 to 345 kPa 2034 to 2482 kPa 2089 to 2551 28' C 30' C
(120' F) (37 to 45 psi g) (41-50 psig) (295 to 360 psig) (303 to 370 psi g) (82' F) (86' F)
"Temperatures shown are highest normal temperatures expected ; actual louver temperatures may be cooler.
Louver temperature measured in the louvers facing the operator.
.. Compressor clutch cycling may occur under low humidity, low temperature condition.
The pressure-temperature chart is based on the following conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Blower speed control in the highest speed position.
4. Door and rear window open.
5. Air conditioner temperature control set to maximum cooling.
6. Air conditioner control switch set to ON (Standard AlC) or DEFOG/DEFROST (ATC) mode.
7. Gauge readings taken 15 minutes after start up.
8. Hood closed with all side panels in position.
9. Heater supply line clamped and return valve closed at the engine.
10. All cab air louvers open.

~ <0
~ f6o
4' ,
8 '"'"
9020-34

LEAK DETECTION

"" WARNING: Never leak test with an open

~ flame or a flame-type detector. M816

WARNING: When refrigerant comes in

""
contact with an open flame , it can form
~ dangerous gas. Never breathe these
fumes. SM109A

Two methods are recommended to test the AIC

system for refrigerant leaks: electronic leak testing
with OEM1437 and UV-florescent leak detecting.
Whatever method is used , the following components
or areas should be checked, always looking for signs
of leakage - oily residue, dust accumulation:

A. Compressor: line connections, surfaces where

parts are joined, compressor to clutch seal.

NOTE: When checking compressor seal for a leak,

remove the dust cover and rotate the compressor
shaft clockwise.
A22090
OEM1437
B. Condenser: line connections, all welded joints,
any visible damage.

C. Receiver-drier: line connections.

D. Thermal expansion valve : line connections.

NOTE: Remove the thermal insulation tape to check

the expansion valve for leaks; replace the tape when
completed.

E. Service ports: valve core under the caps.

AROOF098
F. Low and high pressu re switches: Check UV Leak Detecting Lamp and Goggles
around the entire switch body where it is
threaded into the line.

G. Hoses: line connections where the hose end

meets a metal connector, any area that shows
damage or rubbing contact.

6-13050 Issued 3-03

 9020-35

Electronic Testing with OEM1437

When performing electronic leak detection with
OEM1437, follow these general guidelines:

1. There must be enough refrigerant in the system

to produce normal pressures (at least 50 psi).

2. Leak test in an area free of wind and drafts.

3. Operate the tractor long enough to circulate the

refrigerant and produce normal system
pressures.

4. Shut the tractor and system off when leak

testing .

5. Clean oily spots with dry shop cloths ; solvents

can leave a residue which may confuse
OEM1437.

6. Hold the leak detector probe under the point

being checked , since refrigerant is heavier than
air.

7. The probe on the leak detector should never

come into contact with the component being
checked.

B. If OEM1437 indicates a leak, move the probe

away, blowout the area with clean shop air and
verify the leak with the detector.

9. If the leak cannot be found with OEM1437, use

UV florescent leak testing to locate the problem.

10. Repair all leaks and recharge the system.

6-13050 Issued 3~03

9020-36
Florescent Leak Detection
Fluorescent tracer or dye solutions are now
commonly used to detect refrigerant leaks. Your MX
tractor had an ultraviolet fluorescent tracer or dye
intro duced into the A /C system at the time of
manufacture. This dye will glow a bright yellowl green
at a leak location under ultraviolet light.
The dye has been tested for compatibility with
HFC- t 34a systems and approved for use in all Case
IH HFC-134a A/C systems. Special tools are also
available to aid in injection and leak detection. See
SPECIAL TOOLS, page 4 in this Section.
Fluorescent Dye Injection
Many methods are available to introduce the dye to a
system for the first time or to reinject the dye into an
AlC system. Select the method most appropriate to
the needs of the A/C system and where you are in
the service process:
6-13050
The dye, which dissolves into the SP-20 PAG oil in
the system , is particularly helpful in detecting
intermittent leaks that occur only when the system is
running because of change of temperature , high
system pressures, vibration or contact between
components.
WARNING: Wear safety goggles and non-
& permeable gloves when working with the
fluorescent dye and leak testing. M817
This fluorescent dye will normally remain useful over
the life of the system. However, due to a larg e
refrigerant leak, system flush or major component
failure, it may become necessary to reintroduce the
dye into the refri gerant circuit.
1. Recovery Station Dye Injector Tool with a
System in a Vacuum
2. Recovery Station Dye Injector Tool with a
Charged System
3. Quick and Easy Dye Injector Tool with a
Charged System
4. Compressor Oil Port
5. SP-20 PAG Oil Return Bottle
Issued 3-03
 9020-37

Recovery Station Dye Injector Tool with a System in a Vacuum

The R134a dye injector tool is designed to be used
with the OEM1415 recycling station.
1. Disconnect the low pressure hose (blue) from the
1/2 inch Acme flare fitting on the rear of the
station. Connect the dye injector to the fitting.
2. Connect the low pressure hose to the dye
injector.
NOTE: The dye injector can be permanently
mounted on the recycling station with the two
threaded holes on the bottom of the reservoir.
3. Open the valves on either side of the reservoir on Valves Shown in OPEN Position
the dye injector.
1. VALVE TOWARD 3. VALVE ,OWARD
4. Recover and recycle the refrigerant from the AlC RECYCLING STATION TRACTOR
2. RESERVOIR CAP 4. RESERVOIR
system and evacuate the system.
5. With the system in a vacuum, close the valves on
either side of the reservoir on the dye injector.
6. Remove the cap from the reservoir and fill the
reservoir with the contents of one bottle of
fluorescent dye. Reinstall the cap on the
reservoir and tighten securely.
7. Open the valve on tractor side of the reservoir on
the dye injector.
8. Recharge the AlC system with the proper
amount of refrigerant. Start the recharging
process and immediately open the valve on the
station side of the dye injector to prevent drawing
the dye into the charging station. The dye will be
injected into the system while recharging.
9. Install the dye identification sticker on a clearly
visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.
10. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.
NOTE: The operating time needed for the dye to
penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

11. After repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

6-13050 Issued 3-03

9020-38

Recovery Station Dye Injector Tool with a Charged System

The R134a dye injector tool is designed to be used .r--....:..--- - -- - - - - - - - -
with the OEM1415 recycling station.

1. Disconnect the low pressure hose (blue) from the

1/2 inch Acme flare fitting on the rear of the
station.

2. Connect the dye injector to the fitting.

3. Connect the low pressure hose to the dye

injector.

NOTE: The dye injector can be permanently Valves Shown in OPEN Position
mounted on the recycling station with the two
1. VALVE TOWARD 3. VALVE TOWARD
threaded holes on the bottom of the reservoir. RECYCLING STATION TRACTOR
2. RESERVOIR CAP 4. RESERVOIR
4. Open the valves on either side of the reservoir on
the dye injector.

5. Recover 0.5 Ib (0.23 kg) of refrigerant from the

system . This amount of refrigerant will act as a
carrier to inject the dye.

6. Close the valve on the tractor side of the dye

injector and continue to recove r. This will draw
the refrige rant out of the reservoi r on the dye
injector.

7. Close the valve on the station side of the dye

injector and stop recovering.

8. Remove the cap from the reservoir and fill the

reservoir with the contents of one bottle of
fluorescent dye . Reinstall the cap on the
reservoir and tighten secu rely.

9. Open the valve on tractor side of the reservoir on

the dye injector.

10. Recharge the AlC system with the proper

amount of refrigerant removed earlier· 0.5 Ib
(0.23 kg) . Start the rechargi ng process and
immediately open the valve on the station side of
the dye injector to prevent drawing the dye into
the charging station. The dye will be injected into
the system while recharging.

11. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

6-13050 Issued 3·03

 9020-39

12. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak wi II
be shown by a bright yellowl green glow of the
dye.
13. After repairing the system, use fluorescent dye
cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

NOTE: The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

Quick and Easy Dye Injector Tool with a Charged System

The quick and easy R134a dye injector tool is
designed to insert the dye in a charged system. The
dye injector tool has a quick coupler, for connecting
to the low pressure port of the tractor A/C system,
and a valve with T-handle on the other end.

1. Examine the threaded end of the valve to see if

the point of the valve stem is flush with the
rubber washer. If not, turn the T-handle until the
point is flush.

2. Screw the Quick and Easy can and the valve

together until the can seats on the rubber
washer. ROO1 F247
1. QUICK COUPLER 3. T-HANDLE
NOTE: Do not turn the T-handle at this time to tap 2. VALVE 4. SUPPLY CAN
the can.

3. Connect the quick coupler to the low pressu re

service port under the instructional seat in the
cab.

4. To purge air from the hose, slowly unscrew the

untapped can a half turn or more. Allow
refrigerant from the AlC system to force the air
out of the hose, and then retighten the can on the
valve.

5. Turn the T-handle clockwise to tap the can.

6. Hold the can upside down to allow the can

contents to enter the A / C system. When
complete, turn the T-handle counterclockwise to
close the valve. Disconnect the tool from the low
pressure port.

NOTE: You may have to operate the tractor and the

Ale system for a few minutes to completely empty
the can.

6-13050 Issued 3-03

9020-40

7. Install the dye identification sticker on a clearly
visible area on the compressor body close to the
service port. This will alert service personnel in
the future to the presence of the dye in the
system.
B. Operate the AlC system for about 15 minutes to
circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/ green glow of the
dye.
NOTE: The operating time needed for the dye to
penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.
9. After repairing the system, use fluorescent dye
cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

Compressor Oil Port

1. Recover the refrigerant from the AlC system.

2. Remove the oil filler plug and pour the contents

of one bottle of fluorescent dye into the
compressor.

3. Check the O-ring on the oil filler plug and replace

if necessary. Reinstall the oil plug on the
compressor and torque to 11 to 1B Ib It (15 to 24
Nm).

4. Evacuate and recharge the AlC system with the

proper amount of refrigerant.

5. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

6. Operate the AlC system for about 15 minutes to

circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.

NOTE: The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very small leak could take hours or days
of system operation to appear.

7. Alter repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

6-13050 Issued 3-03

 9020·41

SP-20 PAG Oil Return Bottle

NOTE: This is the least preferred method for

injecting the dye since it requires very careful
measurement of the PAG oil in the bottle and risks
the introduction of air into the system if the dip tube in
the bottle is exposed.

1. Recover the refrigerant from the AlC system.

2. Carefully measure the amount of SP·20 PAG oil

in the reservoir which was separated from the
refrigerant.

3. Pour the new replacement oil rnto the oil return

bailie plus some additional oil to prevent
uncovering the dip tube.

4. Pour the contents of one bottle of fluorescent dye

into the oil return bottle and seal the bottle.

5. Evacuate the system and inject the oil and dye

mixture into the system, making sure the oil level
in the oil return bailie does not drop below the
dip tube.

6. Recharge the AlC system with the proper

amount of refrigerant.

7. Install the dye identification sticker on a clearly

visible area on the compressor body close to the
service ports. This will alert service personnel in
the future to the presence of the dye in the
system.

8. Operate the AlC system for about 15 minutes to

circulate the dye throughout the system. Turn off
the system and use the UV lamp and goggles to
locate leaks. The exact location of the leak will
be shown by a bright yellow/green glow of the
dye.

NOTE: The operating time needed for the dye to

penetrate a leak and show will depend on the size of
the leak. A very sma/lleak could take hours or days
of system operation to appear.

9. After repairing the system, use fluorescent dye

cleaner to remove any traces of dye from around
the leak location to avoid false diagnosis in the
future.

6·13050 Issued 3-03

9020-42

Fluorescent Leak Testing

To perform UV fluorescent leak testing:
1. Operate the tractor long enough to circulate the
refrigerant and produce normal system
pressures.
2. Shut the tractor and system off when leak
testing.
3. Always wear fluorescent enhanced safety
glasses when leak testing.
4. Attach the lamp to a fully charged 12V battery or
RROOF098
an alternate 12V power supply for best lamp
performance.
S. Shine the high intensity ultraviolet light at the
various Ale components, hoses and lines to
search for a glowing fluorescent trail or puddle
which identifies the leak location.
6. The ultraviolet lamp is intended for intermittent
use only. The lamp has a momentary contact
push button switch to briefly light suspected leak
locations.
7. Do not work with the lamp ON for more than 5
minutes. If the lamp heats up uncomfortably,
cease operation.
8. Do not expose eyes or skin to ultraviolet light. Do
not stare into an ultraviolet light beam or operate
the lamp without the ultraviolet lens filter in place.
9. In direct sun sunlight or very bright ambient light,
use a cover of any type over the suspected area
to reduce this light.
10. If the lamp cannot be directed straight at a
suspected leak location, use a mechanics mirror
to reflect the light at the location. Or wipe the
suspected leak site with a clean shop cloth , and
shine the lamp at the cloth to check for traces of
fluorescent dye.
11 . The exact location of a small leak at a connection
point or sealing point can be further narrowed by
daubing a wet film of soap solution over the
suspected area. Watch for bubbles to confirm the
exact point of leakage.
12 . Repair all leaks and recharge the system.
13. Use fluorescent dye cleaner to remove any
traces of dye from around the leak location to
avoid false diagnosis in the future.

6- 13050 Issued 3-03


AlC SYSTEM FLUSHING PROCEDURE
When flushing is necessary, all effected components
should be flushed to eliminate the possibility of
contaminants remaining in the system.
There are two methods of AI C system flushing:
individual component flushing and complete
circuit flushing. The complete circuit is the system
minus the compressor, receiver-drier and thermal
expansion valve. The compressor, receiver-drier and
thermal expansion valve are always bypassed
(removed) during circuit flushing and serviced
individually. The receiver-drier is always replaced
anytime a system is flushed . The expansion valve,
due to its small orifices, is removed from the system
and cleaned (or replaced). The compressor is either
replaced or reused, but is NEVER flushed .
The preferred method of system flushing is individual
component flushing. Given the size of Case IH
equipment and the distance between components,
individual component flushing will dislodge and flush
out more contamination than complete circuit
flushing. Which individual components are flushed
will depend on the source of the contamination and is
left to the discretion of the technician .
For "mildly' contaminated systems, complete circuit
flushing may be used, where the contamination is
oxidized refrigerant oil or small amounts of receiver-
drier desiccant . Complete circuit flushing requires
little system disassembly, minimal special
connectors and the least amount of service time.
The most likely sources of contamination are
compressor failure and receiver-drier failure.
Compressor Failure
A failed compressor generally sends debris
downstream to the condenser, the receiver-drier and
towards the thermal expansion valve. If the
compressor fails internally, it must be replaced. Also
individual flushing of the hose between the
compressor and condenser, of the hose between the
condenser and receiver-drier, of the condenser itself
and replacing the receiver-drier are appropriate
service actions for compressor failure.
For most Case IH condensers with a single flow path,
flushing effectively removes debris. For condensers
with parallel flow paths, since flushing takes the path
of least resistance around any blockage, condenser
replacement may be the only option.
6-13050
9020-43
The receiver-drier has a fine mesh screen to capture
contaminants, but the contaminants may penetrated
the screen. Check the discharge port of the receiver-
drier to see if contaminants have penetrated the
screen. If so, individual flushing of the hose between
the receiver-drier and the expansion valve and
cleaning the thermal expansion valve are
appropriate . If the thermal expansion valve is
damaged, replace it as well.
Additional flushing of the system beyond the thermal
expansion valve is at the discretion of the service
technician who can best judge how far the
contamination has traveled .
Receiver-Drier Failure
Receiver-driers should not normally fail if replaced:
A. when system has been opened before.
B. when receiver-drier has been in service two or
more years.
C. when the system has been open for a long
period of time because of a leak (broken
hoses, loose connection) that has permitted air
and moisture to enter the system.
D. when contaminated refrigerant was recovered
from the system.
However, if the desiccant pouch is punctured by a
debris from a failed compressor or fails from age,
desiccant particles may flow downstream toward the
thermal expansion valve and the evaporator. An
indicator of receiver-drier failure is soft golden-brown
particles found at its outlet. The thermal expansion
valve should always be checked after receiver-drier
failure.
If the receiver-drier fails, it must be replaced . Also
individual flushing of the liquid hose between the
receiver-drier and the thermal expansion valve and
cleaning the valve are appropriate.
Check the suction line from the valve to the
compressor and the compressor suction port. If
golden brown particles is found, flush the evaporator
and suction line individually. The compressor may be
reused AFTER all contaminants are removed:
1. Use the dipstick to measure the compressor oil
level.
2. Drain and refill the compressor with PAG oil until
the drained oil is free of particles.
Issued 3-03
 .. --------------~

9020-44

3. Rotate the compressor clockwise to check for
binding caused by the presence of particles.
4 . Drain or add PAG to return the compressor to
measured dipstick level.
Additional system flushing is at the discretion of the
service technician who can best judge how far the
contamination has traveled and what components
may have been damaged and require replacement.

IMPORTANT: Flushing solvent CANNOT be used to

remove compressor contaminants.

Required Tools
The following tools are required when flushing an AlC system or components:

• Power Flush 17550

• Flush Gun Kit 17585

• Case IH AlC Flushing Solvent, one case of six one

gallon containers, BS33801

• Dry shop air source, use filter below or equivalent:

Coalescing air filter/dryer (Ingersoll-Rand IR5CHE or
(- /
Grainger 4KR65). Desiccant-type air driers should
not be used.

• Adapters to connect flush unit to the various AlC

system components. These adapters can be
purchased in kit form or built in the shop. "RAOOF093
Power Flush 17550
• Clear Plastic Reinforced Hose to connect the tank
to various components and small lengths for
bypassing components like the receiver-drier or
thermal expansion valve.

See SPECIAL TOOLS, page 4 in this Section.

Optional tools include:

• Pressure regulator to control flow to the flush unit;

regulator must be capable of delivering 45-90 psi
(310-620 kPa) at 4.0 cfm (310 kPa at 0.11 cmm). Do
not exceed 90 psi (620 kPa).

• Pressure indicator gauge (which may be

integrated into the pressure regulator)

6- 13050 Issued 3-03


Precautions
WARNING: 00 NOT use solvent containing
alcohol, lacquer thinner, brake cleaner or
A other non-approved solvents. Use only Case
ill IH approved flushing solvent. Other flushing
agents or solvents may damage AlC system
components. M815
Case IH AlC flushing solvent is a hazardous material.
Read all warnings on the flushing solvent container
prior to use and observe these safety precautions:
1. The flushing solvent is combustible. Avoid heat,
sparks and open flame.
2. Use only in a well ventilated area. Mechanical
exhaust and an appropriate respirator may be
needed in warm and confined areas to protect
your safety.
3. Avoid breathing mist and vapor.
4. Wear chemical splash safety goggles.
5. Wear rubber gloves and a rubber apron when
handling the solvent or flushing components.
6. Observe all local, state and federal regulations
regarding the safe disposal of used flushing
solvent. M802
6-13050
9020-45
The goal of flushing is to remove contaminants from
the AIC system . Your shop air must be properly
filtered and dried with coalescing filter, or you will
simply replace one source of contamination with
another using dirty, moisture saturated air.
The compressor, receiver-drier and thermal
expansion valve must be bypassed (removed) when
performing circuit flushing. The compressor and
receiver-drier may never be flushed; the thermal
expansion valve can be back flushed.
Keep the lid on the flushing recovery bucket closed
when flushing to minimize the circulation of solvent
vapors.
Never allow the flushing solvent to remain in or on
the hoses for an extended period of time.
Overexposure of the hoses to the solvent, especially
the ex1erior, may cause hose swelling.
Do not open the fill cap on the flush reservoir when
the reservoir is under pressure. Release pressure
before removing cap.
Issued 3·03
9020-46

Component Flushing Procedure with Power Flush 17550

STEP 52
All refrigerant must be recovered from the system
before flushing.

STEP 53
The 17550 power flush unit uses shop air to atomize
the flushing solvent and a pulsing action to scrub
residue and contaminants out of components.
Attach flushing adapters to the component to be
flushed . These adapters can be shop built or a
universal AlC flushing fitting set is available - Model
17582.

RPOOG013
Evaporator and Universal Fittings Shown

STEP 54
Fill the flushing reservoir 3/4 full with approved Case
IH flushing solvent. Do not overfill the reservoir or
you will restrict the pu lsing action of the unit.

STEP 55
Close the air and the flushing valves.

1. AIR VALVE 2 . FLUSH VALVE

6-13050 Issued 3·03

 9020-47

STEP 56
Remove the flushing tank hose quick coupler from
the evaporation plug.

STEP 57
Connect the flushing tank hose quick coupler to an
extension or an adapter hose.

STEP 58
Connect CLEAN and DRY shop air supp ly to the
quick coupler on the flushing valve.

6·13050 Issued 3-03

9020-48

STEP 59
Connect flushing and drain hoses to flushing
adapters on component being flushed so the flushing
solvent moves in the opposite direction of refrigerant
flow - back flushing . Reinforced clear hose is
preferred to monitor the condition and removal of the
used solvent.

IMPORTANT: Secure the lid on the return bucket so

all flush vapors pass through the bucket filter.

NOTE: Back flushing is done first to dislodge any

contaminants, and then forward flushing is performed
to remove the contaminants. 1. FROM THE FLUSH PUMP 2 . TO THE RETURN
BUCKET

STEP 60
Open the air valve 1/2 to 3/4 turn.

IMPORTANT: Do not exceed this rate of air delivery.

This rate delivers one gallon per minute of flush
solvent which is ideal for the orifice openings on the
components being flushed.
Turn the flushing valve to the FLUSH position and
flush the component for 30 seconds.

1. AIR VALVE 2 . FLUSH VALVE

STEP 61
Close the flushing and air valves. Reverse hose
connections for forward flushing. Open flushing and
air valves and repeat flushing until the solvent is
clear.

1. FROM THE FLUSH PUMP 2 . TO THE RETURN

BUCKET

6-13050 Issued 3-03

 9020-49

STEP 62
Turn the flushing valve to the AIR position. Allow air
to flow through the component until no noticeable
mist is discharged.

NOTE: Air pressure is the only means to remove the

flushing solvent from the Ale system, and no solvent
must remain in the system when it is evacuated and
recharged. Turn the component so gravity can assist
in solvent removal.

STEP 63
Turn the flushing valve to the CLOSED position .
Disconnect the flushing and drain hoses and
adapters from the component.

STEP 64
Install the flushing tank hose quick coupler on the
evaporation plug to prevent evaporation of the
solvent remaining in the tank during storage.
See Post Flushing Procedures, page 57.

6-13050 Issued 3-03

9020-50

Complete Circuit Flushing Procedure with Power Flush 17550

STEP 65
All refrigerant must be recovered from the system
before flushing.

STEP 66
The 17550 power flush unit uses shop air to atomize
the flushing solvent and a pulsing action to scrub
residue and contaminants out of components.
Fill the flushing reservoir 3/4 full with approved Case
IH flushing solvent. Do not overfill the reservoir or
you will restrict the pulsing action of the unit.

STEP 67
Remove the receiver-drier and join the hoses
together with an adapter hose. Discard the receiver-
drier.

Al00G02

STEP 68

~o
Remove the thermal expansion valve and use
adapters to connect the hose lines to the evaporator.

Al00G018

6-1 3050 Issued 3-03

 9020·51

STEP 69
Disconnect the suction and discharge lines from the
compressor. Attach flushing adapters to the lines.

Universal Ale Flush Fittings Shown RH01 F112

STEP 70
Close the air and the flushing valves.

1. AIR VALVE 2. FLUSH VALVE

STEP 71
Remove the flushing tank hose quick coupler from
the evaporation plug.

6·13050 Issued 3-03

 9020-52

STEP 72
Connect the flushing tank hose quick coupler to an
extension or adapter hose.

STEP 73
Connect CLEAN and DRY shop air supply to the
quick coupler on the flushing valve.

STEP 74
Connect flushing and drain hoses to adapters on
compressor lines so flushing solvent moves in the
opposite direction of refrigerant flow - back flushing.
Connect the hose from the flush tank to the suction
line; connect the hose to the return bucket to the
discharge line. Reinforced clear hose is preferred to
monitor the condition and removal of the used
solvent.

NOTE: Back flushing is done first to dislodge any

contaminants, and then forward flushing is performed
to remove the contaminants.

I NOTE: The suction and discharge ports on the

compressor are marked with the letters Sand D,
respectively.

IMPORTANT: Secure the lid on the return bucket so

all flush vapors pass through the bucket filter.

AH01F112
1. FROM THE FLUSH TANK 2. TO RETURN BUCKET

6-13050 Issued 3-03

 9020-53

STEP 75
Open the air valve 1/2 to 3/4 turn .

IMPORTANT: Do not exceed this rate of air delivery.

This rate delivers one gallon per minute of flush
solvent which is ideal for the orifice openings in the
circuit being flushed.
Turn the flushing valve to the FLUSH position and
flush the circuit until the solvent appears clear at the
return hose to the solvent waste container.

1. AIR VALVE 2. FLUSH VALVE

STEP 76
Close the flushing and air valves. Reverse hose
connections for forward flushing . Connect the hose
from the flush tank to the discharge line; connect the
hose to the return bucket to the suction line. Open
flushing and air valves and repeat flushing until the
solvent is clear.

1. FROM THE FLUSH TANK 2. TO RETURN BUCKET

STEP 77
Turn the flushing valve to the AIR position. Allow air
to flow through the circuit until no noticeable mist is
discharged.

NOTE: Air pressure is the only means to remove the

flushing solvent from the Ale system, and no solvent
must remain in the system when it is evacuated and
recharged.

6·13050 Issued 3-03

 9020-54

STEP 78
Turn the flushing valve to the CLOSED position.
Disconnect the flushing and drain hoses and
adapters from the compressor lines.
Install the flushing tank hose quick coupler on the
evaporation plug to prevent evaporation of the
solvent remaining in the tank during storage.
See Post Flushing Procedures, page 57.

6- 13050
Issued 3-03
 9020-55

Back Flushing the Thermal Expansion Valve or Refrigerant Line

STEP 79
Flush gun 17585 can be used to back flush the
thermal expansion valve or a refrigerant line. Solvent
is added to the canister, and then the canister is
pressurized with CLEAN and DRY shop air. Pulse
the trigger on the flush gun for greater flushing
effectiveness.

STEP 80
To fill the canister, remove the cap assembly. Add no
more than 20 oz. (590 ml) of Case IH flushing solvent
to the canister. Replace the cap assembly.

STEP 81
Pressurize the canister to a maximum of 90 psi (620
kPa) with CLEAN and DRY shop air.

6-13050 Issued 3-03

 9020-56

STEP 82
Connect the hose with flush gun to the canister.

RPOOG010

STEP 83
NOTE: To prevent sprayback, press the rubber nose
cone on the gun into the opening on the refrigerant
line or thermal expansion valve when flushing.
When back flushing the thermal expansion valve, the
suction and discharge ports must be flushed in
different directions. Collect used solvent in a
container for proper disposal.

STEP 84
Use CLEAN and DRY shop air to purge the solvent
and dry the valve.
Back flush the discharge port

APOOG012
Back flush the suction port

I 6-13050 Issued 3-03

 9020-57

Post Flushing Procedures

STEP 85
Identify and remove the source of the contamination.

STEP 86
Reconnect all fittings using new HNBR "green"
HFC-134a compatible a-rings. Lubricate the a-rings
with mineral oil prior to installation.

STEP 87
Install a new receiver-drier.

NOTE: The receiver-drier should be replaced just

before the system is drawn to a deep vacuum to
avoid saturating it with moisture.

STEP 88
Clean or replace the thermal expansion valve.

RPOOG011

6-13050 Issued 3-03

9020-58

STEP 89
Install a new compressor if required.

STEP 90
Adjust the level of SP-20 PAG oil in the system.
When each component was flushed, some SP-20
PAG oil was removed from the system. Use the
following guidelines when adjusting PAG oil:
If the compressor is to be replaced and the entire
system was flushed, the new compressor will contain
all the SP-20 PAG oil needed and no further
adjustment is required.
If the compressor is not to be replaced and the entire
system was flushed, drain the oil from the
compressor to remove any remaining contaminants.
Add back to the compressor one container, 8.5 oz
(250 ml), of new SP-20 PAG oil. (Some oil, about 1.2
oz (35 ml), will remain in the compressor even after it
has been drained.)
If the entire system was not flushed, drain the oil from
the compressor to be installed. Add back new SP-20
PAG oil equal to 8.5 oz (250 ml) minus oil amounts
still in the components that were not flushed. Use the
table below.

NOTE: Total system PAG oil should be 9.6 oz (285

ml) and about 1.2 oz (35 ml) will remain in a drained
compressor.

Amount Of SP-20
Component Flushed
PAG Oil To Add
Condenser 1.7 oz (50 ml)
Evaporator 1.4 oz (40 ml)
Receiver-Drier 0.85 oz (25 ml)
Each Hose 0.34 oz (10 ml)

Because the system has been open for a prolonged

time, it is very important to draw the system to a deep
vacuum to remove all moisture. Evacuate the system
for at least 45 minutes to a vacuum of 29.5 inches
(0.75 mm) of mercury.

6-13050 Issued 3·03

 9020-59

Final System Oil Check

After the system has been drawn to a deep vacuum 3. Recover refrigerant from the system. Use the
and recharged, dipstick method to check the PAG oil level in the
compressor. If needed, adjust the oil level. See
1. Operate the AlC system for 15 minutes to
Dipstick Method , page 81 . For MX 210, 230,
thoroughly circulate the PAG oil throughout the
255 and 285 tractors , the oil should cover five
system.
lines on the dipstick.
2. Install the gauge set and test the AlC system for
4. Evacuate and recharge the system.
proper operation referring to the pressure/
temperature table on Page 33.

IMPORTANT : If oil level was measured and

adjusted properly according to the guidelines, Steps
3 and 4 are unnecessary.

Flushing Solvent Disposal

Never reuse contaminated flushi ng solvent. In the United States, SAFETY-KLEEN will recycle
used flushing solvent. For more information o n
Good stewardship of our natural resources is SAFETY-KLEEN's recycling program , call 800-323-
everyone's business. Case IH flushing solvent is a 5040 .
hazardous material. Never dispose of this solvent by
pouring it down the drain or treating it as water
soluble waste. Observe all local, state and federal
regulations when disposing the solvent.

6-13050 Issued 3-03

9020-60

AlC SYSTEM COMPONENTS

Cab HVAC Box Components - Automatic Temperature Control

1. ATC CONTROLLER
2. BLOWER MOTORIFAN ASSEMBLY
3. HEATER CONTROL VALVE
4. BLOWER SPEED DRIVER
5. COMPRESSOR CLUTCH RELAY
6. CAB TEMPERATURE SENSOR
7. EVAPORATOR TEMPERATURE SENSOR
8. THERMAL EXPANSION VALVE
9. LOW PRESSURE SWITCH
10. EVAPORATORIHEATER ASSEMBLY

Rae 6-13050 Issued 3-03

 9020-61

Cab HVAC Box Components - Automatic Temperature Control

1. LID ASSEMBLY
!
• 2. CONTROLLER MOUNTING PLATE
3. ATC CONTROLLER
•-;.-----{ 1 4. BLOWER SPEED DRIVER
5. BLOWER DRIVER MOUNTING PLATE
6. BLOWER/MOTOR ASSEMBLY
7. LOW PRESSURE SWITCH
2 8. THERMAL EXPANSION VALVE
9. AlC SUCTION LINE TUBE
10. AlC LIQUID LINE TUBE
11. HEATER MOTORNALVE ASSEMBLY
12. HEATER SUPPLY TUBE
13. HEATER RETURN TUBE
14. EVAPORATOR/HEATER ASSEMBLY
15. EVAPORATOR TEMPERATURE SENSOR
16. CAB TEMPERATURE SENSOR
17. COMPRESSOR CLUTCH RELAY
18. HVAC GROUND STUD
19. CONDENSATE DRAIN HOSE
20. CHECK VALVE
21. EVAPORATOR BOX ASSEMBLY

16

RI03B049

Rae 6-13050 Issued 3-03

9020-62

Cab HVAC Components - Standard Systems

1. STANDARD CONTROLLER
2. COMPRESSOR CLUTCH RELAY
3. EVAPORATOR/HEATER ASSEMBLY
4. EVAPORATOR TEMPERATURE SENSOR
5. HVAC BOX GROUND
6. HEATER CONTROL VALVE
7. THERMAL EXPANSION VALVE
B. LOW PRESSURE SWITCH
9. BLOWER MOTOR ASSY WITH RESISTORS

Rae &-13050 Issued 3-03

 9020-63

Cab HVAC Components - Standard Systems

RI99M043

1. LID ASSEMBLY 6. LOW PRESSURE SWITCH 13. EVAPORATOR TEMP SENSOR

2. STANDARD AlC CONTROLLER 7. HEATERIEVAPORATOR COIL ASSY 14. BASE WELDMENT
3. BLOWER ASSEMBLY B. HEATER CONTROL VALVE ASSY 15. EVAPORATOR BOX ASSEMBLY
4. RESISTOR ASSEMBLY 9. AlC SUCTION LINE TUBE 16. THERMAL EXPANSION VALVE
A. RESISTOR 10. AlC LIQUID LINE TUBE 17. CLUTCH RELAY
B. MOUNTING BRACKET 11 . HEATER SUPPLY HOSE 1B. DRAIN HOSE
5. WIRE HARNESS (NOT SHOWN) 12. HEATER RETURN HOSE 19. CHECK VALVE

Rae 6-13050 Issued 3-03

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5.
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7.
RECEIVER·DRIER
HEATER SUPPLY LINE
HEATER RETURN LINE
9.
10.
11 .
COMPRESSOR (DISCHARGE LINE) TO CONDENSER HOSE
CONDENSER TO RECEIVER-DRIER HOSE
RECEIVER-DRIER TO THE RMAL EXPANSION VALVE HOSE
i!. ~
8. SHUT-OFF VALVE
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4. CONDENSER 12. EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE

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~
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3. AlC HIGH PRESSURE SWITCH
4. CONDENSER
7. HEATER RETURN LINE
8. SHUT·OFF VALVE
11 . RECEIVER·DRIER TO THERMAL EXPANSION VALVE HOSE
12. EVAPORATOR TO COMPRESSOR (SUCTION LINE) HOSE ~,
i;J . LI______________________________________________________________________________________________________________________ ~ Ol
(}l
 9020-66

AlC COMPRESSOR CLUTCH

Clutch Removal
NOTE: This procedure shows a compresso r with six screws holding the dust cover on the clutch. Your
unit has three Torx'fP screws for attaching the dust cover and only differs in this manner.

STEP 91
See this section for compressor removal. Clean the
external surfaces of the compressor before doing
any work on the compressor.

A21250

STEP 92
Remove the three Torx® screws for the cl utch dust
cover.

STEP 93
Remove the clutch dust cover.

A21252

I 6-13050 Issued 3-03

 9020-67

STEP 94
Remove the retaining nut for the front plate. Use the
special spanner wrench from the service tool set to
keep the plate and shaft from turning.

A2 1253

STEP 95
Install the special puller from the service tool set on
the clutch front plate.

STEP 96
Turn the center screw to pull the clutch front plate.

6-13050 Issued 3-03

 9020-68

STEP 97
Remove the shim(s) from the shaft.

A21256

STEP 98
Carefully remove the dust cover.

STEP 99
Remove the key from the rotor shaft.

A21258

6-13050 Issued 3-03

 9020-69

STEP 100
Remove the external snap ring for the bearing and
pulley assembly.

A21260

STEP 101
Install the special puller internal collars into the
groove in the pulley. Install the special tool onto the
shaft. Tighten the mounting screws finger tight.

A21261

STEP 102
Turn the center screw on the puller.

A21262

6·13050
 9020-70

STEP 103
Remove the pulley and bearing assembly.

A21263

STEP 104
Remove the snap ring for the clutch coil assembly.

STEP 105
Disconnect the clip for the lead wire.

A21 264

I 6-13050 Issued 3-03

 9020-71

STEP 106
Remove the clutch coil assembly.

STEP 107
Remove the internal snap ring and remove the
bearing from the pulley.

A21 267

6-13050 Issued 3-03

 9020-72

Exploded View of Clutch

10161..9
1. COIL ASSEMBLY 4 . BEARING DUST COVER 7. DUST COVER
2. PULLEY 5. FRONT PLATE 8. COMPRESSOR
3. BEARING 6. SHIM(S)

Compressor Clutch Replacement

STEP 108
Method 1: Use a ammeter, voltmeter and a 12 volt
battery to check the amperage of the clutch coil. The
current draw must be 3.6 to 4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short
within the coil.
No amperage reading indicates an open circuit in the 1
coil.
Replace the clutch coil if the amperage reading is not
correct.
OR
102L7

Method 2: Measure resistance. Resistance must be 1. AMMETER 2. 12V BATTERY

2.86 to 3.3 ohms. Replace the clutch coil if the
resistance reading is not correct.

I 6-13050 Issued 3-03

 9020-73

STEP 109
Install a new clutch coil assembly. Align the coil so
the lead wire is next to the clip mounting hole.

"''''
STEP 110
Install the clip for the coil lead wire.

A21",

STEP 111
Install the snap ring for the clutch coil assembly.

6-13050 Issued 3-03

 9020-74

STEP 112
Install the bearing in the pulley and install the internal
snap ring.

A21267

STEP 113
Put the pulley and bearing assembly on the front
housing hub. Install a driver on the pulley assembly.
Make sure that the tool is on the inner race of the
bearing.

RA99D245

STEP 114
Support the compressor on the four mounting ears at
the compressor rear. Press the pulley assembly on
the front housing hUb. Make sure the bearing is
against the bottom of the hub.

RA990245

6-13050 Issued 3·03

 9020-75

STEP 115
Install the external snap ring on the front housing
hub.

A21260

STEP 116
Install the key in the rotor shaft.

STEP 117
Place the bearing dust cover in the bore. Place driver
from special tool kit over the dust cover.

.4.21269

6-13050 Issued 3-03

 9020-76

STEP 118
Install the dust cover.

A21270

STEP 119
Install the shim(s) on the rotor shaft.

STEP 120
Install the front plate on the rotor shaft . Make sure
the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.

A21271

6-13050
Issued 3-03
 9020-77

STEP 121
Use a hammer to tap the plate onto the shaft. Make
su re the plate is against the clutch shims. As the
plate is tapped onto the shaft you can hear the
difference in sound when the plate is fully installed.

A2 1272

STEP 122
Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to a
torque of 11 to 15 Ib ft (15 to 20 Nm).

A21253

6-13050 Issued 3-03

9020-78

STEP 123
Two methods can be used to measure and adjust the
air gap between the clutch plate and pulley:

Magnetic Dial - Mount a magnetic base dial indicator

on the outer face of the pulley so that there is no
interference with the clutch plate. Apply battery
ground to compressor body and 12V B+ to clutch
wire lead. Position the dial indicator pointer on the
flat surface on the outer diameter of the clutch plate
midway between any two outer rivets or on one of the
outer rivet heads. Clutch plate travel should measure
from 0 .016 to 0.031 inch (0.41 to 0.79 mm). This
measurement should be taken between each of the
three rivets or on each outer rivet head to get an
average measurement. If necessary, lightly lift or
push down on plate to even the gap.

Spark Plug Gauge - If a dial indicator is not available

to check air gap clearance, a spark plug gauge with
90° wire feelers may be used to check initial air gap
in the field. Slip the wire between the clutch plate and
the pulley and check the gap at the three rivets. The
gap must be 0.016 to 0.031 inch (0.41 to 0.79 mm).
The gap must be even all the way around the plate. If
necessary, lightly lift or push down on the plate to
make the gap even.

NOTE: If the gap does not meet the above

specifications remove the front plate and add or
subtract clutch shims as required. •

STEP 124
Install the clutch dust cover.

A21 252

6-13050 Issued 3-03

 9020-79

STEP 125
Install and tighten the three Torx® screws that attach
the dust cover to the compressor clutch. Torque to 5
to 8 Ib It (7 to 11 Nm).

A21251

6-13050
9020-80

AlC COMPRESSOR

Oil Level Check or Adjustment

Since the refrigerant is recovered as a gas, during a During normal servicing - recovery, evacuation and
typical recovery only about 25% of the oil in the recharge, oil is simply injected back into the system
vehicle's AIC system is recovered and separated. du ring the recharge proces s. Use the dipsti ck
The other 75% remains in the closed system method to check the compressor oil level or to adjust
normally on the low pressure side . (These oil level when any of the following occurred:
percentages are representative and will vary from
A. Broken refrigerant hose.
recovery unit manufacturer to manufacturer.) The
only reliable method for determining if the AIC B. Large refrigerant leak.
system has the correct amount of oil is the dipstick
C. Compressor leak.
method.
D. Damage to or replaced system components.
Too much oil in the closed system causes poor
E. New compressor installed.
condensatio n and reduced cooling since the oil
accumulates on the evaporator and condenser
IMPORTANT: If a new compressor is to be installed,
surfaces. Too little oil in the system causes poor
its oil level must be adjusted to match the oil volume
lubr ication which equates to poor refrigerant
of the removed compressor.
circulation and reduced compressor efficiency and
high pressures. Both conditions cause more system
NOTE: SP-20 PAG oil must be added whenever
wear and shorter system life.
a component is replaced.
These conditions are not self-correcting.

Injection Method

STEP 126
OEM1415 has an injection system to return new SP-
20 PAG oil equal to the amount recovered at the end
of the evacuation process.
To add the new oil, adjust the O-ring around the oil
return bottle to the required oil charge level.

NOTE: If 2.4 oz (71 ml) was recovered in the oil

reservoir, 2.4 oz (71 ml) of new SP-20 PAG must be
returned.
Open the oil injection valve to add the oil into the
system . Close the valve when the oil level reaches
the O-ring. 1. OIL RETURN BODLE 2. OIL INJECTION VALVE

IMPORTANT: Do not let oil level fall below the dip

tube in the return bottle or air will be introduced into
the refrigerant circuit.

6-13050 Issued 3-03

 9020-81

Dipstick Method

STEP 127
When all refrigerant has been recovered, remove the
oil filler plug.

STEP 128
Use a Torx® socket to remove the three screws, and
remove the dust cover from the clutch. Use a wrench
to rotate the compressor shaft clockwise until the
internal parts are in a position to allow dipstick
insertion.
ALTERNATE METHOD: Use a jumper wire to supply
12V B+ to the compressor clutch and rotate by hand.

STEP 129
Put the dipstick in the oil filler hole to the stop
position. Make sure the dipstick is inserted all the
way to the stop. The dipstick stop should be flush
with the filler hole boss.
Take several readings for accuracy. For all MX 210,
230, 255 and 285 tractors, the oil level shou Id
cover five lines on the dipstick.

NOTE: The illustration shows a front view of the

compressor with the dust cover removed and the
proper positions of the counterweight for insertion of
the dipstick. RB99N057

IMPORTANT: When compressor is replaced, the

old compressor oil should be drained and the oil
volume measured. This amount of new oil should be
put into the replacement compressor after it has
been drained. Or use the dipstick to measure and
match the replacement compressor oil level to the
old compressor oil level.

6-13050 Issued 3-03

 9020-82

STEP 130
If the oil level is not correct, add or subtract oil to the
correct level described above. Always add oil in small
quantities to avoid overfilling; to subtract oil the
compressor must be removed and drained.

IMPORTANT: Use only SP-20 PAG oil.

STEP 131
Check O-ring on the oil filler plug and replace if
necessary. Install the plug and tighten to a torque of
11 to 181b It (15 to 24 Nm).

6-13050
Issued 3-03
 9020-83

Compressor Removal
STEP 132
Open the hood and remove the right hand panel for
access to the fan drive belt.
Recover the refrigerant.

STEP 133
Use a 112 inch ratchet drive in the belt tensioner to
relieve pressure on the belt and remove the belt from
the compressor pulley.

STEP 134
Disconnect the compressor clutch wire above the
test ports on the suction and discharge lines.

6-13050
9020-84

STEP 135
Disconnect the high pressure switch at the
connector.

STEP 136
Disconnect the high pressure line from the discharge
port. Install protective caps on the open port and line.

STEP 137
Support the 90· fitting to the suction port , and
disconnect the low pressure line from the fitting.
Remove the 90· fitting from the suction port. Install
protective caps on the open ports and lines.

6-13050 Issued 3-03

 9020-85

STEP 138
Remove the three mounting bolts and remove the
compressor/clutch assembly from the tractor for
service or replacement.

NOTE: Note the location of the ring terminal ground

on the upper rear mounting bolt.

RD02H045

6-13050 Issued 3-03

9020-86

Compressor Installation
IMPORTANT: If a new compressor is to be installed, its oil level must be adjusted to match the removed
compressor. See Oil Level Check or Adjustment, page 80.

STEP 139
Install the compressor with the three bolts removed
earlier. Torque to 29 ± 4 It Ib (39 ± 4 Nm).

IMPORTANT: Install the ring terminal ground to the

upper rear bolt when installing the compressor.

STEP 140
Slowly remove the protective cap, and install the 90°
elbow in the suction port on the compressor.

NOTE: Use caution when removing the caps on a

new compressor; new compressors are pressurized
when shipped.

STEP 141
Install a new O-ring and connect the low pressure
line to the 90° elbow. Support the elbow with a
wrench when connecting the line.

NOTE: Lubricate the a-ring with mineral oil before

installation.

6-13050 Issued 3-03

 9020-87

STEP 142
Install a new O-ring and connect the high pressure
line to the discharge port on the compressor.

NOTE: Lubricate the O-ring with mineral oil before

installation.

STEP 143
Reconnect the high pressure switch at the connector.

STEP 144
Reconnect the clutch at the connector.

STEP 145
Use a 1/2 inch ratchet drive on the belt tensioner to
release tension and install the belt over the clutch
pulley.
Reinstall the right hand panel.

6·13050 Issued 3~ 03
9020-88

CONDENSER AND RECEIVER-DRIER

Condenser
STEP 146
Keep the condenser (and fuel cooler) fins clean and
straight to make sure that there is maximum air flow
though the condenser and radiator at all times. Use
compressed air or a soft brush to clean the
condenser. Also check and clean the grille screen
and radiator. Maximum air flow prevents engine
overheating and offers the most efficient A/C
operation .

IMPORTANT: Because the condenser fins bend

easily and are sharp, be careful when cleaning the
condenser.

STEP 147
Recover all refrigerant before replacing/servicing the
condenser/fuel cooler.
Use the two hand, two wrench method to disconnect
and reconnect the lines to the condenser.
Cap all A/C lines while the condenser/fuel cooler is
disconnected from the circuit.

&- 13050 Issued 3-03

 9020-89

STEP 148
Remove the two upper and lower bolts on each side
of the condenserlfuel cooler to replace the unit.

STEP 149
When installing a new condenser, also install new 0-
rings on the Al e lines before connecting . Lubricate
the O-rings with clean mineral oil prior to installation.
Use the two hand , two wrench method when
connecting the line from the compressor and to the
receiver-drier.

6-13050 Issued 3-03

 9020-90

Receiver-Drier
STEP 150
Replace the receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years.
C. Disassembly show small particles of moisture
removing material (gold or brown particles).
D. If the system has been open for a long period
of time because of a leak (broken hoses, loose
connection) that has permitted air and
moisture to enter the system.
E. If contaminated refrigerant was recovered from
the system.
The receiver-drier orientation is critical. Make sure
the outlet flange is within 5 degrees of true level (the
decal should face up).
The receiver-drier must be installed with the inlet
connected to the hose from the condenser and the
outlet connected to the hose going to the thermal
expansion valve.
The receiver-drier is normally the last item replaced
when servicing the system, just before the system is
evacuated. This prevents saturating the drier with
moisture.

STEP 151
Use the two hand , two wrench method to prevent
i damage to the tubes and fittings when you loosen or
tighten the tube connections.

6-13050 Issued 3-03

 9020-91

STEP 152
Always install new O-rings when the receiver-drier is
connected to the system. Lubricate the O-rings with
clean mineral oil prior to installation.

6-13050 Issued 3-03

9020-92

ACCESSING THE HVAC BOX

NOTE: The following procedure applies to both the standard and Automatic Temperature Controlled (ATC)
systems.

STEP 153
Disconnect the harness to the right hand control
console. .

STEP 154
For tractors equipped with mechanical remote
hydraulic controls, the right hand control console
must be disconnected from the seat:
A. Loosen the 13 mm nut at the front of the right
hand side of the seat.
B. Remove the 18 mm bolt at the right hand rear
of the seat and remove the console. The
console can be rested on the rear shelf or slid
out the rear window and rested on the three-
point hitch for better access to the HVAC box.

STEP 155
Tilt the steering wheel to the full upright position.
Adjust seat to the full upright and back position .

STEP 156
Remove the floor mat wrap (1) which surround the
seat base.

NOTE: If the return air filter covers are dislodged, be

sure to reinstall later.

STEP 157
Remove four bolts in the seat base corners.

6-13050 Issued 3-03

 9020-93

STEP 158
Disconnect the seat harness.

STEP 159
Hinge seat forward and rest on steering wheel for
access to the box.

ATC HVAC Box Shown

STEP 160
After completion of service:
A. Align ATC controller mounting plate, if
equipped, with mounting holes.
B. Return the seat to its operating position. Align
the seat and HVAC box mounting hole and
reinstall the four bolts removed earlier.
C. Reinstall the seat harness and floor mat wrap.
D. Reinstall right hand control console (if
applicable).
E. Reconnect right hand control harness.
F. Ensure cab recirculation air filter is properly
installed.

6-13050 Issued 3·03

9020-94

THERMAL EXPANSION VALVE TESTING

IMPORTANT: The following test is performed with the thermal expansion valve mounted in the system. No repair
or adjustment is recommended for the valve.

STEP 161
See ACCESSING THE HVAC BOX, page 92. Tilt the
controller mounting plate forward to access the
valve.

•
STEP 162
Disconnect the low pressure cutout switch . Install a
jumper wire across the harness leads.

Standard HVAC Box Shown

STEP 163
Start the tractor and run the engine at 1500 RPM .
Turn blower speed control to maximum position ,
temperature control valve fully clockwise, ATC switch
to DEFOG/DEFROST or Standard AlC switch to ON ,
and check the low pressure gauge reading.
Compare the gauge readings to the Temperature/
Pressure chart for your ambient temperature and
humidity.

Rae 6-13050 Issued 3·03

 9020-95

STEP 164
Remove thermal insulation tape from top of valve.
Use the palm of you r hand to warm the expansion
valve and watch the low pressure gauge.
The valve will open and pressure should rise.

STEP 165
Use ice to cool the expansion valve and watch the
low pressure gauge.
Within seconds, the expansion valve will close and
the pressure must drop at the low pressure gauge.

STEP 166
If there is little or no change at low pressure gauge,
the thermal expansion valve must be replaced.

Rae 6-13050 Issued 3-03

 9020-96

THERMAL EXPANSION VALVE REPLACEMENT

STEP 167
Recover all refrigerant from the system. Remove the
thermal insulation tape from the fittings and
expansion valve to replace the expansion valve.

STEP 168
Using the two hand, two wrench method, disconnect
the liquid and suction lines from the thermal
expansion valve. Discard the O-rings in the fittings.

STEP 169
Using the two hand, two wrench method, disconnect
the thermal expansion valve from the evaporator
tubes. Discard the O-rings on the tubes.

STEP 170
IMPORTANT: L ubricate O-rings with mineral oil
NOT SP-20 PAG.
Lubricate new O -rings with clean mine ral oil
and install between the evaporator core and thermal
expansion valve. Connect the new valve to t he
evaporator using the two hand, two wrench method.

I Rae 6.13050 Issued 3-03

 9020-97

STEP 171
Lubricate new O-rings with clean mineral oil and
install in the fittings on the suction and liquid lines.
Connect the liquid and suction lines to the expansion
valve using the two hand, two wrench method.

STEP 172
Remove air and moisture from the system and
charge the system . Leak test all connections with
OEM1437 before reapplying any thermal insulation
tape.

STEP 173
Replace all thermal insulation tape and reconnect the
low pressure cutout switch.

NOTE: The thermal insulation tape is available in 30

ft (9150 mm) bulk rolls - 1954475C1 - 0.12 x 2.5
inches x 30 ft [3 x 63.5 x 9150 mmj.

Rae 6-13050 Issued 3-03

9020-98

EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION

STEP 174
The evaporator temperature sensor MUST be
installed 4.2 inches (107 mm) from the left hand rear
side of the evaporator. The sensor must be installed
below the second refrigeration tube row at a 30°
downward angle.
Insert the sensor in the evaporator up to the angled
section, being careful not to kink the sensor.

RH990218
Rear View

AlOOA055
Side View
1. EVAPORATOR TEMPERATURE SENSOR
2. 4.2 INCH (107 mm) 3. EVAPORATOR CORE

STEP 175
The cab temperature sensor must be installed
without contact with any box components in the
return air stream at the rear of the HVAC box.

6-13050 Issued 3-03

 9020-99

BLOWER MOTOR REPLACEMENT

STEP 176
To replace the blower motor:
1. See ACCESSING THE HVAC BOX, page 92.
2. Move the controller mounting plate forward to
gain better access to the motor.
3. Disconnect the 18-pin and 5-pin harness
connector to the ATe controller if applicable.

4. Disconnect the blower motor assembly from the

harness at the connector.

5. Remove the four screws across the top of the

motor assembly and two screws (not visible on
photo) at the sides, and remove the assembly.
6. Install a new motor assembly with the existing
hardware and connect the motor to the harness.

Rae 6-13050 Issued 3-03

9020-100

HEATER CONTROL VALVE REPLACEMENT

STEP 177
To replace the heater control valve:
1. See ACCESSING TH E HVAC BOX, page 92.
2. Move the controller mounting plate forward to
gain better access to the valve.
3. Disconnect the control valve from the harness.

NOTE: Be prepared to collect a small amount of

coolant when the valve hoses are disconnected.

4. Pinch the clamp (1) and disconnect the inlet

hose to the core from the valve. Pinch the clamp
(2) and disconnect the supply hose at the bottom
of the valve. Remove the valve.
5. Install a new heater control valve to the same
connecting hoses. Connect the valve to the
harness.

Rae 6-13050 Issued 3·03

 9020-101

EVAPORATOR/HEATER ASSEMBLY

Evaporator/Heater Assembly Removal

NOTE: The thermal expansion valve, heater valve and evaporatorlheater assembly are located under the operator
seat. See ACCESSING THE HVAC BOX, page 92.

NOTE: Rotate the cab temperature control to the Maximum Heat position before shutting off the tractor for service.
This fully opens the heater control valve and allows more coolant to drain from the evaporatorlheater assembly.

STEP 178
Use a vise clamp to clamp off the heater supply hose
on the right hand side of the engine. Close the valve
on the heater return hose at the engine. See
component locations in this Section for your engine.

STEP 179
Remove the thermal insulation tape from the
expansion valve and the evaporator lines.
To test the valve see thermal expansion valve testing
in this section. Recover the AlC system to remove
the evaporator heater core.

STEP 180
Using the two hand, two wrench method, disconnect
the air conditioning suction and liquid lines at the
thermal expansion valve. Remove and discard the 0 -
rings. Cap or plug the lines to prevent dirt and
moisture from entering the system.

NOTE: Clean packaging tape may be used to seal

the expansion valve ports.

6-13050 Issued 3-03

 9020-102

STEP 181
Pinch the clamp with a pliers to open it and move it to
the side. Disconnect the heater return line (1) from
the evaporator heater core.
Loosen the clamp and disconnect the short hose (2)
between the heater valve and evaporator/heater •
core. Be prepared to collect a small amount of
coolant that will drain into the HVAC box.

STEP 182
Remove the two screws securing the blower speed
driver and its mounting plate at the rear of the box.
Remove the 6-pin connector from the driver and
move the blower driver assembly out of the way.

······ ..... ,u ............. " ............. ,

I STEP 183
Remove the evaporator temperature sensor from the
evaporator/heater assembly.

6-13050 Issued 3-03

 9020-103

STEP 184
Remove the evaporator top gasket and save for
reinstallation . Remove the grommet (1) and sensor
harness from the evaporator by sliding it out of the
slot opening.

NOTE: The gasket seals the top of the evaporator

and forces the air to move through the core rather
than around it. Replace the gasket if it is worn or
damaged.

STEP 185
Slide the evaporator assembly straight up and out of
its side mounting brackets.

STEP 186
Put the assembly on a clean bench . Remove the
expansion valve from the evaporator heater core.
Use the two wrench, two hand method when
removing the therma l expansion valve to prevent
damage to the tubes.

6-1 3050 Issued 3·03

9020-104

Evaporator/Heater Assembly Installation

STEP 187
Lubricate new O-rings with clean mineral oil and
install new O-rings on the evaporator suction and
discharge lines.

STEP 188
Install the expansion valve. Tighten the fittings to a
torque of 18 to 25 Ib It (25 to 34 Nm). Use the two
wrench, two hand method when installing the
expansion valve to prevent damage to evaporator
lines.

STEP 189
Install the evaporator/heater assembly into the slide
mounting brackets of the HVAC box.

STEP 190
Install the sensor harness with grommet in slot in the
the evaporator. Reinstall the top gasket on the
evaporator.

NOTE: The gasket seals the top of the evaporator

and forces the air to move through the core rather
than around it. Replace the gasket if it is worn or
damaged.

Issued 3·03
•
6-13050
 9020-105

, •• ' •••• " ....... " ••• " •••• 'to,

STEP 191
Install the evaporator temperature sensor in the
evaporator/ heater assembly. The evaporator
temperature sensor MUST be installed 4.2 inches
(107 mm) from the left hand rear side of the
evaporator. The sensor must be installed below the
second refrigeration tube row at a 30 0 downward
angle.
Insert the sensor in the evaporator up to the angled
section , being careful not to kink the sensor.

STEP 192
Install the 6-pin connector on the blower speed
driver. Install the two screws to secure the driver and
its mounting plate at the rear of the box.

6·13050 Issued 3-03

 9020-106

STEP 193
Connect the short hose (1) from the heater valve to
the evaporator/heater core. Pinch the clamp to open
it and secure the hose at the evaporator line.
Connect the heater return line (2) to the evaporator
heater core and secure with the clamp.

STEP 194
Remove the caps or plugs from the liquid and suction
lines to the thermal expansion valve.
Install new O-rings on the lines before reconnecting .
Lubricate the O-rings with clean mineral oil prior to
installation.

STEP 195
Using the two hand, two wrench method , reconnect
the air conditioning suction and liquid lines to the
valve.

I 6-13050 Issued 3-03

 9020-107

Post Replacement Procedures

STEP 196
Since the evaporator assembly has been replaced ,
adjust compressor oil level.
Evacuate and charge the air conditioning system .
Test system performance following procedures on
the foldout.
Leak test the valve and evaporator connections with
OEM1437.

STEP 197
The thermal expansion valve and line along with the
inlet and outlet to the evaporator must be insulated
for maximum evaporator performance. Apply thermal
insulation tape around the expansion valve ,
connectors , and the inlet and outlet lines of the
evaporator.

NOTE: The thermal insulation tape is available in 30

ft (9150 mm) bulk rolls - 1954475C1 - 0. 12 x 2 .5
inches x 30 ft (3 x 63.5 x 9150 mm).

STEP 198
To remove air from the cooling system after
installation of a replacement evaporator/ heater
assembly:

A. Fill the radiator completely and fill the coolant

recovery bottle to the full line.

B. Operate the engine for 10 minutes.

C. Stop the engine and allow the radiator to cool.

D. Top off radiator and recovery bottle.

6-13050
9020-108

EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING

Sealing
The top and bottom of the evaporator/ heater
assembly must be properly sealed to allow air
movement through the assembly but not around it.
Check the condition of the foam seal on the top of the
assembly where it seals with the HVAC box cover.
Check the condition of the sealing strip at the front of
the evaporator/heater bottom.
Replace/repair any seal which has deteriorated with
age or which no longer seals properly.

Cleaning
If the evaporator/heater assembly is plugged with dirt
and debris, locate the source of the debris, correct
and then clean the assembly. See CAB
PRESSURIZATION TEST, page 114.
If the assembly is dry, clean with low pressure
compressed air. If the assembly is wet, flush with
water using a low pressure hose.

NOTE: Check that the condensate drain valves are

not plugged before cleaning the assembly with low
pressure wash. 1. TOP FOAM SEAL 2. SEALING STRIP

13050 Issued 3-03

 9020-109

BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION

~ [jt--.-------leD

(Df---' ~

AI990080
1. THERMAL EXPANSION VALVE 4. CHECK VALVE 7. EVAPORATOR TEMP SENSOR
2. BLOWER MOTOR 5. CONDENSATE DRAIN TUBE B. EVAPORATOR CORE
3. BOX DRAINAGE 6. EVAPORATOR BOX ASSEMBLY

6-13050 Issued 3-03

 9020-110

CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT

ATC Controller

STEP 199
With the ignition switch in the OFF position, to
replace the ATC controller:

A. See ACCESSING THE HVAC BOX, page 92.

B. Inclining the seat also frees the controller

mounting plate (1).

C. Disconnect the 1B pin (2) and 5 pin (3) wiring

harnesses connected to the ATC controller.

IMPORTANT: Do not touch exposed pins on ATe

controller to avoid static electricity voltage spikes.
Voltage spikes may result in equipment damage.

D. Remove the three screws (4) securing the ATC

controller and remove the controller.

E. Install a new ATC controller using the existing

hardware. Reconnect the harnesses. Align the
controller mounting plate with the cover holes.
Reinstall the seat with existing hardware.

Standard AlC Controller

STEP 200
The standard A/C controlier is located behind the
evaporator and is mounted to the rear of the HVAC
upper case. With the ignition switch in the OFF

I position, to replace the standard controller:

A. See ACCESSING THE HVAC BOX, page 92.
B. Disconnect the 6 pin and 5 pin wiring
harnesses connected to the standard
controller.

MPORTANT: Do not touch exposed pins on the

ontroller to avoid static electricity voltage spikes.
Voltage spikes may result in equipment damage.
C. Remove the single nut securing the controller
to the mounting stud and remove the
controller.
D. Install a new controller using the existing
hardware. Reconnect the harnesses. Reinstall
the seat with existing hardware.

· 130 50 Issued 3-03

 9020-111

Blower Speed Driver (ATe Units Only)

STEP 201
To replace the blower speed driver in ATC systems,
with the keyswitch in the OFF position:

A. See ACCESSING THE HVAC BOX, page 92.

B. Remove the two screws securing the blower

speed driver assembly to the rear of the HVAC
box.

C. Disconnect the six pin connector to the blower

speed driver.

D. Remove the four screws securing the driver to

the mounting plate.

E. Install a new blower speed driver with the

existing hardware . Install the 6-pin connector
on the driver, and secure the assembly to the
HVAC box rear with the two screws removed
earlier. Reinstall the seat.

6-13050 Issued 3-03

9020-112

CAB AIR FILTER SERVICE

NOTE: The cab intake air filter will need service at different intervals according to local operating conditions. Clean
the filter as required. Replace the filter if there is damage or when the filter cannot be cleaned for efficient
operation.

STEP 202
The cab air filter is located under the cab entry door.
The cab pressurizer blower draws outside air from
the vents in the cab cap through the filter and feeds it
directly to the HVAC box.

STEP 203
Open the two retaining clamps and remove the
cover.

STEP 204
Pull the filter straight out. Clean the inside of the filter
housing.
Install a new filter by pushing straight in until it seats
in the upper gasket. Close the cover and the
retaining clamps.

6-13050 Issued 3-03

 9020-113

STEP 205
Clean the filter element by one of two methods:

A. Tap the outside of the filter. This method can

be used to clean the filter when most of the dirt
is dust. Tap the filter against a flat surface. Do
not use force that can cause damage to the
filter.

B. Clean with compressed air. The compressed

air method is used if most of the dirt is dust.
Direct the air flow from the inside of the filter
outward.

IM PORTANT: The maximum air pressure at the

nozzle must not be more than 35 PSI (242 kPa). Too
much air pressure will cause damage to the filter.

IMPORTANT: Do not use a washing method with

filter washing compound to clean the filter.

CAB RECIRCULATIO N AIR FILTE R SERVICE

STEP 206
A. Remove the vent and the recirculation air filter
on both sides of the operators seat.

B. Clean the filter as frequently as required by

operating conditions or whenever the cab air
filter is serviced.

C. Use mild soap and water. Rinse with clear

water and squeeze out the excess.

D. Reinstall the filters and vents.

NOTE: Never place objects in front of the

recirculation vents that could block air flow.

6-130S0 Issued 3·03

9020-114

CAB PRESSURIZATION TEST

NOTE: Perform the cab pressurization test whenever an unusual amount of dirt accumulates in the cab or in the
evaporator box or if the evaporator core is plugged.

NOTE: When performing this test, the door and window must be closed and latched.

STEP 207
Insert the sensing tube from a digital manometer
through the access panel in the right hand corner of
the rear cab window provided for monitor harness
routing between the cab and the implement.

NOTE: Do not attempt this test through the door

since the metal reinforcement in the seal will pinch
off the sensing tube.

STEP 208
Start the engine. Take a reading from the digital
manometer. Cab pressurization must be between
0.25 (6 mm) and 1 inch (25.4 mm) of H20 . r

STEP 209
If a digital manometer is not available, a simple one
can be made with B It (2.B m) of 3/B inch 00 clear
vinyl tubing and a yard stick. Tape the vinyl tubing to
a yard stick as shown .

AD99M029

6-13050 Issued 3-03

 9020-115

STEP 210
Partially fill the looped section of tubing with water.
(Food coloring may be added to the water to improve
visibility.)

STEP 211
Insert the long end of the tube through the access
panel in the right hand corner of the rear cab window
provided for monitor harness routing between the
cab and the implement.

NOTE: Do not attempt this test through the door

since the metal reinforcement in the seal witt pinch
off the sensing tube.

STEP 212 -e
Hold the yard stick vertical. Record the water level

-- ...
-III
reading without the engine running. Start the engine
and measure the movement of water on one side of
the yard stick. Multiply that value by two. Cab --
..._..
pressurization must be between 0.25 (6 mm) and 1
inch (25.4 mm) of H2 0. -N

STEP 213 ...-s

If the reading is below 0.25 inch of H2 0, check the
f,:...
following seals and retest:
- Door and rear window seals
- RD99M02 7
- Window seals
- Customer supplied radio/telephone antenna
cable routing
If the reading is above 1 inch (25.4 mm) of H2 0 ,
check for extra cab sealing, missing filter or broken
fresh air inlet.

6·13050 Issued 3-03

9020-116

CAB PRESSURIZER MOTOR REPLACEMENT

NOTE: The cab pressurizer motor is located under the cab entry and behind the cab air filter. To replace the
motorlblower assembly, the cab fresh air filter must be removed.

STEP 214
Remove the two screws and remove the trim panel at
the filter front.

STEP 215
Open the two clamps and remove the cover for the
fresh air filter.

STEP 216
Remove the air intake line from the cab filter housing
the post. Remove the filter.

6- 13050 Issued 3-03

 9020-117

STEP 217
Remove the four bolts and remove the filter housing.

STEP 218
Disconnect the motor assembly from the harness.

STEP 219
Remove the bolt, nut and washer and remove the
assembly from the tractor.

6-13050 Issued 3·03

9020-11 B

STEP 220
Remove the four screws to disconnect the motor/
blower assembly (1) from the mounting bracket (2).

STEP 221
Reverse the steps to install a replacement motor/
blower assembly.

VISCOUS FAN DRIVE

Since the viscous fan creates air flow at the
condenser, a properly functioning fan drive is
essential to proper air conditioning performance. A
defective fan drive can cause engine overheating
and/or high pressure switch activation. But a plugged
grille, radiator, condenser and oil cooler can also
cause the same.
To separate a fan drive problem from other possible
causes, perform the Viscous Fan Drive Test in this
manual.
NOTE: When performing the viscous fan drive test,
the air conditioning system should be OFF

6-13050 Issued 3-03

9030-10

-
r

Issued 3·03
6-14780
 ELECTRICAL SCHEMATIC DIAGRAM ACTUATORS COLOR ABBREVIATIONS FUSE SECTION CIRCUIT FUSE SECTION CIRCUIT REF. SECTION REF. SECTION REF. SECTION REF. SECTION
HARNESS HARNESS HARNESS HARNESS
EURO MX MAGNUM SERIES TRACTOR (261) LOCATION IDENTIFICATION (262) LOCATION IDENTIFICATION DES. LOCATION DES. LOCATION DES. LOCATION DES. LOCATION
ABBREVIATION---COLOR 1 20 GOV KEY SWITCH 29 67 SEAT HEATER 1 18 31 HEADLIGHT 51 35 CAB 101 63 ROOF 151 54 AUX VALVE
ABBREVIATION---COLOR
R--------------RED 2 NOT USED 30 NOT USED 2 31 55 HEADLIGHT 52 40 CAB 102 63 ROOF 152 54 AUX VALVE
Or-------------ORANGE
CIRCUIT DESCRIPTION SECTION CIRCUIT DESCRIPTION SECTION T--------------TAN 3 28 REAR FENDER WORKLIGHTS 31 70 AFS SWITCHED B+ 3 31 56 HEADLIGHT 53 51 CHASSIS 103 63 ROOF 153 51 CHASSIS
K--------------PINK
W--------------WHITE 4 28 BELT LINE WORKLIGHTS 32 39 TRCU UNSWITCHED B+ 4 31 56 HEADLIGHT 54 51 CHASSIS 104 30 ROOF 154 51 CHASSIS
AIR CONDITIONING 58-61 P--------------VIOLET (PURPLE)
LEVER HAND FOOT TEMP. Y--------------YELLOW 5 28 ROOF WORKLIGHTS 33 49 ARM-REST CONTROL SW 5 31 HEADLIGHT 55 14 51 53 CHASSIS 105 30 ROOF 155 51 CHASSIS
DU-------------DARK BLUE
AUTOGUIDANCE 73-78 - OPTIONAL FRONT HITCH 27 Bk-------------BLACK 6 28 WORKLIGHT INTERLOCK 34 25 RADAR 6 31 55 HEADLIGHT 56 14 44 51 CHASSIS 106 30 ROOF 156 63 ROOF
LU-------------LIGHT BLUE
N--------------BROWN 7 20 KEY BATTERY 35 NOT USED 7 23 56 CHASSIS 57 44 51 CHASSIS 107 30 ROOF 157 68 AUX POWER
AUTOHITCH 25 - OPTIONAL FRONT BELTLINE 28 DG-------------DARK GREEN
S--------------GREY 8 68 SHELF AUX. UNSW POWER 36 53 AUX 8 55 58 51 CHASSIS 108 23 ENGINE 158 45 CHASSIS
LG-------------LIGHT GREEN
ARMREST CONTROLLER 46-50 - OPTIONAL HIGH INTENSITY LAMP 31 9 67 SEAT/OPS 37 24 ICU/PMU SW 9 35 CAB 59 13 51 CHASSIS 109 23 HEADLIGHT 159 45 CHASSIS
10 61 BLOWER CAB PRESSURE 38 45 BRAKE SWITCH 10 19 29 33 36 39 43 44 45 52 71 CAB TO CHASSIS 60 17 24 25 36 57 CAB TO CHASSIS 110 36 CAB 160 45 CHASSIS
AUXILIARY CONTROL SYSTEM 53-54 LIQUID
11 66 CIGAR LIGHTER 39 52 EDC 11 29 CAB 61 17 24 CAB 111 64 CAB TO ROOF 161 20 CAB
AUTOMATIC TEMPERATURE CONTROL UNIT 59 - OPTIONAL REAR FENDER WORK 32-33 LEVEL FLOAT PRESSURE COIL DIODE 12 33 TRAILER AUX (SW) 40 71 ECU B+ 12 28 CAB 62 17 27 CAB 112 64 ROOF 162 45 CAB
13 68 UNSW FRONT/REAR AUX B+ 41 16 CDB TRACTOR B+ 13 28 30 64 66 67 69 CAB TO ROOF 63 57 ENGINE TO CHASSIS 113 64 ROOF 163 45 CAB
AUXILIARY POWER CONN. (IMPLEMENT) 68 - OPTIONAL ROOF WORK CAB 28
CONTACTS 14 69 DISPLAY B+ 42 16 CDB DIAG CONN POWER 14 28 ROOF 64 23 ENGINE 114 66 ROOF 164 57 CAB
AUXILIARY POWER (7-PIN TRAILER) 33 15 56 GOVERNOR 43 39 TRANSMISSION CONTROLLER 15 28 ROOF 65 23 ENGINE 115 65 ROOF 165 68 CAB

BLOWER MOTOR (ATCU OR CCU) 61 MOMENTARY CIRCUIT DIAGRAM LEGENDS 16 24 ICU/PMU (UNSW) 44 39 TRANSMISSION CONTROLLER 16 28 ROOF 66 26 CHASSIS 116 65 ROOF 166 19 CHASSIS
17 36 HORN 45 NOT USED 17 28 ROOF 67 41 CHASSIS 117 167 68 SHELF
VARIABLE
BRAKE PEDAL SWITCHES 45 - STANDARD CAB FENDER 32-33 RESISTOR MAINTAINED 18 29 HIGH BEAM RELAY 46 68 FRONT/REAR AUX SW 18 29 ROOF 68 26 CHASSIS 118 30 ROOF 168 68 SHELF
RESISTOR 702A B-1.0 CIRCUIT TAG IF REQUIRED 19 63 DOME LIGHT, RADIO 47 60 HVAC CONTROLLER 19 29 ROOF 69 26 CHASSIS 119 52 CAB 169 68 SHELF
CHARGING SYSTEM 19 - STANDARD CAB FRONT ROOF 29
CIRCUIT
CAB/CONTROLLER POWER 20 - STANDARD FENDER WARNING LAMPS 32-33
HOUSINGS NUMBER
COLOR CONDUCTOR AREA 20 34 FLASHER 48 68 SHELF AUX POWER SW 20 32 CHASSIS TO FENDER 70 41 CHASSIS 120 30 ROOF 170 68 SHELF
21 29 LH & RH TAIL LIGHTS 49 60 HVAC BLOWER 21 32 55 CHASSIS TO FENDER 71 61 ENGINE 121 23 AUX POWER 171 25 CAB
22 34 STOP LIGHTS 50 69 DISPLAY [SW] 22 22 FRONT HITCH 72 60 ENGINE 122 65 CAB 172 21 CAB
CAN DATA BUS 12-18 - STANDARD BELTLINE WARNING LAMPS N/A

CIGAR LIGHTER 66 V P T M
23
24
66
63
BEACON/STROBE
MIRROR/RADIO
51
52
66
66
FRONT WIPER/WASHER
REAR WIPER/WASHER
23
24
73
74
36
36
ENGINE
ENGINE
123
124
61
61
AC SWITCH
AC SWITCH
173
174
21
16
CAB
CAB

CLIMATE CONTROL UNIT 58 MECHANICAL FRONT DRIVE (MFD) 46 25 36 ETHER 53 NOT USED 25 55 75 26 NON ELECT ENGINE 125 60 CAB 175 12 13 CHASSIS

VACUUM PRESSURE TEMPERATURE 26 43 AXLE SW B+ 54 NOT USED 26 76 26 ENGINE 126 61 AC SWITCH 176 62 ROOF
CRUISE CONTROL 57 PERFORMANCE MONITOR 27 MOTOR LAMP C20
SWITCH SWITCH SWITCH 27 28 SIDE WORKLIGHTS 55 NOT USED 27 55 77 19 ENGINE 127 65 CAB 177 62 ROOF
INDICATES CIRCUIT SPLICE
DIFFERENTIAL LOCK 46 POWER MIRRORS 64 28 60 C/F DISPLAY GND 56 42 ITALIAN BRAKE 28 55 78 19 SOLENOID/STARTER 128 61 AC SWITCH 178 65 CAB

CONTACT CONFIGURATIONS 29 38 55 CHASSIS 79 19 SOLENOID/STARTER 129 66 CAB 179 35 CAB

ELECTRONIC ENGINE CONTROLLER 55-56 PTO CONTROLLER SYSTEM 44-45 INDICATES CIRCUIT CONNECTION 30 37 55 CHASSIS 80 19 SOLENOID/STARTER 130 64 CAB 180

ELECTRONIC PTO 44-45 RADIO ANTENNA 62 31 37 CHASSIS 81 19 ENGINE 131 66 CAB 181 43 CAB
32 38 55 CHASSIS 82 19 ENGINE 132 61 AC SWITCH 182
ETHER START 36 RADIO SOUND SYSTEM 62 INDICATES CIRCUIT CROSSING RELAY SECTION REF.
FUNCTION 33 38 55 CHASSIS 83 19 ENGINE 133 67 CAB 183 43 AXLE SOLENOID
NOT CONNECTED NUMBER LOCATION DES.
FOOT THROTTLE 57 ROTARY LIGHT SWITCH 28 34 38 CHASSIS 84 19 SOLENOID/STARTER 134 19 CHASSIS 184 43 AXLE SOLENOID
1 34 263F BRAKE LIGHT RELAY
35 18 38 CHASSIS 85 19 ENGINE 135 34 CAB 185 43 CHASSIS TO SENSOR
FORWARD/NEUTRAL/REVERSE/PARK 35 SCHEMATIC - LEGEND 1-10 S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T. 2 42 263F SPARE AFS FUSES
INDICATES INTERNALLY 36 37 CHASSIS 86 19 ENGINE 136 186 43 AXLE SOLENOID
3 28 263F REAR WORK LIGHTS
HITCH CONTROL SYSTEM 51-52, 54 SCHEMATIC - SYMBOL DEFINITIONS 2 GROUNDED UNITS 37 37 CHASSIS 87 22 ENGINE 137 47 49 CAB 187 43 AXLE SOLENOID
MISCELLANEOUS SYMBOLS 4 29 263F WORK LAMP INTERLOCK RELAY
FUSE 327,
HIGH POWER RELAY
30 AMPS
38 38 CHASSIS 88 26 CHASSIS 138 21 CAB 188 23 ENG TO HITCH
HEADLIGHT SWTICH 29 SEAT 67 5 40 263F PARK RELAY SECTION 72
39 38 CHASSIS 89 26 CHASSIS 139 58 59 60 CAB TO HVAC 189 56 CHASSIS

4
6 40 263F NEUTRAL RELAY FUSE 328, 20 AMPS

3
INSTRUMENT CLUSTER 24-25 STARTING SYSTEM 19-20 40 32 CHASSIS TO FENDER 90 60 CHASSIS 140 54 AUX VALVE 190
7 42 264F SPARE LOW POWER RELAY
41 32 CHASSIS TO FENDER 91 68 ROOF TO SHELF 141 54 AUX VALVE 191 35 FNRP

2 5
ISO11783 69-72 SUSPENDED AXLE 43 8 28 264F OPTIONAL BELTLINE WORK LAMPS
SECTION 72

1
42 92 62 ROOF 142 54 AUX VALVE 192 43 CHASSIS TO AXLE
9 29 264F FRONT ROOF WORK LIGHTS
LIGHTS - STANDARD HEAD LIGHTS 31 TRAILER CONNECTOR (7-PIN) 33 43 93 62 ROOF 143 54 AUX VALVE 193 43 AXLE SENSOR
RELAYS FUSE BLOCK 10 61 264F CAB PRESSURE BLOWER RELAY
FUSE CIRCUIT BREAKER 44 38 CHASSIS 94 63 ROOF 144 54 AUX VALVE 194 70 ISO11783 CAB
- BEACON 66 TRANSMISSION CONTROL SYSTEM 37-38 GROUND 11 20 264F ENGINE RELAY
45 95 62 ROOF 145 44 CHASSIS 195 29 ROOF
12 29 264F STD AND OPT FENDER WORK LAMPS
- BRAKE 32-33 WINDSHIELD WIPER/WASHER - FRONT 65 46 96 62 ROOF 146 44 CHASSIS 196 29 ROOF
47 41 ENGINE 97 62 ROOF 147 33 CHASSIS TO 7 PIN 197
- DOME/CONSOLE 63 WINDSHIELD WIPER/WASHER - REAR 65
48 41 ENGINE 98 65 ROOF 148 198 19 NON ELECT ENGINE
CIRCUIT 1 CIRCUIT 1
- LICENSE PLATE N/A WIRE BUNDLE
CIRCUIT 2 CIRCUIT 2 49 41 CHASSIS 99 65 ROOF 149 199 60 ENGINE

CIRCUIT 3 CIRCUIT 3 50 39 55 CAB 100 63 ROOF 150 53 CHASSIS 200 56 CHASSIS

LED PHOTO TRANSISTOR CIRCUIT 4 CIRCUIT 4

SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6

REF. SECTION REF. SECTION REF. SECTION REF. SECTION SPL SEC HARNESS SPL SEC HARNESS SPL SEC HARNESS SPL SEC HARNESS
HARNESS HARNESS HARNESS HARNESS CIRCUIT CIRCUIT CIRCUIT CIRCUIT
DES. LOCATION DES. LOCATION DES. LOCATION DES. LOCATION NAME LOC USED ON NAME LOC USED ON NAME LOC USED ON NAME LOC USED ON
201 26 CHASSIS 251 56 ENGINE BLOCK 301 33 FENDER 351 37 43 CHASSIS A1 MAIN CHASSIS NOT USED C21 20 CAB INSTRUMENT B+ S1 55
202 19 ENGINE 252 56 ENGINE BLOCK 302 33 FENDER 352 A2 MAIN CHASSIS NOT USED C22 31 CAB SWITCHED B+ S2
203 22 CHASSIS 253 56 ENGINE BLOCK 303 32 FENDER 353 37 43 CHASSIS A3 33 MAIN CHASSIS LEFT HAZARD C23 24 CAB CHASSIS GROUND S3 55
204 56 254 56 ENGINE BLOCK 304 32 FENDER 354 A4 33 MAIN CHASSIS RIGHT HAZARD C24 68 CAB ICU B+ S4
205 18 ENGINE 255 305 355 37 43 CHASSIS A5 MAIN CHASSIS NOT USED C25 68 CAB SWITCHED B+ S5 55
206 18 ELECT ENGINE 256 57 ENGINE CONTL 306 356 A10 53 MAIN CHASSIS AUX B+ C26 16 CAB CDB CLEAN GROUND S6 55
207 27 ELECT ENGINE 257 57 CAB 307 357 A11 44 MAIN CHASSIS CLEAN GROUND C27 16 CAB CDB SWITCHED B+ S7
208 55 ELECT ENGINE 258 57 CAB 308 358 A12 MAIN CHASSIS NOT USED C28 27 CAB NOT USED S8 55
209 56 ELECT ENGINE 259 39 CHASSIS 309 359 A13 32 MAIN CHASSIS CHASSIS GROUND C29 34 CAB FLASHER S9 55
210 260 310 360 66 A14 MAIN CHASSIS NOT USED C30 43 CAB SUSPENDED AXLE B+
211 26 CHASSIS 261 SEE SECTION 4 CAB 311 41 PREFILL SOLENOID 361 66 A15 MAIN CHASSIS NOT USED C31 66 CAB FRONT WIPER SB1 66
212 65 ENGINE 262 SEE SECTION 4 CAB 312 52 REMOTE HITCH 362 A16 MAIN CHASSIS NOT USED C32 34 CAB CHASSIS GROUND SB2 66
213 65 ENGINE 263 SEE SECTION 4 CAB 313 52 REMOTE HITCH 363 A17 32 MAIN CHASSIS TAIL LAMPS C33 19 CAB UNSWITCHED B+
214 19 NON ELECT ENGINE 264 SEE SECTION 4 CAB 314 52 CHASSIS TO REMOTE 364 66 A18 29 MAIN CHASSIS WORKLIGHT B+ C34 19 CAB UNSWITCHED B+ SH1 69 SHELF CHASSIS GROUND
215 26 NON ELECT ENGINE 265 27, 66 315 52 CHASSIS TO REMOTE 365 66 A19 MAIN CHASSIS NOT USED C35 33 CAB STOP LIGHTS SH2 69 SHELF SWITCHED B+
216 26 NON ELECT ENGINE 266 20 CAB 316 366 A20 MAIN CHASSIS NOT USED C36 CAB NOT USED SH3 69 SHELF UNSWITCHED B+
217 19 NON ELECT ENGINE 267 22 CAB 317 41 PARK SOLENOID 367 C37 40 CAB REVERSE
218 22 7 PIN 268 22 CAB 318 41 PARK SOLENOID 368 GPS 70 C38 66 CAB REAR WIPER T1 37 MAIN CHASSIS B+ COMMON
219 35 FNRP 269 68 CAB 319 41 PARK SOLENOID 369 GPS 70 C39 CAB NOT USED T2 37 MAIN CHASSIS B+ COMMON
220 35 FNRP 270 68 RECEPTACLE 320 40 CAB 370 GPS 72 C40 34 CAB STOP LIGHTS T3 38 MAIN CHASSIS CLEAN GROUND
221 35 FNRP 271 68 RECEPTACLE 321 371 71 GPS 72 C41 CAB NOT USED T4 26 MAIN CHASSIS WHEEL SPEED
222 62 ROOF 272 322 60 CAB TO AC SW 372 70 GPS 72 C42 CAB NOT USED T5 41 MAIN CHASSIS PARK BRAKE SOLENOID
223 62 ROOF 273 70 CAB TO ISO11783 323 273 70 GPS 72 C43 66 CAB STROBE B+ T6 38 MAIN CHASSIS RANGE PRESSURE
224 30 ROOF 274 71 324 374 96 ISO11783 GPS 71 E1 19 ENGINE CHASSIS GROUND T7 38 MAIN CHASSIS RANGE PRESSURE
225 30 ROOF 275 325 41 AIR SWITCH 375 E2 26 ENGINE ICU SENOR GND T8 MAIN CHASSIS NOT USED
226 12 ISO11783 276 326 72 ISO11783 CHASSIS 376 AG1 71 E3 56 ENGINE CONTROLLER B+ T9 MAIN CHASSIS NOT USED
227 32 NOT USED 277 327 72 ISO11783 CHASSIS 377 AG2 71 E4 57 ENGINE CLEAN GROUND T10 MAIN CHASSIS NOT USED
228 32 278 328 72 ISO11783 CHASSIS 378 AG3 71 E5 41 ENGINE LEFT PARK BRAKE T11 MAIN CHASSIS NOT USED
229 32 FENDER 279 20 CAB 329 379 28 E6 41 ENGINE RIGHT PARK BRAKE T12 MAIN CHASSIS NOT USED
230 32 FENDER 280 71 CHASSIS TO ISO11783 330 380 C1 24 CAB SENSOR GROUND F1 25 MAIN CHASSIS CLEAN GROUND T13 MAIN CHASSIS NOT USED
231 281 69 ISO11783 CAB 331 27 FRONT HITCH 381 C2 25 CAB WHEEL SPEED F2 MAIN CHASSIS NOT USED T14 51 MAIN CHASSIS REMOTE UP
232 33 NOT USED 282 72 ISO11783 CHASSIS 332 27 FRONT HITCH 382 C3 29 CAB UNSWITCHED LIGHT B+ F3 41 MAIN CHASSIS CLEAN GROUND T15 51 MAIN CHASSIS REMOTE DOWN
233 33 FENDER 283 72 ISO11783 CHASSIS 333 18 20 23 24 36 41 43 56 57 60 66 CHASSIS TO ENGINE 383 C4 40 CAB NEUTRAL F4 MAIN CHASSIS NOT USED T16 51 MAIN CHASSIS REMOTE B+ COMMON
234 33 FENDER 284 70 334 19 20 25 32 38 45 51 56 57 58 CHASSIS TO ENGINE 384 C5 28 CAB HAZARD F5 MAIN CHASSIS NOT USED T17 51 MAIN CHASSIS DRAFT PIN B+
235 33 FENDER 285 69 ISO11783 CHASSIS 335 54 CHASSIS TO AUX 385 C6 65 CAB MIRROR COMMON F6 25 MAIN CHASSIS ENGINE RPM T18 51 MAIN CHASSIS DRAFT PIN GND
236 32 WIDE MARKER 286 70 ISO11783 CAB 336 44 SPEED SENSOR 386 C7 48 CAB CLEAN GROUND F7 57 MAIN CHASSIS GOVERNOR GROUND T19 MAIN CHASSIS NOT USED
237 33 WIDE MARKER 287 337 39 BACK UP ALARM 387 C8 50 CAB BRAKE SWITCH F8 MAIN CHASSIS NOT USED T20 MAIN CHASSIS NOT USED
238 19 CHASSIS 288 72 ISO11783 CHASSIS 338 39 CHASSIS TO BACKUP 388 C9 21 CAB CONTROLLER B+ F9 25 MAIN CHASSIS ICU SENSOR GND T50 38 MAIN CHASSIS CLEAN GROUND
239 20 CAB 289 70 339 389 C10 28 CAB NOT USED FL1 FENDER NOT USED
240 20 CAB 290 71 340 54 AUX VALVE 390 C11 28 CAB NOT USED FL2 32 FENDER CHASSIS GROUND
241 20, 27 CAB 291 72 ISO11783 CHASSIS 341 54 AUX VALVE 391 C12 40 CAB BOTTOM OF CLUTCH FR1 FENDER NOT USED
242 292 72 ISO11783 CHASSIS 342 54 AUX VALVE 392 C13 24 CAB LIGHTS FR2 33 FENDER CHASSIS GROUND
243 293 72 ISO11783 CHASSIS 343 54 AUX VALVE 393 C14 64 CAB CHASSIS GROUND H1 31 HEADLIGHT CHASSIS GROUND
244 18 55 ENGINE BLOCK 294 71 344 54 AUX VALVE 394 C15 68 CAB SEAT POWER H2 31 HEADLIGHT WORKLIGHT B+ V1 54 AUX VALVE AUX VALVE B+
245 56 ENGINE BLOCK 295 345 395 C16 61 CAB HVAC BLOWER P1 41 PARK SOLENOID PARK SOLENOID
246 56 ENGINE BLOCK 296 69 346 396 53 C17 34 CAB LEFT HAZARD P2 41 PARK SOLENOID PARK SOLENOID
247 56 ENGINE BLOCK 297 72 ISO11783 CHASSIS 347 397 C18 34 CAB RIGHT HAZARD R1 30 ROOF CHASSIS GND
248 56 ENGINE BLOCK 298 69 71 348 398 C19 29 CAB TAIL/POSITION B+ R2 29 ROOF CHASSIS GND
249 56 ENGINE BLOCK 299 69 349 399 53 C20 24 CAB INSTRUMENT B+ R3 29 ROOF WORK LIGHT B+
250 56 ENGINE BLOCK 300 350 13 37 43 CHASSIS 400

SECTION 8 SECTION 9 SECTION 10

SECTION 7

CAN DATA BUS CAN DATA BUS CAN DATA BUS CAN DATA BUS CAN DATA BUS CAN DATA BUS
CAB HARNESS ENGINE HARNESS ENGINE HARNESS

UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER

SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER

TO SPLICE C33
SHT1 SECTION 19

101G R-1.0
FUSE
#42
NOTE: CAN SPL-CHA* ARE LOCATED ON THE CHASSIS HARNESS. 10A

152A R-1.0
NOTE: CAN SPL-CAB* ARE LOCATED NOTE: CAN SPL-CAB* ARE LOCATED
NOTE: CAN SPL-CAB* ARE LOCATED ON THE CAB HARNESS. NOTE: CAN SPL-CAB* ARE LOCATED ON THE CAB HARNESS. NOTE: CAN SPL-ENG1 IS LOCATED
CAN-Y18 Y-0.5
ON THE CAB HARNESS. ON THE CAB HARNESS.
CAN-DG18 DG-0.5
ON THE ENGINE HARNESS.
CAN
CAN CAN CAN CAN CDB CAN CAN CAN
SPL-CAB6 60M 60F
SPL-CHA2 SPL-CAB5 SPL-CAB4 SPL-CAB3 SPL-CAB2 SPL-CAB1 SPL-ENG1
SPL-CHA1
R R R R R R R R 11 11 R
18 18
10M 10F 333M
Y Y CAN-Y21 Y-0.5 Y Y Y Y Y Y Y
CAN-Y19 Y-0.5 CAN-Y18 Y-0.5 64 64 CAN-Y16 Y-0.5 CAN-Y14 Y-0.5 CAN-Y14 Y-0.5 CAN-Y11 Y-0.5 CAN-Y9 Y-0.5 CAN-Y9 Y-0.5 CAN-Y7 Y-0.5 CAN-Y6 Y-0.5 CAN-Y6 Y-0.5 CAN-Y5 Y-0.5 27 27 CAN-Y4 Y-0.5 CAN-Y4 Y-0.5 18 18 CAN-Y3 Y-0.5
BK BK BK BK BK BK BK BK BK
29 29
DG DG CAN-DG21 DG-0.5 DG DG DG DG DG DG DG
CAN-DG19 DG-0.5 CAN-DG18 DG-0.5 66 66 CAN-DG16 DG-0.5 CAN-DG14 DG-0.5 CAN-DG14 DG-0.5 CAN-DG11 DG-0.5 CAN-DG9 DG-0.5 CAN-DG9 DG-0.5 CAN-DG7 DG-0.5 CAN-DG6 DG-0.5 CAN-DG6 DG-0.5 CAN-DG5 DG-0.5 20 20 CAN-DG4 DG-0.5 CAN-DG4 DG-0.5 20 20 CAN-DG3 DG-0.5
CAN-DG22 DG-0.5

333F
CAN-Y22 Y-0.5

CAN-Y13 Y-0.5

CDB-SPL11,SHT 2,SECT 70
CDB-SPL11,SHT 2,SECT 70

CAN-DG12 DG-0.5
CDB-SPL11,SHT 2,SECT 70

CAN-Y12 Y-0.5
CAN-Y21 Y-0.5 CDB-SPL11,SHT 2,SECT 70

CAN-DG8 DG-0.5
CAN-DG13 DG-0.5

CAN-Y8 Y-0.5
CAN-DG21 DG-0.5

CDB-BK28 Bk -0.5
CAN-DG10 DG-0.5

CAN-DG24 DG-0.5
CAN-DG15 DG-0.5

CONN 398M,CAV 3 963A K-0.8

CAN-Y24 Y-0.5
335F
CAN-DG20 DG-0.5

CAN-Y10 Y-0.5
29 27
CAN-Y15 Y-0.5

CDB-R28 R-0.5
CDB-DG28 DG-0.5
175M SHT 2,SECTION 60
CAN-Y20 Y-0.5

29 27

CDB-Y28 Y-0.5
1 2 3 4
335M

CAN-Y1 Y-0.5
CAN-DG1 DG-0.5
1 2 3 4 TO CONN 377M,CAV 5

CAN-Y2 Y-0.5
CAN-DG2 DG-0.5
175F
CAN-Y23 Y-0.5
CAN-DG23 DG-0.5

SHT 2,SECT 69

408M
2 1
2 1
CAN-DG26 DG-0.5

962A R-0.8 398M PORT8, 408F

SEC 60
CAN-Y26 Y-0.5

177AM Bk -1.0

CAN-DG17 Y-0.5
CAN-Y17 Y-0.5
137M TO CONN 377M,CAV 6 CN1
350M 381M
15 16 4 5 SHT 2,SECT69 1 2 3 4 A B C D E F G H J 174M 14 15

53M 256M 205M

TRANSMISSION 16 15 ARMREST STANDARD 46 47 1 2
HVAC DIAGNOSTIC
CONTROLLER CONTROLLER TRACTOR
TRACTOR CONTROLLER CONNECTOR
TO CHASSIS GND MONITOR ENGINE
(TRCU) (ARU) PASSIVE
MULTIFUNCTION (ICU)
AT SPL C14 CONTROLLER TERMINATOR
CONTROLLER SHT2 SECTION 64 (GOV)
(TMF) TO CONN 413M,CAV 11 TO CONN 413M,CAV 5
TO CONN 282M,CAV 4,SHT 2,SECT 72 TO CONN 282M,CAV 5,SHT 2,SECT 72 SHT 3,SECT 74 SHT 3,SECT 74

CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND

CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND

SECTION 13 SECTION 14 SECTION 15 SECTION 16 SECTION 17 SECTION 18

TO RING TERM
TO SPLICE C33
CAB/CONTROLLER POWER
240F CHARGING SYSTEM STARTING SYSTEM
SECTION 19

UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER

SWITCHED POWER SWITCHED POWER SWITCHED POWER

SPLICE C33 SPLICE C34

102S R-1.0

TO RING TO RING
101E R-1.0
101C R-2.0
101B R-1.0
101D R-2.0
101F R-3.0
101G R-1.0
101M R 1.0

101H R-2.0
101J R-3.0
101K R-3.0
101L R-2.0

C21 TO CONN
101R R-3.0

102B R-5.0
102C R-3.0

102E R-3.0
102F R-2.0
102M R-3.0

103S R-2.0
103B R-3.0
103C R-2.0
103D R-3.0

103F R-2.0
103G R-3.0
103K R-2.0

WIRE # TO SECT WIRE # TO SECT TERMINAL 138A TERMINAL 138A RING TERMINAL 138A RING TERMINAL 138B
102A R-3.0
975A R-0.8

102B R-5.0 SECTION 21 10F,CAV 43

SECTION 21
SHT 1,SECT 19 WIRE WIRE
101B FUSE #16 24 101H FUSE #18 29
101C R-2.0 TO SECTION TO SECTION

MAGNUM 225, 250, 280, 310 SERIES TRACTORS

NO. NO.
SEE RING
101A R-13.0

101C FUSE #7 20 101J FUSE #15 56

101A R-13.0

102U R-3.0 TO FUSE #52, CAV A10 TERM 138A 102A CONN 241F 20 103H FUSE #25 ?
101D FUSE #11 67 101K FUSE #13 68
SHT2 SECTION 65 AND 138B
102B SPL-C21 20 103B FUSE #46 68
101E FUSE #32 39 101L FUSE #8 68 FUSE #7
102J R-3.0 TO FUSE #29, CAVITY D14 10 AMPS CAB POWER 102C CONN 10F 22 103C FUSE #48 68
C33 101F FUSE #20 34 101P CONN 10 19
C34 REF DES RELAY
SHT2 SECTION 67 102E FUSE #5 28 103D FUSE #49 60
101N R-8.0

101G FUSE #42 16 101R FUSE #53 27 261F 240F

102F FUSE #9 67
101M FUSE #10 61 975A FUSE #14 69 102R R-3.0 TO BREAKER #51, CAVITY A12 138A 138B

EURO ELECTRICAL SCHEMATIC

102M FUSE #47 60 103F FUSE #22 34
107A R-2.0

101N CONN 10 19 SHT2 SECTION 65

102S FUSE #50 69 103G FUSE #3 28
101P R-13.0 102L R-3.0 TO FUSE 26,CAV 26, SHT 2,SECTION 43 239F 279F 103S FUSE #27 28
10F 126Y DG-1.0 TO CONN 395M,CAV 6
48 43 60 103K FUSE #30 66
SHT 1,SECT 25
10M 48 43 60
IGNITION
161F

87389709
121E Y-1.0 ALTERNATOR EXCITE TO INSTRUMENT SWITCH
101AA R-13.0

1 177J Bk -0.8
CONN 395M,CAV 5 89A R-1.0 1 TO CHASSIS GND
101BB R-13.0
101CC R-8.0

SHT 1,SECT 25 AT SPLICE C22

102G T-0.8

2 START SHT 1 SECTION 31

TO STARTER RELAY 104A R-0.8 2
RUN
623C W-0.8

VIA CONN 10F, CAV 78 RING TERMINAL 173F

85F 86F SHT 1 SECTION 23 3 160A R-0.8
3 OFF TO CONN 255F, CAV F2 WIRE
SHT 2, SECT 50 TO SECTION
NO.
W D+ 622A W-1.0 TO START RELAY 4 4
238F ACC
266M 177E CONN 165M 68
CONN 108M, CAV E J3 TO FUSE #2 266F 160B R-0.8 TO CONN 255F, CAV D2

LEGEND
78F 82F SHT 2, SECT 57 5 START
SECTION 23 A A 105A R-0.8 5 SHT 2, SECT 71 177F CONN 139F 60
166F 134F
FUSE #1 RUN
B+ 177G CONN 13F 68
ALTERNATOR 5 AMPS 6
6 160E R-0.8 TO CONN 255F, CAV C2
106B Or-1.0

REF DES OFF 177L CONN 356M 29

77F SHT 2, SECT 47
CAB_PWR R-13.0

261F
177BF SPL-35 27
104B T-0.8

FRAME ACC
238A
268A T-0.8

GROUND 160D R-0.8 TO CONN 255F, CAV B2

106A R-1.0

623B R-0.8 TO CONN CN1,CAV 26 SHT 2, SECT 39

84F 83F
INTERMEDIATE
STARTING RELAY
TO RADIO
FUSE #24
C49

623A W-0.8
SHT 1, SECTION 24

TO FNRP MODULE
VIA CONN 51M, CAV 1
171B R-0.8 TO CONN 255F, CAV A1
SHT 2, SECT 50
WIRE
NO.
RING TERMINAL 172F

TO SECTION INDICATES CONSTANT POWER

POS R-3/0 FUSE 178B CONN 139F 60
BATT R-3/0

BLOCK SHT1 SECTION 35

178C CONN 13M 63
261
120A R-19.0
620A R-1/0

CAV A10 178D CONN 13M 30

600A Bk -1.0

106C R-0.8 TO FUSE #56

625A W-8.0

INDICATES POWER WHEN

SHT 2
SECTION 63 SHT 2, SECTION 42 178F SPL-32 34
264F 106A R-1.0
B1 B3 178H CONN 13M 30
C20
TO CONN 264F, 178J CONN 11F 29
81F CAV A2 1 3

KEY SWITCH IS ON
BATTERY 80F SHT 2 SECTION 61 ENGINE RELAY 160C Bk -0.8 TO CONN 255F, CAV A1
177AT Bk -0.8

SHT 2, SECT 50 RING TERM 172F RING TERM 173F

(ELECTRONIC
81A 79F
ENGINE ONLY) CAB HARNESS CAB HARNESS
E1 SPLICE E1 #11 171D Bk -0.8 TO CONN 255F, CAV C1
2 5 4
GND Bk -3/0

SHT 2, SECT 47
GND Bk -3/0

WIRE # TO SECTION
179BE Bk -3.0
179BF Bk -3.0

600E Bk -8.0

600H Bk -0.8
600G Bk -0.8
600D Bk -0.8

CONN 256M,CAV 39
600A CONN 83F 19 B2 B5 B4 172F 173F
264F SHT 2,SECT 57 171E Bk -0.8
179BF CONN 64M 23 C9
179BE CONN 65M 23 171A Bk -0.8 TO CONN 255F, CAV D1
10F 10M 333F SHT 2, SECT 71
333M
177BF Bk -0.8
178B Bk -3.0
178C Bk -2.0
178D Bk -3.0
178F Bk -2.0

177L Bk -2.0
177E Bk -3.0
178H Bk -3.0

177G Bk -3.0

600D CONN 76F 26

177F Bk -3.0

223A W-0.8 77 77 223B W-0.8 5 5 223C W-0.8

TRANSMISSION CONTROL IN PARK

200M 600E CONN 87F 22 171F Bk -0.8 TO CONN 265F,CAV F2
1 FRAME SHT 1,SECT33
600G CONN 213M 65
GROUND
177AL Bk -0.8 TO FENDER WORK LAMP RELAY
600H CONN 12M 65
AT CONN 264F, CAV C2
SHT 1 SECTION 29

CLEAN GROUND
CHASSIS GROUND CHASSIS GROUND

CLEAN GROUND
CHASSIS GROUND

CLEAN GROUND
MFD IS OFF RI05N071
SECTION 19 SECTION 20 SECTION 21
 POWER DISTRIBUTION BOX
UNSWITCHED POWER
ACTUATORS COLOR ABBREVIATIONS
UNSWITCHED POWER
SWITHED POWER SWITCHED POWER
ELECTRICAL SCHEMATIC DIAGRAM
ABBREVIATION---COLOR
TO SPL-F2
HEADLIGHT HARNESS
NAO MX MAGNUM SERIES TRACTOR ABBREVIATION---COLOR
R--------------RED

MAGNUM 225, 250, 280, 310

RING TERMINAL 138C A A 881A K-0.8 CONTINUED IN SECTION 31

102C R-3.0
163D R-3.0
163B R-3.0
163A R-3.0
164A R-3.0
163C R-3.0
TO RING TERM 138A SHT1, SECT 27 Or-------------ORANGE
TO INTERMEDIATE
WIRE
TO SECTION
SHT 1,SECT 21 188M 188F
STARTING RELAY
T--------------TAN
NO. FRONT HITCH 622A W-1.0 K--------------PINK
AT RING TERM 82F W--------------WHITE
CIRCUIT DESCRIPTION SECTION CIRCUIT DESCRIPTION SECTION

743A DU-1.0
POSITION LIGHTS P--------------VIOLET (PURPLE)

742A DU-1.0

170B Bk -3.0
170A Bk -3.0
740A DU-1.0
741A DU-1.0
738A R-3.0
163A CONN 255F 71 SHT1 SECTION 19 LEVER HAND FOOT TEMP. Y--------------YELLOW
DU-------------DARK BLUE

SERIES TRACTORS
163B CONN 255F 50
AIR CONDITIONING 58-61 Bk-------------BLACK
163C CONN 255F 39 LU-------------LIGHT BLUE
N--------------BROWN
163D CONN 255F 47 10F 744D K-0.8 ARMREST CONTROLLER 44-48 - OPTIONAL FRONT HITCH 27 DG-------------DARK GREEN
6
S--------------GREY
164A CONN 265F 33 10M
6 AUTOGUIDANCE 73-78 - OPTIONAL FRONT BELTLINE 28 LG-------------LIGHT GREEN
GRAY A B C D E F G H 108M GREEN B G F C D E H A 109M

LT AUXILIARY CONTROL SYSTEM 54 - OPTIONAL HIGH INTENSITY LAMP 31 LIQUID

138C LOW
AUTOMATIC TEMPERATURE CONTROL UNIT 59 LEVEL FLOAT PRESSURE COIL DIODE

EURO ELECTRICAL SCHEMATIC

HIGH BEAM BEAM
267M 267F F4 15A AUXILIARY POWER CONN. (IMPLEMENT) 68 - OPTIONAL REAR FENDER WORK 32-33
LT RT

102P R-3.0
TO INSTR CLUSTER 724A K-0.8 A A 727D K-0.8 TO SPLICE C13 HIGH HIGH CONTACTS
AUXILIARY POWER (7-PIN TRAILER) 33 - OPTIONAL ROOF WORK CAB 28
AT CONN CN1, CAV 3 SHT1 SECTION 24 BEAM BEAM RT
SHT1 SECTION 24 F8 15A F9 15A LOW BLOWER MOTOR (ATCU OR CCU) 59
BEAM MOMENTARY CIRCUIT DIAGRAM LEGENDS
F5 BRAKE PEDAL SWITCHES 50
VARIABLE
TO CONN 9M, CAV 6
SHT1 SECTION 35
728A K-0.8 268M
A
LOW BEAM
268F
A 727C K-0.8 TO SPLICE C13
SHT1 SECTION 24
4 5 2 4 5 2 4 5 2 4 5 2 4 5 2 4 5 2
15A
CHARGING SYSTEM

CAB/CONTROLLER POWER

CAN DATA BUS - TRACTOR 13-18

19

20
- STANDARD CAB FENDER

- STANDARD CAB FRONT ROOF

- STANDARD FENDER WARNING LAMPS

32-33

29

32-33
RESISTOR
RESISTOR

HOUSINGS
MAINTAINED

CIRCUIT
702A B-1.0

COLOR
CIRCUIT TAG IF REQUIRED
CONDUCTOR AREA
87389709
NUMBER
RING TERMINAL 87F
CIGAR LIGHTER 66 - STANDARD BELTLINE WARNING LAMPS N/A
3 1 3 1 3 1 3 1 3 1 3 1
WIRE
NO.
TO SECTION
3
333M STARTER FUEL CENTER WK LT HIGH LOW CLIMATE CONTROL UNIT 58 V P T M
RELAY SHUT & SIDE HI BEAM BEAM BEAM
724B K-0.8

600E SPL-E1 19 CRUISE CONTROL 57 MECHANICAL FRONT DRIVE (MFD) 44

728B K-0.8

3 OFF

LEGEND
333F
DIFFERENTIAL LOCK 44 POWER MIRRORS 64 VACUUM PRESSURE TEMPERATURE
RING TERMINAL 218F
F1
MOTOR LAMP C20
WIRE
F2 30A EGRESS LIGHTING 27 PTO CONTROLLER SYSTEM 49-50 SWITCH SWITCH SWITCH INDICATES CIRCUIT SPLICE
30A DIODE 1
TO SECTION
NO.
ELECTRONIC ENGINE CONTROLLER 55-56 RADIO ANTENNA 62

102N R-3.0
173A CONN 147A 33
F3 F6
NOT REQUIRED CONTACT CONFIGURATIONS
25A 25A ELECTRONIC PTO 49-50 RADIO SOUND SYSTEM 62
DO NOT INSTALL INDICATES CIRCUIT CONNECTION

DIODE 2
WIRE
RING TERMINAL 203F
TO RING TERMINAL 202F
SHT 2, SECTION 57 F7
25A
EMERGING MARKET 79-80 ROTARY LIGHT SWITCH 28
INDICATES CONSTANT POWER
620B R-5.0
TO SECTION ETHER START 80 SCHEMATIC - LEGEND 1-10 INDICATES CIRCUIT CROSSING
NO.
FOOT THROTTLE 57 SCHEMATIC - SYMBOL DEFINITIONS 2 NOT CONNECTED
183A CONN 60F 24 TO CONN 161F, CAV 1
SHT1 SECTION 20
FORWARD/NEUTRAL/REVERSE/PARK 35-36 SEAT 67 D.P.D.T.
S.P.S.T. S.P.D.T. D.P.S.T.

TERM 87F
RING
RING
TERM 218F
TRAILER
TERM 203F
RING

ICU GND
TO CONN 264F, CAV C1
SHT1 SECTION 29
A B C D E F G H 121M

BLUE CONNECTOR
65M C A GRAY 64M C A BLACK 7M A B G D E F H C BLACK
HITCH CONTROL SYSTEM

HEADLIGHT SWTICH
51-52

29
STARTING SYSTEM

SUSPENDED AXLE
19-20

43 MISCELLANEOUS SYMBOLS
INDICATES INTERNALLY
GROUNDED UNITS
INDICATES POWER WHEN
ENGINE CONNECTOR CLEAN
TO CONN 51M, CAV 2

750B K-0.8

726C K-0.8

172C W-0.8
792E K-1.0
724D K-1.0
728D K-0.8
KEY SWITCH IS ON
OPERATOR SUPPLIED POWER INSTRUMENT CLUSTER 24-25 SWCD MONITOR 69

89C R-1.0
HARNESS HARNESS HARNESS

4
SHT1 SECTION 35 102N R-3.0

3
179BE Bk -3.0 ISO11783 70-72 TRAILER CONNECTOR (7-PIN) 33

2 5
TO CONN 9M, CAV 5 179BF Bk -3.0
LIGHTS - STANDARD HEAD LIGHTS 31 TRANSMISSION CONTROL SYSTEM 37-40

1
SHT1 SECTION 35 620B R-5.0
10F 10M 333M 333F
- BEACON 66 WINDSHIELD WIPER/WASHER - FRONT 65
173A Bk -3.0

89A R-1.0 7878 89B R-1.0 1313 FUSE CIRCUIT BREAKER RELAYS FUSE BLOCK
600E Bk -8.0

183A Bk -1.0

792C K-0.8 4747 792D K-1.0 2525 - BRAKE 32-33 WINDSHIELD WIPER/WASHER - REAR 65
GROUND
172B W-0.8 7979 172A W-0.8 1414
- DOME/CONSOLE 63
726A Bk -1.0 5050 726B K-0.8 2121
TO SPLICE C19
724B K-0.8 5656 724C K-1.0 1919 - LICENSE PLATE N/A
SHT1 SECTION 29
750M K-0.8
728B K-0.8
5353
5151
750N K-0.8
728C K-0.8
TO SPL-E1, SHT 1 SECTION 19
2626
2222 CIRCUIT 1
CIRCUIT 2
WIRE BUNDLE
CIRCUIT 1
CIRCUIT 2
TRANSMISSION CONTROL IN PARK
CHASSIS GROUND CHASSIS GROUND
LED CIRCUIT 3 CIRCUIT 3

CLEAN GROUND

SECTION 22 SECTION 23
CLEAN GROUND
PHOTO TRANSISTOR
CIRCUIT 4 CIRCUIT 4
MFD IS OFF RI05N072
OPTIONAL FRONT HITCH LAMPS OPTIONAL WORKLAMPS OPTIONAL WORKLAMPS OPTIONAL 360° STANDARD WORKLAMPS ROOF WARNING LIGHTS (EURO)
INSTRUMENT CLUSTER INSTRUMENT CLUSTER
CAB REAR ROOF CAB BELTLINE WORKLAMPS CAB FRONT ROOF
UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHD POWER UNSWITCHED POWER
SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER
TO SPLICE C33, SHT1, SECTION 19 LEFT RIGHT LEFT RIGHT RIGHT RIGHT LEFT LEFT
TO REAR WIPER MOTOR
JUMPER TO HORN LEFT RIGHT HIGH LOW
88F P HYDRAULIC 50W 50W 50W 50W TO RING TERM 138B AT CONN 99M, CAV1 TO SPLICE C34 LH RH HIGH LOW
FUSE #17 50W 50W 65W 55W
202B R-1.0 101B R-1.0 FILTER FUSE#53 TO RING SHT1 SECTION 21 SHT2 SECTION 65 SHT1, SECTION 19 LICENSE LICENSE 65W 55W
SHT1 SECTION 36 88F

J9 RESTRICTION 262F TERM 138A PLATE PLATE

FUSE #16 5 AMP LEFT RIGHT TO BUSINESS BAND

103G R-3.0

103S R-2.0
30A SHT1, LIGHT LIGHT
REF DES 261F 60M 60F C28 50W 50W RADIO AT CONN 165A, CAV B 23M
201F P 101R R-3.0 960A R-3.0 SECTION 21 24M
OPERATOR PRESENCE SHT2 SECTION 63 1 2 1 2
267A DG-0.8 30 30 267B DG-0.8 TRANSMISSION
CONN 133M, CAV 6 201F
TO CONN 188F, CAV A 16F A B 17F A B 15F 1 2 14F 1 2 195M A B 18M A B

102E R-3.0
267D DG-0.8 31 31 267C DG-0.8 FILTER RESTRICTION TO FRONT WIPER MOTOR
CN1 SHT2 SECTION 67 SHT1, SECT 23 16M A B 17M A B 15M 1 2 14M 1 2 A B C A B C
788A K-3.0 AT CONN 116M, CAV 1

178S Bk -1.0
178T Bk -1.0
178R Bk -1.0
305M 306M

784C K-2.0
178AF Bk -2.0

178AH Bk -2.0
10F 10M TO STROBE/BEACON
RADAR PRESENT 1 211M 211F 1 2 3

178U Bk -0.8
262A Y-0.8 LEFT RIGHT SHT2 SECTION 65 178Y Bk -1.0 1 2 3

709B K-0.8
178V Bk -0.8
E1 E3 255F

178AL Bk -2.0

178AM Bk -2.0

178AD Bk -1.0

178AE Bk -1.0
197F 1 2 198F 1 2

709A K-0.8
AT CONN 114M, CAV 2
87 87

793C R-2.0

793B R-2.0

783B P-1.0

783C P-1.0
SEAT SWITCH 2

798Z K-0.8
303A T-0.8 285B Y-0.8 IMPLEMENT

178X Bk -1.0
285B Y-0.8 A A

752E K-1.0

178W Bk -1.0
197M 198M 1 2

752D K-0.8
LOW HIGH LOW HIGH

751D R-1.0
TO DIODE 267M SHT1 SECTION 22 1 2 SHT2 SECTION 66
HIGH BEAM 3 724A K-0.8 179AT Bk -0.8 B B SWITCH 784E R-2.0
60M 60F PILOT PILOT 1 3
LIGHT SWITCH 5 727A K-0.8 EGRESS

731B Y-0.8
SHT2, SECT 57, CONN 257M, CAV 6 SHT2,SPL-F3,SECT 41

960B R-3.0
CRUISE ON/OFF 7 547A S-0.8 121A Y-1.0 10 10 121B Y-0.8 LIGHTING 177AY Bk -0.8
SHT2,CONN 258,CAV 3,SECT 57

960C R-0.8
CRUISE INCREMENT 8 358A Y-0.8 215D Y-0.8 TO TRANS CONTROLLER RELAY #20 177AX Bk -0.8
HYD FILTER REST. 10 267D DG-0.8 5 5 AT CONN 351M, CAV 34
SHT2,CONN 10F,CAV 30,SECT 40 2 5 4 R4
PNUMATIC IND. 11 566A LU-0.8 234A R-0.8 8 8 234B R-0.8 SHT2 SECTION 40 784B R-2.0 178AK Bk -5.0 178Z Bk -3.0
ALTERNATOR SPEED 19 216A Y-0.8 216A Y-0.8 12 12 216B Y-0.8 J10 R2 R1 178G Bk -3.0 R3
332M 1 2 3 4 331M 1 2 3 4 255F E2 E5 E4
RADAR SPEED 13 199A Y-0.8 262A Y-0.8 28 28 262B Y-0.8 69M 69F
T4 332F 1 2 3 4 331F 1 2 3 4 TO CHASSIS GND
TRANS SPEED 12 215E Y-0.8 215A Y-0.8 215A Y-0.8 15 15 215B Y-0.8 215C Y-0.8 A A WHEEL FUSE FUSE
C48 AT SPLICE C22 TO CONN 280M,CAV P

881A K-0.8

881C K-0.8
FUEL LEVEL 22 236A Y-0.8 24 24 181N Bk -0.8 B B SPEED #6 #5 793D R-2.0 186F R-0.8 787K K-1.0 TO CONN 147M, CAV A
787C K-2.0

751E R-2.0
SHT1 SECTION 31 SHT2,SECT71

880C Bk -2.0

880B Bk -2.0
R7

881B K-0.8

961A R-3.0
TRANS OIL TEMP 24 264A Y-0.8 266A Y-0.8 7 7 266B Y-0.8 261F 261F 186E R-0.8 SHT1 SECTION 33
IGNITION START B+ 26 623B R-0.8 236A Y-0.8 13 13 236B Y-0.8 10A 30A TO CONN 21M, CAV 1
INSTRUMENT CLUSTER (ICU)

13F 10F 10M 787D K-1.0

961A R-3.0
G D E 356F A B C D E F G H
CAV5, 408M 23 23 66M 66F SHT1 SECTION 32
215F Y-0.8 13M G D E 356M A B C D E F G H
TO SPLICE C49 26 26 4 TO CONN 20M, CAV 1
SEC 17 234B R-0.8 A A 787A K-3.0 4 787B K-3.0 787J R-1.0
SHT 1,SECTION 20 22 22 SHT2 A18 SHT1 SECTION 32
264A Y-0.8 264B Y-0.8 216K Y-0.5 236B Y-0.8 B B FUEL SENDER 793A P-2.0
FH2
181M Bk -0.8 C C 783A P-2.0 784A P-2.0 786A R-2.0
TO TRANSMISSION TO PARK RELAY 13F M F A B C
181A Bk -0.8 4 4 181B Bk -1.0 177U Bk -0.8 177U Bk -0.8 177K Bk -0.8
CONTROLLER AT AT CONN 263F, CAV B2 13M M F A B C
199B Y-0.8 25 25 199D Y-0.8 216E T-0.5 177V Bk -0.8 177W Bk -0.8 177AL Bk -0.8 789A R-1.0

177AR Bk -0.8
CONN 351M, CAV 33 177AS Bk -0.8 SHT2 SECTION 40
SEE SECTION 17 F6 89M 89F 22M FH1 22F 177X K-1.0

177L Bk -2.0
60M 60F SHT2 SECTION 37 D4D5D2 264F F4F5F2 264F 264F C4C5C2 263F A4 A5 A2

178D Bk -3.0
178H Bk -3.0
751C K-1.0

752C K-1.0
750A P-1.0
264B Y-0.8 1 1 TRANSMISSION 1 880D Bk -3.0 1
263F D4D5D2 264F E4 E5 E2
AUTOHITCH 11 777B T-0.8 RADAR 181N Bk -0.8 181D Bk -0.8 2 2 T OIL TEMPERATURE 2 886 R-3.0 2 STANDARD
TO NEUTRAL 4 5 2 FRONT 4 5 2 ROOF HID 4 5 2 4 5 2 TO CONN 265F,CAV F1,SHT 1,SECT 33
TRAILER #2 18 770A K-0.8 CAV3, 310F SEC 34 171M 171F 181M Bk -0.8 3 882 DU-1.0 3 J4 AND WORK 164C R-0.8
CAV2, 310F SEC 34 RELAY
4 2 5 4 2 5 ROOF WORK
TRAILER #1 17 769A K-0.8 199A Y-0.8 B B 181D Bk -0.8 4 884 DU-1.0 4 OPTIONAL OPTIONAL LAMP
REAR WORK LIGHTS

241A R-1.0
26 F9 68M 68F AT CONN 263F
AIR FILTER 266A Y-0.8 181L Bk -0.8 A A 5 885 DU-1.0 5 BELTLINE FUSE FUSE FENDER INTERLOCK

731B Y-0.8
10M 10F CAV C2 WORK LAMPS RELAY TO ENGINE RELAY
TRAILERED IMP UP SW 24 285A Y-0.8 C1 181E Bk -0.8 181E Bk -0.8 A A 6 887 R-3.0 6 WORK #4 #3 FUSE WORK RELAY
SHT2 SECTION 40 LIGHTS 3 1 #9 3 1 #7 3 1 3 1 AT CONN 264F, CAV B2
TRANS FILTER 23 267A DG-0.8 777B T-0.8 58 58 199D Y-0.8 883 DU-1.0 7 LAMPS 261F 261F #27 LAMPS #4
B B 7
RADAR
3 1 #3 3 1
SHT1 SECTION 20
FUEL LEVEL SUPPLY 21 234A R-0.8 283B R-0.8 C C 8 880A Bk -3.0 8 #8 10A 20A 261F #12
D3 D1 264F F3 F1 264F 264F C3 C1 263F A3 A1
BUZZER SIGNAL 20 656A R-0.8 380M 262B Y-0.8 D D 20A
CONN 258F,CAV 1, 263F D3 D1 264F E3 E1 TO CENTER AND TO RIGHT
CRUISE DECREMENT 19 498A P-0.8 1 785A R-2.0
BUZZER GROUND 14 SHT2,SECT 57 SIDE RELAY VIA INDICATOR
655 Bk -0.8 2 791B P-0.8 794A R-2.0 795A K-3.0 792C K-0.8
SENSOR GROUND 10 10M 10F 177AR Bk -0.8 CONN 10F, CAV 47 AT SPLICE C18
181K Bk -0.8 BUZZER 777A T-0.8 788A K-3.0 788B K-2.0 788B K-2.0
6 SHT1 SECTION 23 SHT1 SECTION 34

750K K-0.8
EGRESS LIGHTING CNTL 731A Y-0.8 83 83 283A R-1.0 J7 JUMPER TO FUSE 33 792H K-0.8 792B K-0.8 792B K-0.8
BLOWER MOTOR CONTROL 5 312D Or-0.8 TO CONN 264F, CAV A1, SHT2, SECT 61 333M 333F 732A R-0.8 241A R-1.0 750A P-1.0
FUSE #34 CAVITY D6
CLEAN GROUND 4 183B Bk -0.8 266B Y-0.8 15 15 SHT2 SECTION 47 789B K-1.0 789A R-1.0 TO TAIL LAMPS VIA TO LEFT INDICATOR
5A
UNKEYED B+ 3 SEMIKRON CONN 10M, CAVITY 52 AT SPLICE C17
EGRESS 790C P-0.8

792G K-0.8
KEYED B+ 2 AIR FILTER C10 C11 P1000A SHT1 SECTION 33 SHT 1 SECTION 34
203A R-1.0 265F DIODE 790B P-0.8 164C R-0.8
JUMPER TO FUSE 36 B4B5B2 FUSE #21 10A
ALT EXCITATION 1 RESTRICTION SWITCH PACK #1
121A Y-1.0 FUSE #37, 5 AMPS CAVITY C14
REF DES 262F CONN 265F,CAV E2 TO CONN 9M, CAV 4 B+ POWER FOR
SHT2 SECTION 54 76F 177AH Bk -0.8 725A R-0.8 707A Or-1.0 750C Or-1.0 750D K-1.0
CN2 V 76F 4 5 2 207F 207M
SHT2,SECT 66 SHT1 SECTION 35 C19 FRONT HITCH
J8 EGRESS 706B R-1.0 750M K-0.8
C5

WORK LIGHTS
A 259M 395F 395M

725B
707D
TO RING TERM 86F POSITION LAMPS

FRONT ROOF
1

792A K-1.0
792J K-0.8
791A P-0.8
791C K-0.8
790A P-0.8
790E P-0.8
121E Y-1.0 266C Y-0.8 2 600D Bk -0.8 177AJ Bk -0.8 LIGHTING A A

REAR ROOF
60M 60F A 259F SHT1,SECT 19 TO FLASHER AT FUSE #18 10A TO CONN 10F, CAV 53
5 5 SPL-35 RELAY B B 707C K-0.8
CONN 265F, CAV D2 B1 W H/L T B2 R 12F CONN 135M, CAV 3 BLACK SHT1 SECTION 23
2 2 183A Bk -1.0 216C Y-0.8 6 6 177BD Bk -0.8 #17 C C 706A R-1.0 101H R-2.0
TO CHASSIS GND 1 ROTARY CONN

177BF Bk -0.8
TO CONN 13M, CAV T TO RING TERM 85F SHT 2,SECTION 66 3 SHT*** SECTION 34 C3
727B K-1.0 126Y DG-1.0 D D 790D P-0.8 B1 W H/L T B2 R

SHT2 SECTION 63 SHT1,SECT 19 AT SPLICE E1 SWITCH 10 9 8 7 6 5 4 3 2 1 11M

178D Bk -3.0
178H Bk -3.0
C13 265F JUMPER TO FUSE #19

OFF
AUTO E E J1 TO RING
SHT1 SECTION 19 B3 B1 HEADLIGHT 10 9 8 7 6 5 4 3 2 1 FUSE BLOCK 261, CAV B6
HITCH F F 706D R-0.8 TERM 172F
379M A B C D E F SWITCH
TO DIODE AT CONN 268F SHT2 SECTION 63
727C K-0.8 SHT1

600

HAZARD
SHT1 SECTION 22 TO SELF CANCEL SENSOR
TO RING TERMINAL 173F TO CHASSIS GROUND 706E R-0.8 SECTION 21

OFF
ROAD
VIA CONN 179M CAV 1 TO UNIVERSAL SWITCH
TO RING TERMINAL 203F SHEET 1,SECT 21 AT RING TERM 173F
TO DIODE AT CONN 267F SHT1 SECTION 35 VIA CONN 9M, CAV 7
727D K-0.8 SHT 1 SECTION 22 EGRESS DIODE PACK #2 SHT1, SECTION 21
SHT1 SECTION 22 731A Y-0.8 SHT1 SECTION 35
731A Y-0.8 731A Y-0.8 790D P-0.8 TO RING TERM172F SHT 1SECTION 21
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND

CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND

SECTION 24 SECTION 25 SECTION 26 SECTION 27 SECTION 28 SECTION 29 SECTION 30

OPTIONAL HIGH STANDARD STANDARD WIDE MARKER SINGLE, OR OPT TWIN LEFT FENDER STOP, RIGHT FENDER STOP, SINGLE, OR OPT TWIN WIDE MARKER FORWARD NEUTRAL REVERSE PARK (FNRP) HORN
INTENSITY LAMP HEADLAMPS HEADLAMPS LIGHT LAMP FENDER LIGHTS TAIL, TURN LIGHT TAIL, TURN LIGHT LAMP FENDER LIGHTS LIGHT
UNSWITCHED POWER UNSWTICHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER
SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER
STOP TAIL STOP TAIL
LEFT RIGHT TO RING TERM 138B TO TRANS CONT VIA CONN 10F, CAV 91, SHT 2 SECTION 40
HID SIDE LEFT LEFT CENTER RIGHT RIGHT SIDE TO RING TERM 138C
H3 H3 H3 H3 SHT 1 SECTION 21 409F 409M

101F R-3.0
CENTER 50W HIGH LOW 50W HIGH LOW 50W SHT 1,SECT 22 TO SPLICE C12, SHT 2 SECTION 40
55W 55W 55W 55W UNSWITCHED B+ A
65W 55W 65W 55W 312A R-1.0 103F R-2.0 FUSE A 722D R-2.0
TO TRANS CONT VIA CONN 10F, CAV 88, SHT 2 SECTION 40 JUMPER FROM #17 B B
FUSE #22 723D Bk -1.0
10A TO SPLICE C33 FUSE #16 5A
1 2 3 4 SPL-37, SHT 2, SECT 40
230F 1 2 1 2 3 4
235F 1 2 10M

J2
OPTIONAL SHT1 SECTION 19 SHT1 SECTION 24 10F
230M 1 2 228M 1 2 3 4 1 2 3 4 233M 235M 1 2 TO TRANS CONT VIA CONN 10F, CAV 26, SHT 2 SECTION 39
RIGHT J9 722A R-1.0 80 80 722B R-2.0
430M A B 431M A B 432M A B JUMPER TO FUSE 23
FENDER
750P R-0.8
174Z Bk -0.8

A B C A B C
TO SWITCHED B+ AT SPLICE C4, SHT 2 SECTION 40
HID LAMP AT 261F, CAVITY A12
FUSE
4M 2M SHT2 SECTION 66 TO START RELAY VIA CONN 10F, CAV 79, SHT 1 SECTION 23 60M 60F 333M
A B C A B C #20
787G R-0.8

412A+
174M Bk -0.8

174P Bk -1.0

750L R-0.8 26F 20A

170K Bk -1.0

TO IGNITION SWITCH SPL-49 1 1

170C Bk -1.0

170E Bk -1.0

TO PTO CONTROLLER
170D Bk -1.0

1
738B R-1.0

738C R-1.0

738D R-1.0

4 4
170J Bk -1.0

755D R-0.8 1 311A R-0.8 723A Bk -0.8 16 16 723B Bk -0.8 722C R-1.0
VIA CONN 10F, CAV 14 SHT1 SECTION 20
263F F1F3 12 12
HID 753C R-0.8 2 723C Bk -1.0 1

164A R-3.0
SHT2 SECTION 45
HID 51M 51F
REGULATOR 4 412B-
753C R-0.8

1 3 START INPUT 333F

6M
750L R-0.8
755D R-0.8

753D R-0.8 REGU- 623A W-0.8 1 1 001A Bk -0.8

START OUTPUT
A 27F 25M LATOR 172B W-0.8 2 2 002A Bk -0.8 HORN
755L R-0.8 787N R-1.0 RUN INPUT
B 1 A BRAKE CAV 11 , 335F 565F LU-0.5 550J R-0.8 3 3 003A Bk -0.8
H1 FL2 NOT PARK
170H Bk -1.0 174AB Bk -0.8 2 B LIGHT SEC 51 A5 511A T-0.8 4 4 004A Bk -0.8 FNRP POD TRUTH TABLE
FR2 2 5 4 REVERSE
174L Bk -0.8 RELAY 552C T-0.8 5 5 005A Bk -0.8
H2 FORWARD
SHUTTLE NOT
738F R-1.0 #1 CAV1, 70M 551D T-0.8 6 6 006A Bk -0.8 START
174V Bk -3.0

F2 F5 F4 565E LU-0.5 LEVER NOT PARK (NEUTRAL REVERSE FORWARD

263F SEC 41 NOT NEUTRAL OUTPUT
LEFT RIGHT NOTE: CONNECTOR 235M IS CONNECTED TO 553F T-0.8 7 7 007A Bk -0.8 POSITION OR PARK)
1 2 3 4 5 6 21F 6 5 4 3 2 1 20F B+ FROM 10F 10M 5Vreff
743A DU-1.0 FENDER FENDER CONNECTOR 27F WHEN OPTIONAL RIGHT FENDER 561B R-0.8 8 8 008A Bk -0.8
1 2 3 4 5 6 21M 6 5 4 3 2 1 20M SPLICE A18 HORN PARK 0 0 12 1.5 1.5
CONN CONN 787J R-1.0 HID LIGHT IS USED 565C LU-1.0 28 28 565A LU-1.0 723A Bk -0.8 9 9 009A Bk -0.8
SHT1 SECTION 29 10M
170B Bk -3.0

170A Bk -3.0

10F COMMON
FORWARD CAB POWER CAB POWER 0 1.5 3.4
740A DU-1.0

741A DU-1.0

742A DU-1.0 178AB Bk -0.8 10 10 010A Bk -0.8 1 1

102 102 CHASSIS GND AT SPLICE C22 SHT1 SECTION 31
787D K-1.0
753B K-0.8
751M K-0.8

750F K-1.0

750H K-1.0
755C K-0.8
752L K-0.8
754B K-0.8

164D R-3.0 FUSE #41 177Y Bk -1.0 752A K-0.8 11 11 011A Bk -0.8 2 2
755J K-0.8

NEUTRAL CAB POWER 0 0 1.5 1.5

738A R-3.0

20A 751A K-0.8 12 12 012A Bk -0.8 3 3

A 41M 40M A 147M 147F 147A REVERSE CAB POWER CAB POWER 0 3.4 1.5

002A Bk -0.8
004A Bk -0.8
005A Bk -0.8
177J Bk -0.8 TO POWER RELAY 766A R-3.0 221M 221F
A 41F 40F A
AT RING TERM 279F 787C K-2.0 A A 784X K-2.0 2 FIELD L TRAILER 006A Bk -0.8
SHT1 SECTION 20 751K K-1.0 B B 754X K-1.0 1 LEFT T CONNECTOR 755A K-2.0 RIGHT INDICATOR LEFT/RIGHT TURN 001A Bk -0.8

OFF
752J K-1.0 C C 752R K-1.0 4 RIGHT T (EURO) LEFT INDICATOR INDICATORS 008A Bk -0.8

ON
B+ FROM
738G R-1.0
738E R-1.0

177Y Bk -1.0 TO BRAKE LIGHT RELAY 755F K-1.0 D D 703H K-1.0 6 STOP 49 6 723A Bk -0.8 003A Bk -0.8
SPLICE A18 E E HAZARD
AT CONN 263F, CAV F2 164E R-3.0 707Z K-1.0 5 R TAIL L C 5 007A Bk -0.8
SHT1 SECTION 29 SWITCH
174K Bk -3.0

SHT1 SECTION 34 TO CONN 109M 222C R-3.0 F F 707Y K-1.0 7 L TAIL L 49A 4 SELF-
707X K-2.0

F1F3 TO UNSWITCHED B+
AT BUSMANN BOX G G 3 GND 265F C3 3 CANCEL
SHT1 SECTION 23 AT SPLICE C3 SENSOR UNIVERSAL
177H Bk -0.8 TO CONN 27, 255F, CAV F1 TRAILER C2 2
1 3 1 2 3 4 5 6 7 8 9 10 SHT1 SECTION 29 CAB
TO WORKLIGHT B+ TO SPL-C19 TAIL 179M 179F 191F SWITCH 219F
SHT2, SECT 50 164C R-0.8 31 1 POWER
316M
164B R-3.0

177AK Bk -0.8
AT SPLICE A18 SHT 1,SECT 29 LIGHT 1 2 3 4 5 6 7 8 9 10 706E R-0.8 1 1 R_ R-0.8 R B+ 2
310F TURN SIGNAL COMMON 220A
SHT1 SECTION 29

769A K-0.8
3M RELAY 178AC Bk -0.8 2 2 N_ N-0.8 N GROUND 1 49a

B 170G Bk -1.0 #13 20 COMMON LEFT TURN SWITCH 220B LEFT 219F
A13

770A K-0.8

751U R-0.8
2 5 4 TO HIGH BEAM RELAY 1 R

177AC Bk -0.8 TO CONN 133M, CAV 3 A 174F Bk -3.0 TR1 21 LEFT TURN 4
OPTIONAL VIA CONN 10F, CAV 50

20A_ Bk -0.8
A4 TO SPL-C9 265F CAV1, C14 KEY SW REED 7
SHT2 SECTION 67 171F Bk -0.8 177S Bk -0.8 22 RIGHT TURN RIGHT REED PARK SWITCH
HID F2F5F4 SHT1 SECTION 23 220C TURN
START
SHT 1,SECT 21 SEC 64

21A_ Bk -0.8
TO 294F,CAV S TURN SWITCH SW 1 SW 2
LIGHTS 752K K-1.0 766C R-2.0 22 RIGHT TURN 1 L SIGNAL
N.C.
SHT2,SECT 71 10M 10F INPUT N.O. 3.9 NOT PARK 219F

22A_ Bk -0.8
5M RIGHT
177AD Bk -0.8 TO CONN 133M, CAV 4 TO C22, 752B K-1.0 21 LEFT TURN HEAD A B

3 3 TO CONN 11M, CAV 4 LAMP B+ 220D

SHT2 SECTION 67 B 170F Bk -1.0 174K Bk -3.0 222C R-3.0 SEC 31 20 COMMON 1 56
2
REED
41 41 SHT1 SECTION 29 NOT
174A Bk -5.0

CAV17, CN2 220E 219F 3.9 NEUTRAL SWITCH SW 3

A 754B K-0.8 1 3
44 44 SEC 24 751B K-1.0 751J K-1.0 1 56a N.C. 3.9 (NEUTRAL OR PARK)
177AE Bk -1.0 753B K-0.8 9M 9F HIGH/LOW
5 START
TO CONN 133M, CAV 8
42 42
C17 220F BEAM
C D
219F
752H K-1.0 752G K-1.0 766B R-3.0 1 1 020A Bk -0.8 1 56b OUTPUT
SHT2 SECTION 67
45 45 CAV18, CN2 REED 5 Vreff
751F K-1.0 751J K-1.0 2 2 021A Bk -0.8 REED 8
TO BACK UP ALARM
A3 52 52 SEC 24
FORWARD SW 4 REVERSE SW 5
177K Bk -0.8 TO CONN 264F, CAV F2 174G Bk -0.8 751H K-1.0 750D K-1.0 752N K-1.0 752N K-1.0 3 3 022A Bk -0.8 SWITCH
N.O. SWITCH N.O.
AT CONN 338F, CAV 2 99 99 2.2k
L
2.2k
J
219F
DIPPING
SHT1 SECTION 42 750E K-1.0 755A K-2.0 725A R-0.8 4 4 023A Bk -0.8 K I
560 REVERSE
SHT2 SECTION 25 A17 HIGH BEAM
755F K-1.0 726A Bk -1.0 5 5 024A Bk -0.8 E F 1
755C K-0.8
C18 C32 728A K-0.8 6 6 025A Bk -0.8
LOW BEAM
177AK Bk -0.8 TO CONN 264F, CAV 1 T8 219F
TO CONN 335F, CAV B 220G 560
C22 SHT 1 SECTION 34 174C Bk -0.8 755J K-0.8 755B K-2.0 7 7 026A Bk -0.8
HEADLAMP DIPPING B+
1 56d
G H

SHT2 SECTION 49

178F Bk -2.0
GROUND FORWARD 6
173A Bk -3.0

178AA Bk -0.8 8 8 027A Bk -0.8

TO CONN 13M, CAV C, SHT 1 SECTION 30 220H MU8 FNRP CIRCUIT - PWM
177C Bk -5.0 752C K-1.0 HORN
TO CONN 335F, CAV B TO SPLICE C19 TO UNSWITCHED B+ 1 31b
219F
TO CHASSIS GROUND 174E Bk -0.8 706D R-0.8 (NORMAL STATE - NO MAGNETIC FIELD APPLIED)
10F 54 SHT2 SECTION 9 TO CONN 294F,CAV 9 TO CONN 294F,CAV R SHT1 SECTION 29 TO CONN 13M, CAV A, SHT 1 SECTION 30 AT SPLICE C3 220J
AT RING TERM 189F 750R K-1.0 751L K-1.0 751C K-1.0 1 31

10M 54 SHT2,SECT 71 SHT2,SECT 71 TO LOW BEAM RELAY SHT1 SECTION 29

SHT 2, SECTION 56
VIA CONN 268M
177A Bk -8.0 TO RING TERMINAL 189F
RING TERMINAL 218F TO RING TERM 172F, SHT 1 SECT 21 SHT1 SECTION 22
SHT2, SECTION 56
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND

CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND
SECTION 31 SECTION 32 SECTION 33 SECTION 34 SECTION 35 SECTION 36

TRANSMISSION CONTROL SYSTEM TRANSMISSION CONTROL SYSTEM TRANSMISSION CONTROL SYSTEM TRANSMISSION CONTROL SYSTEM PNEUMATIC BRAKE OPTION ITALIAN BRAKE OPTION MU8 SUSPENSION AXLE CONTROLLER
UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER
SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER
350M
TO NOT PARK SIGNAL TO RING TERM 138C
SWITCHED B+ 12V 1 550B R-0.8 550A R-2.0 511A T-0.8 PNEUMATIC OFF
T1 (1-2) EVEN MASTER (3-4) ODD CREEP AT CONN 51M, CAV 4 SHT 1, SECT 22 50M
SWITCHED B+ 12V 2 550D R-0.5 PREFILL LOCK/UNLOCK
SOL SOL SOL SOL SOL SOL SHT1 SECTION 35 CAV1, A5
SWITCHED B+ 12V 3 550H R-0.5 BOC B 568A T-0.8 SOLENOID
550F R-1.0

(N/C) 263F B1 B3 263F C1C3

558A Or-0.8

550G R-2.0

SWITCHED B+ 12V 8 550M R-0.8 SWITCH A 553B R-0.8 SEC 32 70M 70F 311F 181M
UNSWITCHED B+ TO
C1-2 CLUTCH HIGH SIDE 6 201C R-0.5 SWITCHED B+ 565E LU-0.5 565D DG-1.0
A A A 1

1 2 3 4 5 6 7 8 9 10
CN1-A (CENTER RIGHT)

B6 CONTROLLER VIA 1 3 1 3
TO CONN 51M, CAV 3
EVEN CLUTCH HIGH SIDE 10 201E R-0.5 550J R-0.8 179BB Bk -1.0 B B 179BS Bk -1.0 B 531C R-0.8 2
CONN 335F, CAV 24 PARK
SHT1 SECTION 35
MASTER CLUTCH HIGH SIDE 5 586A R-0.5 SHT2 SECTION 49 NEUTRAL 3
RELAY
C3-4 CLUTCH HIGH SIDE 7 201F R-0.8 FUSE #43 15A RELAY 4
1 2 1 2 A B 1 2 1 2 1 2 C4 #5
163C R-3.0

ODD CLUTCH HIGH SIDE 9 201B R-0.5 550K R-2.0 #6 PNEUMATIC 5

114D R-0.8

31M 35M 32M 29M 39M

30M 2 5 4 2 5 4 10M 10F
220B T-0.5

TO SPL-C21
201B R-0.5
583AT-0.8

CREEP CLUTCH HIGH SIDE 11 201N R-0.5 AIR SWITCH 102L R-3.0 531A R-1.0 6
580A T-0.8

201N R-0.5

114C R-0.5 67M 67F 325A P 17 17 TO SPL-C49 SHT 1,SECTION 20

UNSWITCHED B+ 12V 14 155A R-0.8 106C R-0.8 7
263F B2 B5 B4 263F C2 C5 C4 1 FUSE
558B Or-0.5 J13 566B LU-0.8 566C LU-0.8 SHT 1,SECT 20
PARK BRAKE CONTROL 4 1 1 FUSE #26 531D R-0.8 8
CAN BUS SEE SECTION 13 586A R-0.5 FUSE #44 15A 179BA Bk -0.8 2 2 179AB K-0.8 #56 10A 9
1
177AW Bk -0.8

10F
177AS Bk -0.8

177AW Bk -0.8

C7-8 CLUTCH HIGH SIDE 12 201F R-0.8 5A 10

562A T-0.8

177X K-1.0
220M R-2.0

325B
10M SHT2
CASE GROUND 19 179M Bk -0.8 T2 OPTIONAL 599K R-0.8
B+ 12V FROM NEUTRAL RELAY 20 220F R-0.8 220A R-2.0 1 1 220M R-2.0 PNEUMATIC C30 AXLE

155B R-0.8
CLEAN GROUND 23 557A Bk -0.5 2 2 FUSE #32 10A PARK PARK REGULATION
T10 UNSWITCHED B+
CHASSIS GROUND 25 175J R-0.5 114C R-0.5 114B R-1.0 20 20 114A R-1.0 101E R-1.0 SOLENOID SOLENOID SWITCH
AT SPL-C33 317F

532A DU-0.8
26 26 49MM 318F 318M

531B R-1.0
536A DU-0.8
CHASSIS GROUND 26 175H Bk -0.8 511B T-0.5 ORANGE
12 12 SHT1 SECTION 19
353M 550A R-2.0 550C R-2.0 1 567G R-1.0 567F R-1.0 A A 567H R-1.0 A COLORED
C1-2 CLUTCH LOW SIDE 6 582A T-0.5 2 179CA Bk -1.0 179BV Bk -1.0 B B 179BW Bk -1.0 B CONN
581A T-0.8 10F
CN2 (TOP RIGHT)

EVEN CLUTCH LOW SIDE 1

TO PARK SOLENOIDS 10M 10M 10F
ODD CLUTCH LOW SIDE 8 580A T-0.8
VIA CONN 333M, CAV 7 16 16 1 149F 19 19
CREEP CLUTCH LOW SIDE 3 590A T-0.5 590A T-0.5 562B T-1.0 562A T-0.8
TRANSMISSION CONTROLLER - TRCU

SHT 2 SECTION 41 100

100 1 149M 21 21
MASTER CLUTCH LOW SIDE 4 220B T-0.5 TO REAR WORKLIGHTS RELAY 49F
P1 (CENTER RIGHT)
POWER GROUND 26 175G Bk -0.8 558B Or-0.5 92 92 558A Or-0.8 1 567D R-1.0 24 24
TO INTERLOCK RELAY AT AT CONN 263F, CAV D2 350M
97 97
1 2

CN1-A
SEE SECTION 43 558B Or-0.5 2 179BT Bk -1.0

536B DU-0.5
CONN 263F, CAV A2 SHT1 SECTION 28

532B DU-0.8
EGRESS LIGHTING OUTPUT 11 SHT1 SECTION 29 49F CONNECTS WITH CONN 49M P2 FSUS UPPER LOCK 13
TO SPL-A11 RAISE LOWER
C3-4 CLUTCH LOW SIDE 13 583A T-0.8 583A T-0.8 WHEN TRACTOR IS EQUIPPED
T50

TRANSMISSION CONTROLLER - TRCU

SHT2 SECT 49 SPL-C20
CHASSIS GROUND 21 175F Bk -0.5 179C Bk -3.0 160D R-0.8 553F T-0.8 TO FNRP MODULE WITH PNEUMATIC BRAKES
T7 SHT1, SECT 21 (TOP RIGHT) 353M
557A Bk -0.5 557C Bk -0.8 C12 VIA CONN 51M, CAV 7
355M B1 B3 255F TO ENGINE GROUND
C5-6 CLUTCH LOW SIDE 1 584A T-0.8 SHT1 SECTION 35 179AG Bk -3.0 POS SIG (4 TO 20mA) 2
CONN 333M, CAV 2
557B Bk -0.8

CN2
REVERSE CLUTCH LOW SIDE 2 585A T-0.5 585A T-0.5 SUS IND LED 18
1 3 SHT2, SECTION 56
C7-8 CLUTCH LOW SIDE 3 MASTER CLUTCH 276M 276F FSUS UPPER LOCK 7
PARK 1 2
TO CAB PRESS BLOWER 1 2
SYSTEM PRESSURE HIGH SIDE 17 846A R-1.0 CONN 74M,CAV 1 TRCU PEDEL POT 179AY Bk -1.0 A A 155C R-0.8 192M 192F
566B LU-0.8

BRAKE
AT CONN 90, CAB B 355M 183M 184M
CN3-B (TOP LEFT)

SEE SECTION 43 SHT3, SECT 78 CONTROLLER 52M PRESSURE P B B 156A LU-0.8 538A R-0.5 1 1 538C W-0.8
SHT2 SECTION 60 (TOP LEFT)
HIGH CLUTCH HIGH SIDE 16 220E R-0.5 220E R-0.5 34M RELAY # 23 A SWITCH 179BG Bk -0.8 2 2 179BK N-0.8
SYSTEM 2 5 4
REVERSE CLUTCH HIGH SIDE 5 201G R-0.5 201G R-0.5 1 B FSUS LOWER 7 537A LG-0.5 3 3 537C Y-0.8
PRESSURE

CN3-B
REV SOL SHT1,CONN 211M,CAV B,SECT 26
MID CLUTCH HIGH SIDE 6 588A R-0.5 37M 33M 2 TRANSDUCER C 179AT Bk -0.8 FSUS LOWER LOCK 15 179BH Bk -0.8 4 4 179BL DG-0.8
1
44M 255F B2 B5 B4 F3 FSUS RAISE
B+ 12V FROM NEUTRAL RELAY 25 220G R-0.8 MID SOL 1 8 542A LU-0.5 5 5 542B LU-0.8
2 5-6 SOL 10M 10F
MID CLUTCH LOW SIDE 10 220C T-0.8 2 38M A FSUS LOWER LOCK 3 546A LU-0.5 6 6 546B LU-0.8
C5-6 CLUTCH HIGH SIDE 13 201D R-0.5 1 B 162C R-3.0 30 30 566A LU-0.8 TO PNEUMATIC INDICATOR 274A 548A Y-0.8 7 7 541B Y-0.8
HI SOL TO PARK RELAY TRACTOR (BOTTOM RIGHT)
LOW CLUTCH HIGH SIDE 14 587A R-0.5 589A T-0.5 2 563A LU-0.8 C 555A LU-0.8 38 38 555D LU-0.8 CONN CN1,CAV 11,SHT1,SECT 24 1 541A Y-0.8 8 8 548B Y-0.8
179AA Bk -5.0

VIA CONN 10M HYDRAULIC 351M 186M 187M

HIGH CLUTCH LOW SIDE 4 589A T-0.5 556A R-0.8 39 39 556D R-0.8 TO CONN 51M, CAV 6 562B T-1.0 47M

CN1-B
36M
179AF Bk -1.0

CAVITY 16 RIGHT BRAKE PRESSURE 2 1 2 1

B+ 12V FROM NEUTRAL RELAY 34 220H R-0.8 1 557C Bk -0.8 40 40 557D Bk -0.8 SHT1 SECTION 35 561F T-1.0 A P SUS ENABLE B+ 26
LO SOL PARK SOLENOID 1 158A DG-0.8
SHT2 SECTION 39 SWITCH OPEN
LOW CLUTCH LOW SIDE 18 220D T-0.8 2 58 58 552C T-0.8 TO CONN 51M, CAV 5 567A T-1.0 B 2
SWITCH (N/C) 274B
BACK UP ALARM POWER 9 571A R-0.8 551A T-0.5 88 88 551D T-0.8 SHT1 SECTION 35
T6 C37
351M 561C R-0.8 552A T-0.5 90 90 552B T-0.8 552H T-0.8 TO CONN 408M,CAV 6 278F
333M 48M TO FOOT THROTTLE
RANGE PRESSURE SIGNAL 11 563A LU-0.8 553A T-0.5 89 89 553D T-0.8 SHT3,SECT 73 275A
E6 LEFT BRAKE 1 TRAILER
VIA CONN 60F, CAV 3
PARK BRAKE FEEDBACK 567L Bk -0.5 567L Bk -0.5 561A R-0.8 91 91 561B R-0.8 7 7 561E T-0.8 561G T-1.0 A
28 TO FNRP TRAILER 1 182A Bk -0.8 182B Bk -0.8 2 BRAKE
8 8 PARK SOLENOID SHT2 SECTION 57 UPPER LOWER
CN1-B (BOTTOM RIGHT)

FNRP SWITCH 5V 16 561D R-0.5 561D R-0.5 561A R-0.8 AT CONN 51M, CAV 8 567K Bk -0.8 567J T-0.8 567B T-1.0 B IB1 SOLENOID

179L Bk -1.0
SWITCH (N/C) PRESSURE 3 LOCK LOCK
E5 P TO CONN 10F, CAV 95

531F R-0.8
MASTER CLUTCH SIGNAL 1 555A LU-0.8 555A LU-0.8 SHT1 SECTION 35 SWITCH 1 GND
SHT2 SECTION 48
30 31

179K Bk -3.0
333F

544A T-0.5
AUTOGUIDANCE ISOLATION VALVE 17 556A R-0.8 556A R-0.8
275B
NOT PARK SIGNAL 22 511B T-0.5 511B T-0.5 49M
T5
FORWARD SIGNAL 13 551A T-0.5 551A T-0.5 567L Bk -0.5 567L Bk -0.5 567L Bk -0.5 567C T-1.0 1 PARK 277F
333F 193M
REVERSE SIGNAL 12 552A T-0.5 552A T-0.5 179AF Bk -1.0 2 SOLENOID 185F 185M
337A 182C Bk -0.8 2 CONNECT TO CONN
NOT NEUTRAL 553A T-0.5 553A T-0.5 338F 338M 9 9 531H R-0.8 531G R-0.8
23 159A LU-0.8 1 67M (AIR SWITCH A A 2
EGRESS LIGHTING INPUT SELECTION 571A R-0.8 571A R-0.8 1 1 571B R-1.0 BACKUP 10 10 544D T-0.5 544C N-0.8 3
24 337A
NOT USED) C C
174G Bk -0.8 2 2 174H Bk -1.0 ALARM 179J Bk -5.0 179CL Bk -0.8 11 11 179CN Bk -0.8 B B 179BC Bk -0.8 1
SEE SECTION 43 TO ALTERNATOR FREQUENCY VIA SPLICE F6, SHT 1 SECTION 25 CHASSIS GND TO CLEAN GND
337B F1
FROM SPLICE A13 337B AT RING TERM 200 333M
ENGINE ALT SPEED 33 216E T-0.5 WHEEL SPEED SIG FROM SPL-T4 SHT 1 SECTION 26 L.H. POSITION
SHT1 SECTION 32 TO SPL-200F, SHEET 2, SECTION 56 SHT2 SECTION 56
TRANS WHEEL SPEED 34 215D Y-0.8 SENSOR ON AXLE
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND
CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND CLEAN GROUND
SECTION 37 SECTION 38 SECTION 39 SECTION 40 SECTION 43
SECTION 41 SECTION 42
 ARMREST CONTROLLER (ARU) ARMREST CONTROLLER (ARU) ARMREST CONTROLLER (ARU) ARMREST CONTROLLER (ARU) ARMREST CONTROLLER (ARU)
UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER UNSWITCHED POWER
SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER
160E R-0.8 TO RING TERM 138C

163D R-3.0
JUMPER TO FUSE 34
SHT 1, SECT 22 J7
SPL-C20 CAVITY D4
SHT1 SHT1 SECTION 25
SCRAPER CREEPER SECT 21

ON (MOM)
ON POS C
ON POS A
FUSE #33

NONE
C1C3 255F

OFF

OFF
10A
AUX 1 - FLOW

162D R-3.0
1 3
ARU
CONTROLLER 1 AUX 2 - FLOW

171D Bk -0.8
RELAY # 24 2
1 2 3 7 8 1 2 3 7 8 9 3
2 5 4 AUX 3 - FLOW
4
INSET "A" 5
255F C2 C5 C4
6 AUX 4 - FLOW
TO CONN 10F, CAV 29
EDC SLIP CONTROL 7
SHT2 SECTION 50
8

SLIP SELECT
AUX -TIMER
MFD DIFF LOCK AUX 5TH REMOTE HITCH UP/DOWN AUTO SHIFT PROGRAMMABLE SHIFT 9

ON RETRACT

ON (NOM)
10

ON EXTEND
ON AUTO

DIFF LOCK ON

SLIP SET

SLIP SET

ON DWN
FBAT
11 HITCH - UPPER LIMIT

DOWN

DOWN

ON UP
NONE
UP
12
OFF

OFF

OFF

OFF
AUTO
OFF

OFF

OFF

179Z Bk -1.0
13
ON

ON
HITCH - DROP RATE
14

293B Y-0.8

179Z Bk -1.0
2.4K

65A R-0.8
SEE HITCH - TRAVEL
1 2 3
INSET

AUX 3 AUTO

AUX 1 AUTO
1 2 3 7 8 9 1 2 3 4 5 6 7 8 9 10 1 2 3 7 8 9 10 1 2 3 7 8 9 C E D J K G 1 2 3 4 5 6 1 2 3 7 8 9 1 2 3
"A" SECONDARY
FOR
SWITCH
AUX EXTEND LIMIT SET CONTROL
AUX RETRACT LIMIT SET
OPTION PANEL
4 1 5 6 2 3 J210 5 1 6 3 2 4 J212 137M 1 2 3 6 7 8 9 10 11 12
10

10

10

10

10

10

10
11
12

10
11
12
13
14
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3

1
2
3

1
2
3

1
2
3
4
5
6

4
1
5
6
2
3

1
2
3

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
3

5
1
6
2
3
4

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

2
SIGNAL, DIF LOCK ON PILOT/CONT LED
SIGNAL, POSITION C (DIFF LOCK ON)

TRANS CONTROLLER UNIT BUMP DOWN

HITCH POSITION COMMAND - SIGNAL

SIGNAL, PROGRAMMABLE SHIFT DOWN

SIGNAL, PILOT/AUTO HITCH ADJ LED

CREEPER,NOT USED/SCRAPER POS A

TRANS CONTROLLER UNIT BUMP UP
HITCH POSITION COMMAND - HIGH

HITCH POSITION COMMAND - HIGH

SIGNAL, POS A (DIFF LOCK AUTO)

SIGNAL, PROGRAMMABLE SHIFT UP

SIGNAL, CREEPER/SCRAPER POS C
HITCH POSITION COMMAND - LOW
HITCH LOAD COMMAND - SIGNAL

AUXILIARY RETRACT LIMIT SET

AUXILIARY EXTEND LIMIT SET
C7

HITCH LOAD COMMAND - LOW

IMPLEMENT DEPTH CONTROL SET UPPER

AUXILIARY 5 FLOW - SIGNAL
AUXILIARY 5 FLOW - HIGH

IMPLEMENT DEPTH CONTROL LOWER

AUXILIARY 5 FLOW - LOW
SIGNAL, AUX 5 RETRACT
SIGNAL, AUX 5 EXTEND

THROTTLE - SWITCH 1

THROTTLE - SWITCH 2

HITCH - UPPER LIMIT

SIGNAL, SLIP SELECT

SIGNAL, AUTO SHIFT

AUXILIARY 1 SWITCH

AUXILIARY 2 SWITCH

AUXILIARY 3 SWITCH

AUXILIARY 4 SWITCH

THROTTLE - SIGNAL

AUXILIARY 1 - FLOW
AUXILIARY 2 - FLOW
AUXILIARY 3 - FLOW
AUXILIARY 4 - FLOW

HITCH - DROP RATE

CAN DATA BUS HIGH
AUXILIARY 1 LEVER

AUXILIARY 2 LEVER

AUXILIARY 3 LEVER

AUXILIARY 4 LEVER

AUXILIARY - TIMER
AUXILIARY GROUND

AUXILIARY GROUND

AUXILIARY GROUND

AUXILIARY GROUND

AUXILIARY GROUND
SIGNAL, MFD AUTO

FRONT DIFF LOCK

HITCH DOWN FAST
THROTTLE - HIGH

CAN DATA BUS LOW

SIGNAL, SLIP SET

REAR DIFF LOCK

THROTTLE - LOW

AUTOGUIDANCE ENGAGE
SIGNAL, MFD ON

SYSTEM GROUND
SWITCH, POWER

SWITCH, POWER

SWITCH, POWER

SWITCH, POWER

SWITCH, POWER
SWITCH POWER

SWITCH POWER

SWITCH POWER

HITCH TRAVEL
BATTERY FEED

BATTERY FEED

BATTERY FEED

BATTERY FEED

BATTERY FEED

BATTERY FEED

BATTERY FEED

BATTERY FEED
SWITCHED B+

HITCH DOWN

STCU COMBO
LED GROUND

HI-LO RELAY
HITCH UP
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

NOT USED

NOT USED
NOT USED

NOT USED
NOT USED
NOT USED

NOT USED
NOT USED

NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED
NOT USED

NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

NOT USED

NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED

NOT USED
NOT USED
NOT USED

NOT USED

NOT USED
CAV7, 408M SEC 17

PTO OFF

SOL PWR

BATTERY
GROUND

177BB Bk -0.8

AUTO PTO
PTO ON

PTO ON
+8VDC

+8VDC

+8VDC

+8VDC

+8VDC
FBAT

FBAT

FBAT

FBAT

FBAT
TO CONN 377M,CAV 11,SHT 2,SECT 69
79CR Bk -0.8

TO HVAC SIGNAL GND AT CONN

179AV Bk -0.8
139F, CAV N, SHT} 2 SECTION 60

TO HVAC SIGNAL GND AT CONN

179AU Bk -0.8
139F, CAV P, SHT 2 SECTION 60

TO GROUND CONTINUITY FUSE #28

179AW Y-0.8

IMP DEPTH CNTL LOW

IMP DEPTH CNTL UP
FUSE BLOCK 261 SHT2 SECTION 60

HITCH LOAD

PROG SHIFT
AUTO SHIFT
TRCU BUMP
HITCH POS

SECONDARY

AUTOGUIDANCE
THROTTLE
COMMAND

COMMAND

CREEPER

SCRAPER

HARNESS
UP/DOWN
SWITCH

SWITCH

SWITCH

SWITCH

AUTO PTO
HITCH

SHIFT
WHEEL
SW201

SW202

SW203

SW205

SW206

SW204
AUX 5

AUX 1

AUX 2

AUX 3

AUX 4

AUX 5

PANEL
STCU
DIFF

FLOW
LOCK

MAIN
#137
TO CONN 273M,CAV 4
SLIP

J201

J202

J203

J204

J205

J206

J207

J208

J210

J211

J213

J212
MFD

PTO
179AZ Bk -1.0

OR

J14

J15
J1

J2

J3

J6
SHT2,SECT 70